U.S. patent application number 12/375767 was filed with the patent office on 2009-12-31 for sealed package and method of making.
This patent application is currently assigned to ZYNON TECHNOLOGIES, LLC. Invention is credited to Jay S. Tourigny.
Application Number | 20090321283 12/375767 |
Document ID | / |
Family ID | 39082725 |
Filed Date | 2009-12-31 |
United States Patent
Application |
20090321283 |
Kind Code |
A1 |
Tourigny; Jay S. |
December 31, 2009 |
SEALED PACKAGE AND METHOD OF MAKING
Abstract
A sealed package (10) encloses a pad (14) which has an
impervious backing layer which may optionally be the base layer
(10b) of the package (10). At least the interior of the package
(10) and the sealed pad (14) are made of materials which are
substantially free of micro-contaminants. The package is openable
by separating the cover layer (1 Oa) from the base layer (10b) and
thereby breaking the seal (12). The pad (14) may be dry or it may
be impregnated with any suitable treatment substance, such as a
solvent, which facilitates cleaning and which dissipates
electrostatic charges. When the sealed pad (14) is dry, a suitable
liquid or gel treatment substance, such as a solvent, may be
applied to the pad or to a portion of it. A retainer hole (20) may
be provided in the package (10) in the extra-peripheral area (11)
outside the seal (12) to hold an optic fiber connector with which
the package (10) may be sold as a unit.
Inventors: |
Tourigny; Jay S.;
(Collinsville, CT) |
Correspondence
Address: |
CANTOR COLBURN, LLP
20 Church Street, 22nd Floor
Hartford
CT
06103
US
|
Assignee: |
ZYNON TECHNOLOGIES, LLC
New Britain
CT
|
Family ID: |
39082725 |
Appl. No.: |
12/375767 |
Filed: |
August 15, 2007 |
PCT Filed: |
August 15, 2007 |
PCT NO: |
PCT/US2007/018123 |
371 Date: |
January 30, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60837721 |
Aug 15, 2006 |
|
|
|
Current U.S.
Class: |
206/205 ;
206/210; 53/461 |
Current CPC
Class: |
G02B 6/3807 20130101;
B29C 66/1122 20130101; B29C 66/71 20130101; B08B 1/00 20130101;
B29C 65/48 20130101; B29C 66/71 20130101; B65D 2575/365 20130101;
B29C 65/08 20130101; B29C 66/24249 20130101; B29C 66/43 20130101;
B29C 65/3656 20130101; G02B 6/3866 20130101; B29C 65/368 20130101;
B65D 75/366 20130101; B29K 2023/0633 20130101; B29C 66/71 20130101;
B08B 2240/02 20130101; B29L 2031/7406 20130101; B29C 66/72321
20130101; B29K 2067/00 20130101 |
Class at
Publication: |
206/205 ; 53/461;
206/210 |
International
Class: |
B65D 81/24 20060101
B65D081/24; B65B 9/02 20060101 B65B009/02 |
Claims
1. A sealed package comprising: an impervious base layer having a
pad-receiving surface on which is disposed a liquid-permeable pad;
an impervious cover layer having a pad-facing surface, the cover
layer being secured to the base layer by a rupturable seal, with
the pad-facing surface fully overlying the pad, the pad-facing
surface, the pad-receiving surface and the pad being free of
micro-contaminants, whereby the pad is hermetically sealed within
the package in an environment which is free of micro-contaminants,
and may be exposed for use by at least partly separating the cover
layer from the base layer.
2. The sealed package of claim 1 wherein the liquid-permeable pad
is affixed directly to the pad-receiving surface of the base
layer.
3. The sealed package of claim 1 wherein the pad is a dry pad and
the sealed package is free of liquid agents.
4. The sealed package of claim 1 wherein one or more suitable
liquid agents are impregnated in the pad within the sealed
package.
5. The sealed package of any one of claims 1, 2, 3 or 4 wherein the
pad has a periphery and the base layer and the pad are configured
so that the base layer extends beyond the entire periphery of the
pad to leave a continuous peripheral portion of the base layer
uncovered by the pad.
6. A sealed package comprising: an impervious base layer having a
pad-receiving surface on which a liquid-permeable pad having a
periphery is affixed, the pad being selected from the group
consisting of one or more of non-woven and washed woven materials,
the base layer and the pad being configured so that the base layer
extends beyond the entire periphery of the pad to leave a
continuous peripheral portion of the base layer uncovered by the
pad; an impervious cover layer having a pad-facing surface and
secured to the peripheral portion of the base layer by a
rupturable, peripheral seal, with the pad-facing surface fully
overlying the pad, the pad-facing surface, the pad-receiving
surface and the pad being free of micro-contaminants, whereby the
dry pad is hermetically sealed within the package in an environment
which is free of micro-contaminants, and may be exposed for use by
at least partly separating the cover layer from the base layer by
pulling the respective layers apart to rupture at least a portion
of the peripheral seal.
