Composite fibre optic

Abstract

The product has an elongate fibre optic member 101, an elongate sheath 103 for the fibre optic member comprising an internal longitudinal void; and a first base material 105. The fibre optic member pa

Description

The present invention relates to products comprising a fibre optic supported by textile structure. Preferably the textile structure surrounds the fibre optic member. The invention also relates to methods of production of such a composite fibre optic product. In addition, the Invention relates to the use of the product. In particular the invention also relates to the use and / or installation of products in vehicles, preferably automobiles, buildings, and / or furniture. In addition, the invention also considers use of methods, products, and apparatuses of the invention in manufacture and maintenance of vehicles, buildings, and / or furniture. In particular, the products of the invention are suitable for use in automotive interiors such as headliners, i.e. the interior of the roof of an automobile cabin. Products of the invention are also suitable for use in other areas of automotive interiors. A central function of an automobile is the comfort and convenience it provides the user in being conveyed from place to place. Thus the cabin of a vehicle, especially an automobile, provides both the interface between the occupants and the user of the driving controls and the environment in which the controls and be utilised safely and all of the occupants conveyed in comfort. Accordingly, the aesthetic appeal of the cabin contributes significantly to the comfort and wellbeing of the occupants. Decorations and adornments such as sculptural features or flourishes are well known. However, decoration can also be achieved by the use of lighting effects, which also contribute to the overall appearance and design appeal of the vehicle cabin. Furthermore, lights, by dint of placement and controllability lend themselves well to functional characteristics, such as signalling vehicle status or other alerts and / or updates as to the state of the vehicle and the wider world. Car headliners (i.e. the lining of the roof panel of an automobile) have previously been embedded with fibre optic members whereby the output of the fibre points through the surface of the headliner into the cabin. In this way a “starfield” or other lighting effect made up of a multiplicity of points of light projected from inside or from the surface headliner has been achieved. This is described in UK patent no. 2563250. Thus previous uses of fibre optics in the car headliner to produce a star field or similar effect have necessarily been installed with the terminus / emission point of the fibre optic member being set in line or flush with the material or structure of the headliner. Fibre optic members are typically brittle and therefore such members are not used typically as structural elements of products. This is particularly the case in technological areas such as automobile design and manufacture where fragile or brittle items of equipment often cannot meet the stringent regularity requirements for inclusion in a vehicle, particularly an automobile. Consequently use of fibre optics in the context of a piece of furniture or other element of the automotive interior has been limited to the surface of the product in which the fibre optics are installed and thus protected. An object of the invention is to provide a product comprising a fibre optic member or members wherein the emission point of the fibre optic is removed or distant from the structure in which it is installed. A further object of the invention is to provide fabric or textile effects whereby area or pieces of fabric are arranged in three dimensions and whereby the structure and arrangement of the fabric constructions so formed are both aesthetically pleasing and acceptable for use in an automobile. The acceptability for use in an automobile is based on engineering and regularity considerations. An additional object of the invention is to provide lighting effects on the context of the three dimensional (3D) fabric structure. It is a further object of the invention that the methods and products of the invention should be capable of adaptation in order to cater to the aesthetic demands of multiple different designers and styles of installation and artistic creation. A particular design problem addressed by the present invention is to allow the construction of a vehicle headliner that is not constrained in form to being a lining or shell within the structure of the vehicle roof. Within a vehicle cabin headroom is dictated by the position of the headliner and protrusions or other adornments on the headliner must be carefully considered for safety and comfort reasons. However, adornment of the headliner with three dimensional decorations or other additions is desired by some designers and automobile owners. However, installation of objects on the headliner roof can present safety and access difficulties accordingly it is an object of the invention to provide a means of allowing craftsman and / or designers to adapt the interior space of a vehicle cabin and in particular a headliner to include textile constructs that are three dimensional in form such that they may project into the vehicle cabin, but such constructs are sufficiently resilient for use in a vehicle cabin but are sufficiently soft to not contravene vehicle safety regulations. The invention provides a product comprising: an elongate fibre optic member; an elongate sheath for the fibre optic member comprising an internal longitudinal void; and a first base portion, wherein the fibre optic member passes through all or a portion of the longitudinal void, and wherein at least one end of the elongate sheath is attached to the base portion. Preferably the product comprises a multiplicity of products of the invention. The base portion may be composed or comprise a wide variety of materials. The base portion may comprise textiles and / or other composite materials. The base portion in this context is a preferably the base portion is a car headliner and most preferably the elongate sheath is attached to the outer layer of the car headliner. Typically, the outer layer of the car headliner is a fabric or