Per
`
`WORLD INTELLECTUAL PROPERTY ORGANIZATION
`International Bureau
`
`INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT)
`wo 94/01716
`
`(11) International Publication Number:
`
`(51) International Patent Classification 5 :
`
`F21V7/04
`
`A1
`
`(43) International Publication Date:
`
`20 January 1994 (20.01.94)
`
`(21) International Application Number:
`
`PCT/US93/06448
`
`(22) International Filing Date:
`
`8 July 1993 (08.07.93)
`
`(81) Designated States: JP, European patent (AT, BE, CH, DE,
`DK, ES, FR, GB, GR, IE, IT, LU, MC, NL, PT, SE).
`
`(30) Priority data :
`07/911,507
`
`IOJuly 1992 (10.07.92)
`
`us
`
`Published
`With international search report.
`
`(71) Applicant: LUMITEX, INC. [US/US]; 8443 Dow Circle,
`Strongsville, OH 44136 (US).
`
`(72) Inventors: PARKER, Jeffery, R. ; 14272 Bridle Trail Drive,
`Strongsville, OH 44136 (US). MILLER, Mark, D. ; 2419
`Fortune Avenue, Parma, OH 44134 (US).
`
`(74) Agent: OTTO, Donald, L.; Renner, Otto, Boisselle & Sklar,
`1621 Euclid Avenue, 19th Floor, Cleveland, OH 44115
`(US).
`
`(54) Title: FIBER OPTIC LIGHT EMITTING PANEL ASSEMBLIES AND METHODS OF MAKING SUCH PANEL AS(cid:173)
`SEMBLIES
`
`(57) Abstract
`
`Fiber optic light emitting panel assemblies ( 1) include one or more light emitting layer ( 1 ') which are sealed along the side
`edges and/or an end edge to hold the fill threads (7) in position and keep the light emitting portions (2) from fraying at the edges.
`A thin film, sheet or coating (42', 44') may be applied to one or both sides of the light emitting portions of the panel assemblies
`(I). At one or both ends of the light emitting portions (2) is a light cable (3) which may be formed by randomly distributing the
`optical fibers (6) which comprise the light cable into a plurality of discrete bundles each including fibers extending from different
`locations across substantially the entire width of the light emitting -portions (2) bringing the discrete bundles together to form a
`single bundle of all of the fibers in each light cable (3), and applying a connector assembly (5, 5') to the cut ends of all of the fib(cid:173)
`ers in each light cable (3).
`
`Page 1 of 30
`
`TOYOTA EXHIBIT 1008
`
`

`

`FOR THE PURPOSES OF INFORMATION ONLY
`
`Codes used to identify States party to the Per on the front pages of pamphlets publishing international
`applications under the Per.
`
`AT
`AU
`BB
`BE
`BF
`BG
`BJ
`BR
`BY
`CA
`CF
`CG
`CH
`Cl
`CM
`CN
`cs
`cz
`DE
`DK
`ES
`Fl
`
`Austria
`Australia
`Barbados
`Belgium
`Burkina Faso
`Bulgaria
`Benin
`Brazil
`Belarus
`Canada
`Central African Republic
`Congo
`Switzerland
`Cllte d 'lvoire
`Cameroon
`China
`Ctechoslovakia
`Czech Republic
`Germany
`Denmark
`Spain
`Finland
`
`FR
`GA
`GB
`GN
`GR
`HU
`IE
`IT
`JP
`KP
`
`KR
`KZ
`Ll
`LK
`LU
`LV
`MC
`MG
`ML
`MN
`
`France
`Gabon
`United Kingdom
`Guinea
`Greece
`Hungary
`Ireland
`Italy
`Japan
`Democratic People's Republic
`of Korea
`Republic of Korea
`Kazakhstan
`liechtenstein
`Sri Lanka
`Luxembourg
`Latvia
`Monaco
`Madagascar
`Mali
`Mongolia
`
`MR
`MW
`NE
`NL
`NO
`NZ
`PL
`PT
`RO
`RU
`so
`SE
`Sl
`SK
`SN
`TO
`TG
`UA
`us
`uz
`VN
`
`Mauritania
`Malawi
`Niger
`Netherlands
`Norway
`New Zealand
`Poland
`Portugal
`Romania
`Russian Federation
`Sudan
`Sweden
`Slovenia
`Slovak Republic
`Senegal
`Chad
`·Togo
`Ukraine
`United States of America
`Uzbekistan
`VietNam
`
`..
`~
`
`~
`
`Page 2 of 30
`
`