7. The sealed package of claim 6 wherein the pad is a dry pad and
the sealed package is free of liquid agents.
8. The sealed package of claim 1 or claim 6 wherein the rupturable
seal is a peripheral seal which encircles the pad and defines an
extra-peripheral area of the package lying outside the seal, with
at least a portion of the extra-peripheral area left unsealed so
that the base and cover layers are readily separable from each
other to expose at least part of the pad for use.
9. The sealed package of any one of claims 1, 2, 3, 4 or 6 wherein
the pad comprises a single layer of material and lies flat and
unfolded within the package.
10. The sealed package of claim 1 or claim 6 wherein the pad
comprises a 100% polyester fabric which is free of chemical
binders, salts, detergents, surfactants, glue, bleach, starch and
cellulose.
11. The sealed package of claim 10 wherein the pad comprises a
fabric having a basis weight of from about 2.7 to 4 ounces per
square yard.
12. The sealed package of claim 10 wherein the pad is comprised of
a non-woven fabric.
13. The sealed package of claim 1 or claim 6 wherein both the base
layer and the cover layer comprise aluminum foil having adhered to
the entirety of their respective pad-receiving and pad-facing
surfaces a plastic film.
14. The sealed package of claim 1 or claim 6 wherein the rupturable
seal encloses and defines a sealed area of the package, and further
comprising a retention opening outside the sealed area, the
retention opening being configured to receive and retain therein a
length of optic fiber having a connector affixed to at least one
end thereof.
15. A method of making the sealed package of any one of claim 1,
claim 2, claim 3, claim 6 or claim 7 comprising: preparing an
impervious base layer having a pad-receiving surface which is free
of micro-contaminants; affixing to the pad-receiving surface a pad
which is free of micro-contaminants; preparing an impervious cover
layer having a pad-facing surface which is free of
micro-contaminants and securing the cover layer to the base layer
by a rupturable seal with the pad-facing surface fully overlying
the pad; whereby the pad is hermetically sealed within the package
in an environment which is free of micro-contaminants and may be
exposed for use by at least partly separating the cover layer from
the base layer.
16. The method of claim 15 wherein the steps of preparing the cover
layer and the base layer each includes securing one or more plastic
layers to an aluminum layer, one of the plastic layers comprising
the pad-receiving surface and another of the plastic layers
comprising the pad-facing surface, and the pad comprises a
non-woven polyester material.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is concerned with a wipe which is
useful for cleaning or otherwise treating various objects, in
particular, optic fiber ends, optic fiber connectors and the like.
More specifically, the present invention concerns a wipe having an
impervious backing layer and which is contained in a sealed,
impervious package, and is otherwise configured to eliminate or at
least drastically reduce contamination by trace oils and/or
micron-size contaminates including dust motes and the like.
[0003] 2. Related Art
[0004] Sealed foil packages containing gauze or other pads soaked
with a liquid such as alcohol are well known. For example, in the
medical field, alcohol-soaked gauze pads are sealed within
impervious foil packages to protect the pads from contamination and
prevent evaporation of the alcohol. The packages are opened only at
the point of use, e.g., to swab a site on a patient's body to
sterilize the site prior to an injection or other procedure.
[0005] For example, U.S. Pat. No. 5,320,217, issued Jun. 14, 1994
to M. D. Lenarz and entitled "Wet Swab Captured Package", discloses
a sealed package containing a moistened pad. As best seen in FIGS.
1 and 2, an absorbent pad 18 is enclosed within the package 10
which contains a transverse seal line 20 which grips pad 18 and
prevents it from being readily removed from the package when head
portion 22 of package 10 is removed to expose a portion of
absorbent pad 18. The user may grip the package 10 and apply the
exposed portion of absorbent pad 18 to a patient, as illustrated in
FIG. 4.
[0006] Lenarz '217 (column 1, lines 23-41) mentions U.S. Pat. Nos.
4,427,111 and 5,046,608, both to Laipply. The Laipply Patents show
a device in which an absorbent pad is folded in the sealed package,
which is opened flat for use. Laipply '111 illustrates a number of
alcohol or other fluid applicators. At column 5, line 58 et seq.,
Laipply '111 describes FIGS. 2A-2D as disclosing a device 10
including a pad 11 which is attached (see column 8, lines 19-20) to
the fluid-impermeable material 12 and is in a folded, closed
position. As best seen in FIG. 2B, unsealed tabs or flanges 17
(column 6, lines 7-10) permit opening the device 10 to expose the
pad for use. Laipply '608 notes at column 8, line 57 et seq.,
situations where it is undesirable to get fluid from the absorbent
pad (11 in FIGS. 2A-2C) on the user's fingers.