other textile material. The sheath may be made out of or may comprise a textile, fabric, or cloth material. The material of the sheath may be woven or nonwoven. Preferably the material of the sheath is woven, knitted, or crocheted. Most preferably the material of the sheath is knitted or crocheted. The advantage of knitting, crocheting or otherwise looping the filament of the material to form the material is that the material may intrinsically have a degree of extensibility or stretch. This characteristic contribute to the resilience of the sheath and thus the composite material in which it is comprised. The material of the sheath may comprise synthetic or natural fibres. The textile may be made of synthetic fibres. The textile may be made of natural fibres. The natural fibres may include wool and / or cotton. The synthetic fibres may be nylon, rayon, polyester, or acrylic materials. The present invention has the advantage that it is suitable for use with a wide range of textile materials. Thus the fibre optic member is installed within the internal longitudinal void of the sheath and extends within the longitudinal void. The fibre optic may be shorter or longer than the sheath that surrounds it. Accordingly, fibre optic member may protrude beyond one or both ends of the sheath. The advantage of the combination of the sheath material with the fibre optic material is that a composite material is formed. The composite material has the synergistic combination of characteristics yielded by the sheath protecting the fibre optic from bending so far that it becomes damaged but benefiting from the resilience of the otherwise brittle fibre optic material to provide the structural characteristics of the composite material. The longitudinal void may be centrally located within the sheath. The diameter of the longitudinal void may be greater than the diameter of the fibre optic member. Accordingly, a space may be provided that substantially partially or completely surrounds the fibre optic member. In this way, portions of the fibre optic member may be in contact with the internal wall of the sheath and parts of fibre optic member may be clear of the internal wall of the sheath. This offers the advantage of the fibre optic member being able to easily move, especially longitudinally, within the sheath. Accordingly, the composite material comprised of the sheath and the fibre optic material has the particular characteristics of being able to bend while reducing the friction between the fibre optic member and the sheath. Thus the spacing between the fibre optic member and the surrounding sheath yields particular characteristics of movement and resilience that are advantageous in the context of producing vehicle furniture and upholstery. These characteristics may also be advantageous in the context of regulatory and safety requirements. In the context of the present invention, a fibre optic member (fiber optic member) or optical fibre (optical fiber) is a cylindrical dielectric waveguide (nonconducting waveguide) that transmits light along its axis through the process of total internal reflection. The fibre optic member may be linked to a light source. Typically optical fibres include a core surrounded by a transparent cladding material with a lower index of refraction. Light is confined to the core of the optical fibre by the phenomenon of total internal reflection which causes the fibre to act as a waveguide for the light carried therein. Typically, a fibre optic member will have a proximal end, from which light is emitted, and a distal end, into which light is projected and thus conveyed by the fibre optic member. Preferably light is projected into the fibre optic member from a light source, however ambient light may also be conveyed through a fibre optic member. Use of fibre optic members in this way has the advantage of allowing designs to be rendered by multiple light outputs. Advantageously, the output of the light transmitted by the fibre optic members allows alternative colours to be displayed and the incorporation of lighting effects such as flashing, pseudomovement (e.g. “shooting-star” effects). Preferably the fibre optic members are single optical fibres. However, the use of bundles of optical fibres to provide an optical fibre is also envisaged. The use of multiple optical fibres in a single sheath yields the benefit of greater stiffness and / or resilience while still conveniently using the same stock of fibre optic material. In the present context light is defined as electromagnetic radiation of any wavelength that is visible to the human eye. Electromagnetic radiation of the wavelengths of visible light is particularly well suited to transmission through optical fibres. However, fibre optical transmission of infra-red (IR) and ultraviolet (UV) wavelengths may be transmissible by the optical fibres of the invention and therefore these wavelengths fall within the definition of the term “light” in the context of the present invention. A light source producing light transmitted by the fibre optic members described herein preferably comprises or is composed of a light emitting diode (LED) or array of LEDs. The first base material may be flat or contoured. This yields the advantage that the base material can be shaped to fit and operate in concert with other products such as furniture or equipment, particularly the furniture or equipment installed in automobiles. The first base material may comprise an aperture and the fibre optic member travels through that aperture. . In the present context the term aperture encompasses a hole, passageway, or portal through a material. Alternatively or in addition, the second base material may comprise an aperture and the fibre optic member travels through that aperture. The end of the sheath located distally from the first base material may be attached to a second section of material. Accordingly, a second section of material may be attached to the distal end of the sheaths of a multiplicity of products of the invention. Thus, individual second sections of material can be mounted on each product of the invention or a single larger second section of material can extend over multiple products of the invention. The multiplicity of elongate sheaths and fibre optic members running