`

`wo 94/01716
`
`PCf /US93/06448
`
`FIBER OPTIC LIGHT EMITTING PANEL ASSEMBLIES
`AND ~THODS OF MAKING SUCH PANEL ASSEMBLIES
`
`FIELD OF THE INVENTION
`
`5
`
`This invention relates generally to improvements in light emitting panel
`
`assemblies made of woven optical fibers and to methods of making such panel
`
`assemblies.
`
`BACKGROUND OF THE INVENTION
`
`It is generally known to make light emitting panel assemblies from one
`
`10
`
`or more layers of woven optical fiber strands. Light is caused to be emitted
`
`from the light emitting portion of the panel assemblies by disrupting the surface
`
`of the optical fibers in the light emitting portion as by scratching or otherwise
`
`deforming or bending the optical fibers at a plurality of discrete locations along
`
`the length of the fibers such that the angle of bend approximately exceeds the
`
`15
`
`angle of internal reflection. The percentage of light emitted from each bend is
`
`proportional to the bend radius and arc length. By controlling the weave
`
`spacing and pattern of the woven optical fibers in the light emitting portion, one
`
`can control the desired light output pattern therefrom.
`
`Woven fiber optic light emitting panel assemblies generally of this type
`
`20
`
`are disclosed in U.S. Patents 4,885,663; 4,907,132 and 5,042,900, assigned to
`
`the same assignee as the present application, which are incorporated herein by
`
`reference.
`
`SUMMARY OF THE INVENTION
`
`The present invention relates to certain improvements in such fiber optic
`
`25
`
`light emitting panel assemblies and to the methods of making same.
`
`In accordance with one aspect of the invention, the light emitting portions
`
`of the panel assemblies are sealed along one or more edges to hold the fill
`
`threads in position and keep the light emitting portions from fraying at the
`
`sealed edge or edges. In one form of the invention, the side edges are heat
`
`30
`
`sealed. Alternatively, the side edges may be sealed by applying an adhesive to
`
`the side edges or by taping the side edges. In lieu of or in addition to sealing
`
`Page 3 of 30
`
`

`

`WO 94/01716
`
`PCf /US93/06448
`
`-2-
`
`the side edges, one or both end edges of the light emitting portions may be
`
`similarly sealed.
`
`In accordance with another aspect of the invention, a plurality of smaller
`
`panel assemblies may be made from a single larger panel assembly by sealing
`
`5
`
`the larger light emitting portion along one or more spaced apart longitudinal
`
`areas or strips intermediate the side edges, and then slitting the larger light
`
`emitting portion intermediate the width of the intermediate sealed areas to
`
`separate the larger light emitting portion and associated light cable fibers into a
`
`plurality of individual smaller light emitting panel assemblies.
`
`1 0
`
`In accordance with another aspect of the invention, the light emitting
`
`portions of the panel assemblies may comprise a plurality of individually formed
`
`layers of woven optical fibers joined together along one or more edges to
`
`maintain the weave spacing in such layers staggered in relation to each other to
`
`provide for more uniform light output from the light emitting portions.
`
`15
`
`In accordance with another aspect of the invention, one or more light
`
`cables may be provided at one or both ends of the light emitting portion of each
`
`panel assembly. Preferably the light cables are formed during the continuous
`
`manufacture of a plurality of panel assemblies by interrupting the weaving
`
`process between light emitting portions while continuing to advance the optical
`
`20
`
`fibers to form non-woven optical fiber lengths which comprise the light cable
`
`portions. Predetermined optical fibers within each light cable length may be
`
`separated into different groups or layers of fibers and the layers mechanically
`
`maintained separated from each other so that when the continuously made panel
`
`assemblies are cut apart and the separate layers of fibers which comprise the
`
`25
`
`light cables are bundled together, the optical fibers will be randomly distributed
`
`within the bundle. A connector assembly is then attached to a remote end of
`
`each bundle of optical fibers which comprise each light cable to maintain the
`
`Page 4 of 30
`
`

