WO2000070370A2 - Apparatus forming laterally light emitting cable - Google Patents

Apparatus forming laterally light emitting cable Download PDF

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Publication number
WO2000070370A2
WO2000070370A2 PCT/US2000/013681 US0013681W WO0070370A2 WO 2000070370 A2 WO2000070370 A2 WO 2000070370A2 US 0013681 W US0013681 W US 0013681W WO 0070370 A2 WO0070370 A2 WO 0070370A2
Authority
WO
WIPO (PCT)
Prior art keywords
strands
cable
micro
fiber optic
jacket
Prior art date
Application number
PCT/US2000/013681
Other languages
French (fr)
Other versions
WO2000070370A3 (en
Inventor
Jack Caruso
Original Assignee
Optic-Tech International Corp.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Optic-Tech International Corp. filed Critical Optic-Tech International Corp.
Priority to AU51421/00A priority Critical patent/AU5142100A/en
Publication of WO2000070370A2 publication Critical patent/WO2000070370A2/en
Publication of WO2000070370A3 publication Critical patent/WO2000070370A3/en

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Classifications

    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/02Optical fibres with cladding with or without a coating
    • G02B6/032Optical fibres with cladding with or without a coating with non solid core or cladding
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/0001Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems
    • G02B6/0005Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems the light guides being of the fibre type
    • G02B6/001Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems the light guides being of the fibre type the light being emitted along at least a portion of the lateral surface of the fibre
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/04Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings formed by bundles of fibres
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24Coupling light guides
    • G02B6/26Optical coupling means
    • G02B6/28Optical coupling means having data bus means, i.e. plural waveguides interconnected and providing an inherently bidirectional system by mixing and splitting signals
    • G02B6/2804Optical coupling means having data bus means, i.e. plural waveguides interconnected and providing an inherently bidirectional system by mixing and splitting signals forming multipart couplers without wavelength selective elements, e.g. "T" couplers, star couplers
    • G02B6/2852Optical coupling means having data bus means, i.e. plural waveguides interconnected and providing an inherently bidirectional system by mixing and splitting signals forming multipart couplers without wavelength selective elements, e.g. "T" couplers, star couplers using tapping light guides arranged sidewardly, e.g. in a non-parallel relationship with respect to the bus light guides (light extraction or launching through cladding, with or without surface discontinuities, bent structures)
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/44Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
    • G02B6/4479Manufacturing methods of optical cables
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/0001Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24Coupling light guides
    • G02B6/26Optical coupling means
    • G02B6/28Optical coupling means having data bus means, i.e. plural waveguides interconnected and providing an inherently bidirectional system by mixing and splitting signals
    • G02B6/2804Optical coupling means having data bus means, i.e. plural waveguides interconnected and providing an inherently bidirectional system by mixing and splitting signals forming multipart couplers without wavelength selective elements, e.g. "T" couplers, star couplers
    • G02B6/2817Optical coupling means having data bus means, i.e. plural waveguides interconnected and providing an inherently bidirectional system by mixing and splitting signals forming multipart couplers without wavelength selective elements, e.g. "T" couplers, star couplers using reflective elements to split or combine optical signals

