U.S. patent number 3,718,515 [Application Number 05/060,183] was granted by the patent office on 1973-02-27 for process for manufacturing shaped energy transmission arrays.
This patent grant is currently assigned to Decicom Systems, Inc.. Invention is credited to Amnon Goldstein.
United States Patent |
3,718,515 |
Goldstein |
February 27, 1973 |
PROCESS FOR MANUFACTURING SHAPED ENERGY TRANSMISSION ARRAYS
Abstract
A shaped energy transmission array made by forming an energy
transmission sheet having a plurality of channels therein, a pair
of opposed edges defining a plurality of discrete inputs to said
channels and a plurality of discrete outputs from said channels
respectively, bending the sheet along a line intermediate the pair
of opposed edges so that portions of the sheet are in overlapping
relation, shaping the portion of the sheet extending normally from
the first of said pair of opposed edges to the desired shape
whereby the first edge defines the desired shape, and fixing the
conformation of the shaped array. The array may be formed from a
plurality of filaments such as electrical conductors or fiber
optical filaments aligned in side by side relation so that the pair
of opposed edges are defined by the opposed ends of the
filaments.
Inventors: |
Goldstein; Amnon (Forest Hills,
NY) |
Assignee: |
Decicom Systems, Inc.
(N/A)
|
Family
ID: |
22027894 |
Appl.
No.: |
05/060,183 |
Filed: |
June 29, 1970 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
709474 |
Feb 29, 1968 |
3544192 |
Dec 1, 1970 |
|
|
Current U.S.
Class: |
156/174; 156/175;
156/202; 385/121; 156/196; 385/116 |
Current CPC
Class: |
H01B
13/00 (20130101); H01B 7/08 (20130101); G02B
6/448 (20130101); G02B 6/4403 (20130101); Y10T
156/1011 (20150115); Y10T 156/1002 (20150115) |
Current International
Class: |
H01B
13/00 (20060101); H01B 7/08 (20060101); G02B
6/44 (20060101); B65h 054/00 () |
Field of
Search: |
;156/174,175,196,211,202
;350/96 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Quarforth; Carl D.
Assistant Examiner: Lehmann; E. E.
Parent Case Text
BACKGROUND OF THE INVENTION
This is a division of application Ser. No. 709,474, filed Feb. 29,
1968, now U.S. Pat. No. 3,544,192 issued Dec. 1, 1970.
Claims
What is claimed is:
1. A process for manufacturing shaped energy transmission arrays
having a plurality of energy transmission channels, each of said
channels extending between a first and second terminal from a
flexible energy transmission sheet having a plurality of said
channels formed therein and first and second opposed edges, said
first and second opposed edges being defined by said first and
second terminals respectively, which comprises bending said sheet
along a bend line intermediate said first and second opposed edges
so that portions of said sheet are in overlapping relation; flexing
the portion of said bent sheet extending normally from said first
edge to said bend line and including said bend line as a unit to
the desired shape other than a straight line so that said first
edge defines the desired shape substantially in a single plane
while the transverse cross-sections of said array portions between
said first edge and said bend line are substantially uniform and
substantially define said desired shape; and fixing the
conformation of said shaped array.
2. A process for manufacturing shaped filamentary arrays as recited
in claim 1 wherein said sheet is bent so that both of said first
and second opposed edges extend beyond said overlapping portions of
said sheet.
3. A process for manufacturing shaped energy transmission arrays as
recited in claim 1 wherein said energy transmission sheet is formed
by helically winding a length of energy transmission filament on a
mandrel; securing the filamentary windings together; and cutting
said filamentary windings along the line substantially normal to
the longitudinal axes of the filaments.
Description
This invention relates generally to shaped energy transmission
arrays having a plurality of channels therein and a pair of opposed
edges thereof defining a plurality of discrete inputs and a
plurality of discrete outputs of said channels respectively and to
a process for manufacturing such arrays. Shaped energy transmission
arrays are utilized wherever it is desired to transmit energy from
a plurality of outputs disposed in one configuration to a plurality
of inputs disposed in another configuration. One principal type of
shaped energy transmission array is formed from a plurality of
filaments such as electrical conductors or fiber optical filaments
disposed in side by side relation, a pair of edges of the array
being defined by the opposed ends of the filaments. For example,
filamentary arrays are frequently used in scanning and printing
devices incorporated in detectors, facsimile transmission systems,
and copying machines. Filamentary arrays formed of electrical
conductors are generally required in sequential lined printers and
electrostatic printers. Examples of shaped fiber optical arrays are
shown in U.S. Pat. Nos. 3,325,594 issued on June 13, 1967 to J. S.
