Optical converter formed from flexible strips

• US 20040108046A1
• Filed: 12/09/2002
• Published: 06/10/2004
• Est. Priority Date: 12/09/2002
• Status: Active Grant

• Current Assignee: Eastman Kodak Company
• Original Assignee: Eastman Kodak Company
• Inventors: Kerr, Roger S., Kessler, David, Cok, Ronald S.
• Granted Patent: US 7,292,760 B2
• Time in Patent Office: Days
• US Class Current: 156/204
• CPC Class Codes: G02B 6/04 formed by bundles of fibres G02B6/24 takes precedence
• CPC Class Codes: H10K 50/80 Constructional details
• CPC Class Codes: H10K 50/85 Arrangements for extracting light from the devices
• CPC Class Codes: H10K 59/18 Tiled displays
• CPC Class Codes: Y10T 156/1002 with permanent bending or reshaping or surface deformation of self sustaining lamina
• CPC Class Codes: Y10T 156/1015 Folding
• CPC Class Codes: Y10T 156/1051 by folding

Abstract

A fiber optic faceplate fabricated using a series of stacked ribbon structures. Each ribbon structure comprises optical fiber segments that run from an input edge to an output edge with fixed input and output fiber-to-fiber spacing. Input and output edge spacers may be used to provide spacing between stacked ribbon structures. Ribbon structures may be provided individually or as one or more sheets of ribbon structures.

Claims

1. A fiber optic faceplate, comprising:

a series of stacked ribbon structures, each ribbon structure comprising a single row of parallel disposed optical fibers, each optical fiber running from an input edge to an output edge of said ribbon structure, the length of each optical fiber thereby determining a depth dimension of said ribbon structure, each fiber having, relative to an adjacent fiber, an input spacing at said input edge and an output spacing at said output edge for directing light from an input position to an output position respectively.

2. A fiber optic faceplate according to claim 1, wherein each said stacked ribbon structure further having, relative to an adjacent ribbon structure, an input row-to-row spacer for setting the distance between said input edges, each said stacked ribbon structure further having, relative to an adjacent ribbon structure, an output row-to-row spacer for setting the distance between said output edges.

3. A fiber optic faceplate according to claim 2, wherein said input row-to-row spacer is plastic.

4. A fiber optic faceplate according to claim 2, wherein said input row-to-row spacer is magnetic.

5. A fiber optic faceplate according to claim 1, further comprising a filler material for securing each said optical fiber in place.

6. A fiber optic faceplate according to claim 1, wherein said optical fibers in said each ribbon structure have the same radius dimension.

7. A fiber optic faceplate according to claim 1, wherein said optical fibers in said each ribbon structure have a plurality of shapes.

8. A fiber optic faceplate according to claim 5, wherein said filler material is black.

9. A fiber optic faceplate according to claim 5, wherein said filler material comprises a reflective material.

10. A fiber optic faceplate according to claim 1, wherein said optical fiber is circular in cross-section.

11. A fiber optic faceplate according to claim 1, wherein said optical fiber is non-circular in cross-section.

12. A fiber optic faceplate according to claim 1, wherein successive stacked ribbon structures differ in said depth dimension.

13. A fiber optic faceplate according to claim 1, wherein successive stacked ribbon structures are formed with a predetermined curvature.

14. A fiber optic faceplate according to claim 1, further comprising a coating.

15. A fiber optic faceplate according to claim 1, further comprising a polarizer at said output edge.

16. An image forming device comprising:

(a) an emissive device comprising a spaced array of light-emitting components; and

(b) a fiber optic faceplate comprising a plurality of stacked ribbon structures, each ribbon structure comprising a single row of parallel disposed optical fibers.

17. An image forming device according to claim 16, wherein said emissive device is taken from the group consisting of OLED, PLED, LED.

18. An image forming device according to claim 16, wherein said emissive device is fabricated against said fiber optic faceplate.

19. A method for forming an optical converter comprising:

(a) forming a plurality of ribbon structures, each ribbon structure having a ribbon width defined by an input edge and an output edge and having a single row of side-by-side light pipe segments, each light pipe segment providing an optical path from an input at said input edge to an output at said output edge; and

(b) successively stacking said ribbon structures atop one another to build up said optical converter as a stack of adjacent rows of said light pipe segments.