`

`' WO 94/01716
`
`PCf /US93/06448
`
`-3-
`
`desired distribution of the optical fibers in each light cable and provide an
`
`interface between the light cable and a remote light source.
`
`In accordance with another aspect of the invention, a thin film, sheet or
`
`coating may be applied to one or both sides of sealed or non-sealed light
`
`5
`
`emitting portions of the panel assemblies. In one form of the invention, the film
`
`or sheet covering comprises a tube or sleeve surrounding the light emitting
`
`portion. One or both ends of the tube may be joined to one or both end edges
`
`of the light emitting portion as desired. Also, one or more light cables may be
`
`connected to one or both ends of the light emitting portion for transmitting light
`
`1 0
`
`to the light emitting portion from one or more remote light sources. In another
`
`form of the invention, the film or sheet covering comprises a pocket having an
`
`opening along one side edge only for insertion of the light emitting portion into
`
`the pocket. This film or sheet covering or coating over one or both sides of the
`
`light emitting portion may comprise a clear or translucent film, a prismatic or
`
`15
`
`polarizer film, or a diffuser for diffusing or directing the light emitted from the
`
`light emitting portion. Alternatively, the film or sheet covering or coating over
`
`one side of the light emitting portion may comprise a reflector for reflecting
`
`light emitted from one side of the light emitting portion back through the light
`
`emitting portion such that light is emitted from only one side of the light
`
`20
`
`emitting portion.
`
`These and other objects, advantages, features and aspects of the present
`
`invention will become apparent as the following description proceeds.
`
`To the accomplishment of the foregoing and related ends, the invention,
`
`then, comprises the features hereinafter fully described and particularly pointed
`
`25
`
`out in the claims, the following description and the annexed drawings setting
`
`forth in detail certain illustrative embodiments of the invention, these being
`
`indicative, however, of but several of the various ways in which the principles
`
`of the invention may be employed.
`
`Page 5 of 30
`
`

`

`wo 94/01716
`
`Per /US93/06448
`
`-4-
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`In the annexed drawings:
`
`Fig. 1 is a schematic fragmentary top plan view of one form of light
`
`emitting panel assembly in accordance with this invention;
`
`5
`
`Fig. 2 is an enlarged schematic top plan view of the upper right-hand
`
`comer of the light emitting portion of the panel assembly of Fig. 1;
`
`Fig. 3 is an enlarged schematic longitudinal section through an end edge
`
`of the light emitting portion of Fig. 2 taken generally on the plane of the line 3-
`
`3 thereof showing one or more fill threads adjacent the end edge heat sealed to
`
`1 0
`
`the longitudinal fibers;
`
`Fig. 3A is an enlarged fragmentary transverse section through an end
`
`edge of a light emitting portion similar to Fig. 3 but showing more severe heat
`
`sealing of the fill threads and longitudinal fibers together at the end edge;
`
`Fig. 4 is an enlarged fragmentary transverse section through one of the
`
`15
`
`side edges of the light emitting portion of Fig. 2 taken generally along the plane
`
`of the line 4-4 thereof showing one or more fill threads heat sealed to the
`
`longitudinal fibers adjacent such side edge;
`
`Fig. 4A is an enlarged fragmentary transverse section through a side edge
`
`of a light emitting portion of a panel assembly similar to Fig. 4 but showing one
`
`20
`
`or more fill threads adhesively bonded to the longitudinal fibers;
`
`Fig. 5 is an enlarged fragmentary longitudinal section through an end
`
`edge of a light emitting portion of a panel assembly similar to Fig. 3 but
`
`showing one or more fill threads and longitudinal fibers sealed together adjacent
`
`the end edge by applying pressure sensitive adhesive tape thereto;
`
`25
`
`Fig. 6 is an enlarged fragmentary longitudinal section through an end
`
`edge of a light emitting portion of a panel assembly similar to Fig. 3 but
`
`showing a thin film, sheet or coating over opposite sides of the light emitting
`
`portion;
`
`Page 6 of 30
`
`