Definitions

  • lateral emitting or leakage of light flux from a fiber optic cable is known to be used is such areas as aesthetic lighting or safety illumination.
  • the fiber optic cable often has a plurality of individual optical or fiber optic strands, e.g., formed of plastic or glass, which are bundled together by a transparent or translucent jacket and positioned so that at least one light source optically coupled to at least one end of emits lights into the at least one end of the fiber optic cable.
  • the light from the source is then distributed throughout the length of the fiber optic cable and is emitted laterally from the surface of the jacket.
  • This laterally emitted light can then be used in various applications including, for example, back-lighting or surface illumination for swimming pools, spas, ponds, or waterfalls.
  • the fiber optic cable has many advantages over other lighting techniques, e.g., neon tubes, incandescent lamps, or other discrete light source, such as cable flexibility, immunity from electrical shock and noise, and low cost.
  • Fiber optic cables wnich are often used m these applications can include a light-scattering scheme to enhance the lateral emission of light from the cable.
  • tne plurality of individual strands can be bundled and twisted together.
  • this prior technique generally involves twisting the individual optical fiber strands, e.g., about 7-14 strands, into a sub-bundle. This is generally achieved by rotating a plurality of fibers around a fixed closing die to produce the sub-bundle. A plurality of sub-b ⁇ ndles, e.g., about 3-10, are then rotated into a fixe ⁇ closing die to produce a fiber optic cable, e.g., having about 40-140 individual fiber optic strands.
  • Fiber optic cables used m various applications including, for example, back-lighting or surface illumination for swimming pools, spas, ponds, fountains, or waterfalls, for decorative outlining of buildings, scripting for signs and advertisement displays, etc., may include a light-scattering scheme to enhance the lateral emission of light from the cable.
  • the plurality of individual strands can be twisted and bundled together. More specifically, about 7 to 14 strands can be twisted into a sub-bundle by rotating a plurality of fibers around a fixed closing die to produce the sub-bundle. A plurality of sub-bundles, e.g. about 3 to 10, are then rotated (twisted) into a fixed closing die to produce a fiber optic cable, e.g. having about 40 to 140 individual fiber optic strands.
  • n 2 index of refraction of the cladding.
  • NA numerical aperture
  • a ray that encounters the exterior fiber face with an angle of less than or equal to the acceptance angle will undergo total internal reflection wnen it encounters the difference index of refraction between the cladding and the fiber (PMMA) media.
  • the numerical aperture can r>e "tuned" for larger NA by making the difference between the core and cladding greater.
  • the apparatus preferably includes a supply having a plurality of plastic fiber optic strands, micro-bend forming means positioned downstream from the supply and positioned to individually receive each of the plurality of plastic fiber optic strands m a spaced-apart relation for forming a plurality of micro-bends m a relatively uniform pattern m each of the plurality of strands, strand guiding means positioned downstream from the micro-bend forming means and positioned to receive each of the plurality of micro-bend strands for guiding the plurality of spaced- apart, micro-bent strands into an abuttingly contacting relation, and wrapping means positioned downstream from the strand guiding means for wrapping a jacket, e.g., an inner cable jacket, of material such as Mylar or Teflon around the plurality of abuttingly contacting strands so as to form a cable having a plurality of individually micro-bent fiber optic strands.
  • a jacket e.g., an inner cable
  • the apparatus can also advantageously include encasing means positioned downstream from the wrapping means for encasing the inner cable jacket with an outer cable jacket, cable pulling means positioned downstream from the encasing means for pulling the encased cable of the plurality of micro-bent fiber optic strands from the supply and through the micro-bend forming means, the guiding means, the wrapping means, and the encasing means, and cable collecting means positioned downstream from the cable pulling means for collecting the cable having the plurality of micro-bent fiber optic strands.
  • micro-bend as used herein throughout refers to micro-flexures or fractures m fiber cladding of individual fiber optic strands.
  • micro-bends preferably occur due to rotation or twisting of the individual fiber optic strands m a positive direction from 1-360 degrees of rotation either m a clockwise or counter-clockwise direction.
  • the ratio of rotation or twist preferably is from 1-360 degrees and during 1-50 meters per minute of travel .
  • the back tension is preferably from 100-300 grams total to any individual fiber optic strand by the use of either a mechanical, electrical, or electro-mechanical braking system on the supply, e.g., a spool pay-out to control backlashmg. This, turn, can have the effect of controlling attenuation losses from 100-500 dB/Km which improves attenuation control.
  • the present invention also advantageously provides a plastic fiber optic cable for increasing lateral transmission of light therefrom.
  • the cable preferably includes a plurality of plastic fiber optic strands. Each strand has a plurality of micro-bends formed therein m a relatively uniform pattern.
  • At least one jacket e.g., formed of Mylar, Teflon, or translucent plastic material, preferably is formed around the plurality of plastic fiber optic strands.
  • the fiber optic cable can advantageously include an inner core around which the plurality of strands is positioned.
  • the plurality of strands can each extend generally parallel to each other and generally parallel to the lengthwise extent of the core or each of the plurality of strands can be twisted about the core, e.g., in sub-bundles.
  • the core also can include a fluid such as water which can advantageously be used for fountains, pools, spas, or other water lighting applications.
  • the sub-bundles can also be advantageously be tiered or nested about the core as well .
  • the apparatus and method of forming micro- bends in a generally uniform pattern in individual fiber optic strands advantageously can be used with existing methods of forming fiber optic cable and with existing types of fiber optic cable configurations to add control and uniformity to lateral light emission on these existing technologies. For example, by decreasing the amount of back tension currently required on existing fiber optic cable production, more uniformity and control of attenuation can be achieved. This, in turn, allows the overall cladding fracture to be controlled to a much greater extent, enhances light emission uniformity, and provides a more uniform lateral light emission drop-off.
  • a method preferably includes the steps of forming a plurality of micro-bends in each of a plurality of fiber optic strands, positioning each of the plurality of strands closely adjacent at least one other of the plurality of strands, and forming a jacket around the plurality of micro-bent strands.
  • the plurality of micro-bends preferably are formed m a generally uniform pattern m each of the plurality of fiber optic strands.
  • Another method of forming a laterally light emitting fiber optic cable having enhanced and uniform light emitting capabilities preferably includes imparting a generally continuous twist each of a plurality of plastic fiber optic strands moving along a predetermined path of travel so as to form a generally uniform pattern of micro-bends each of the plurality of strands and bundling the plurality of micro-bent strands so as to define a laterally light emitting fiber optic cable.
  • An additional method of forming a laterally light emitting fiber optic cable preferably includes supplying a plurality of plastic fiber optic strands m spaced-apart relation, forming a plurality of micro- pends m eacn of the plurality of plastic fiber optic strands m a generally uniform pattern, guiding each of the plurality of spaced-apart and micro-bent strands into an abutting contact relation, and positioning a jacket of material around the plurality of strands.
  • another embodiment of the present invention a ⁇ vantageously provides improve ⁇ materials comprising, and methods for manufacturing, laterall light emitting fiPer cptic ca le providing improved high lateral light emission.
  • the intensity of laterally emitted light in increased by increasing the diameter of the core of PMMA optical fiber to 0.980 mm.
  • This 0.980 mm diameter fiber preferably is used in conjunction with a relatively thin cladding (jacket) having, for example, a thickness of 0.1 mm.
  • This structure provides a ratio of core area to fiber cross- section of 96% and a concomitant increase of the numeric aperture to 0.50, wmch in turn will increase the amount of light entering the PMMA core, known as the acceptance angle, to 60J
  • This structure can yield more light capacity and throughput than the prior art structures .
  • FIG. 2 is a perspective view of an apparatus for forming a laterally light emitting fiber optic cable according to a first embodiment of the present invention
  • FIG. 3 is a perspective view of a micro-bend former of an apparatus for forming a laterally light emitting fiber optic cable according to the present invention
  • FIG. 4 is an enlarged and fragmentary front elevational view of a micro-bend former of an apparatus for forming a laterally light emitting fiber optic cable according to the present invention
  • FIG. 5 is a side elevational view of a micro- bend former of an apparatus for forming a laterally light emitting fiber optic cable according to the present invention
  • FIG. 7 is a perspective view of a micro-bend former, a strand oundle twister, ana a strand guide of an apparatus for forming a laterally light emitting fiber optic cable according to a second embodiment of the present invention
  • FIG. 8 is a perspective view of a fiber optic cable having a plurality of strands which each include a plurality of micro-bends formed therein according to a first embodiment of a laterally light emitting fiber optic cable of the present invention
  • FIG. 9 is a sectional view of a fiber optic cable having a plurality of strands wmch each include a plurality of micro-bends formed therein and taken along line 9-9 of FIG. 8 according to a first embodiment of a fiber optic cable of tne present invention
  • FIG. 10 is a sectional view of a fiber optic cable having a plurality of strands which each include a plurality of micro-bends formed therein and taken along line 10-10 of FIG. 8 according to a first embodiment of a fiber optic cable of the present invention
  • FIG. 11 is a strand of a fiber optic cable having a plurality of micro-bends formed therein according to the present invention.
  • FIG. 13 is a sectional view of a strand of fiber optic cable having a plurality of micro-bends formed therein and taken along line 13-13 of FIG. 11 according to the present invention
  • FIG. 14 is a fragmentary view of a fiber optic cable having a plurality of strands each which includes a plurality of micro-bends formed therein according to a second embodiment of a fiber optic cable of the present invention
  • FIG. 15 is a sectional view of a fiber optic cable having a plurality of strands each which includes a plurality of micro-bends formed therein and taken along line 15-15 of FIG. 14 according to a second embodiment of a fiber optic cable of the present invention
  • FIG. 16 is a fragmentary view of a fiber optic cable having a plurality of strands each which includes a plurality of micro-bends formed therein according to a third embodiment of a fiber optic cable of the present invention
  • FIG. 17 is a sectional view of a fiber optic cable having a plurality of strands eacn wmch includes a plurality of micro-bends formed therein and taken along line 17-17 of FIG. 16 according to a third embodiment of a fiber optic cable of the present invention