[0007] As described at column 8, lines 19-41 of Laipply '111, the
package 12 of FIG. 2D is preferably formed of a metal foil 20 and a
thermoplastic liner 21. (See column 6, lines 52-59.) An interface
material 23 may be disposed between the pad 11 and plastic liner 21
and heated to cause the interface material 23 to bond with the
surface 24 of pad 11 and the plastic liner 21. At column 8, lines
42-48, other techniques for attaching the pad 11 to the package
material 12 are briefly described.
[0008] The embodiment illustrated in FIGS. 8A through 8C, as
described at column 12, lines 20-41 of Laipply ' 111, provides a
"handle portion" 226 formed by putting a crimp in the package
material 222. As described starting at column 14, line 57, an
integral fluid-applying device 220 includes a rectangular pad 221
adhered to the packaging material 222 having a crimped handle
portion 226.
SUMMARY OF THE INVENTION
[0009] Generally, the present invention provides a
liquid-permeable, non-contaminating pad which is secured to a layer
of impervious material to provide a "backed pad", and which is
contained within an impervious, manually openable package which is
sealed against the environment and which provides within the sealed
package an environment which is free of micro-contaminants. (The
term "micro-contaminants" and "free of micro-contaminants" are
defined below.) One aspect of the present invention provides that
the impervious layer to which the backed pad is secured comprises a
base layer of the sealed package, the base layer having a cover
layer which is peripherally sealed to the base layer to provide a
sealed package completely enclosing the pad within the sealed
area.
[0010] Specifically, in accordance with the present invention there
is provided a sealed package comprising an impervious base layer
having a pad-receiving surface on which is disposed a
liquid-permeable pad, and an impervious cover layer having a
pad-facing surface, the cover layer being secured to the base layer
by a rupturable seal, with the pad-facing surface fully overlying
the pad. The pad-facing surface, the pad-receiving surface and the
pad are free of micro-contaminants, whereby the pad is hermetically
sealed within the package in an environment which is free of
micro-contaminants, and may be exposed for use by at least partly
separating the cover layer from the base layer.
[0011] Other aspects of the present invention provide the following
features, alone or in combination of two or more. The
liquid-permeable pad may be affixed directly to the pad-receiving
surface of the base layer; the pad may be a dry pad and the sealed
package may be free of liquid agents; alternatively, one or more
liquid agents may be impregnated in the pad within the sealed
package; and, in certain aspects, the pad has a periphery and the
base layer and the pad are configured so that the base layer
extends beyond the entire periphery of the pad to leave a
continuous peripheral portion of the base layer uncovered by the
pad.
[0012] Another aspect of the present invention provides for a
sealed package comprising an impervious base layer having a
pad-receiving surface on which a liquid-permeable pad having a
periphery is affixed, the pad being selected from the group
consisting of one or more of non-woven and/or washed woven
materials, the base layer and the pad being configured so that the
base layer extends beyond the entire periphery of the pad to leave
a continuous peripheral portion of the base layer uncovered by the
pad. An impervious cover layer has a pad-facing surface and is
secured to the peripheral portion of the base layer by a
rupturable, peripheral seal, with the pad-facing surface fully
overlying the pad. The pad-facing surface, the pad-receiving
surface and the pad being free of micro-contaminants, whereby the
dry pad is hermetically sealed within the package in an environment
which is free of micro-contaminants, and may be exposed for use by
at least partly separating the cover layer from the base layer by
pulling the respective layers apart to rupture at least a portion
of the peripheral seal.
[0013] Other aspects of the present invention provide for the
following features, alone or in combination of two or more. The
rupturable seal may be a peripheral seal which encircles the pad
and defines an extra-peripheral area of the package lying outside
the seal, with at least a portion of the extra-peripheral area left
unsealed so that the base and cover layers are readily separable
from each other to expose at least part of the pad for use; the pad
may comprise a single layer of material and lie flat and unfolded
within the package; the pad may comprise a 100% polyester fabric
which is free of chemical binders, salts, glue, bleach and
cellulose; the pad may comprise a fabric having a basis weight of
from about 2.7 to 4 ounces per square yard; the pad may be
comprised of a non-woven fabric; both the base layer and the cover
layer may comprise aluminum foil having adhered to the entirety of
their respective pad-receiving and pad-facing surfaces a plastic
film; and the rupturable seal may enclose and define a sealed area
of the package, the package further comprising a retention opening
outside the sealed area, the retention opening being configured to
receive and retain therein a length of optic fiber having a
connector affixed to at least one end thereof.
[0014] In accordance with a method aspect of the present invention,
there is provided a method of making the sealed package described
above, the method comprising the following steps. An impervious
base layer having a pad-receiving surface which is free of
micro-contaminants is prepared, and a pad which is free of
micro-contaminants is affixed to the pad-receiving surface. An
impervious cover layer having a pad-facing surface which is free of
micro-contaminants is prepared and the cover layer is secured to
the base layer by a rupturable seal, with the pad-facing surface
fully overlying the pad. Consequently, the pad is hermetically
sealed within the package in an environment which is free of
micro-contaminants, and the pad may be exposed for use by at least
partly separating the cover layer from the base layer.