`

`W094/01716
`
`PCf /US93/06448
`
`-5-
`
`Fig. 7 is a schematic perspective view, on a reduced scale, of a pocket
`
`for receiving one or more light emitting portion layers of a panel assembly
`
`therein;
`
`Fig. 8 is a schematic perspective view, on a reduced scale, of a tube for
`
`5
`
`receiving one or more light emitting portion layers of a panel assembly therein;
`
`Fig. 9 is an enlarged schematic fragmentary longitudinal section showing
`
`a light emitting portion of a panel assembly inserted into the pocket of Fig. 7;
`
`Fig. 10 is an enlarged schematic fragmentary longitudinal section
`
`showing a light emitting portion of a panel assembly inserted into the tube of
`
`10
`
`Fig. 8 with one end of the tube in sealing engagement with an end edge of the
`
`light emitting
`
`portion;
`
`Fig. 1 OA is an enlarged schematic fragmentary longitudinal section
`
`through a light emitting portion of a panel assembly inserted into a tube similar
`
`15
`
`to Fig. 10 but showing one or more light cables connected to both ends of the
`
`light emitting portion;
`
`Fig. 11 is an enlarged schematic fragmentary longitudinal section through
`
`a multi-layered light emitting portion of a panel assembly;
`
`Fig. 12 is an enlarged schematic fragmentary longitudinal section through
`
`20
`
`a multi-layered light emitting portion of a panel assembly similar to Fig. 11, but
`
`showing a thin film, sheet or coating over opposite sides of the light emitting
`
`portion;
`
`Fig. 13 is a schematic perspective view, on a reduced scale, showing a
`
`panel assembly in accordance with this invention heat formed into a desired
`
`25
`
`shape for a particular application;
`
`Fig. 14 is a schematic fragmentary top plan view of a multi-width panel
`
`assembly in accordance with this invention;
`
`Page 7 of 30
`
`

`

`WO 94/01716
`
`PCf /US93/06448
`
`-6-
`
`Fig. 15 is a schematic fragmentary top plan view of a plurality of panel
`
`assemblies made from the enlarged panel assembly of Fig. 14;
`
`Figs. 16 through 23 are schematic illustrations sequentially showing how
`
`automatic process equipment used to weave the light emitting portions of the
`
`5
`
`panel assemblies may also be used to randomly distribute the optical fibers
`
`which comprise the light cable portions of the panel assemblies into a plurality
`
`of discrete bundles each including fibers from different locations across
`
`substantially the entire width of the light emitting portions;
`
`Fig. 24 is an enlarged schematic transverse section through a plurality of
`
`1 0
`
`such discrete bundles of optical fibers which comprise a light cable spaced apart
`
`from each other;
`
`Fig. 25 is an enlarged schematic fragmentary transverse section through a
`
`plurality of discrete bundles of optical fibers which comprise a light cable
`
`similar to Fig. 24 but showing the bundles in close relation to each other; and
`
`15
`
`Fig. 26 is an enlarged schematic fragmentary longitudinal section through
`
`a connector assembly applied to all of the cut ends of the bundled optical fibers
`
`of Fig. 25.
`
`DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
`
`Referring now in detail to the drawings, and initially to Fig. 1, there is
`
`20
`
`schematically shown one form of fiber optic light emitting panel assembly 1 in
`
`accordance with this invention including a light emitting portion 2 and one or
`
`more fiber optic light cable portions 3 at one or both ends of the light emitting
`
`portion for transmitting light from one or more remote light sources 4 to one or
`
`both ends of the light emitting portion. One such light cable portion 3 is shown
`
`25
`
`in solid lines in Fig. 1 connected to one end of the light emitting portion, and
`
`two additional light cable portions 3' are shown in phantom lines connected to
`
`the other end of the light emitting portion. At the outermost end of each light
`
`cable is a connector assembly 5 or 5' which serves as an interface between the
`
`Page 8 of 30
`
`

