Fiber Optic Substrate Marring for Illumination Control
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Solution Overview
Problem
There is a need for effective methods and systems to create fiber optic illuminators with desired illumination patterns, as existing methods like stamping, machining, molding, and sandblasting are limited in variability and cost-effectiveness.
Innovation Solution
The system employs various methods such as using a roller with an abrasive surface on a tapered support, an abrasive sheet, rotating blades, multiple rollers with different abrasives, an oscillating hammer, a water jet nozzle, and a centrifugally driven wheel with abrasive flaps to produce progressive and varied marring patterns on fiber optic substrates, allowing for customizable light emission along the length of the substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional methods like stamping, machining, molding, or sandblasting are used to mar fiber optic substrates, then a desired marring pattern can be created, but the process is limited in variability and cost-effectiveness
Solution Approach 1:
The patent applies parameter changes by varying the abrasiveness, pressure, and speed of the rolling element to create different marring patterns. By changing these parameters, the system can produce various light emission intensities and patterns without requiring different manufacturing processes, thus improving adaptability while maintaining cost-effectiveness
Solution Approach 2:
The patent uses a dynamic rolling element system where the rolling element can be moved along the fiber optic substrate with variable pressure and speed. This dynamic approach allows for continuous variation in marring patterns, enabling customization of light emission characteristics without complex tooling changes, thereby resolving the contradiction between versatility and manufacturing ease
2Illumination intensity
If increased surface marring is applied to increase light emission intensity, then more light is emitted from the substrate, but the marring aggressiveness must be precisely controlled to achieve uniform illumination
Solution Approach 1:
The patent incorporates feedback control where the illumination output is monitored and used to adjust the rolling parameters (pressure, speed, abrasiveness) in real-time. This ensures uniform light emission across the substrate by continuously compensating for variations in marring aggressiveness, resolving the contradiction between achieving high illumination intensity and maintaining manufacturing precision
Solution Approach 2:
The system dynamically adjusts multiple parameters including rolling pressure, surface abrasiveness, and rolling speed to achieve the desired light emission intensity while maintaining uniformity. By coordinating changes in these parameters, the system can increase illumination intensity without sacrificing marring uniformity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
These methods enable the creation of relatively inexpensive fiber optic illuminators with controlled light emission patterns, providing uniformity and flexibility in light intensity by varying the marring density and aggressiveness along the substrate length.
Implementation Method 1
At least one of the roller and the support supports or has an abrasive or textured surface thereon to produce a progressively more aggressive marring pattern along the length of the substrate
Implementation Method 2
pressing a length of fiber optic substrate against a tapered surface on an elongate support while causing relative movement between the roller and support
Implementation Method 3
at least one wheel which when rotated, causes circumferentially spaced abrasive flaps on the wheel to move radially outward due to centrifugal force and strike a length of fiber optic substrate
Implementation Method 4
a nozzle that directs a water jet abrasive slurry at a length of fiber optic substrate on an elongate support during movement of the support lengthwise relative to the water jet abrasive slurry
Implementation Method 5
an oscillating hammer having an abrasive surface thereon that strikes a length of fiber optic substrate on an elongate support to produce a marring pattern on the substrate
Data Source
AI summary
Methods and systems for marring fiber optic substrates may include rollers with abrasive surfaces that press lengths of the substrates against elongated supports, which may be tapered, during relative lengthwise movement between the rollers and supports; abrasive sheets that are vibrated against the substrates; abrasive flap wheels that are rotated to cause flexible abrasive flaps on the wheels to strike the substrates; rotating blades that cut a transverse marring pattern in the substrates; hammers having abrasive surfaces that are oscillated to strike the substrates; and water jet abrasive slurries that are directed at the substrates.