[0015] Another method aspect of the invention provides that the
steps of preparing the cover layer and the base layer each includes
securing one or more plastic layers to an aluminum layer, and the
pad comprises a non-woven polyester material.
[0016] Other aspects of the present invention will be discerned in
the following description and the appended drawings.
[0017] As used herein and in the claims, the following terms,
whether in singular or plural form, have the indicated meanings. A
"plastic" means a synthetic organic polymeric material. An
"impervious layer" is one or more layers of one or more materials
which are impervious to passage therethrough of moisture, air and
the treatment liquid, if any, with which the pad may optionally be
impregnated while sealed in the package of the present invention.
The term "micro-contaminants" means contaminants including, but not
limited to, micron-sized particles of any material, such as dust
motes, micron-sized droplets or other forms of skin oils or other
oils, grease, plasticizers, plastisols or oily or other materials
which are released from adhesives, from plastic sheets or from
other plastic materials or the like, particles of starch, sizing or
other materials, lint or threads from paper or other cellulosic
materials, woven or non-woven materials, including particles,
threads and droplets as small as one micron in diameter, or even
smaller, or smears or films of liquids or other materials. A
material or package environment which is stated to be "free of
micro-contaminants" means a material or package environment in
which the level of micro-contaminants, if any, is low enough that
three or more passes of the end of an optic fiber over a cleaning
pad just removed from the sealed package environment will leave at
least the light-transmitting portion of the optic fiber end free of
micro-contaminants. The term "free of micro-contaminants" also
means and embraces freedom from contaminants larger than
micro-contaminants. A "contaminant" is any material which would
diminish light transfer through an optic fiber if disposed on the
end face of the optic fiber itself (as distinguished from the
surrounding epoxy and ceramic (or other material) header, or if
otherwise disposed in the light-transmission path of the optic
fiber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of a sealed package in
accordance with one embodiment of the claimed invention;
[0019] FIG. 2 is a side view in elevation of the sealed package of
FIG. 1;
[0020] FIG. 3 is a plan view of the opened package of FIGS. 1 and
2, with the cover layer omitted;
[0021] FIG. 4 is a side elevation view of the opened package of
FIG. 3 being used to clean the end of an optic fiber;
[0022] FIG. 5 is a view corresponding to that of FIG. 3, but
schematically showing use of the opened package to clean the end of
an optic fiber;
[0023] FIG. 6A is a schematic view showing the tip of an optic
fiber with a dome-shaped end being cleaned on a pad in accordance
with the practice of the present invention;
[0024] FIG. 6B is a schematic view showing the tip of an optic
fiber with a beveled end being cleaned on a pad in accordance with
the present invention; and
[0025] FIG. 7 is a plan view of a second embodiment of a sealed
package in accordance with the present invention, showing an optic
fiber cable with connector secured to the unopened package.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0026] As shown in FIGS. 1-3, a sealed foil package 10 is comprised
of a cover layer 10a sealed to a base layer 10b along the entire
periphery of the package at seal 12, as best shown in FIG. 3 (from
which cover layer 10a is omitted). Cover layer 10a and base layer
10b are each impervious layers, i.e., they are impervious to
passage therethrough of moisture and air and any treatment
substance which may be contained within package 10. Layers 10a and
10b may be the same or different materials and may comprise any
suitable impervious materials. For example, layers 10a and 10b may
comprise conventional packaging material comprised of aluminum foil
coated on both sides with a plastic layer such as low-density
polyethylene. The materials of layers 10a and 10b are peripherally
sealed together (seal 12) by any suitable means such as thermal
bonding, ultrasonic welding, thermal or magnetic induction,
adhesives, mechanical "zip-lock" type seals, etc., as is well-known
in the art. An opening end 10c (FIG. 1) is formed by leaving
unsealed an area which is large enough to facilitate manual opening
of package 10 by separating and pulling apart cover layer 10a and
base layer 10b. The area of package 10 outside peripheral seal 12
defines an extra-peripheral area 11 (FIGS. 1 and 2). A single-use
seal or a reusable mechanical seal or a resealable adhesive seal
may be utilized. Reusable seals permit resealing and subsequent
reopening of package 10 for multiple use embodiments of the
invention.