Goldhammer et al. and 3,104,324 issued on Sept. 17, 1963 to J.
Rabinow.
In the past, shaped energy transmission arrays have been expensive
to form while the energy transmission characteristics of the
discrete energy transmission channels making up the array have
varied substantially. Thus, filamentary arrays have frequently been
formed by the laborious hand placement of each filament within the
array. Another approach, utilized to form fiber optical filamentary
arrays is to start with a plurality of fibers of substantially
uniform length and conformation, heat the filaments to the drawing
temperature thereof and draw the filaments into the desired
positions. This approach results in variations in cross-sectional
area and length among the various filaments, which in turn results
in variations in light transmission characteristics.
SUMMARY OF THE INVENTION
Generally speaking, in accordance with the invention, a shaped
energy transmission array is formed from an energy transmission
sheet having a plurality of energy transmission channels therein
and a pair of opposed edges defining a plurality of discrete inputs
and a plurality of discrete outputs of said channels respectively,
said sheet being bent along a line intermediate said pair of
opposed edges so that portions of said sheet are in overlapping
relation, the portion of said array extending normally from the
first of said pair of opposed edges being shaped so that said edge
defines the desired shape. The array may be formed of a plurality
of filaments aligned in side by side relation so that the pair of
opposed edges is defined by the opposed ends of the filaments.
Filamentary arrays may be formed from a plurality of electrical
conductors or a plurality of fiber optical filaments. The shaped
edge may be disposed in the shape of a circle or of an information
imparting symbol. The other edge of the array may be disposed in a
line or, when the sheet forming the array is folded at least twice
intermediate the pair of opposed edges, the other edge may also be
disposed in a desired shape.
The shaped energy transmission array is manufactured by forming a
sheet having a plurality of channels therein and a pair of opposed
edges defining a plurality of discrete inputs and a plurality of
discrete outputs of said channels respectively, bending the sheet
along a line intermediate the pair of opposed edges so that
portions of the sheet are in overlapping relation, shaping the
portion of the bent sheet extending normally from the first of the
pair of opposed edges to the desired shape whereby the first edge
defines the desired shape, and fixing the conformation of the
shaped array.
Accordingly, it is an object of this invention to provide a simple
and inexpensive process for manufacturing shaped energy
transmission arrays.
Another object of the invention is to provide a shaped energy
transmission array, one edge of which may be disposed in the shape
of any of a plurality of information imparting symbols.
A further object of the invention is to provide a shaped
filamentary energy transmission array which provides substantially
uniform energy transmission characteristics between a plurality of
discrete inputs and a plurality of corresponding discrete
outputs.
Still another object of the invention is to provide a shaped energy
transmission array which will permit transfer of energy between a
plurality of discrete outputs disposed in one configuration and a
plurality of corresponding inputs disposed in a second
configuration.
Another object of the invention is to provide a shaped filamentary
energy transmission array wherein each of the filaments making up
the array is of substantially uniform length and conformation.
A further object of the invention is to provide a shaped energy
transmission array for interconnection between a plurality of
discrete outputs disposed in one plane and a plurality of
corresponding discrete inputs disposed in a second plane.
Still other objects and advantages of the invention will in part be
obvious and will in part be apparent from the specification.