`

`W094/01716
`
`PCf /US93/06448
`
`-7-
`
`optical fiber ends of the light cable and the remote light source 4 or 4'. The
`
`light cable 3 or 3' and connector assembly 5 or 5' may be of the type disclosed,
`
`for example, in the aforementioned U.S. Patent No. 5,042,900.
`
`As schematically illustrated in Fig. 2, the light emitting portion 2 of the
`
`5
`
`panel assembly comprises one or more layers of woven optical fibers 6. Usually
`
`the optical fibers 6 of each layer are woven only in the warp direction, with fill
`
`threads 7 woven in the weft direction. However, the fill threads 7 could also be
`
`optical fibers if desired. The spacing between both the optical fibers 6 and the
`
`fill threads 7 is greatly exaggerated in Fig. 2 for reasons of clarity.
`
`10
`
`Each optical fiber 6 may consist of one or more optical fiber strands each
`
`including a light transmitting core portion of a suitable transparent material and
`
`an outer sheath or cladding of a second transparent material having a relatively
`
`lower index of refraction than the core material to assist in preventing the escape
`
`of light along its length. The core material can be made of either glass or
`
`15
`
`plastic or a multi-strand filament having the desired optical characteristics. The
`
`index of refraction of the. outer sheath material is less than that of the core
`
`material, whereby substantially total reflection is obtained at the sheath-core
`
`interface, as well known in the art.
`
`Light is emitted from the light emitting portion 2 as by weaving the
`
`20
`
`optical fibers 6 and fill threads 7 to produce bends 14 in the optical fibers as
`
`schematically shown in Fig. 3 that cause a percentage of the light to escape at
`
`the bends. By controlling the weave spacing and pattern of the optical fibers
`
`and fill threads in the light emitting portion, any desired output pattern of light
`
`from the light emitting portion can be achieved.
`
`25
`
`At least one edge of the light emitting portion 2 is desirably sealed by
`
`adhering the optical fibers 6 and fill threads 7 together to hold the fill threads 7
`
`in position and· keep the optical fibers 6 from separating or fraying from the
`
`light emitting portion. In the embodiment shown in Figs. 1 through 4, the
`
`Page 9 of 30
`
`

`

`W094/01716
`
`PCT /US93/06448
`
`-8-
`
`optical fibers 6 and fill threads 7 adjacent both side edges 8, 9 and one end edge
`
`10 of the light emitting portion 2 are heat sealed together at 11. Fig. 3A shows
`
`more severe heat sealing between the fibers 6 and fill threads 7 than in Figs. 2
`
`through 4.
`
`5
`
`Alternatively, one or both side edges and, if desired, one or both end
`
`edges may be sealed either by ultrasonic welding or gluing the optical fibers and
`
`fill threads together at 12 along one or both side edges and end edges as
`
`schematically shown in Fig. 4A, or by applying pressure sensitive adhesive tape
`
`15 thereto as schematically shown in Fig. 5. Moreover, the border areas 16 of
`
`10
`
`the side edges 8, 9 of the light emitting portion 2 which are sealed may be
`
`woven with nonoptical fibers 17 as schematically shown in Fig. 2 if desired.
`
`Although two optical fibers 6 and fill threads 7 are shown sealed together along
`
`one or more edges of the light emitting portion in Figs. 2 through 5, it should be
`
`understood that more or less fibers and fill threads may be sealed together along
`
`15
`
`such edges as desired.
`
`During the manufacturing process, a plurality of smaller panel assemblies
`
`1' may be made from a single larger panel assembly 1 by sealing the larger light
`
`emitting portion 2 at one or more areas 20 intermediate the side edges 8, 9 along
`
`the axial length thereof as schematically shown in Fig. 14, and then slitting the
`
`20
`
`larger light emitting portion 2 intermediate the width of the intermediate sealed
`
`areas 20 to separate the larger light emitting portion and associated light cable
`
`fibers 6 into a plurality of smaller light emitting panel assemblies 1 ' as
`
`schematically shown in Fig. 15.
`
`The light cables 3 may be formed during the continuous manufacture of
`
`25
`
`such light emitting panel assemblies 1 by periodically interrupting the weaving
`
`process while continuing t? advance the optical fibers 6 through automatic
`
`process equipment 25 to produce the non-woven optical fiber lengths which
`
`comprise the light cable portions as schematically shown in Figs. 16-23. After
`
`Page 10 of 30
`
`