  • FIG. 18 is a fragmentary view of a fiber optic cable having a plurality of strands each which includes a plurality of micro-bends formed therein according to a fourth embodiment of a fiber optic cable of the present invention
  • FIG. 19 is a sectional view of a fiber optic cable having a plurality of strands each which includes a plurality of micro-bends formed therein and taken along line 19-19 of FIG. 18 according to a fourth embodiment of a fiber optic cable of the present invention;
  • FIG. 20 is a fragmentary view of a fiber optic cable having a plurality of strands each which includes a plurality of micro-bends formed therein according to a fifth embodiment of a fiber optic cable of the present invention
  • FIG. 21 is a sectional view of a fiber optic cable having a plurality of strands each which includes a plurality of micro-bends formed therein and taken along line 21-21 of FIG. 20 according to a fifth embodiment of a fiber optic cable of the present invention.
  • FIG. 22 is a perspective view of a fiber optic cable in the form of a relatively flat strip having a plurality of individual fiber optic strands which each include a plurality of micro-bends formed therein according to yet another embodiment of the present invention.
  • FIGS. 1-2 illustrate an apparatus 30 for forming a fiber optic cable C having a plurality of micro-bends B m a relatively uniform pattern m each of a plurality of plastic fiber optic strands ⁇ thereof to thereoy increase the amount of light laterally and uniformly transmitted from the fiber optic cable C according to the present invention.
  • the apparatus 30 preferably includes a supply 40 having a plurality of spools 41 of plastic fiber optic strands S mounted to a frame defining a rack 45.
  • the spools 41 are positioned on the rack 45, and each spool 41 is preferably controlled by a spool braking system, e.g., electromechanical or motor controlled as understood by those skilled m the art, connected to a control unit 25 to control backlash and tension the individual strand S.
  • the supply 40 also preferably includes a strand spacer 46 illustrated the form of a strand spacer ring, e.g., formed of metal having a plurality of spaced apart guides or openings 47 formed therein for spacing and guiding the individual strands from the supply 40.
  • the apparatus 30 also preferably has micro- bend forming means, e.g., preferably provided by a micro-bend former 50, preferably positioned downstream from the supply 40 and positioned to individually receive eacn of the plurality of plastic fiber optic strands S a spaced-apart relation for forming a plurality of micro-bends B in a relatively uniform pattern m each of the plurality of strands S (see also FIGS. 3-5) .
  • the micro-bend former 50 preferably includes a housing 51, e. g., mounted on a floor pedestal 52 navmg a plurality of spaced-apart openings
  • the twisting means 55 can include a motor 59, a shaft 56 connected to the motor 54 for being rotat gly driven by the motor 54, and a fiber optic interface member 57 connected to the shaft
  • the interface member 57 preferably includes an interface ring 58a formed of an elastomeric material which defines a fiber optic strand contact, friction drive belt mounted to a spline drive hears 58b.
  • the spline drive gear 58b, m turn, is mounted to tne drive shaft 56.
  • Strand guiding means e.g., preferably provided by a strand guide 60, guide belts, or closer, preferably is positioned downstream from the micro-bend former 50 and positioned to receive each of the plurality of micro-bent strands S for guiding the plurality of spaced-apart, micro-bent strands S into an abuttingly contacting relation.
  • the guiding operation for example, can be achieved by a frusto-co cal shaped housing 61, such as illustrated, and can include a motor 62 and drive belt 63. Guide belts or other closers can be used, alternatively, as well.
  • Wrapping means e.g., preferably provided by a wrapper 70, is positioned downstream from the strand guide 60 for wrapping a jacket, e.g., an inner cable jacket JI, of material around the plurality of abuttingly connecting strands S so as to form a cable C having a plurality of individually micro-bent fiber optic strands S.
  • the wrapper 70 can include a roll 72 or spool of material mounted to a frame member 73 and a wrap guide 74 for guiding the wrapping material around the bundle of strands S.
  • the material of the wrapper 70 preferably includes at least one of either Mylar or Teflon, and the material preferably is overlappmgly wrapped around the plurality of micro-bent strands S.
  • the apparatus 30 can also advantageously include encasing means, e.g., preferably provided by an encaser 80, positioned downstream from the wrapper 70 for encasing the inner cable jacket JI with an outer cable jacket J2.
  • the encaser preferably encases or surrounds the inner jacket JI with a translucent plastic material as it passes through a trough or channel 81.
  • a pair of pipes 82, 83 are connected to the trough 81 to supply fluid plastic material and/or a coolant thereto.
  • Cable pulling means e.g., preferably provided by a cable puller 90 or caterpillar- type device as understood by those skilled in the art, is positioned downstream from the encaser 80 for pulling the encased cable C of the plurality of micro-bent fiber optic strands S from the supply 40 and through the micro-bend former 50, the strand guide 60, the wrapper 70, and the encaser 80.
  • the cable puller 90 preferably includes a drive motor 92 which drives a plurality of drive rolls 94.
  • a pair of belts 95, 96 are mounted to the drive rolls for contact gly engaging the outer jacket J2 of the cable C.
  • cable collecting means e.g., preferably provided by a spool collector 100, is positioned downstream from the cable puller 90 for collecting cable C having the plurality of micro-bent fiber optic strands S m a controlled manner.
  • the spool collector 100 preferably includes a drive motor 102 for rotatmgly driving the spool for take-up of the cable C.
  • the spool collector 100 also preferably includes a cable guide 105 for guiding the cable onto the spool during rotation thereof.
  • the cable guide 105 preferably includes a motor 106 mounted to a frame member 107 and an eyelet 108 connected to the motor 106 by a drive chain or other drive link. The eyelet 108 advantageously travels along the frame member 107 during take-up operation so that the cable C is collected onto the spool m a smooth and organized process .
  • the apparatus 30 preferably has drive controlling means, e.g., a control unit 25, including one or more processing circuits, e.g., microprocessors, and/or associated control software as understood by those skilled m tne art, connected at least to the micro-bend former 50, the cable puller 90, and the spool collector 100, for controlling the drive of the same.
  • the control unit 25 preferably includes synchronizing means, e.g., a timing synchronizer 26 of hardware and/or software, for synchronizing the drive of the micro-bend former 50, the cable puller 90, and the spool collector 100.
  • the guide ring 68 has a plurality of openings 69 extending therethrough and into which sub-groups or sub-bundles of fiberoptic strands pass.
  • the drive belt 67 imparts a twist to the strands S as the strands pass through the opening.
  • a plurality of twisted sub-bundles is the output of the stand bundle twister 65 and travel downstream to the stand guide 60' for initiating the formation of the cable C ⁇ , for example.
  • micro-bend B or micro-bent refers to micro- flexures or fractures m fiber cladding of individual fiber optic strands S such as due to twisting at strong enough force or tension to cause the fracture. These micro-bends preferably occur due to rotation or twisting of the individual fiber optic strands S m a positive direction from 1-360 degrees of rotation either in a clockwise or counter-clockwise direction. The ratio of rotation or twist will be from 1-360 degrees and from 1-50 meters per minute of travel.
  • the plastic strands S are preferably formed of a poly ⁇ nethyl methacrylate ("PMMA") core, a fluormated polymer cladding, and a structure having a step index type.
  • the PMMA is an optical fiber cylindrical guide which permits the propagation of the visible light wave. Forms in the mode of a "light" signal. According to the refraction index profile, it is possible to have these signals propagated in single mode or multi -mode fiber “step index. "
  • the dimensions of the multi-mode fibers are characterized by the cladding diameter and core diameter. The number of micro-bends can vary between a few per meter to several hundred per meter. As the flex or "twist" becomes “tighter” micro-bending losses are introduced. The dimensions control between radii, is expected to be reasonably assured to tens of microns and perhaps less.
  • the individual fiber strand S allows a uniformly controlled fracturing of the fiber's clad to effect attenuation losses by effecting light wave transit times. This will cause lucent light leakage, the luminance of the light leakage can be increased or decreased under the influence of micro-bendmg or micro-flexure .
  • the refracting and scattering actions of the light leaks at a high luminance.
  • the cable C having the strands S constructed m this manner as described above is fabricated by twisting the individual optical fiber strands S and thereby form a rotational light leakage. formed therein according to the present invention.
  • the present invention also advantageously provides a plastic fiber optic cable C for increasing lateral transmission of light therefrom.
  • the cable C preferably includes a plurality of plastic fiber optic strands S as described herein above (see FIGS. 8-15) .
  • At least one jacket e.g., inner cable jacket JI formed of Mylar, Teflon, or translucent plastic material, preferably is formed around the plurality of plastic fiber optic strands S.
  • the individual strands S' can be twisted into sub-bundles prior to wrapping and/or encasing the sub-bundles.
  • the fiber optic cable C ' can advantageously include an inner core I around whicn the plurality of strands S * ' is positioned (see FIGS.
  • the plurality of strands S 1 * can each extend generally parallel to each other and generally parallel to the lengthwise extent of the core I or each of the plurality of strands S ' ' can be twisted about the inner core I.
  • the inner core I' also can include a fluid F such as water which can advantageously be used for fountains, pools, spas, or other water lighting applications.
  • the fluid F for example, can be positioned in a translucent or transparent tube T which m combination with the fluid defines the core of the cable C ' . Further, as illustrated m FIGS.
  • the fiber optic sub-bundles can advantageously be nested m a plurality, e.g., two or more, tiers of sub-bundles about the inner core I so that light can also readily be emitted from regions R between adjacent bundles.
  • the inner sub-bundles can also advantageously be formed of smaller diameter individual fiber optic strands S' ' and can have a fewer number of strands S'' within the sub-bundles for more efficient packing within a jacket JI ' ' and for more efficient lateral light emission qualities.
  • FIG. 22 illustrates yet another embodiment of a fiber optic cable C" m the form of a relatively flat strip having a plurality of individual fiber optic strands S which each include a plurality of micro-bends
  • This embodiment also preferably includes a translucent outer jacket J'" which readily allows laterally emitted light to emit therefrom.
  • this arrangement also illustrates the individual strands S being positioned in a side-by-side, e.g., preferably abuttingly contacting, relation so that light can be emitted from both sides of the relatively flat outer jacket J'" .
  • the plurality of micro-bends B preferably are formed in a generally uniform pattern in each of the plurality of fiber optic strands S.
  • Another method of forming a laterally emitting fiber optic cable C having enhanced and uniform light emitting capabilities preferably includes imparting a generally continuous twist m each of a plurality of plastic fiber optic strands S moving along a predetermined path of travel so as to form a generally uniform pattern of micro-bends B in each of the plurality of strands S and bundling the plurality of micro-bent strands S so as to define a laterally emitting fiber optic cable C.