[0027] A pad 14 is made of any suitable absorbent material, such as
polyester woven or non-woven fabric, and is securely bonded to base
layer 10b by any suitable means such as those mentioned above to
make seal 12, except that there is no need or reason for a reusable
seal as pad 14 is preferably permanently secured to base layer 10b,
for simplicity of construction. In the illustrated embodiment,
thermal bonding is used in a pattern of spot-bondings 14a shown in
FIG. 3 to non-removably affix pad 14 to base layer 10b. Obviously,
other bonding patterns may be employed to secure pad 14 to an
impervious backing layer such as base layer 10b. Pad 14 may be
bonded to base layer 10b at all or part of the periphery of pad 14,
or in a grid or other pattern or in a full coverage pattern. Top
side 14b (FIG. 4) of pad 14 faces cover layer 10a and pad 14 is
absorbent in order that it can absorb through top side 14b and
retain a treatment substance in liquid, gel or pulverulent form.
Thus, pad 14 is thick enough to retain a desired quantity of
treatment substance. The bottom side (unnumbered) of pad 14, i.e.,
the side of pad 14 affixed to base layer 10b, may optionally be
lined with any suitable material to facilitate bonding of pad 14 to
base layer 10b. Pad 14 should be made of a fabric which does not
generate particles large enough to interfere with light
transmission through the end face of optic fibers. To that end, pad
fabric ideally should not generate any particles. As a practical
matter, the pad fabric should not generate particles larger than
about 2 microns in diameter, preferably, it should not generate
particles larger than about 1 micron in diameter. Ideally, any
particles generated will be few in number and less than one micron
in diameter, preferably less than one-half micron in diameter.
Particles are often generated from fabrics which have been treated
with or contain chemical binders, bleach (which weakens some
fibers), salts, sizing, detergents, surfactants, glue or starch
(some of which will separate from the fibers) or from fabrics which
contain residues or threads which may separate from the fabric as
lint or the like. Inasmuch as woven fabrics are usually treated at
least with sizing and usually with both sizing and bleach, in order
to avoid or minimize the generation of micron-size particles large
enough to significantly attenuate the passage of light through the
end face of an optical fiber, non-woven fabrics are preferred.
Further, fabrics which are free of cellulose or other natural
fibers are preferred because fabrics made of or including cellulose
or other natural fibers tend to generate particles of problematic
size and quantity. Accordingly, non-woven, unsized and unbleached
fabrics are preferred. A highly preferred material for the fabric
of the pad 14 is a 100% polyester material manufactured without
chemical binders or thermal bonding and made by using
hydroentanglement. That is, high-pressure water jets are used to
knit the individual fibers together into a non-woven fabric. It is
also desirable that the fabric be thick enough so that dome-shaped
or beveled faces of the ends of optic fibers, when held
perpendicularly to the surface of the fabric, are sufficiently
enclosed by the nap of the fabric to assure thorough cleaning. In
this regard, see the description below of FIGS. 6A and 6B. A
suitable fabric is available from LymTech, a division of the John
R. Lyman Company of Chicopee, Mass. That Company offers under the
designation C3H a hydroentangled, non-woven 100% polyester fabric
having a basis weight in ounces per square yard ("oz/yd.sup.2") of
3.2 (108.5 grams per square meter, "g/m.sup.2") and an average
thickness of 17.5 mils. Generally, a basis weight of from about 2.5
to 4.0 oz/yd.sup.2 (84.8 to 135.6 g/m.sup.2), e.g., from about 2.7
to 3.8 oz/yd.sup.2 (91.6 to 128.8 g/m.sup.2) is preferred. It has
been found that fabrics with a basis weight less than about 2.5
oz/yd.sup.2 (84.8 g/m.sup.2) are likely to be torn by the pressure
of an optic fiber drawn across it, as illustrated in FIG. 4,
thereby generating lint and thread particles. Fabrics with a basis
weight above 4 add cost and bulk to the package without any
noticeable advantage over fabrics whose basis weight falls within
2.5 to 4.0 oz/yd.sup.2 (84.8 to 135.6 g/m.sup.2) range. (Any
discrepancy between the same values given in English and metric
units should be resolved in favor of the value in English units.)
The materials used for the package and its seal should be such that
opening of the sealed package does not tear or otherwise shred any
material, as tearing or shredding may create problematic fiber
particles or the like.
[0028] The exterior side of layers 10a and 10b may be made of any
suitable material, including paper, provided that their interior
surfaces, i.e., the pad-receiving surface of base layer 10b and the
pad-facing surface of cover layer 10a, are made of a suitable
material such as a plastic material, e.g., polyester or Surlyn, or
other non-fiber material. However, it is preferable to avoid the
use of fiber materials such as paper in order to reduce the
presence of potential contaminants. Aluminum foil lined with a
suitable plastic is a preferred material of construction for base
layer 10b and cover layer 10a. Among other virtues, including
imperviousness and freedom from fibers or particles, aluminum helps
to dissipate static charges which may be generated upon opening the
package or by dragging an optic fiber face across the fabric.
Static charges are problematic because they may attract lint, dust
motes or other particles.