`

`wo 94/01716
`
`PCf /US93/06448
`
`-9-
`
`one or more of the continuously formed panel assemblies have cleared the exit
`
`fiber web guide 26, the desired length of non-woven optical fibers 6 needed to
`
`form the light cable portion 3 is severed from the next panel assembly as
`
`schematically shown in Fig. 23 and the cut fibers are bundled together to form
`
`5
`
`either a ribbon cable or a round cable as described hereafter. The guide 26 may
`
`either be a pair of bars or rolls used to maintain the fibers at the desired height
`
`during the manufacturing process. During the bundling of the light cable fibers
`
`together, it is desirable to randomly distribute the optical fibers within the cable
`
`so that when a connector assembly is attached to the cable fibers adjacent the
`
`1 0
`
`cut ends thereof, the relative position of each optical fiber is generally random
`
`or in a predetermined position to produce predetermined lighting effects in the
`
`light emitting portion of the panel assembly when the light cable is coupled with
`
`a light source.
`
`In the process equipment 25 shown in Figs. 16-22, the fiber harnesses
`
`15
`
`27-30 which raise and lower different optical fibers 6 to permit the fill threads 7
`
`to be passed between the optical fibers 6 during the weaving process, may also
`
`be used to separate predetermined individual optical fibers into different groups
`
`or layers of fibers. In the example shown in Figs. 16-22, four harnesses 27-30
`
`are shown, each including a plurality of spaced apart heddles 31 through which
`
`20
`
`individual optical fibers pass at different locations across substantially the entire
`
`width of the weaving section. However, it should be understood that more or
`
`less than four harnesses may be provided as desired. The fiber harnesses 27-30
`
`may be raised and lowered in any desired sequence to separate predetermined
`
`individual fibers into different layers or groups and the fibers in the different
`
`25
`
`layers or groups maintained separate from each other by insertion of mechanical
`
`dividers or separators such as strings or cable ties 32-35 between the respective
`
`layers as described hereafter.
`
`Page 11 of 30
`
`

`

`wo 94/01716
`
`PCT /US93/06448
`
`-10-
`
`Figs. 16-21 show the fibers in the randomization area of the panel
`
`assembly being separated into four separate layers 36-39 first by raising a first
`
`harness 27 and inserting a first separator 32 between a first group 36 of raised
`
`fibers and the remaining fibers as shown in Figs. 16 and 17, then raising a
`
`5
`
`second harness 28 and inserting a second separator 33 between a second group
`
`37 of raised fibers and the remaining fibers as shown in Figs. 18 and 19, and
`
`then raising a third harness 29 and inserting one or two additional separators 34
`
`and 35 between a third group 38 of raised fibers and the remaining group 39 of
`
`fibers. Then all of the raised harnesses 27-29 are returned to their original
`
`10
`
`positions and the fibers are advanced through the exit fiber web guide 26 with
`
`the separators 32-35 still in position between the various groups 36-39 of fibers
`
`as schematically shown in Fig. 22. After one or more continuously formed
`
`panel assemblies have cleared the exit fiber web guide 26, the desired length of
`
`non-woven optical fibers 6 needed to form the light cable 3 is severed by a
`
`15
`
`knife 41 as schematically shown in Fig. 23 and the individual separators 32-35
`
`are wrapped around the separate groups of fibers to hold them in the separate
`
`bundles as shown in Fig. 24. If desired, only one separator 34 need be inserted
`
`between the third group 38 of raised fibers and the remaining group 39 of fibers,
`
`in which event the fourth separator 35 is wrapped around the remaining group
`
`20
`
`39 of fibers at this time. Then the separate bundles are brought together as
`
`shown in Fig. 25 and a connector assembly 5 is applied to the cut ends as
`
`schematically shown in Fig. 26. Finally the separators 32-35 are removed to
`
`complete the assembly.
`
`If desired, two or more of these panel layers 1' may be joined together
`
`25
`
`along one or both end edges and/or side edges to form a multi-layered light
`
`emitting portion 2' that emits a brighter and/or more uniform light. These layers
`
`may be joined together as by heat sealing, ultrasonic welding or gluing the end
`
`and/or side edges together. Also, they may be joined together by weaving,
`
`Page 12 of 30
`
`