The invention accordingly comprises the several steps and the
relation of one or more of such steps with respect to each of the
others, and the article possessing the features, properties, and
the relation of elements which are exemplified in the following
detailed disclosure, and the scope of the invention will be
indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention, reference is had to
the following description taken in connection with the accompanying
drawings, in which:
FIG. 1 is a plan view of a filamentary energy transmission sheet
from which a shaped energy transmission array in accordance with
the invention may be formed:
FIG. 2 is a plan view of the filamentary energy transmission sheet
of FIG. 1 after bending;
FIG. 3 is an end view of the bent sheet of FIG. 2;
FIG. 4 is a sectional view taken along line 4--4 of FIG. 2;
FIGS. 5 and 6 are perspective views of two embodiments of the
shaped energy transmission filamentary array in accordance with the
invention;
FIG. 7 is a plan view of a mandral or drum upon which has been
wound an energy transmitting filament for use in forming the sheet
of FIG. 1;
FIGS. 8 through 11 are partial sectional views taken along the line
8--8 of FIG. 5 showing various types of filaments from which the
shaped energy transmission filamentary array according to the
invention may be formed; and
FIG. 12 is a perspective view of a further embodiment of the shaped
energy transmission array in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now more particularly to FIG. 1 of the drawings, the
energy transmission sheet 10 comprises a plurality of energy
transmission channels which are defined, in the embodiment of the
invention pictured in the drawings, by a plurality of energy
transmission filaments 12 aligned in side by side relation and
secured together to form sheet 10. The pair of opposed edges 14 and
16 of sheet 10 are defined by the terminals of the plurality of
energy transmission channels making up the sheet. Thus, in the
embodiment shown in the drawings, edges 14 and 16 are defined by
the opposed ends of filaments 12. Edge 14 may define the input to
sheet 10 and to the plurality of energy transmission channels
therein while edge 16 may define the output or vice versa.
To form the shaped energy transmission array according to the
invention, sheet 10 is bent along line 18 intermediate edges 14 and
16 as shown in FIGS. 2 and 3, so that portions 19 of sheet 10 are
in overlapping relation. Shaped energy transmission array 20, shown
in FIG. 5 is formed from the bent sheet 10 by shaping the portion
of said bent sheet extending normally from edge 16 to the desired
shape so that edge 16 defines the desired shape, an S in the
example of FIG. 5. Sheet 10 is bent and a portion thereof shaped so
that each of the discrete energy transmission channels making up
the sheet remain intact and edges 14 and 16 are defined by the
terminals of the channels and define the terminals of the shaped
array 20.
Shaped energy transmission arrays are frequently utilized to
transmit energy from a plurality of outputs disposed in a
particular configuration in a single plane to a plurality of
corresponding inputs disposed in a different configuration in a
second plane. In such a case, it is necessary to provide a shaped
energy transmission array having one edge, defining the input to
said array, disposed in a single plane and shaped to correspond to
the disposition of outputs to which it is to be connected. In like
manner, the edge of the shaped array defining the output of the
array should be configured and disposed in a plane whereby it will
operatively connect with the above mentioned input.
One principal advantage of the shaped energy transmission array
according to the invention over the known shaped energy
transmission arrays is that each of the edges 14 and 16 may be
disposed in a single plane without altering the length or
conformation of the individual energy transmission channels. This
result may be achieved because the folding of the sheet 10 before
shaping permits the shaping, as a unit, of the entire portion of
bent sheet 10 extending normally from edge 16. The portion of bent
sheet 10 shaped as a unit is indicated by brackets 22 in FIGS. 2
and 3. In the preferred embodiment, sheet 10 is bent so that edges
14 and 16 extend beyond overlapping portion 19 of sheet 10, so that
the folding of portion 22 as a unit does not disturb the
configuration and disposition of edge 14. Accordingly, by bending
sheet 10 so that edges 14 and 16 extend beyond the overlapping
portion, and by shaping portion 22 as a unit, a shaped array having
input and output edges each lying in a single plane is
provided.
Edge 16 of shaped energy transmission array 20 of FIG. 5 is
disposed in the shape of an S. This is intended merely by way of
example, edge 16 and the portion extending normally therefrom,
being shapeable in any of a plurality of desired configurations
including but not limited to letters of the alphabet and numbers 0
through 9. Edge 14 of shaped array 20 is disposed in a straight
line. If desired, edge 14 and the portion of bent sheet 10
extending normally therefrom could be shaped and edge 16 disposed
in a straight line.
One extremely common shaped energy transmission array is the circle
to line array 24 of FIG. 6. Edge 26 of array 24 is disposed in a
line while edge 28 is disposed in a circle. The circular shape is
particularly adapted for scanning by a rotating scanner. Still
another embodiment of the shaped energy transmission array
according to the invention is shown in FIG. 12. Shaped array 30 is
formed from an energy transmission sheet 32 which is bent twice
along lines 34 and 36 respectively. The array is also disposed in
the circle to line configuration, the terminals of the energy
transmission channels making up the array being defined by edges 38
and 40. The portion of bent sheet 32 extending normally from edge
40 is shaped, as a unit, so that edge 40 defines a circle. As
shown, edge 38 is disposed in a straight line, but it is clear that
the portion of bent sheet 32 extending normally from edge 38 may be
shaped in the manner described above to the desired shape without
interfering with the disposition of the portion extending normally
from edge 40. This lack of interference is insured if the portion
of sheet 32 extending normally from edge 38 is independent from and
does not include any of the portions of sheet 32 extending normally
from edge 40.
