Crystal-free Formation of Non-Oxide Optical Fiber

The electromagnetic properties of the material are engineered by optimizing its complex dielectric function through the volume filling fraction of its components. A low-index polymeric binder, such as thermal polymers and epoxies, serves as the host medium to minimize reflectance in the conductively loaded dielectric media. To ensure thermal compatibility with metal substrates in cryogenic environments, dielectric powders are incorporated to match thermal expansion. Additionally, alumina frit compensates for thermal contraction at cryogenic temperatures, while non-magnetic conductive particles such as bronze, carbon allotropes, and degenerately doped silicon help tailor the material’s dielectric response. To enhance performance, small-particle scatterers reduce heat capacity and limit resonant dispersion, while dirty alloys stabilize resistance under conductive loading. The formulation incorporates reststrahlen materials and supports applications across the microwave to terahertz range, making it suitable for baffles, Lyot stops, and optical terminations, or as a primer for enhancing near-infrared and visible black paints. This high-emissivity, non-magnetic coating is designed for microwave to far-infrared instrumentation in space and cryogenic systems. It also benefits industries producing absorptive epoxies, EMI/EMC shielding, and quantum sensing components. It has reached Technology Readiness Level (TRL) 5 (component validation in relevant environment) and is now available for patent licensing.

A solar cell manufactured from this new optical fiber has photovoltaic (PV) material integrated into the fiber to enable electricity generation from unused light, including non-visible portions of the spectrum and visible light not transmitted to a lighting application. These new solar cells are based around cylindrical optical fibers, providing two distinct advantages over the flat panels that lead to increased efficiency. The core fiber, used to transmit light, can be adjusted to increase or decrease the amount of available light that is transmitted to the lighting application at any point in real time. This invention can be applied wherever optical concentrators are used to collect and redirect incident light. Wavelengths as large as 780 nanometers (nm) can be used to drive the conversion process. This technology has very low operating costs and environmental impacts (in particular, no greenhouse gas emissions). The fiber uses low-cost polymer materials. It is lightweight and flexible, and can be manufactured using low-cost solution processing techniques. Such multifunctional materials have great potential for the future of solar and photovoltaic devices. They will enable new devices that are small and lightweight that can be used without connection to existing electrical grids.

This technology was developed to improve Armstrong's multi-patented FOSS system, which has long been used to measure temperature and liquid levels in cryogenic environments. When the sensing system's fibers trapped humidity from the surrounding environment before their submersion into cryogenic liquids, the moisture adversely affected outputs. A new manufacturing process solves this problem, increasing reliability and accuracy not only of NASA's FOSS but also any fiber optic sensing system. How It Works Armstrong has developed a two-step process to assemble the sensors. First, the bare sensor fiber is inserted into an oven to expel all moisture from the fiber coating. Then, the moisture-free fiber is placed inside a humidity-controlled glove box to prevent it from absorbing any new moisture. While inside the glove box, the fiber is inserted into a loose barrier tubing that isolates the fiber yet is still thin enough to provide adequate thermal transfer. The tubing can be further purged with various gases while it is inside the glove box to provide additional moisture isolation. This innovation is particularly useful for fiber optic systems that measure temperature and that identify any temperature stratifications within cryogenic liquids. Why It Is Better This process seals sensor fibers from environmental moisture, enabling fiber optic sensing systems to operate reliably in humid environments. The innovation eliminates erroneous readings that can occur due to moisture collection on the fiber sensors. For more information about the full portfolio of FOSS technologies, see DRC-TOPS-37 or visit https://technology-afrc.ndc.nasa.gov/featurestory/fiber-optic-sensing

NASA’s laser mount technology introduces a unique flexible crystal mount to accommodate the dynamics of thermal expansion to eliminate unsymmetrical thermally induced mechanical stresses on the crystal. In addition, while the mount accommodates thermal expansion, it also offers fixed placement of the crystal to maintain alignment and provides continuous and uniform surface contact between the mount and crystal for rapid dissipation of heat. The mount is compatible with any heat sink reservoir. The mount design allows unrestrained thermal expansion of the crystal in two dimensions (i.e. a- and c- axes) because of the design shown in the figure below. The L-shape blocks also deliver cooling to the crystal by providing a path to the heat sink reservoir. The L-shape blocks are manufactured with a high thermal conductivity material such as copper. A softer material with high thermal conductivity such as indium is used to buffer the interface between the crystal and the L-shape blocks surfaces. A coolant medium acts to transfer the heat from the crystal to the cooled mount. Cooling can be provided in different ways – for example by water or by heat pipes with radiator (for use in space). The springs used to hold the laser crystal also provide the adjustment method to align the beam, and once aligned, the crystal mount is very stable. The related patent is now available to license. Please note that NASA does not manufacture products itself for commercial sale.

Precision, Non-Contact Metrology measure optical surfaces with unusual prescriptions, high departure, and/or high slope error. This method has the advantage of being faster and more robust to systematic errors than other, more traditional, optical test techniques. Furthermore, it facilitates the accurate placement of optical surfaces within a system. The software and algorithm part of this innovation enables this hardware accomplishment. Measurement of aspheric mirrors of moderate size yields differences with interferometry of about ~30 nm RMS in terms of figure error. This technique pushes the limits of state-of-the-art coordinate measuring techniques toward enabling larger, lower cost, and higher quality freeform and aspheric optics, and their assemblies, decreasing the gap between commercial coordinate measuring techniques and interferometry and, for some applications, replacing interferometry and other optical shop techniques as the primary means of feedback to optical fabrication and requirements verification. Current and near-future applications for freeform and large optics would benefit from these techniques by reducing their cost and schedule and improving their technical risk posture.