therethrough may be of a multiplicity of different lengths. This yields the advantage that the second section or sections of material can be arranged and / or mounted on the products of the invention such that a contoured or otherwise shaped surface can be rendered by positioning and / or installation of products of the invention. Alternatively, a planar or geometric form can also be produced. Thus there is a further advantage that the shape of the interior of an automobile or other volume can be modified by installation of products of the present invention. Furthermore, the product of the present invention may be removed from an automobile in order that the form of the automobile can be updated or refurbished. The first section and / or second section of material may comprise a textile, fabric, or cloth material. The textile may be woven or nonwoven. The textile may comprise synthetic or natural fibres. The textile may be made of synthetic fibres. The textile may be made of natural fibres. The natural fibres may include wool and / or cotton. The synthetic fibres may be nylon, rayon, polyester, or acrylic materials. The present invention has the advantage that it is suitable for use with a wide range of textile materials. The first base material may be comprised in an automobile interior, preferably an automobile headliner. In the present context an automobile headliner is the material used for lining the roof of an automobile. Preferably the exterior material of an automobile headliner is a textile, cloth, or other fabric. A terminus of a fibre optic element may be bonded to the second section of material such that, preferably, the light emitted by the fibre optic element is projected through or from the front surface of the second section of material. The terminus of the fibre optic element may be fixed in position using a bonding material. The bonding material may be a clear or transparent epoxy resin, preferably Plexus MA300. The terminus of the fibre optic may be bonded to the rear of the second section of material. A member, preferably an annular member, most preferably a bead, may fixed or threaded on the distal end of the fibre optic member. Preferably all or a portion of the bead is transparent or translucent. The bead may be tinted or otherwise coloured. Threading such an annular member or a fixing on the end of the fibre optic yields the benefit of additional lighting effects. In particular, the light from the fibre optic member can be spread an / or otherwise tinted by passage of light through the member. The end of the fibre optic member distal to the first base material may be flattened. This can be conveniently achieved through the use of a soldering iron or other heated flat object to melt and spread the terminus of the fibre optic member will stop this is especially the case when the fibre optic member is made of plastics material. Flattening the end of the fibre optic member in this way when an annular member, such as a bead, has been threaded on the fibre optic member yields a convenient and means of securing the annular member in position at or near the terminus of the fibre optic member. A product according to any preceding claim, wherein the first base material and / or the second section of material are attached to the sheath by one or more loops of thread. Preferably the means of attachment is by sewing, i.e. passing an elongate filament (i.e. a thread) through both the first section and the sheath. Alternatively, or in addition an elongate filament (i.e. a thread) may be passed through both the second section and the sheath. A further method of attachment that is illustrated in the figures is for an elongate filament to pass from the rear of the first base material and through the sheath to emerge on the far side of the second section of material before looping back again through the sheath to return to the rear side of the first base material. In this way the sheath is secured in position between aperture is in the first and second sections of material with a single thread. This has the advantage of simplifying the securing process and allowing simplified uninstallation and movement of products of the invention as only a single filament must be cut and reinstated. The invention also provides method of manufacturing a product of the invention as described herein, wherein the method comprises the steps of: installing a sheath around a fibre optic member; and attaching at least one end of the sheath to a first base material. The method may additionally comprise the step of passing the fibre optic member through an aperture in the first base material. The method may additionally comprise the step of wherein the distal end of sheath located distally from the first base material is attached to a second section of material. The method may additionally comprise the step of passing the fibre optic member through an aperture in the second section of material. Thus the invention also provides a product obtainable according to the methods described herein. The invention also provides products as described herein that are suitable for use in a vehicle, furniture, or part of a building. Preferably the product is for use in a vehicle, most preferably wherein the vehicle is an automobile or car. Advantageously, products of the invention and products produced according to methods of the invention have characteristics of sufficient strength and structural stability to comply with the engineering requirements for installation in vehicles, including automobiles. The vehicle may be an automobile, train, boat, or aeroplane (airplane). Products of the invention may be for use in the interior or cabin of a vehicle. Preferably products of the invention are, or are comprised in, the dashboard, fascia, instrument panels, and or door panels of the vehicle. Advantageously, products of the invention and products produced according to methods of the invention can be coloured or patterned in order to match and accommodate other elements within a vehicle cabin or interior. Installation of the product in a vehicle may by mounting the product on a subassembly of a vehicle. Preferably the subassembly is a carrier structure. The subassembly may be a carrier for inclusion as a component or subassembly in a vehicle