Referring again to FIG. 2, line 18, along which sheet 10 is bent,
defines an angle of about 45 degrees with edge 16. By varying this
angle, the angle between edges 14 and 16 can be varied. This in
turn results in variations in the angle between the planes in which
edges 14 and 16 of shaped array 20 lie. In the embodiments of FIGS.
5 and 6, edges 14 and 16 lie in planes normal to each other. On the
other hand, in the embodiment of FIG. 12, edges 38 and 40 lie in
parallel planes. Accordingly, it can be seen that the shaped array
according to the invention is extremely flexible in that it can be
disposed between inputs and outputs lying in a wide range of
planes. The embodiment shown in FIG. 12 offers greater flexibility
in this regard since the disposition of both bent lines 34 and 36
may be varied.
Referring now to FIG. 4, it is seen that the bend of the preferred
embodiment is gradual and substantially arcuate. This arrangement
is necessary where sharp discontinuities in the energy transmission
channels, as would be occasioned by a sharp fold, would adversely
affect the energy transmission characteristics of the array. This
is particularly true in the case of energy transmission sheets
formed from a plurality of fiber optical filaments which would be
damaged by a sharp fold. Further, the gradual bend permits the
spacing of overlapping sections 19. This spacing is particularly
important where the energy transmission sheet is formed from
electrical conductors in order to avoid cross-talk. Means may be
provided in the array to maintain overlapping portions 19 in spaced
relation if the array is formed from a plurality of electrical
conductors.
The energy transmission sheet 10 may be formed from a variety of
materials provided the sheet contains a plurality of energy
transmission channels, a pair of opposed edges of said sheet being
defined by the discrete terminals of said channels. Thus, a shaped
energy transmission array may be formed from a sheet of flexible
circuitry. A more common type of shaped array would be formed from
a plurality of energy transmitting filaments such as electrical
conductors and fiber optical filaments. Each filament may serve as
a single channel, the ends of the filaments serving as the
terminals of the channel. The filaments making up the energy
transmission sheet are disposed in side by side relation so that
one pair of opposed edges of the sheet are defined by the opposed
ends of the filaments.
Each channel of the shaped energy transmission array according to
the invention may be able to transmit energy in either direction,
as in the case of filamentary arrays formed from electrical
conductors or fiber optical filaments or in only one direction as
in some flexible circuitry. Some channels, such as those formed
from fiber optical filaments can simultaneously transmit energy in
both directions. Accordingly, each of the channel terminals
defining edges 14 and 16 of array 22 may, depending on the nature
of the channel and the desired use, represent either the input, the
output or both the input and output of its respective channel.
Further, a portion of the terminals defining edge 14 may represent
inputs to their respective channels while the balance may represent
the output of their respective channels. In like manner, the
corresponding terminals of edge 16 would represent outputs and
inputs respectively. Accordingly, edge 14 of array 22 may serve as
either the input, the output or a combination input and output to
the array, as may edge 16.
One process for manufacturing a filamentary energy transmission
sheet is to helically wind a single length of filament on a
mandral. Referring to FIG. 1, a cylindrical mandrel or drum 42 is
shown upon which a length of energy transmission filament has been
helically wound. The windings are secured together by an adhesive
tape 46 such as Mylar tape. Flexible resins, R.T.V. Silicon Rubber
or the like may also be used to hold adjacent windings of filaments
together. The cylinder of filaments formed thereby is cut along
line 48 to form a filamentary energy transmission sheet such as the
sheet 10 of FIG. 1. Edges 14 and 16 of sheet 10 define the line 48
along which the cylinder was cut while the longitudinal axes of
filaments 22 are substantially parallel. If the length of filament
wound about the mandrel is of uniform conformation, the filaments
making up a filamentary energy transmission sheet manufactured in
this manner will be of substantially uniform length and
conformation, and therefore have substantially uniform energy
transmission characteristics. One advantage of the shaped energy
transmission array according to the invention is that the
substantially uniform energy transmission characteristics of the
sheet is substantially preserved in the array.