`

`wo 94/01716
`
`PCf /US93/06448
`
`-11-
`
`sewing, laminating or other joining method. Preferably, the multi-layers of the
`
`light emitting portion 2' are joined together such that their relative weave
`
`spacings are staggered as schematically shown in Figs. 11 and 12 so that the
`
`light emitting portion 2' will produce a more uniform light output. The
`
`5
`
`individual optical fibers 6' in the cable portion 3' of each panel layer may be
`
`randomly grouped into a plurality of discrete bundles and then bundled together
`
`to form one or more light cables for connection to one or more remote light
`
`sources as desired.
`
`Also, a thin film, sheet or coating may be applied to one or both sides of
`
`10
`
`the light emitting portion 2 or 2' and joined thereto as by heat sealing, ultrasonic
`
`welding, laminating, gluing, epoxying or any other method. Figs. 6 and 12
`
`show a separate sheet or film 40, 42 and 40', 42' suitably applied to opposite
`
`sides of a single and multi-layered light emitting portion 2 and 2', respectively.
`
`One or both layers 40, 42 and 40', 42' may be a clear or translucent film,
`
`15
`
`prismatic film, or coating used to protect the light emitting portion and/or
`
`diffuse or direct the light output from one or both sides of the light emitting
`
`portion. Also, one or both layers may be used to produce light or color effects.
`
`Moreover, one of the layers may comprise a back reflector for reflecting light
`
`back through the light emitting portion such that light is emitted from only one
`
`20
`
`side of the light emitting portion.
`
`The two layers 40, 42, one of which may be a back reflector 44, may
`
`initially be in the form of a tube 45 sealed along two sides 46, 47 as
`
`schematically shown in Fig. 8. One or more light emitting layers 2, 2' may be
`
`inserted into one end 48 of the tube 45, and one or both ends 48, 49 sealed to
`
`25
`
`the end edges of the light emitting layers to hold the light emitting layers within
`
`the tube as schematically shown in Figs. 1 0 and 1 OA. Also, one or more light
`
`cables 3 may be connected to one or both ends of the light emitting portion 2
`
`through the open ends of the tube 45 as schematically shown in Fig. 1 OA.
`
`Page 13 of 30
`
`

`

`WO 94/01716
`
`PCf /US93/06448
`
`-12-
`
`Where more than one light emitting layer is inserted, the sealing of one or both
`
`ends of the tube 45 to the multi-layers 2' may be used to maintain the weave
`
`spacing in such layers in the desired staggered relation to provide more uniform
`
`light output from the light emitting portion similar to Fig. 12.
`
`5
`
`Alternatively, the two layers 50, 52, one of which may be a back
`
`reflector 53 if desired, may be in the form of a pocket 54 sealed along two sides
`
`55, 56 and one end 57, leaving the other end 58 open as shown in Fig. 7 for
`
`insertion of one or more light emitting layers 2 or 2' into the pocket 54 to
`
`complete the panel assembly as schematically shown in Fig. 9.
`
`10
`
`The light emitting portions 2 and 2' and light cable portions 3 and 3' of
`
`the panel assemblies may be left flat or heat formed to different shapes for
`
`different applications. One such panel assembly 1 is schematically shown in
`
`Fig. 13 heat formed into a generally U-shape with the ends 60, 61 of the light
`
`emitting portion 2 and light cable portion 3 extending generally at right angles
`
`15
`
`to the remainder of the light emitting portion.
`
`Such light emitting panel assemblies may be used for different
`
`applications, including for example back lighting, medical light sources, product
`
`lighting and theatrical applications and safety lighting. Typical back lighting
`
`· applications would be back lighting liquid crystal displays, membrane switches,
`
`20
`
`alphanumeric displays, camera systems used in inspection, sorting, counting and
`
`assembly operations, and other instrumentation involving graphics, color or high
`
`information content and the like. Typical medical light sources would be for
`
`phototherapy, diagnostic, dental and other medical applications. Typical product
`
`lighting applications would be food inspection lighting, hazardous area lighting,
`
`25
`
`and exit lighting. Typical safety lighting would be automotive courtesy and
`
`safety lighting and athletic safety lighting, for example, for jogging suits and
`
`running shoes ·and the like.
`
`Page 14 of 30
`
`