Abstract

An apparatus (30) is provided for forming a fiber optic cable (C) having a plurality of micro-bends (B) in a relatively uniform pattern in each of a plurality of plastic fiber optic strands (S) thereof to thereby increase the amount of light laterally and uniformly transmitted from the fiber optic cable (C). The apparatus preferably includes a supply having a plurality of plastic fiber optic strands (S), a micro-bend former (50) positioned downstream from the supply and positioned to individually receive each of the plurality of plastic fiber optic strands (S) in a spaced apart relation for forming a plurality of micro-bends (B) in a relatively uniform pattern in each of the plurality of strands (S), and a strand guide positioned downstream from the micro-bend former (50) and positioned to receive each of the plurality of micro-bend strands for guiding the plurality of spaced-apart, micro-bent strands into an abuttingly contacting relation.

Description

APPARATUS FOR FORMING LATERALLY LIGHT EMITTING FIBER OPTIC CABLE, LATERALLY LIGHT EMITTING FIBER OPTIC CABLE AND ASSOCIATED METHODS
Field Of The Invention
This application relates to fiber optic cable and, more particularly, to laterally light emitting fiber optic cable which laterally emits light along the length thereof from at least one light source.
Background Of The Invention
Generally, lateral emitting or leakage of light flux from a fiber optic cable is known to be used is such areas as aesthetic lighting or safety illumination. The fiber optic cable often has a plurality of individual optical or fiber optic strands, e.g., formed of plastic or glass, which are bundled together by a transparent or translucent jacket and positioned so that at least one light source optically coupled to at least one end of emits lights into the at least one end of the fiber optic cable. The light from the source is then distributed throughout the length of the fiber optic cable and is emitted laterally from the surface of the jacket. This laterally emitted light can then be used in various applications including, for example, back-lighting or surface illumination for swimming pools, spas, ponds, or waterfalls. The fiber optic cable has many advantages over other lighting techniques, e.g., neon tubes, incandescent lamps, or other discrete light source, such as cable flexibility, immunity from electrical shock and noise, and low cost.
Fiber optic cables wnich are often used m these applications can include a light-scattering scheme to enhance the lateral emission of light from the cable. For example, tne plurality of individual strands can be bundled and twisted together. More specifically, this prior technique generally involves twisting the individual optical fiber strands, e.g., about 7-14 strands, into a sub-bundle. This is generally achieved by rotating a plurality of fibers around a fixed closing die to produce the sub-bundle. A plurality of sub-bαndles, e.g., about 3-10, are then rotated into a fixeα closing die to produce a fiber optic cable, e.g., having about 40-140 individual fiber optic strands. Because this technique relies primarily on tension and force at the closing die, any fractures in fiber optic cladding which may occur then generally occur m groups of 7-14 fiber optic strands and greatly reduces the uniformity of fractures to the individual strands. This twisting technique, m turn, also results m rapid light emission drop-off and little control to structural cladding uniformity.
Examples of some of these twisting techniques are illustrated m U.S. Patent No. 5,345,531 by Keplmger et al . titled "Opti cal Fiber Lighting
Apparatus and Method, " U.S. Patent No. 5,617,497 by
Kmgstone titled "La teral Illumina tion Fiber Opti c
Cable Device And Method Of Manufacture, " U.S. Patent No. 5,333,228 by Kmgstone titled "La teral Ill umination
Fiber Opti c Cable Devi ce And Method Of Manufacture, " and U.S. Patent No. 5,333,228 by Kmgstone titled "La teral Illumina tion Fiber Opti c Cabl e Devi ce And
Method Of Manufacture . " In addition, with these prior techniques the elongation of the strands is generally induced by relatively high back tension on the individual strands and even more back tension can occur when attempts to control back lash are implemented so that the total back tension can be in the range of about 850-1500 grams. This high back tension, m turn, greatly impacts attenuation losses. For example, the initial attenuation characteristics of a plastic optical fiber strand is approximately 135 dB/Km, and the effect of accumulated back tension can change the attenuation of the plastic optical fiber strand to approximately 1200 dB/Km to 2700 dB/Km which dramatically effects performance of the individual strands. Other techniques, for example, for increasing laterally emitting light include spreading the strands into a flat strip such as illustrated in U.S. Patent No. 4,763,984 by Awai et al . titled "Lighting Appara tus
And Method " and forming a track for cable or portions of cable to positioned therealong such as illustrated in U.S. Patent No. 5,617,496 by Kmgstone titled Lateral Illumina tion Fiber Optic Cabl e Devi ce And
Method Of Manufacture . "
These prior techniques also generally lack uniformity m the light emission throughout the length of the cable, strip, or track. Further, complex and costly systems are often required to manufacture cable, strips, or tracks such as illustrated the apparatus or system of U.S. Patent No. 5,376,201 by Kmgstone titled "Method Of Manufacturing An Image Magnification
Devi ce . "
Generally, PMMA optical fiber based optical cables have a predetermined index of refraction that is a function of the core diameter and of the characteristics of the cladding (jacketing) that is present . Historically, only 0.75 mm diameter PMMA fiber has been used m the production and manufacturing of laterally light emitting fiber optic cable. Examples of some of this PMMA fiber usage can be found in U.S. Patent No. 5,345,531 (Keplmger et al . ,
"Optical fiber lighting apparatus and method"); U.S. Patent No. 5,617,497 (Kmgstone, "Lateral illumination fiber optic cable device and method of manufacture") ; and U.S. Patent No. 5,333,228 (Kmgstone, "Lateral illumination fiber optic cable device and method of manufacture" ) .
Fiber optic cables used m various applications including, for example, back-lighting or surface illumination for swimming pools, spas, ponds, fountains, or waterfalls, for decorative outlining of buildings, scripting for signs and advertisement displays, etc., may include a light-scattering scheme to enhance the lateral emission of light from the cable. For example, the plurality of individual strands can be twisted and bundled together. More specifically, about 7 to 14 strands can be twisted into a sub-bundle by rotating a plurality of fibers around a fixed closing die to produce the sub-bundle. A plurality of sub-bundles, e.g. about 3 to 10, are then rotated (twisted) into a fixed closing die to produce a fiber optic cable, e.g. having about 40 to 140 individual fiber optic strands.
These techniques, which have all made exclusive use of 0.75mm diameter PMMA fiber optic strands, allow for limited lateral light transmission due to the low refractive index (1.495) of the 0.75 mm diameter PMMA fiber optic strands. These techniques also generally lack sufficient light throughput due to the low numerical aperture (0.46) of 0.75 mm diameter PMMA optical fiber strands. This combination results in a low light acceptance angle of 55 degrees. The use of 0.75mm diameter PMMA optical fiber strand has been the standard with the industry for all prior techniques for forming laterally light emitting fiber optic cable.
The formulae for representing the mtermodal dispersion - propagation delay between modes and the refractive index of PMMA by wavelength are seen on pages 17 and 18. Those formulae are used for calculation of the bandwidth of a fiber having a core with an index of refraction of nl , surrounded by a cladding with an index of refraction of n2. Where numerical aperture determines total internal reflection :
NA= sin A = (n --n ) "
NA= Nominal numerical aperture
A= entrance (acceptance) angle n,= index of refraction of the fiber medium (PMMA) n2= index of refraction of the cladding.
This is based on "Snell's" law for determining the numerical aperture (NA) of a fiber. When light encounters a surface of a different index of refraction, it is refracted a relationship of
Figure imgf000007_0001
n2smsιt index of refraction of tne first media = PMMA core ι1 =angle of incidence from first media h2= index of refraction of the second media (cladding) ι2= resulting angle the second media Although it is frequently applied for rays across the fiber optic edge, it really is derived for the meridian ray (of center ray) only. Light must enter into the fiber from a medium with an index of refraction close to 1 (e.g. air or space) . A ray that encounters the exterior fiber face with an angle of less than or equal to the acceptance angle will undergo total internal reflection wnen it encounters the difference index of refraction between the cladding and the fiber (PMMA) media. The numerical aperture can r>e "tuned" for larger NA by making the difference between the core and cladding greater.
The historically used 0.75 mm diameter PMMA fiber has a core diameter of 0.735 mm. The refractive index of the core is 1.495 and the refractive index of the cladding is 1.402. The numerical aperture is 0.46 and the light acceptance angle (2er) is 55°. This has remained as a constant within the industry to date.
Summary Of The Invention
