Optical fiber substrate useful as a sensor or illumination device component

Abstract

This disclosure generally pertains to a method for manufacturing a distributed optical fiber scrim comprising a functional optical fiber, the functional optical fiber scrim thus manufactured, and composites in which an optical fiber scrim is incorporated. The present disclosure describes a variety of textile scrims, particularly adhesively bonded nonwoven scrim materials, each comprising at least one optical fiber with a continuous path across at least the length or width of the fabric. Such optical fiber scrims may be useful as sensor components (for example, as a detector of breakage, strain, pressure, or torque), as illumination components (for example, in a variety of light-providing applications), or as data-distribution components, either alone or in combination with other materials, such as fabrics, films, foams, and the like.

1 . A scrim fabric comprising (a) at least one warp yarn set having at least two yarns and (b) at least one yarn that crosses said warp yarn set, wherein at least one of said yarns is comprised of an optical fiber.  
     
     
         2 . The scrim fabric of  claim 1 , wherein said scrim has a construction selected from the group consisting of an adhesively bonded laid scrim, a thermally bonded laid scrim, a woven scrim, a weft-inserted warp knit scrim, a multi-axial knit scrim, a stitch-bonded scrim, and a cross-plied scrim.  
     
     
         3 . The scrim of  claim 1 , wherein said warp yarn set has yarns that are present in an amount of between about 1 yarn per every 60 inches and about 25 yarns per inch.  
     
     
         4 . The scrim of  claim 3 , wherein said warp yarn set has yarns that are present in an amount of between about 1 yarn per 30 inches and about 12 yarns per inch.  
     
     
         5 . The scrim fabric of  claim 1 , wherein said optical fiber has a core made of a material selected from the group consisting of glass and polymers.  
     
     
         6 . The scrim of  claim 1 , wherein said optical fiber has a change in light transmission characteristics when exposed to one or more sources selected from the group consisting of mechanical agents, chemical agents, moisture, temperature, pH changes, biological sources, neutrons, and ionizing radiation.  
     
     
         7 . The scrim fabric of  claim 1 , wherein said at least one optical fiber is of a type selected from the group consisting of single mode fibers, multi-mode fibers, light pipes, photosensitive fibers, polarization-maintaining fibers, multiple step-indexed fibers, graded index fibers, reduced cladding fibers, high index fibers, wave-guiding films, and photonic lattice fibers.  
     
     
         8 . The scrim fabric of  claim 7 , wherein said optical fiber is a single-mode fiber.  
     
     
         9 . The scrim of  claim 1 , wherein said at least one optical fiber comprises a compressible sheath.  
     
     
         10 . The scrim fabric of  claim 1 , wherein said warp yarn set comprises at least one optical fiber.  
     
     
         11 . The scrim fabric of  claim 1 , wherein at least one optical fiber crosses said warp yarn set.  
     
     
         12 . The scrim fabric of  claim 11 , wherein more than one optical fiber crosses said warp yarn set.  
     
     
         13 . The scrim fabric of  claim 11 , wherein said yarn that crosses said warp yarn set further comprises yarns selected from the group consisting of polyesters, polyamides, polyolefins, ceramics, fiberglass, aramids, cotton, wool, metal, carbon, and combinations thereof.  
     
     
         14 . The scrim fabric of  claim 11 , wherein said warp yarn set comprises yarns selected from the group consisting of polyesters, polyamides, polyolefins, ceramics, fiberglass, aramids, cotton, wool, metal, carbon, optical fibers, and combinations thereof.  
     
     
         15 . The scrim fabric of  claim 14 , wherein said warp yarn set further comprises at least one optical fiber.  
     
     
         16 . The scrim fabric of  claim 11 , wherein said at least one optical fiber is positioned in a sinuous path across said warp yarn set.  
     
     
         17 . The scrim fabric of  claim 16 , wherein said scrim construction has a square pattern.  
     
     
         18 . The scrim fabric of  claim 16 , wherein the smallest radius of curvature of said optical fiber within said sinuous path is greater than about 0.1 inches.  
     