cabin, preferably the headliner of the vehicle. Accordingly, the invention also provides a vehicle comprising a product of the invention. The vehicle may be an automobile, train, aeroplane, or boat. Preferably the vehicle is an automobile. Examples and Drawings The invention will now be described with reference to the following drawings and examples in which: Fig. 1 shows a photograph of a composite fibre optic member wherein the fibre optic 101 transits the central void in a braided nylon sheath 103 that affixed to a cowl 105. The terminus of the fibre optic member protrudes through the base of the cowl and is fixed to the interior base thereof (not shown). Fig. 2 shows a multiplicity of the elements shown in figure 1 installed on a multi-layer supporting structure 205 that could be installed as part of a vehicle headliner. The fibre optic elements from each of the sub elements 110 are gathered into bundles of fibre optic elements 203. Fig. 3 shows a close-up photograph of the installation of the elements such as those shown in Figs. 1 and 2 with the braided section protecting the fibre optic element that would otherwise be exposed between the substrate layer and the cowl structure. Fig. 4 shows a photograph of a view from an upper perspective of the installed elements shown in Fig 3 wherein the fibre optic elements at the centre of each of the cowl elements is lit by a fibre optic light. Fig. 5 is a diagram showing installation of the elements of Figure 1 illustrating sewing threads 505 being used to secure the textile structure in place on the substrate of the roof liner. Fig.6 shows a semi exploded diagram of the elements shown in Fig. 1 wherein the central fibre optic element 101 is shown with the other elements installed thereon partially unthreaded to show gaps between each of the elements of the braided nylon textiles section (sheath) 105 the cowl element 107 a transparent bead 109 and the flattened terminus of the fibre optic element 111. Figure. 7 shows an element of Fig.1 installed in an automobile headliner lining structure as shown in Figure. 5 with the fibre optic member transiting the headliner layer from the element. Fig. 8 shows an alternative method of installation of the elements of Fig.1 wherein not only the fibre optic member transits the structure of the roof headliner but also the braided sheath surrounding the fibre optic or also transits the roof headliner. Such an arrangement has the advantage of offering additional strength and support to the fibre optic as it bends in the limited space beyond the roof headliner and the outer shell of the roof. Figs 9a and 9b show a method of securing the cowl element to the braided nylon sheath element of the element shown in Figure 1 wherein the braided longitudinally and travels through the cowl element to the transit back through the cowl element through a separate hole and thereby back longitudinally in the other direction through the braided nylon sheet. Accordingly, and as shown in Figure 9b the element can then be installed on a headliner and the threads made to transit the headliner and be drawn tight in order to secure the element thereto. Example 1 A car headliner comprising a multiplicity of 3D structures is created from a number of separate elements. Each element comprises a conical cowl made from glove leather that is substantially circular and has a radial slice or sector removed and then the edges rejoined or slipped pass one another in order to provide a shallow cone. A fibre optic element is threaded through the tip of the cone and a transparent bead threaded on the fibre optic in the dish of the cone. The end of the fibre optic is then flattened using a heating element such as a soldering iron in order to secure the bead in position once the fibre optic element is pulled tight and the flattened section abuts the bead. On the other side of the cowl a braided nylon sheath is threaded onto the fibre optic member. The length of the sheath can be varied in order to cause the cowl to be located at varying distances from the headliner. In installing the element in the headliner the fibre optic member transits the headliner and is gathered into a bundle with the fibre optic members from other elements of the headliner. The fibre optic members are attached to a light source in order to illuminate each of the elements installed in the headliner. Thus a headliner is created with a multiplicity of elements of different lengths and heights arrayed in a defined pattern across the headliner. Moreover, the structural resilience and capacity of each of these elements means that injury will not be caused by impact of an occupant with the decorative elements, but a 3D effect is provided by the installation of elements over the headliner. Example 2 In a further example a sheet or other larger section of textile material may be arranged and installed to form a three-dimensional structure by way of draping, whorls, waves, or other three-dimensional form wherein the structure and three-dimensional motifs of the arranged fabric are supported and enabled by installation of fibre optic composite members secured to the headliner and to the “B” of the side of the fabric. In this way a three-dimensional fabric headliner can be provided with effectively any three-dimensional contour. Furthermore, the fibre optics can be installed to emit light at the level of the installed fabric no matter the shape that the fabric is made to take up. The three-dimensional form of the fabric can be dictated by the various lengths of composite fibre optic member (wherein the composite fibre optic member comprises a fibre optic member surrounded by a braided nylon sheath). Thus the form of the headliner thus anaesthetically pleasing draped effect or other fabric effect can be installed as a fabric sculpture or installation on the ceiling of a motor vehicle, i.e. an adaptation of the headliner for this purpose. Thus the invention is particularly well suited for producing components for inclusion in vehicles, preferably automobiles, that meet and / or can be adapted to meet specific engineering, design, and / or aesthetic parameters. In particular the invention yields improved methods of producing and installing such products and the intermediate products useful in their production.