In view of the foregoing bacκground the present invention advantageously provides an apparatus and method for forming laterally light emitting fiber optic cable which generally uniformly distributes light for lateral emission from the outer surface thereof throughout the length of the cable and laterally emits a high amount of light, e.g., increased intensity, from the outer surface of the cable. By increasing or controlling the uniform distribution and intensity of the light with a correspondingly similar light source (s), a user thereof advantageously improves light emission qualities of the fiber optic cable for desired applications. The present invention also advantageously provides a less costly and less complex apparatus and method of forming laterally emitting fiber optic cable having generally uniform light distribution and increased intensity. Additionally, the present invention advantageously provides an apparatus and method which control cladding fracture uniformity effecting individual plastic optical fiber strands and thereby greatly reduce the attenuation losses to the individual strands of optical fiber as well as to the overall attenuation of the plurality of strands wmch form a laterally emitting fiber optic cable . More particularly, an apparatus and methods are provided for forming a fiber optic cable having a plurality of micro-bends m a relatively uniform pattern m each of a plurality of plastic fiber optic strands thereof to thereby increase the amount of light laterally and uniformly transmitted from the fiber optic cable. The apparatus preferably includes a supply having a plurality of plastic fiber optic strands, micro-bend forming means positioned downstream from the supply and positioned to individually receive each of the plurality of plastic fiber optic strands m a spaced-apart relation for forming a plurality of micro-bends m a relatively uniform pattern m each of the plurality of strands, strand guiding means positioned downstream from the micro-bend forming means and positioned to receive each of the plurality of micro-bend strands for guiding the plurality of spaced- apart, micro-bent strands into an abuttingly contacting relation, and wrapping means positioned downstream from the strand guiding means for wrapping a jacket, e.g., an inner cable jacket, of material such as Mylar or Teflon around the plurality of abuttingly contacting strands so as to form a cable having a plurality of individually micro-bent fiber optic strands. Additionally, the apparatus can also advantageously include encasing means positioned downstream from the wrapping means for encasing the inner cable jacket with an outer cable jacket, cable pulling means positioned downstream from the encasing means for pulling the encased cable of the plurality of micro-bent fiber optic strands from the supply and through the micro-bend forming means, the guiding means, the wrapping means, and the encasing means, and cable collecting means positioned downstream from the cable pulling means for collecting the cable having the plurality of micro-bent fiber optic strands. The term micro-bend as used herein throughout refers to micro-flexures or fractures m fiber cladding of individual fiber optic strands. These micro-bends preferably occur due to rotation or twisting of the individual fiber optic strands m a positive direction from 1-360 degrees of rotation either m a clockwise or counter-clockwise direction. The ratio of rotation or twist preferably is from 1-360 degrees and during 1-50 meters per minute of travel . The back tension is preferably from 100-300 grams total to any individual fiber optic strand by the use of either a mechanical, electrical, or electro-mechanical braking system on the supply, e.g., a spool pay-out to control backlashmg. This, turn, can have the effect of controlling attenuation losses from 100-500 dB/Km which improves attenuation control.
The present invention also advantageously provides a plastic fiber optic cable for increasing lateral transmission of light therefrom. The cable preferably includes a plurality of plastic fiber optic strands. Each strand has a plurality of micro-bends formed therein m a relatively uniform pattern. At least one jacket, e.g., formed of Mylar, Teflon, or translucent plastic material, preferably is formed around the plurality of plastic fiber optic strands. According to other embodiments of a fiber optic cable of the present invention, the fiber optic cable can advantageously include an inner core around which the plurality of strands is positioned. The plurality of strands, for example, can each extend generally parallel to each other and generally parallel to the lengthwise extent of the core or each of the plurality of strands can be twisted about the core, e.g., in sub-bundles. The core also can include a fluid such as water which can advantageously be used for fountains, pools, spas, or other water lighting applications. Further, the sub-bundles can also be advantageously be tiered or nested about the core as well .
The apparatus and method of forming micro- bends in a generally uniform pattern in individual fiber optic strands advantageously can be used with existing methods of forming fiber optic cable and with existing types of fiber optic cable configurations to add control and uniformity to lateral light emission on these existing technologies. For example, by decreasing the amount of back tension currently required on existing fiber optic cable production, more uniformity and control of attenuation can be achieved. This, in turn, allows the overall cladding fracture to be controlled to a much greater extent, enhances light emission uniformity, and provides a more uniform lateral light emission drop-off.
Methods of forming a fiber optic cable are also provided according to the present invention. A method preferably includes the steps of forming a plurality of micro-bends in each of a plurality of fiber optic strands, positioning each of the plurality of strands closely adjacent at least one other of the plurality of strands, and forming a jacket around the plurality of micro-bent strands. The plurality of micro-bends preferably are formed m a generally uniform pattern m each of the plurality of fiber optic strands.
Another method of forming a laterally light emitting fiber optic cable having enhanced and uniform light emitting capabilities preferably includes imparting a generally continuous twist each of a plurality of plastic fiber optic strands moving along a predetermined path of travel so as to form a generally uniform pattern of micro-bends each of the plurality of strands and bundling the plurality of micro-bent strands so as to define a laterally light emitting fiber optic cable. An additional method of forming a laterally light emitting fiber optic cable preferably includes supplying a plurality of plastic fiber optic strands m spaced-apart relation, forming a plurality of micro- pends m eacn of the plurality of plastic fiber optic strands m a generally uniform pattern, guiding each of the plurality of spaced-apart and micro-bent strands into an abutting contact relation, and positioning a jacket of material around the plurality of strands. In view of the foregoing background, another embodiment of the present invention aαvantageously provides improveα materials comprising, and methods for manufacturing, laterall light emitting fiPer cptic ca le providing improved high lateral light emission. In one emboαiment of the invention, the intensity of laterally emitted light in increased by increasing the diameter of the core of PMMA optical fiber to 0.980 mm. This 0.980 mm diameter fiber preferably is used in conjunction with a relatively thin cladding (jacket) having, for example, a thickness of 0.1 mm. This structure provides a ratio of core area to fiber cross- section of 96% and a concomitant increase of the numeric aperture to 0.50, wmch in turn will increase the amount of light entering the PMMA core, known as the acceptance angle, to 60J This structure can yield more light capacity and throughput than the prior art structures .
Brief Description Of The Drawings
Some of the features, advantages, and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken m conjunction with the accompanying drawings m which:
FIG. 1 is a block diagram of an apparatus for forming a laterally light emitting fiber optic cable according to a first embodiment of tne present invention;
FIG. 2 is a perspective view of an apparatus for forming a laterally light emitting fiber optic cable according to a first embodiment of the present invention;
FIG. 3 is a perspective view of a micro-bend former of an apparatus for forming a laterally light emitting fiber optic cable according to the present invention;
FIG. 4 is an enlarged and fragmentary front elevational view of a micro-bend former of an apparatus for forming a laterally light emitting fiber optic cable according to the present invention; FIG. 5 is a side elevational view of a micro- bend former of an apparatus for forming a laterally light emitting fiber optic cable according to the present invention;
FIG. 6 is a block diagram of an apparatus for forming a laterally light emitting fiber optic cable according to a second embodiment of the present invention;
FIG. 7 is a perspective view of a micro-bend former, a strand oundle twister, ana a strand guide of an apparatus for forming a laterally light emitting fiber optic cable according to a second embodiment of the present invention;
FIG. 8 is a perspective view of a fiber optic cable having a plurality of strands which each include a plurality of micro-bends formed therein according to a first embodiment of a laterally light emitting fiber optic cable of the present invention;
FIG. 9 is a sectional view of a fiber optic cable having a plurality of strands wmch each include a plurality of micro-bends formed therein and taken along line 9-9 of FIG. 8 according to a first embodiment of a fiber optic cable of tne present invention;
FIG. 10 is a sectional view of a fiber optic cable having a plurality of strands which each include a plurality of micro-bends formed therein and taken along line 10-10 of FIG. 8 according to a first embodiment of a fiber optic cable of the present invention;