[0029] Pad 14 may optionally be impregnated with any suitable
treatment substance, for example, with a liquid treatment
substance, such as a cleaning solvent, after which the package 10
is sealed by applying cover layer 10a and carrying out thermal
bonding or the like to form seal 12, thereby enclosing pad 14
within the seal 12, which seals cover layer 10a to base layer 10b.
The result is a sealed package 10 within which pad 14 is enclosed
and sealed from the environment. Any suitable solvent or cleaning
agent, such as a high purity mixture of alcohol and water, may be
used to soak the pad 14. Alternatively, a suitable cleaning agent
or solvent may be applied to the pad or a portion thereof only
after opening the sealed package. By sealing a dry pad within the
package without any liquid agents of any kind present, possible
adverse effects of a liquid agent such as a solvent or cleaning
agent on the package materials or the pad is avoided.
[0030] An alcohol/water mixture is well suited for cleaning the end
faces of optic fiber lines or cables. For example, a mixture of 90
percent by volume of either high purity anhydrous grade isopropyl
alcohol or high purity anhydrous grade ethyl alcohol plus 10
percent by volume deionized water makes a suitable cleaning agent
for cleaning the end faces of optic fiber lines or cables. Such
solvent facilitates cleaning the end face and also serves to
dissipate or preclude the formation of static electricity generated
upon the opening of package 10 and/or by the dragging of the optic
fiber end face across the fabric during cleaning. As noted above,
the pad 14 may be left dry in the sealed package and used dry, or
the treatment substance, e.g., one of the above alcohol-water
mixtures, may be applied to pad 14 or a portion thereof only after
opening package 10, e.g., at the point of use.
[0031] In use, package 10 is opened by separating cover layer 10a
from base layer 10b at opening end 10c. The chevron-like pattern of
thermal seal 12 leaves a substantial portion of layers 10a and 10b
unsealed at end 10c of package 10, thereby facilitating manually
separating layers 10a and 10b from each other and pulling back
cover layer 10a to expose pad 14 as shown in FIG. 4. The pad 14 may
be used for any cleaning purpose such as, as illustrated in FIG. 4,
cleaning the end face 16a of an optic fiber line 16. End face 16a
protrudes from connector 18 and is cleaned by rubbing end face 16a
in a linear direction as indicated by the arrows in FIG. 4, or,
preferably, in only one direction as indicated in FIG. 5 and
described below. Alternatively, layer 10b may be folded over a
length of optic fiber line, cable or the like to permit drawing the
pad 14 over a length of the optic fiber or the like, to clean it
prior to making a splice-type connection.
[0032] In cases where the pad 14 within the sealed package is dry,
a preferred technique for cleaning the optic fibers is to wet only
about one-half the pad with the cleaning agent or solvent and to
drag the end of the optic fiber through the wet portion of the pad
and into the dry portion to dry the end of the optic fiber.
Moistening a portion of pad 14 with a cleaning agent or solvent
such as a water-alcohol mixture, prepares the pad 14 for use and
helps to dissipate any static electric charges generated by opening
sealed package 10 and/or by the dragging of the optic fiber end
face across the fabric during cleaning. For example, FIG. 5 shows
base layer 10b from which cover layer 10a (not shown in FIG. 5) has
been removed, leaving the residue of seal 12 and pad 14 exposed. If
pad 14 is a dry pad, the user will preferably moisten a portion
only of it with a suitable liquid cleaning agent such as a mixture
of isopropyl or ethyl alcohol and deionized water. In FIG. 5, area
14a represents the moistened area of pad 14 and area 14b,
demarcated from area 14a by the vertical (as viewed in FIG. 5)
unnumbered dash line, is left dry. Area 14a should be moistened
sufficiently to adequately clean the optic fiber end but not
excessively, as too much cleaning agent will not be adequately
dried by dry end 14b and may remain on the fiber end. The arrows A,
B and C show the several passes of the tip 16a (FIG. 4) of the
optic fiber 16 from the wetted area 14a into the dry area 14b.
After being rubbed along the path of arrow A, the tip 16a is lifted
clear of pad 14 and returned to area 14b at the origin of arrow B.
As many passes as required are made, with care being taken to avoid
twice traversing the same part of pad 14. That is, travel paths
represented by arrows A, B and C should be slightly spaced-apart
and not cross each other to avoid picking up previously deposited
(onto pad 14 from tip 16a) contaminants.
[0033] FIG. 6A shows a dome-shaped tip 16a' of optic fiber 16',
which has a ceramic jacket 17' and an optic fiber strand 19'
extending therethrough. The pad 14 has a thickness t which is thick
enough to encase tip 16a'. Similarly, FIG. 6B shows a beveled tip
16a'' of optic fiber 16'', comprised of ceramic jacket 17'' with
optic fiber strand 19''.