Claims

1. A product comprising:an elongate fibre optic member;an elongate sheath for the fibre optic member comprising an internal longitudinal void; anda first base material,wherein the fibre optic member passes through all or a portion of the longitudinal void,and wherein at least one end of the elongate sheath is attached to the material.

2. A product according to claim 1, wherein the fibre optic protrudes beyond one or both ends of the sheath3. A product according to claim 1 or claim 2, wherein the longitudinal void is centrally located within the sheath4. A product according to any preceding claim, wherein the first base material may be flat or contoured.

5. A product according to any preceding claim, wherein the first base material comprises an aperture and the fibre optic member travels through the aperture.

6. A product according to any preceding claim, wherein the first base material comprises a textile or fabric material.

7. A product according to any preceding claim, wherein the first base material is comprised in an automobile interior, preferably an automobile headliner.

8. A product according to any preceding claim, wherein the end of the sheath located distally from the first base material is attached to a second section of material.

9. A product according to any preceding claim, wherein the second section of material comprises an aperture and the fibre optic member travels through the aperture.

10. A product according to claim 8 or claim 9, wherein the second section of material is attached to the distal end of the sheaths of a multiplicity of products according to claim 111. A product according to claim 10, wherein the multiplicity of elongate sheaths and fibre optic members running therethrough are of a multiplicity of different lengths.

12. A product according to any preceding claim, wherein the second section of material may be flat or contoured.

13. A product according to any preceding claim, wherein the fibre optic member is linked to a light source.

14. A product according to any preceding claim, wherein a member, preferably an annular member, most preferably a bead, is threaded on the distal end of the fibre optic member.

15. A product according to any preceding claim, wherein the end of the fibre optic member distal to the first base material is flattened.

16. A product according to any preceding claim, wherein the second section of material is a textile or fabric material.

17. A product according to any preceding claim, wherein the second section of material is contoured18. A product according to any preceding claim, wherein the first base material and / or the second section of material are attached to the sheath by one or more loops of thread.

19. A method of manufacturing a product of any of claims 1 to 18, comprising the steps of:Installing a sheath around a fibre optic member; andattaching at least one end of the sheath to a first base material.

20. A method of manufacturing a product according to claim 19, additionally comprising the step of passing the fibre optic member through an aperture in the first base material21. A method of manufacturing a product of claim 19 or claim 20, additionally comprising the step of wherein the distal end of sheath located distally from the first base material is attached to a second section of material.

22. A method of manufacturing a product of any of claims 19 to 21, additionally 5 comprising the step of passing the fibre optic member through an aperture in the second section of material.

23. A product according to any of claims 1 to 18, or produced by a method according to any of claims 19 to 22, wherein the product is for use in a vehicle, furniture, or part of a building.10 24. A product according to claim 23, wherein the vehicle is an automobile, train, boat, or aeroplane, preferably the vehicle is an automobile.

25. A vehicle comprising a product according to any of claims 1 to 15, or comprising a product produced by a method according to any of claims 19 to 22.15

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