Method for Advanced Production Techniques for In-line Deposition of Diamond Scratch Resistant Coatings on Optical Glass Fibers

We propose a SBIR Phase I project to develop and demonstrate the technology for coating optical glass fibers with a hard, hermetic and chemically inert and scratch resistant layers of Diamond-Like Carbon (DLC). The DLC coatings will provide improved reliability and performance, and maintain the design and dimensional characteristics of the optical fibers against the abrasion, chemical erosion and environmental degradation. DLC layers are inert, moisture and H2 impermeable and will be applied at near room temperature. The DLC films will be applied on commercially available optical glass fibers by magnetically enhanced plasma chemical vapor deposition using an innovative high-intensity cylindrical magnetron reactor developed and pioneered by Plasmatron Coatings and Systems, Inc. Systematic investigations of (i) dependence of hermeticity, (ii) adhesion of DLC to the fiber, (iii) hardness, (iv) scratch resistance and (v) optical and micro-bend losses as a function of microstructure, structure, composition and process parameters will be performed to achieve the proposed objectives. Different layer configuration of DLC films will be studied in Phase I. The cylindrical magnetron reactor, studies in Phase I will be scaled-up to produce an in-line, high-rate, deposition system for coatings optical fibers during manufacturing in Phase II.