[0034] Manufacture of the pad 14 and the sealed package 10
including pad 14, is preferably carried out under clean-room
conditions free of dust, lint, etc. The degree of cleanliness
required in the practices of the present invention is generally
greater than that required for medical products. While medical
products, such as alcohol-soaked pads contained with sealed
aluminum foil/plastic packages must be sterile, they need not be
"clean" in the sense that medical products can readily endure the
presence of trace amounts of oils or of numerous particles greater
or smaller than one micron, provided that the trace amounts of oils
and/or the particles are sterile. Because the diameter of an optic
fiber may be as small as 8 microns, the optic fibers should be free
of micron-size particles greater than about one micron in diameter.
Preferably, the sealed package of the present invention is free of
trace oils and contaminant particles greater than one-half micron
in diameter. For example, a dust mote or other particle three
microns in diameter which lands on the end face of an optic fiber 8
millimeters in diameter will obscure a significant percentage of
the light-transmitting surface area of the end face. The same is
true with trace oils which can leave a smear, film or haze-like
residue that can reduce or block the light-transmitting surface
area of the end face. While such contamination is not visible or
apparent to the naked eye, this contamination is readily seen when
viewed at high magnification of 200.times. or more as when using a
special fiber inspection scope such as the Noyes "OFS 300-200C;
optical fiber scope", made by Noyes/AFL Telecommunications,
Belmont, N.H., or the equivalent. Typical magnifications at which
the optic fiber ends are examined with such optical fiber scopes
are 70.times., 200.times. and 700.times..
[0035] The clean-room conditions under which the sealed package is
manufactured includes avoiding touching the pad 14 or the inner,
pad-facing and pad-receiving surfaces of the package with fingers
or hands because the oils and perspiration inherent on human skin
severely contaminate the materials. Tests have shown that even
fleeting contact of the pad with uncovered finger tips results in a
disastrous rise in the rate of failure to adequately clean optic
fiber end faces. In one test, normal handling of the pads as
required during manufacture by workers with clean but ungloved
hands, resulted in a 70% rate of failure to provide acceptable
cleaning of optic fiber ends by the method illustrated in FIG. 5
and described herein, using a mixture of high purity anhydrous
grade 98% isopropyl alcohol in deionized water. The cleaning was
deemed to be a failure if the optic fiber end "cleaned" with the
pad sustained any measurable loss of light transmission through the
cleaned end face of the optic fiber, or any form of visible
streaking, smearing caused by residues of oils, liquid
contaminants, or the presence of one or more particles of solid
particulate of size sufficient to cause at least some measurable
blockage of light transmission, as determined by visual inspection
using a fiber inspection scope of the type described above.
[0036] Operators working on manufacturing the sealed packages of
the invention must utilize gloves which are free from lubricating
powders such as talc, and which are also free of oily residues of
plasticizer or plastisols from their manufacture. Use of plastics
which include or exude even a minute amount of such oily substances
has been found to seriously and adversely affect the ability of the
cleaning pad to provide satisfactorily clean end faces for optic
fibers. In another manufacturing test, workers using gloves made of
either vinyl or latex which had dipped their gloved fingers into
alcohol to provide cleaner glove surfaces as well as a better grip
on the pads, also resulted in a high rate of failure. Investigation
showed that the alcohol apparently leached a plasticizer from the
gloves which plasticizer was transferred to the pads and some of it
was deposited on the "cleaned" ends of the optic fibers. It has
been found that for purposes of the present invention nitrile
gloves free of talc or other lubricants are satisfactory for
handling the pad 14, and for contact with the interior portions
generally of package 10.
[0037] The present invention is not limited to cleaning optic fiber
lines or cables, but provides an inexpensive, portable, cleaning
(or other treatment) pad which is sealed in an environment which is
"clean-room" free of micro-contaminants. The pad 14 may be packaged
dry, and solvent or other liquid or other treatment substance added
afterwards, or the treatment substance may be applied to pad 14
before sealing package 10. The treatment substance need not be a
liquid, but could be a paste or a gel. Polishing, smoothing,
cleaning and application of treatment, therapeutic or test
substances in procedures which require or are enhanced by the
sealed package being free of micro-contaminants are among the uses
to which the present invention may be put. The impervious backing
on pad 14 protects the user's fingers from the treatment substance
and reduces the possibility of contamination of the test or
treatment site by the user's fingers.
[0038] The present invention differs from known products such as
packaged alcohol wipes because, in the case of the present
invention, the pad 14 is made of relatively (as compared to
starched, bleached, natural fiber, etc., fabrics) non-contaminating
fabric such as 100% polyester non-woven fabric and the interior of
the package is made from non-contaminating, static-dissipating
materials. Further, manufacturing of the sealed packages of the
present invention is carried out under clean-room conditions.