FIG. 11 is a strand of a fiber optic cable having a plurality of micro-bends formed therein according to the present invention;
FIG. 12 is a sectional view of a strand of fiber optic caple having a plurality of micro-bends formed therein and taken along line 12-12 of FIG. 11 according to the present invention;
FIG. 13 is a sectional view of a strand of fiber optic cable having a plurality of micro-bends formed therein and taken along line 13-13 of FIG. 11 according to the present invention; FIG. 14 is a fragmentary view of a fiber optic cable having a plurality of strands each which includes a plurality of micro-bends formed therein according to a second embodiment of a fiber optic cable of the present invention; FIG. 15 is a sectional view of a fiber optic cable having a plurality of strands each which includes a plurality of micro-bends formed therein and taken along line 15-15 of FIG. 14 according to a second embodiment of a fiber optic cable of the present invention;
FIG. 16 is a fragmentary view of a fiber optic cable having a plurality of strands each which includes a plurality of micro-bends formed therein according to a third embodiment of a fiber optic cable of the present invention;
FIG. 17 is a sectional view of a fiber optic cable having a plurality of strands eacn wmch includes a plurality of micro-bends formed therein and taken along line 17-17 of FIG. 16 according to a third embodiment of a fiber optic cable of the present invention; FIG. 18 is a fragmentary view of a fiber optic cable having a plurality of strands each which includes a plurality of micro-bends formed therein according to a fourth embodiment of a fiber optic cable of the present invention; FIG. 19 is a sectional view of a fiber optic cable having a plurality of strands each which includes a plurality of micro-bends formed therein and taken along line 19-19 of FIG. 18 according to a fourth embodiment of a fiber optic cable of the present invention;
FIG. 20 is a fragmentary view of a fiber optic cable having a plurality of strands each which includes a plurality of micro-bends formed therein according to a fifth embodiment of a fiber optic cable of the present invention;
FIG. 21 is a sectional view of a fiber optic cable having a plurality of strands each which includes a plurality of micro-bends formed therein and taken along line 21-21 of FIG. 20 according to a fifth embodiment of a fiber optic cable of the present invention; and
FIG. 22 is a perspective view of a fiber optic cable in the form of a relatively flat strip having a plurality of individual fiber optic strands which each include a plurality of micro-bends formed therein according to yet another embodiment of the present invention.
Detailed Description Of Preferred Embodiments
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, which preferred embodiments of the invention are shown. This invention may, however, be embodied many different forms and should not be construed as limited to the embodiments set forth herein Ratner, tnese embodiments are provided so that this disclosure will oe thorough and complete, and will fully convey the scope of the invention to those skilled m the art. Prime or multiple prime notation where used indicates alternative embodiments. Like numbers refer to like elements throughout.
FIGS. 1-2 illustrate an apparatus 30 for forming a fiber optic cable C having a plurality of micro-bends B m a relatively uniform pattern m each of a plurality of plastic fiber optic strands Ξ thereof to thereoy increase the amount of light laterally and uniformly transmitted from the fiber optic cable C according to the present invention. The apparatus 30 preferably includes a supply 40 having a plurality of spools 41 of plastic fiber optic strands S mounted to a frame defining a rack 45. The spools 41 are positioned on the rack 45, and each spool 41 is preferably controlled by a spool braking system, e.g., electromechanical or motor controlled as understood by those skilled m the art, connected to a control unit 25 to control backlash and tension the individual strand S. The supply 40 also preferably includes a strand spacer 46 illustrated the form of a strand spacer ring, e.g., formed of metal having a plurality of spaced apart guides or openings 47 formed therein for spacing and guiding the individual strands from the supply 40. The apparatus 30 also preferably has micro- bend forming means, e.g., preferably provided by a micro-bend former 50, preferably positioned downstream from the supply 40 and positioned to individually receive eacn of the plurality of plastic fiber optic strands S a spaced-apart relation for forming a plurality of micro-bends B in a relatively uniform pattern m each of the plurality of strands S (see also FIGS. 3-5) . The micro-bend former 50 preferably includes a housing 51, e. g., mounted on a floor pedestal 52 navmg a plurality of spaced-apart openings
53 formed therein and extending therethrough, e.g., through a position gathering ring 54 to position a single fiber optic strand S in each of the plurality of openings 53 and twisting means 55 positioned to abuttingly contact each of the plurality of strands S when positioned m the plurality of openings 53 for imparting generally continuous twists m each of the plurality of strands S to thereby form the plurality of micro-bends B therein m a relatively uniform pattern as the plurality of fiber optic strands S travel downstream. The twisting means 55, for example, can include a motor 59, a shaft 56 connected to the motor 54 for being rotat gly driven by the motor 54, and a fiber optic interface member 57 connected to the shaft
56 for abuttingly interfacing with each of the plurality of strands. The interface member 57 preferably includes an interface ring 58a formed of an elastomeric material which defines a fiber optic strand contact, friction drive belt mounted to a spline drive hears 58b. The spline drive gear 58b, m turn, is mounted to tne drive shaft 56.
Strand guiding means, e.g., preferably provided by a strand guide 60, guide belts, or closer, preferably is positioned downstream from the micro-bend former 50 and positioned to receive each of the plurality of micro-bent strands S for guiding the plurality of spaced-apart, micro-bent strands S into an abuttingly contacting relation. The guiding operation, for example, can be achieved by a frusto-co cal shaped housing 61, such as illustrated, and can include a motor 62 and drive belt 63. Guide belts or other closers can be used, alternatively, as well.
Wrapping means, e.g., preferably provided by a wrapper 70, is positioned downstream from the strand guide 60 for wrapping a jacket, e.g., an inner cable jacket JI, of material around the plurality of abuttingly connecting strands S so as to form a cable C having a plurality of individually micro-bent fiber optic strands S. The wrapper 70, for example, can include a roll 72 or spool of material mounted to a frame member 73 and a wrap guide 74 for guiding the wrapping material around the bundle of strands S. The material of the wrapper 70 preferably includes at least one of either Mylar or Teflon, and the material preferably is overlappmgly wrapped around the plurality of micro-bent strands S.
Additionally, the apparatus 30 can also advantageously include encasing means, e.g., preferably provided by an encaser 80, positioned downstream from the wrapper 70 for encasing the inner cable jacket JI with an outer cable jacket J2. The encaser preferably encases or surrounds the inner jacket JI with a translucent plastic material as it passes through a trough or channel 81. A pair of pipes 82, 83 are connected to the trough 81 to supply fluid plastic material and/or a coolant thereto. Cable pulling means, e.g., preferably provided by a cable puller 90 or caterpillar- type device as understood by those skilled in the art, is positioned downstream from the encaser 80 for pulling the encased cable C of the plurality of micro-bent fiber optic strands S from the supply 40 and through the micro-bend former 50, the strand guide 60, the wrapper 70, and the encaser 80. The cable puller 90 preferably includes a drive motor 92 which drives a plurality of drive rolls 94. A pair of belts 95, 96 are mounted to the drive rolls for contact gly engaging the outer jacket J2 of the cable C.
Also, cable collecting means, e.g., preferably provided by a spool collector 100, is positioned downstream from the cable puller 90 for collecting cable C having the plurality of micro-bent fiber optic strands S m a controlled manner. The spool collector 100 preferably includes a drive motor 102 for rotatmgly driving the spool for take-up of the cable C. The spool collector 100 also preferably includes a cable guide 105 for guiding the cable onto the spool during rotation thereof. The cable guide 105 preferably includes a motor 106 mounted to a frame member 107 and an eyelet 108 connected to the motor 106 by a drive chain or other drive link. The eyelet 108 advantageously travels along the frame member 107 during take-up operation so that the cable C is collected onto the spool m a smooth and organized process .
Further, the apparatus 30 preferably has drive controlling means, e.g., a control unit 25, including one or more processing circuits, e.g., microprocessors, and/or associated control software as understood by those skilled m tne art, connected at least to the micro-bend former 50, the cable puller 90, and the spool collector 100, for controlling the drive of the same. The control unit 25 preferably includes synchronizing means, e.g., a timing synchronizer 26 of hardware and/or software, for synchronizing the drive of the micro-bend former 50, the cable puller 90, and the spool collector 100.