     
         19 . The scrim fabric of  claim 18 , wherein the smallest radius of curvature of said optical fiber within said sinuous path is greater than about 0.5 inches.  
     
     
         20 . The scrim fabric of  claim 11 , wherein said scrim construction has a tri-axial pattern.  
     
     
         21 . The scrim fabric of  claim 20 , wherein said triaxial scrim has a construction in which said crossing yarns are present in an amount of between about 1 of said crossing yarns per 6 inches and about 4 of said crossing yarns per inch in an upward diagonal direction and a downward diagonal direction.  
     
     
         22 . The scrim fabric of  claim 11 , wherein said scrim is an adhesively bonded scrim.  
     
     
         23 . The scrim fabric of  claim 22 , wherein said at least one yarn that crosses said warp yarn set is positioned between two warp yarn sets.  
     
     
         24 . The scrim fabric of  claim 22 , wherein said warp yarn set contains yarns that are present only at selvage areas of said scrim fabric and wherein said scrim fabric is attached to a flexible carrier sheet, said carrier sheet being selected from the group consisting of films, foils, nonwoven fabrics, woven fabrics, and knit fabrics.  
     
     
         25 . The scrim fabric of  claim 1 , wherein said scrim fabric comprises more than one type of said optical fiber.  
     
     
         26 . A method of making a fiber optic scrim, said method comprising manufacturing a scrim fabric by a process selected from the group consisting of adhesively bonding, thermally bonding, projectile weaving, weft-insert warp knitting, multi-axial warp knitting, stitch-bonding, and cross-plying, wherein said scrim fabric comprises (a) at least one warp yarn set having at least two yarns and (b) at least one yarn that crosses said warp yarn set, wherein at least one of said yarns is comprised of an optical fiber.  
     
     
         27 . The method of  claim 26 , wherein said scrim is manufactured by adhesive bonding.  
     
     
         28 . The method of  claim 26 , wherein said at least one optical fiber is positioned in a sinuous path across said warp yarn set.  
     
     
         29 . The method of  claim 26 , wherein said at least one optical fiber is laid in a substantially crimp-free manner.  
     
     
         30 . The method of  claim 26 , wherein said scrim is attached to a flexible carrier during manufacturing.  
     
     
         31 . A composite having multiple components, wherein a first of said components is a scrim comprising (a) at least one warp yarn set having at least two yarns and (b) at least one yarn that crosses said warp yarn set, wherein at least one of said yarns is comprised of an optical fiber and wherein a second of said components is an energy-absorbing component selected from the group consisting of an open cell foam, a closed cell foam, a nonwoven, rubber, a gel material, and a spacer fabric.  
     
     
         32 . The composite of  claim 30 , wherein said composite has a symmetrical construction comprising said scrim layer centrally positioned in said composite, an energy-absorbing layer in contact with each side of said scrim layer, and a stress-distributing layer in contact with each of said energy-absorbing layers, said stress-distributing layer selected from the group consisting of rigid and semi-rigid materials.  
     
     
         33 . The composite of  claim 31 , wherein said composite comprises an adhesively bonded scrim, a foam layer in contact with each side of said scrim, and a rigid thermoplastic material in contact with each of said foam layers.  
     
     
         34 . A composite having multiple components, wherein a first of said components is a scrim comprising (a) at least one warp yarn set having at least two yarns and (b) at least one yarn that crosses said warp yarn set, wherein at least one of said yarns is comprised of an optical fiber and wherein a second of said components is an stress-distributing material selected from the group consisting of metal sheets, metal panels, composites, plywood, oriented strand board, gypsum panels, cementitious panels, ceramic panels, thermoplastic panels, and thermosetting panels.  
     
     
         35 . A composite comprising a flexible carrier sheet to which is attached at least one optical fiber, wherein said optical fiber is positioned in a sinuous path across said flexible carrier sheet, said flexible carrier sheet being of a material selected from the group consisting of films, foils, papers, nonwoven fabrics, woven fabrics, and knit fabrics.