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Robust, Thin Optical Films for Extreme Environments
Industrial Productivity and Manufacturing Technology
Originating Technology/NASA Contribution
The environment of space presents scientists and engineers
with the challenges of a harsh, unforgiving laboratory
in which to conduct their scientific research. Solar astronomy
and X-ray astronomy are two of the more challenging areas
into which NASA scientists delve, as the optics for this
high-tech work must be extremely sensitive and accurate,
yet also be able to withstand the battering dished out
by radiation, extreme temperature swings, and flying debris.
Recent NASA work on this rugged equipment has led to the
development of a strong, thin film for both space and laboratory
use.
Partnership
Through a Small
Business Innovation Research (SBIR) contract
with Goddard
Space Flight Center, Luxel
Corporation, of
Friday Harbor, Washington, developed key materials that
will help NASA researchers as they explore the unforgiving
environment of space. With NASA’s assistance, the company
developed a novel manufacturing process for ultra-thin
films that have application in enhancing X-ray and extreme
ultraviolet (EUV) filter technology.
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Luxel
Corporation is a top supplier of thin foil filters. The
company supports customer requirements for X-ray
and extreme ultraviolet (EUV) research programs.
Its work with NASA under a Small Business Innovation
Research (SBIR) contract helped to create key filtering
materials for protecting optics in harsh environments.
These materials are now helping researchers everywhere. |
The films incorporate composite polymer support mesh with
polyimide or metallic ultra-thin films, which makes them
stronger and more durable, while still maintaining their
optical filtering integrity. The mesh was specially characterized
for adhesion, mechanical and vibration strength, X-ray
transmittance, and throughput gain.
This is the fourth successful NASA SBIR contract that Luxel
has completed in this area, with others including “Applications
of Thin Polyimide Films to X-ray Optics,” “High Throughput
Thin Foil Filters with Enhanced Durability for the Soft
X-ray and EUV Regions,” and “Polyimide X-ray Filters Optimized
for Strength at Cryogenic Temperatures.”
While NASA will find use for these filtering films in
a variety of optical and plasma research venues during
future missions, Luxel’s customers have been finding
uses for this new technology in government and commercial
laboratories.
Product Outcome
In the 30 years that Luxel has been in operation, it has
pioneered development of new filter materials and techniques
for the fabrication of the filtering films,
and with its years of industry experience, it can produce
filters and windows larger and stronger than previously
thought possible.
Its filters are cutting edge. Many of the new Luxel designs
are allowing researchers to better discriminate regions
of the electromagnetic spectrum, and its filters routinely
demonstrate remarkable strength for their size. Many of
them are able to withstand spacecraft launch, pressure
differentials, and maintain gas cell integrity. Luxel delivers
some of the highest quality foil filters available, produced
from over 70 different materials, compounds, and organics,
supplied on both standard and custom frames. The polyimide
and metallic foil filters that were advanced under the
NASA contracts are now part of Luxel’s commercial offerings
and being used by a plethora of researchers.
The new filters, combined with Luxel’s new manufacturing
process—a late discovery in the SBIR work that resulted
in a radical new method for producing composite polymer
supports using photolithography and polyimide—are a viable
option for many of Luxel’s customers. This new manufacturing
capability is a boon to customers, as it allows Luxel to
provide large quantities of the ultra-thin films.
The researchers also increased the performance of the films.
They discovered that by incorporating either high-modulus
polymer fibers or tungsten filaments into a filter’s construction,
the average burst strength increases by 200-percent more
than that of the baseline electroformed nickel mesh; and
the ultra-fine diameter filaments used in filter construction
have the ability to reduce obscuration effects by 10 to
15 percent over those same existing mesh systems.
These filters fabricated for X-ray and EUV applications
using polymer composite support mesh are highly transparent
in the high-energy wavelengths, even in extreme conditions.
They are hardy enough to survive rough handling, which
makes them ideal for a variety of research applications.
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