One-Piece NNOC Extended Dome for Electro-Optic Sensors
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Solution Overview
Problem
Conventional transparent domes for airborne electro-optic sensors have a limited spanning angle of 180 degrees due to manufacturing challenges, leading to a restricted field of regard and potential target tracking discontinuities when attempting to create domes with larger angles, which are costly and complex to produce.
Innovation Solution
A one-piece extended dome integrally formed from Nano/Nano class Nanocomposite Optical Ceramic (NNOC) material with seamless transitions between non-complementary geometric shapes, such as spherical and conical or ogive geometries, eliminating optical interfaces and discontinuities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional dome is made of Sapphire or other transparent materials, then the dome can sustain aerodynamic and thermal stresses, but the spanning angle is limited to at most 180 degrees due to manufacturing challenges
Solution Approach 1:
The patent uses nanocomposite optical ceramic materials combining multiple phases (e.g., alumina, magnesia, yttria) with nanoscale grain dimensions to create a dome that achieves both high strength for stress resistance and the capability to be manufactured with spanning angles exceeding 180 degrees. The composite structure allows simultaneous optimization of mechanical and optical properties.
Solution Approach 2:
The patent changes the grain dimension parameter to nanoscale (less than one-tenth of the wavelength of transmitted light) to eliminate light scattering while maintaining strength. This parameter change enables the material to support larger spanning angles without compromising optical or mechanical performance.
2Shape
If two separate dome portions are fabricated and attached to achieve a spanning angle greater than 180 degrees, then the field of regard is increased, but optical interfaces create discontinuities that cause target tracking loss
Solution Approach 1:
The patent merges the dome into a single integral structure without separate attached portions. The one-piece design eliminates optical interfaces that would cause discontinuities, ensuring continuous target tracking across the entire field of regard while achieving spanning angles greater than 180 degrees.
3Shape
If a Sapphire dome with a spanning angle substantially larger than 180 degrees is produced, then the field of regard is increased, but the production becomes very expensive and complicated
Solution Approach 1:
The patent employs nanocomposite optical ceramics that can be manufactured using established ceramic processing techniques, avoiding the expensive and complicated procedures required for large-angle Sapphire domes. The composite material system allows for more feasible production of extended domes with spanning angles exceeding 180 degrees.
Solution Approach 2:
The patent adopts a cost-effective nanocomposite material system that can be produced through relatively simple and economical manufacturing processes, replacing the expensive Sapphire material that requires complex and costly production methods for large spanning angles.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables a spanning angle greater than 180 degrees without optical interface discontinuities, enhancing the field of regard and maintaining target tracking seamlessly, thus increasing the operational effectiveness of guided projectiles and DIRCM systems.
Implementation Method 1
fabricated through processes like Flame Spray Pyrolysis and hot isostatic pressing
Implementation Method 2
fabricated through processes like Flame Spray Pyrolysis and hot isostatic pressing
Data Source
AI summary
A one-piece extended dome having a spanning angle greater than 180 degrees. The dome is integrally formed of a Nano/Nano class Nanocomposite Optical Ceramic (NNOC) material. The extended dome comprises seamless first and second non-complementary geometric shapes, such as a first spherical geometry and a second conical or ogive geometry. The Nano/Nano class NNOC material comprises two or more different chemical phases (nanograins) dispersed in one another, each type having a sub-micron grain dimension in at least the direction of light transmission. The material is a true NNOC material in that all of the constituent elements have sub-micron grain dimensions, there is no host matrix.