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Development of Polymer Processing Techniques for Dramatic Cost Reduction of Large Core Plastic Optical Fiber, for Use with Advanced, High Intensity Discharge (HID) Distributed Accent Lighting System—Fiberstars, Inc., 32000 Aurora Road, Solon, OH  44139-2814; 440-836-7421, http://www.fiberstars.com

Mr. Chris Jenson, Principal Investigator, cjenson@fiberstars.com

Mr. Roger Buelow, Business Official, rbuelow@fiberstars.com

DOE Grant No. DE-FG02-04ER83957

Amount:  $749,749

Incandescent and halogen accent lights remain some of the last lighting applications without cost effective, energy efficient solutions.  Potential energy efficient lighting systems exist; for example, one high efficiency metal halide lamp and ballast can run eight points of light.  However, these systems have product limitations due to their high cost.  This project will optimize the fabrication of the plastic optical fiber components of the system, reducing the cost per point below that of conventional halogen sources.  In Phase I, eight alternatives were identified that would simplify the downstream polymer processing.  Two of the processing alternatives were shown to offer dramatically reduced post-extrusion processing time and lower costs.  In Phase II, the two polymer processing alternatives will be further developed.  The best approach will be carried into a pilot scale demonstration of the technology. 

Commercial Applications and Other Benefits as described by the awardee:  The lighting system should provide the energy efficiency of a metal halide lamp at the cost of a halogen lamp.  Applications include:  supermarkets, where the lack of infrared and ultraviolet radiation would permit food to stay fresh longer; clothing and jewelry stores at malls, where savings in energy usage and the costs of lamps will be significant; and office buildings where low fixture costs and an 80% savings in installation costs will be a factor.  Altogether, approximately 0.19 quads of energy per year could be saved as this product is used in new installations and energy retrofits.