Contact with the pad 14 or the interior sides of the base layer and
cover layer is limited to contact with gloved bands wearing gloves
which themselves are non-contaminating in that they do not have
talc or residues of oily material such as plasticizers. The pad 14
is desirably made of at least a 2.5 oz/yd.sup.2 (84.8 g/m.sup.2)
basis weight material, to provide sufficient thickness ("t" in
FIGS. 6A and 6B) to insure good cleaning of the tip (16a', 16a'')
of the optic fiber. It is preferred that the pad material not be
folded, because folding forms a crease which may fatigue the fibers
to the point where the crease causes fibers to break or otherwise
generates undesirable micron-size particulates.
[0039] It is within the purview of the invention to provide pad 14
with a backing layer other than the base layer 10b and to enclose
pad 14 and its backing layer within sealed package 10. However, for
simplicity and efficiency of construction, it is preferred that pad
14 be directly adhered to backing layer 10b. The backing layer
desirably is made thick and resilient enough to provide a secure
base for the pad, yet is resilient enough to give somewhat under
pressure of the end of the optic fiber to insure that the optic
fiber end makes good contact with the cleaning pad, as illustrated
in FIGS. 6A and 6B.
[0040] Optic fiber connectors such as connector 18 may measure
1.25, 1.6, 2.0 or 2.5 millimeters wide and the glass optic fiber
strand 19 of optic fiber 16 contained within such connectors are
typically 8 microns in diameter for telecommunications or other
electronic equipment or 25 microns in diameter for medical
instrument applications. For comparison, the average human hair has
a diameter of about 40 microns. When it is considered that the
optic fiber end may have an effective diameter of only 8 or 25
microns, it will be appreciated that trace amounts of oil or the
like or extremely small particles or threads, as small as two,
three or four microns in diameter, or even less, could have
disastrous effects on the ability of the optic fiber to transmit
light if the thread or particle lies across the face of the optic
fiber.
[0041] The construction and clean-room manufacturing conditions
provide an impervious backing layer to pad 14 and keeps pad 14 and
its solvent or other treatment substance clean and untouched during
use. In this way, the most stringent cleaning requirements, such as
those which obtain in connection with on-site cleaning of the end
faces of optic fiber lines or cables, may be successfully carried
out. The package 10 is sealed and the pad 14 is protected until it
is ready for use. If, in use, the user has to pick up pad 14, for
example, to fold it around a length of optic fiber line or the
like, the user does not contaminate with perspiration or oil from
the user's fingers the surface of the pad 14 or the treatment
substance, e.g., a solvent, or get the treatment substance on his
or her fingers. This is because the user is able to pick up and
hold the backed pad 14 by taking between the fingers the impervious
backing layer, base layer 10b in the illustrated embodiment, and
need not touch pad 14 itself.
[0042] The present invention is especially well suited for cleaning
optic fiber lines and cables although, as stated above, it is not
limited to that field. Some studies have shown that a failure rate
of about 30 percent attends the making of optic fiber connections
in the field, using connectors such as connector 18 illustrated in
FIG. 4. Approximately 90 percent of such failures occur because of
end face (16a in FIG. 4) contamination of the optic fiber line. As
noted above, impregnation of the cleaning pad 14 with cleaning
solvent or other liquid or paste treatment substance prior to
sealing package 10 helps to eliminate static charge which may be
generated when separating cover layer 10a from base layer 10b
and/or the dragging of the optic fiber end face across the fabric
during cleaning. This is highly advantageous in cleaning optic
fibers because generating an electrostatic charge tends to attract
airborne dust particles and motes. The above-described advantages
of the present invention over known materials for cleaning or other
uses are especially important for cleaning optic fibers. By
protecting the user's fingers from contact with solvent or other
materials on the pad 14, the user's fingers are not contaminated
with the solvent, or chilled by evaporation of alcohol-containing
or other such solvents. This can be a not insignificant factor when
working in cold weather as it may obviate the need for gloves.
Further, by folding the impervious layer-backed cleaning pad 14
about the length of optic fiber or the like, materials such as the
"gooey material" used to coat optic fibers or optic fiber cables
(bundles of optic fibers) can readily be cleaned away to facilitate
splicing without the user's fingers being contaminated by the
"gooey stuff".
[0043] FIG. 7 shows a package 110 which is identical to package 10
of FIG. 1 except that it has a retainer opening provided by a
"buttonhole" 20 formed in opening end 10c outside the sealed
periphery formed by seal 12, that is, in the extra-peripheral area
11 thereof. A length of optic fiber 16 having a connector 18
affixed to one end thereof is threaded through slit 20. This
provides a combination which may be sold as a unit, so as to
provide a cleaning pad with the optic fiber connector, for use in
cleaning the end faces of the optic fiber lines prior to
installation.
[0044] While the invention has been described in detail with
respect to a particular embodiment thereof, it will be appreciated
that numerous variations may be made to the described and
illustrated embodiment which nonetheless lie within the scope of
the present invention.
* * * * *