As best illustrated m FIGS. 6-7, and for alternate cable configurations (see FIGS. 16-21) for example, the apparatus 30' can also include strand bundle twisting means, e.g., preferably provided by a strand bundle twister 65, positioned downstream from the micro-bend former 50 for twisting individual strands S into sub-bundles prior to positioning or wrapping the inner jacket JI ' around a plurality of these sub-bundles. The sub-bundles also can be positioned around an inner core I as well . The strand bundle twister 65 for example, can include another guide ring 68 mounted to a floor support stand. The guide ring 68 has an inner ring connected to the stand m a stationary manner and an outer ring surface wmch interfaces with a drive belt 67 driven by a drive motor
68. The guide ring 68 has a plurality of openings 69 extending therethrough and into which sub-groups or sub-bundles of fiberoptic strands pass. The drive belt 67 imparts a twist to the strands S as the strands pass through the opening. In turn , a plurality of twisted sub-bundles is the output of the stand bundle twister 65 and travel downstream to the stand guide 60' for initiating the formation of the cable C Λ , for example.
The terms micro-bend B or micro-bent as used herein throughout refers to micro- flexures or fractures m fiber cladding of individual fiber optic strands S such as due to twisting at strong enough force or tension to cause the fracture. These micro-bends preferably occur due to rotation or twisting of the individual fiber optic strands S m a positive direction from 1-360 degrees of rotation either in a clockwise or counter-clockwise direction. The ratio of rotation or twist will be from 1-360 degrees and from 1-50 meters per minute of travel. The back tension is preferably from 100-300 grams total to any individual fiber optic strand S by the use of either a mechanical, electrical, or electro-mechanical braking system on the supply, e.g., a spool pay-out to control backlashmg. This, m turn, can have the effect of controlling attenuation losses from 100-500 dB/Km which improves attenuation control.
For example, as understood by those skilled m the art, the plastic strands S are preferably formed of a polyτnethyl methacrylate ("PMMA") core, a fluormated polymer cladding, and a structure having a step index type. Fiber optic strands S having a plurality of micro-bends B or micro-flexures of rotation α, -. , y of positive X, Y, and Z axes into the assigned direction along the line between 0° and 180°. The direction cosines, turn, are cos α, cos (3, and cos Y and satisfy the equation: cos2 + cos2β + cos2γ = 1. Direction numbers a, b, c can be any three numbers proportional to the direction cosines. In other words, a=Kcos α, b=Kcosβ, and c=Kcosγ (with K≠O) . The direction cosine of a line is the coordinates of the point a unit distance from tne origin along its positive direction.
Figure imgf000022_0001
Assuming a numerical aperture ("N.A.") equals about 0.54 and an acceptance angle of 65°, then the bandwidth step index modulation of PMMA strands can be shown as follows:
A. Inter odal dispersion: propagation delay between modes is represented by:
ηΔ (7_ [N.A.]-
L ra= - C V 2
where (n) is the refractive index of the core, (c) is light velocity the vacuum, (Δ) is the difference of specific index, and v) is normalized frequency.
Material dispersion: for visible light from 398 nanometers to 1200 nanometers spectral content material dispersion σc is calculated by: di σ. c=-iλ 2 d Lλ 2 dλ d
The refractive index of PMMA by wave length is given by "Cauchy's" series as follows: η (2) =r)0+A2~'+BK2-Δ
where η0 = 1.4779.
A= 5.0496 X 103 B= 6.9486 X 107 These figures are used for calculation of the bandwidth of the fiber.
CALCUL A TIONS OFβAλ/PMPiy
Figure imgf000023_0001
I AV I CMGTH
The PMMA is an optical fiber cylindrical guide which permits the propagation of the visible light wave. Forms in the mode of a "light" signal. According to the refraction index profile, it is possible to have these signals propagated in single mode or multi -mode fiber "step index. " The dimensions of the multi-mode fibers are characterized by the cladding diameter and core diameter. The number of micro-bends can vary between a few per meter to several hundred per meter. As the flex or "twist" becomes "tighter" micro-bending losses are introduced. The dimensions control between radii, is expected to be reasonably assured to tens of microns and perhaps less.
The index of refraction of the cladding being smaller than that of the core, for example, from 50μ (microns) to 300μ (microns) as compared to 500μ (microns) to 1500μ (micron) for the core. Owing to this difference in the index of refraction between the materials constituting the core and cladding, light entering one end of the micro-flexed fiber is propagated inside the fiber itself and transmitted as a uniformly controlled brightness or "lateral light transmission along the line between 0° (degrees) and 180° (degrees) a unit distance from the origin θ. Along its positive direction this method of micro-bendmg the individual fiber strand S allows a uniformly controlled fracturing of the fiber's clad to effect attenuation losses by effecting light wave transit times. This will cause lucent light leakage, the luminance of the light leakage can be increased or decreased under the influence of micro-bendmg or micro-flexure . The refracting and scattering actions of the light leaks at a high luminance. The cable C having the strands S constructed m this manner as described above is fabricated by twisting the individual optical fiber strands S and thereby form a rotational light leakage. formed therein according to the present invention.
As perhaps best illustrated m FIGS. 8-21, the present invention also advantageously provides a plastic fiber optic cable C for increasing lateral transmission of light therefrom. The cable C preferably includes a plurality of plastic fiber optic strands S as described herein above (see FIGS. 8-15) .
Each strand S has a plurality of micro-bends B formed therein as described herein above m a relatively uniform pattern. The strands, as illustrated, extend generally parallel to each other and parallel to the axis of the extent of the one or more jackets JI, J2.
At least one jacket, e.g., inner cable jacket JI formed of Mylar, Teflon, or translucent plastic material, preferably is formed around the plurality of plastic fiber optic strands S. Alternatively, as illustrated in FIGS. 14-15, the individual strands S' can be twisted into sub-bundles prior to wrapping and/or encasing the sub-bundles. According to other embodiments of a fiber optic cable of the present invention, the fiber optic cable C ' can advantageously include an inner core I around whicn the plurality of strands S* ' is positioned (see FIGS. 16-21) The plurality of strands S1 *, for example, can each extend generally parallel to each other and generally parallel to the lengthwise extent of the core I or each of the plurality of strands S ' ' can be twisted about the inner core I. As perhaps best illustrated in FIGS. 18-19, the inner core I' also can include a fluid F such as water which can advantageously be used for fountains, pools, spas, or other water lighting applications. The fluid F, for example, can be positioned in a translucent or transparent tube T which m combination with the fluid defines the core of the cable C ' . Further, as illustrated m FIGS. 20-21, the fiber optic sub-bundles can advantageously be nested m a plurality, e.g., two or more, tiers of sub-bundles about the inner core I so that light can also readily be emitted from regions R between adjacent bundles. The inner sub-bundles can also advantageously be formed of smaller diameter individual fiber optic strands S' ' and can have a fewer number of strands S'' within the sub-bundles for more efficient packing within a jacket JI ' ' and for more efficient lateral light emission qualities.
FIG. 22 illustrates yet another embodiment of a fiber optic cable C" m the form of a relatively flat strip having a plurality of individual fiber optic strands S which each include a plurality of micro-bends
B formed therein according to the present invention.
This embodiment also preferably includes a translucent outer jacket J'" which readily allows laterally emitted light to emit therefrom. As will be understood by those skilled m the art, this arrangement also illustrates the individual strands S being positioned in a side-by-side, e.g., preferably abuttingly contacting, relation so that light can be emitted from both sides of the relatively flat outer jacket J'" .
As illustrated m FIGS. 1-21, methods of forming a fiber optic cable C are also provided according to the present invention. A method preferably includes the steps of forming a plurality of micro-bends B in each of a plurality of fiber optic strands S, positioning each of the plurality of strands
S closely adjacent at least one other of the plurality of strands S, and forming a jacket JI around the plurality of micro-bent strands S. The plurality of micro-bends B preferably are formed in a generally uniform pattern in each of the plurality of fiber optic strands S.
Another method of forming a laterally emitting fiber optic cable C having enhanced and uniform light emitting capabilities preferably includes imparting a generally continuous twist m each of a plurality of plastic fiber optic strands S moving along a predetermined path of travel so as to form a generally uniform pattern of micro-bends B in each of the plurality of strands S and bundling the plurality of micro-bent strands S so as to define a laterally emitting fiber optic cable C.
An additional method of forming a laterally emitting fiber optic cable C preferably includes supplying a plurality of plastic fiber optic strands S in spaced-apart relation, forming a plurality of micro- bends B in each of the plurality of plastic fiber optic strands m a generally uniform pattern, guiding each of the plurality of spaced-apart and micro-bent strands S into an abutting contact relation, and positioning a jacket JI of material around the plurality of strands
S.
Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.