20. A method for forming an optical converter according to claim 19, wherein the step of forming a plurality of ribbon structures comprises:

(i) defining said input edge by positioning an input edge spacer, running in a length direction, and defining said output edge by positioning an output edge spacer, running in said length direction;

(ii) lining up, side-by-side in a single layer and generally in parallel to each other along said length direction, a plurality of optical fiber segments for directing light from said input edge to said output edge; and

(iii) fixing an input spacing between said fiber segments at said input edge spacer and an output spacing between said fiber segments at said output edge spacer.

21. A method for forming an optical converter according to claim 19, wherein the step of stacking said ribbon structures comprises the step of aligning each successive ribbon structure, thereby aligning said light pipe segments in each row.

22. A method for forming an optical converter according to claim 20, wherein the step of positioning said output edge spacer comprises the step of applying an adhesive.

23. A method for forming an optical converter according to claim 19, further comprising adding a filler material to adhere said adjacent rows within said stack.

24. A method for forming an optical converter according to claim 20, wherein the step of positioning said input edge spacer comprises the step of positioning a ferromagnetic component.

25. A method for forming an optical converter according to claim 20, wherein the step of positioning said input edge spacer comprises the step of positioning said input edge spacer comprising ferrous material.

26. A method for forming an optical converter according to claim 19, wherein the step of stacking comprises the step of providing an offset for image tiling.

27. A method for forming an optical converter according to claim 19, wherein the step of forming a plurality of ribbon structures further comprises the step of bending to provide a curvature to said output edge.

28. A method for forming an optical converter according to claim 19, wherein the step of stacking further comprises the step of positioning an alignment element.

29. A method for forming an optical converter according to claim 19, further comprising the step of applying heat for finishing ends of said optical fiber segments.

30. A method for forming an optical converter according to claim 19, wherein the step of stacking said ribbon structures comprises repeatedly folding said ribbon structure back upon itself to form adjacent, overlaid rows of said light pipe segments, thereby forming the optical converter having a depth determined by said ribbon width.

31. A method for forming an optical converter according to claim 19, further comprising the step of immersing said optical fiber faceplate in a liquid for providing a filler material.

32. A method for forming an optical converter according to claim 19, further comprising the step of inserting an additional spacer between adjacent rows.

33. A method for forming an optical converter according to claim 32, wherein said additional spacer determines spacing between adjacent said ribbon structures at said input edge.

34. A method for forming an optical converter according to claim 32, wherein said additional spacer determines spacing between adjacent said ribbon structures at said output edge.

35. A method for forming an optical converter according to claim 29, wherein the step of applying heat forms a lens structure for each said optical fiber.

36. A method for forming an optical converter according to claim 20, further comprising the step of slitting said input edge spacer to provide relief cuts.

37. A method for forming an optical converter according to claim 20, further comprising the step of trimming said output edge spacer to provide a curvature.

38. A method for forming an optical converter according to claim 19, further comprising the step of applying a surface coating.

39. A method for forming an optical fiber faceplate comprising:

(a) forming a sheet comprising a plurality of ribbon structures, each ribbon structure having a ribbon width defined by an input edge and an output edge, by

(i) defining said input edge by positioning an input edge spacer, running in a length direction, and defining said output edge by positioning an output edge spacer, running in said length direction;

(ii) lining up, side-by-side in a single layer and generally in parallel to each other along said length direction, a plurality of optical fiber segments for directing light from said input edge to said output edge;

(iii) fixing an input spacing between said fiber segments at said input edge spacer and an output spacing between said fiber segments at said output edge spacer;

(iv) providing a separation gap between any two adjacent said ribbon structures on said sheet;

each said ribbon structure comprising thereby a single row of said optical fiber segments having said fixed input and output spacing;

(b) accordion-folding said sheet together, folding at said separation gap, thereby stacking successive said ribbon structures atop one another to build up said optical fiber faceplate as a stack of adjacent rows of said optical fiber segments having said fixed input and output spacing.

40. A method for forming an optical fiber faceplate comprising

(a) forming a ribbon structure having a ribbon width defined by an input edge and an output edge, by

(i) defining said input edge by positioning an input edge spacer, running in a length direction, and defining said output edge by positioning an output edge spacer, running in said length direction;

(ii) lining up, side-by-side in a single layer and generally in parallel to each other along said length direction, a plurality of optical fiber segments for directing light from said input edge to said output edge;

(iii) fixing an input spacing between said fiber segments at said input edge spacer and an output spacing between said fiber segments at said output edge spacer;

said ribbon structure comprising thereby a single row of said optical fiber segments having said fixed input and output spacing; and

(b) repeatedly folding said ribbon structure back upon itself to form adjacent, overlaid rows of said optical fiber segments, thereby forming the optical fiber faceplate having a depth determined by said ribbon width.