While FIG. 7 shows a cylindrical mandrel, a filamentary energy
transmission sheet may be formed on a mandrel of any shape. If a
cylindrical mandrel is used, the length of the sheet will depend
upon the diameter of the mandrel. Further, a filamentary energy
transmission sheet may be formed by other processes, the process of
winding on a mandrel being described by way of example and not
limitation.
There are two principal types of shaped filamentary arrays. The
first is formed from fiber optical filaments and transmits light
energy. FIGS. 8, 9 and 10 show three types of fiber optical
filaments which may be utilized in forming filamentary energy
transmission arrays. FIG. 8 shows a section of an array formed from
plastic filaments 50 which had been temporarily secured together by
an adhesive tape 52. After the array had been formed, the array was
potted in potting material 54 to maintain the conformation of the
array. The filaments 50 may be formed of a polymethyl acrylate such
as Lucite or other suitable plastic material. The filaments are
preferably coated and/or polished to ensure internal reflection of
the light being transmitted along the filament. FIG. 9, shows a
filament 56 having a core 58 formed from glass having a high
refractive index and an outer thin surface layer or coating 60 of
glass of a relatively lower refractive index. FIG. 10 shows an
array formed from fiber optical filaments 62, each of which is
formed from a plurality of smaller fibers 64. Each filament 62
defines a single channel even though it is itself made up of a
plurality of smaller filaments. The above described fiber optical
filaments are presented as examples of the types of fiber optical
filaments from which shaped energy transmission arrays according to
the invention may be formed. Fiber optical filaments of other
designs, such as filaments having square cross-sections may be used
in forming the shaped energy transmission arrays according to the
invention.
Shaped filamentary energy transmission arrays may also be formed
from a variety of types of electrical conductors. One example of
such conductors is shown in FIG. 11 wherein the array is formed
from insulated two-wire cable 66. Each electrical conductor 68 is
surrounded by insulation 70 while the pair of wires making up a
single cable are surrounded by further insulation 72. The adjacent
cables are secured together by tape 74. In the example of FIG. 11,
each cable 66, represents one filamentary energy transmission
channel. If other types of electrical conductors are utilized, a
channel may be defined, for example, by a single insulated
electrical conductor or by a multi-element cable.
Turning now to the process for manufacturing a shaped energy
transmission array according to the invention, an energy
transmission sheet having a plurality of energy transmission
channels therein and a pair of opposed edges defined by the opposed
terminals of said channels is formed. A process for forming a
filamentary energy transmission sheet is described above. The sheet
is then bent along a line intermediate said first pair of opposed
edges so that portions of said sheet are in overlapping relation.
The portion of the array extending normally from one of said pair
of opposed edges is then shaped so that that edge defines the
desired shape. The entire portion extending normally from that edge
is preferably shaped as a unit. Shaping may be accomplished by hand
or through the use of mating dies of the desired shape adapted to
receive the portion of the bent sheet to be shaped between them.
The array is then fixed in the desired conformation by some fixing
means. The fixing means can be a potting material such as an epoxy
or can take the form of brackets, or braces shaped as desired and
secured to the array. Such brackets could also be utilized to shape
the array if desired.
While most of the materials in question can be bent and shaped at
room temperature, other materials, such as certain glass fiber
optical filaments, are not sufficiently flexible at room
temperature and must be heated to a temperature at which they may
be manipulated as part of the bending and shaping steps.
By the above described process, a shaped energy transmission array
may be formed while substantially preserving uniform energy
transmission characteristics among the plurality of discrete
channels making up the array. An additional advantage of this
method is its simplicity. For example, in the case of electrical
conductors, rather than wiring each electrical conductor separately
as is the practice now, a sheet of electrical conductors can be
formed as described above and this sheet, by simple manipulation,
can be converted into a shaped array.
It will thus be seen that the object set forth above, among those
made apparent from the preceding description, are efficiently
attained and, since certain changes may be made in carrying out the
above process and in the article set forth without departing from
the spirit and scope of the invention, it is intended that all
matter contained in the above description and shown in the
accompanying drawings shall be interpreted as illustrative and not
in a limiting sense.
It is also to be understood that the following claims are intended
to cover all of the generic and specific features of the invention
herein described, and all statements of the scope of the invention
which, as a matter of language, might be said to fall
therebetween.
* * * * *