Claims

THAT WHICH IS CLAIMED:
1. An apparatus for forming a fiber optic cable having a plurality of micro-bends m a relatively uniform pattern each of a plurality of plastic fiber optic stranαs tnereof to thereby increase the amount of light laterally and uniformly transmitted from the fiber optic cable, the apparatus comprising: a supply having a plurality of plastic fiber optic strands; micro-bend forming means positioned downstream from said supply and positioned to individually receive each of the plurality of plastic fiber optic strands m a spaced apart relation for forming a plurality of micro-bends m a relatively uniform pattern m each of the plurality of strands; strand guiding means positioned downstream from said micro-bend forming means and positioned to receive each of the plurality of micro-bend strands for guiding the plurality of spaced-apart, micro-bent strands into an abuttingly contacting relation; and wrapping means positioned downstream from said strand guiding means for wrapping a jacket of material around the plurality of abuttingly contacting strands so as to form a cable having a plurality of individually micro-bent fiber optic strands.
2. An apparatus as defined Claim 1, wherein said jacket comprises an inner cable jacket, and wherein the apparatus further comprises encasing means positioned downstream from said wrapping means for encasing said inner cable jacket with an outer cable acket .
3. An apparatus as defined in Claim 2, further comprising cable pulling means positioned downstream from said encasing means for pulling the encased cable of the plurality of micro-bent fiber optic strands from said supply and through said micro- bend forming means, said guiding means, said wrapping means, and said encasing means.
4. An apparatus as defined m Claim 3, further comprising cable collecting means positioned downstream from said cable pulling means for collecting the cable having the plurality of micro-bent fiber optic strands.
5. An apparatus as defined m Claim 1, wherein the material of said wrapping means includes at least one of either Mylar or Teflon, and wherein the material is overlappmgly wrapped around the plurality of micro-bent strands.
6. An apparatus as defined m Claim 1, wherein said micro-bend forming means includes a housing having a plurality of spaced-apart openings formed therein to position an individual fiber optic strand m each of the plurality of openings and twisting means positioned to abuttingly contact each of the plurality of strands when positioned m the plurality of openings for imparting generally continuous twists each of the plurality of strands to thereby form the plurality of micro-bends therein in a relatively uniform pattern as the plurality of fiber optic strands travel downsteam.
7. An apparatus as defined m Claim 6, wherein said twisting means includes a motor, a shaft connected to the motor for being rotatmgly driven by said motor, and a fiber optic interface member connected to said shaft for abuttingly interfacing with each of the plurality of strands.
8. An apparatus as defined m Claim 7, wherein said interface member includes an interface ring formed of an elastomeric material .
9. An apparatus as defined m Claim 4, further comprising drive controlling means connected at least to said micro-bend forming means, said pulling means, and said collecting means for controlling the drive of the same.
10. An apparatus as defined m Claim 9, wherein said drive controlling means includes synchronizing means for synchronizing the drive of said micro-bend forming means, said pulling means, and said collecting means.
11. An apparatus for forming a fiber optic cable having a plurality of micro-bends m a relatively uniform pattern in each of a plurality of plastic fiber optic strands thereof to thereby increase the amount of light laterally and uniformly transmitted from the fiber optic cable, the apparatus comprising: a supply having a plurality of plastic fiber optic strands; a micro-bend former positioned downstream from said supply and positioned to individually receive each of the plurality of plastic fiber optic strands m a spaced apart relation for forming a plurality of micro-bends m a relatively uniform pattern m each of the plurality of strands; a strand guide positioned downstream from said micro-bend former and positioned to receive each of the plurality of micro-bend strands for guiding the plurality of spaced-apart, micro-bent strands into an abuttingly contacting relation; and a wrapper positioned downstream from said strand guide for wrapping a jacket of material around the plurality of abuttingly contacting strands so as to form a cable having a plurality of individually micro- bent fiber optic strands.
12. An apparatus as defined m Claim 11, wherein said jacket comprises an inner cable jacket, and wherein the apparatus further comprises an encaser positioned downstream from said wrapper for encasing said inner cable jacket with an outer cable jacket.
13. An apparatus as defined m Claim 12, furtner comprising a cable puller positioned downstream from said encaser for pulling the encased cable of the plurality of micro-bent fiber optic strands from said supply and through said micro-bend former, said strand guide, said wrapper, and said encaser.
14. An apparatus as defined in Claim 13, further comprising a spool collector positioned downstream from said cable puller for collecting the cable having the plurality of micro-bent fiber optic strands .
15. An apparatus as defined m Claim 14, wherein the material of said wrapper includes at least one of either Mylar or Teflon, and wherein the material is overlappmgly wrapped around the plurality of micro- bent strands .
16. An apparatus as defined m Claim 15, wherein said micro-bend former includes a housing having a plurality of spaced-apart openings formed therein to position a single fiber optic strand in each of the plurality of openings and twisting means positioned to abuttingly contact each of the plurality of strands when positioned m the plurality of openings for imparting generally continuous twists m each of the plurality of strands to thereby form the plurality of micro-bends therein m a relatively uniform pattern as the plurality of fiber optic strands travel downstream.
17. An apparatus as defined m Claim 16, wherein said twisting means includes a motor, a shaft connected to the motor for being rotatmgly driven by said motor, and a fiber optic interface member connected to said shaft for abuttingly interfacing with each of the plurality of strands.
18. An apparatus as defined m Claim 17, wherein said interface member includes an interface ring formed of an elastomeric material .
19. An apparatus as defined m Claim 18, further comprising a drive controller connected at least to said micro-bend former, said cable puller, and said spool collector for controlling the drive of the same .
20. An apparatus as defined m Claim 19, wherein said drive controller includes synchronizing means for synchronizing the drive of said micro-bend former, said cable puller, and said spool collector.
21. A plastic fiber optic cable for increasing lateral transmission of light therefrom, the cable comprising: a plurality of plastic fiber optic strands, each strand having a plurality of micro-bends formed therein m a relatively uniform pattern; and at least one jacket formed around the plurality of plastic fiber optic strands.
22. A cable as defined Claim 21, wherein the at least one jacket includes an inner jacket formed of at least one of either Mylar or Teflon and an outer jacket formed of a translucent plastic material.
23. A cable as defined Claim 21, further comprising an inner core around which the plurality of strands is positioned.
24. A cable as defined in Claim 21, wherein the plurality of strands each extend generally parallel to each other.
25. A cable as defined Claim 23, wherein the plurality of strands each extends generally parallel to the core.
26. A cable as defined Claim 21, wherein each of the plurality of strands is twisted about the core .
27. A cable as defined m Claim 21, wherein the plurality of strands includes at least one sub-set of the plurality of strands having a multiplicity of micro-bent strands twisted about each other.
28. A cable as defined m Claim 23, wherein the plurality of strands includes a least one sub-set of the plurality of strands having a multiplicity of micro-bent strands twisted about each other and about
29. A cable as defined Claim 23, wherein said core is formed of a translucent material.
30. A cable as defined Claim 29, wherein said core includes a translucent tube.
31. A cable as defined Claim 30, wherein said core includes a fluid positioned said translucent tube.
32. A plastic fiber optic cable for increasing lateral transmission of light therefrom, the cable comprising: a core; a plurality of plastic fiber optic strands positioned around said core, each strand having a plurality of micro-bends formed therein m a relatively uniform pattern; and at least one jacket formed around the plurality of plastic fiber optic strands.
33. A cable as defined m Claim 32, wherein the at least one jacket includes an inner jacket formed of at least one of either Mylar or Teflon and an outer jacket formed of a translucent plastic material.
34. A cable as defined m Claim 32, further comprising the core includes a fluid around which the plurality of strands is positioned.
35. A cable as defined m Claim 32, wherein the plurality of strands each extend generally parallel to each other.
36. A cable as defined m Claim 34, wherein the plurality of strands each extends generally parallel to the core.
37. A cable as defined m Claim 32, wherein each of the plurality of strands is twisted about the core .
38. A cable as defined m Claim 32, wherein the plurality of strands includes at least one sub-set of the plurality of strands having a multiplicity of micro-bent strands twisted about each other.
39. A cable as defined m Claim 34, wherein the plurality of strands includes a least one sub-set of the plurality of strands having a multiplicity of micro-bent strands twisted about each other and about
40. A cable as defined m Claim 34, wherein said core is formed of a translucent material .
41. A cable as defined m Claim 40, wherein said core includes a translucent tube.
42. A cable as defined m Claim 41, wherein said core includes a fluid positioned in said translucent tube.
43. A method of forming a fiber optic cable, the method comprising the steps of: forming a plurality of micro-bends m each of a plurality of plastic fiber optic strands; positioning each of the plurality of strands closely adjacent at least one other of the plurality of strands; and forming a jacket around the plurality of micro-bent strands.
44. A method as defined m Claim 43, wherein the plurality of micro-bends are formed m a generally uniform pattern m each of the plurality of plastic fiber optic strands.
45. A method of forming a laterally light emitting fiber optic cable having enhanced and uniform light emitting capabilities, the method comprising: imparting a generally continuous twist m each of a plurality of plastic fiber optic strands moving along a predetermined path of travel so as to form a generally uniform pattern of micro-bends in each of the plurality of strands; and bundling the plurality of micro-bent strands so as to define a laterally emitting fiber optic cable.
46. A method of forming a laterally light emitting fiber optic cable, comprising: supplying a plurality of plastic fiber optic strands m spaced-apart relation; forming a plurality of micro-bends m each of the plurality of plastic fiber optic strands in a generally uniform pattern; guiding each of the plurality of spaced-apart and micro-bent strands into an abutting contact relation; and positioning a jacket of material around the plurality of strands.
PCT/US2000/013681 1999-05-19 2000-05-19 Apparatus forming laterally light emitting cable WO2000070370A2 (en)

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US60/134,907 1999-05-19

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WO2000070370A3 (en) 2002-01-10

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