`

`wo 94/01716
`
`PCf /US93/06448
`
`-13-
`
`A variety of remote light sources may also be used for providing light to
`
`the panel assemblies including for example light emitting diodes, halogen lights,
`
`incandescent bulbs, arc lamps, and so on.
`
`Although the invention has been shown and described with respect to
`
`5
`
`certain preferred embodiments, it is obvious that equivalent alterations and
`
`modifications will occur to others skilled in the art upon the reading and
`
`understanding of the specification. The present invention includes all such
`
`equivalent alterations and modifications, and is limited only by the scope of the
`
`claims.
`
`Page 15 of 30
`
`

`

`wo 94/01716
`
`PCf /US93/06448
`
`-14-
`
`What is claimed is:
`
`1.
`
`A light emitting panel assembly comprising a light emitting
`
`portion formed by a plurality of woven optical fibers and fill threads extending
`
`transversely of said fibers, said fibers having disruptions or bends at discrete
`
`5
`
`locations along the length of said fibers to allow light to be emitted therefrom,
`
`said light emitting portion having side edges and end edges, and means for
`
`adhering said fibers and said fill threads together along at least one of said edges
`
`of said light emitting portion to prevent said fibers from separating from said
`
`light emitting portion at said one edge.
`
`10
`
`2.
`
`The assembly of claim 1 wherein said fibers are made of plastic,
`
`and said means for adhering comprises heat sealing said fibers to said fill
`
`threads along said one edge.
`
`3.
`
`The assembly of claim 1 wherein said means for adhering
`
`comprises adhesive means adhering said fibers and said fill threads together
`
`15
`
`along said one edge.
`
`4.
`
`The assembly of claim 1 wherein said means for adhering
`
`comprises tape means adhering said fibers and said fill threads together along
`
`said one edge.
`
`5.
`
`The assembly of claim 1 wherein said fibers and said fill threads
`
`20
`
`are adhered together along at least one of said end edges of said light emitting
`
`portion.
`
`6.
`
`The assembly of claim 1 wherein said fibers and said fill threads
`
`are adhered together along said side edges of said light emitting portion.
`
`7.
`
`The assembly of claim I further comprising a light cable
`
`25
`
`extending from an end of said light emitting portion, and connector means at a
`
`remote end of said light cable which serves as an interface between said light
`
`cable and a remote light source.
`
`Page 16 of 30
`
`

`

`wo 94/01716
`
`PCf /US93/06448
`
`-15-
`
`The assembly of claim 7 wherein said light cable comprises a
`8.
`continuation of said fibers in said light emitting portion.
`The assembly of claim 8 wherein said fibers which comprise said
`9.
`light cable are randomly distributed into a plurality of discrete bundles which
`collectively form a single bundle of all of said fibers in said light cable.
`The assembly of claim 9 wherein each of said discrete bundles
`10.
`includes fibers extending from said light emitting portion at different locations
`across substantially the entire width of said light emitting portion.
`The assembly of claim 1 wherein said light emitting portion
`11.
`comprises a plurality of separate layers of said woven optical fibers joined
`together along one of said edges of said light emitting portion.
`The assembly of claim 11 wherein said layers are joined together
`12.
`such that the fill threads in one layer are offset with respect to the fill threads in
`another layer to provide for more uniform light output from said light emitting
`portion.
`
`The assembly of claim 11 wherein the fill threads in each layer
`13.
`provide a predetermined weave spacing in each layer, said layers being joined
`together such that the weave spacing in one of said layers is staggered with
`respect to the weave spacing in another layer to produce a more. uniform light
`output from said light emitting portion.