Abstract:
A method of making silver halide fibers involves reducing turbulence and friction during extrusion by moving an extrusion die in a direction opposite from flowing fiber and against a stationary preform arrangement. In another embodiment, the preform is doped with AgI or is a metal compound of the formula MY wherein M is selected from Li, Na, K, Rb, Cs; or MY 2  wherein M is selected from Mg, Ca, Sr, Pb, Ba, Cd or Hg, and Y is selected from Cl, Br, or I. The resulting fiber has a more even core/clad interface with decrease in grain size to fiber surface and texture elongated along the fiber axis. This structure together with strengthening and stabilizing dopants, added to fiber material, gives decreased and stabilized optical losses and a higher elasticity of fibers.

Description:
REFERENCE TO RELATED CASE 
     This application is a continuation-in-part of currently co-pending patent application designated as U.S. Ser. No. 07/980,289 filed on Nov. 23, 1992 now U.S. Pat. No. 5,309,543 entitled- &#34;Method of Making Infrared Crystalline Fiber and Product&#34;, by the same inventors herein, now incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a method of making silver halide crystalline fibers capable of transmitting infrared light and to the fiber product made by the process. More specifically, it involves such methods and products which relate to improved AgCl x  Br 1-x  fibers (where x is 0 to 1.0). 
     2. Information Disclosure Statement 
     Silver halide fibers consisting of silver chloride (AgCl), silver bromide (AgBr), and their solid solutions (AgCl x  Br 1-x ) show promising properties for the transmission of middle infrared radiation. The fibers can either be bare core fibers, with gas functioning as the lower refractive index, total reflecting medium or polymer coated fibers or core/clad fibers where the cladding contains more AgCl for total internal reflection. These are described in U.S. Pat. Nos. 4,253,731; 4,381,141; 4,504,298 and 4,552,434 and considerable improvements have been reported over time. 
     Nevertheless, there are some drawbacks in present silver halide crystalline fibers. One basic disadvantage of both bare core and step-index core/clad silver halide fibers is their tendency to deteriorate optically and mechanically probably due to recrystallization of the grain structure, phase separation and silver colloids formation as well as absorption and diffusion of extrinsic impurities. 
     Transmission and elasticity have been observed to decrease remarkably when present state-of-the-art fibers are bent repeatedly. This is a result of defect formation linked to the plastic deformation of the granular structure of the fibers. Present core/clad fibers frequently show intermeshing between the core and the clad material during their extrusion and, as a result, bad transmission. This defect arises due to inhomogeneous deformation during the conventional extrusion process. Further, fibers produced by alternative manufacturing methods such as multiple step-deformation by drawing the fiber through a row of dies as in, for example, U.S. Pat. Nos. 4,381,141; 4,504,298 and 4,552,434, show defects such as microvoids and microcracks. It is assumed that these scattering defects result from the stretching stress applied in these manufacturing methods. The core/cladding boundary also shows defects if the process of successive rolling by grooved rolls is applied as suggested in some of the above prior art, probably due to the non-symmetric deformation mechanism. Additionally, trace contamination by lubricants or other extrinsic impurities is generally observed when multiple deformation methods are employed and these methods are more complicated and less productive than the conventional extrusion process. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a method of making silver halide fibers and to the product resulting from that method. In one embodiment, the present invention method involves reducing turbulence and friction during extrusion by moving an extrusion die in a direction opposite from flowing fiber and against a stationary preform arrangement. In another embodiment, the preform is doped with AgI or is a metal compound of the formula MY wherein M is selected from Li, Na, K, Rb, Cs, or MeY 2  where Me is selected from Mg, Ca, Sr, Pb, Ba, Cd or Hg, and Y is selected from Cl, Br and I. The resulting fiber has a more even core/clad interface with decrease in grain size to fiber surface and texture elongated along the fiber axis. This structure together with strengthening and stabilizing dopants, added to fiber material, gives decreased and stabilized optical losses and a higher elasticity of fibers. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention is more fully understood when the instant specification is taken in conjunction with the drawings which are appended hereto, wherein: 
     FIG. 1 shows a side cut view of a conventional extrusion processing equipment with the process in progress; 
     FIG. 2 shows the resulting cross-section for a step-index type infrared crystalline fiber using the method of the prior art shown in FIG. 1; 
     FIG. 3 shows a cut side view of equipment for the extrusion in accordance with the process of this invention with the present invention method in progress; 
     FIG. 4 shows a related cross-section of step-index fiber being produced by the present invention method shown in FIG. 3; 
     FIG. 5 shows a preferred starting preform geometry for the laminar flow of extrusion in the present invention process; 
     FIG. 6 shows a cross-section of a preform of the present invention with more details and being successively deformed at is periphery, consisting of a crystalline core and a crystalline cladding layer, a layer of polymer lubricant and a protective polymer or metal coating; 
     FIGS. 7a and 7b show a cross sectional cut of the fiber texture after extrusion of a predeformed core/clad preform of the present invention, and a side cut view of that fiber; and, 
     FIG. 8 shows a side cut view of a present invention method arrangement for hydraulic extrusion in progress. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     One object of the present invention is to provide a material composition and process for producing an infrared light transmitting crystalline fiber having good and stable elasticity and a stable, low level of optical losses. 
     The production method should guarantee a grain structure reacting favorable to multiple bending of the fibers. At the same time, the method should avoid the current shortcomings of core/clad intermeshing and microcracks/microvoids as well as surface contamination. 
     The present invention achieves these objectives and overcomes the deficiencies of conventional techniques by stabilizing the composition of the main silver halide components by suitable dopants, by a pre extrusion treatment of the preform to form a strengthened profile of texture elongated along the preform axis, and by maintaining laminar flow conditions during the extrusion process by applying the extrusion pressure to the prepared preform in a direction opposite to the fiber flow. 
     We have found that photodegradation can be remarkably reduced by partially replacing halide anions by iodine and/or partially replacing silver cations by any alkali metals or by double valent cations. It is assumed that the homogenous distribution of the above listed elements in the fiber material creates additional barriers for the sliding and recrystallization effect in polycrystalline fibers and restricts the silver ion diffusion. This self-diffusion of interstitial silver ions determines the formation of silver colloids, that absorb the transmitted radiation. 
     Metal compounds suitable for doping are MY, type compound wherein M is a metal selected from Li, Na, K, Rb, Cs, or they are MeY 2  type where Me is selected from Mg, Ca, Sr, Ba, Cd, Pb or Hg, and Y is Cl, Br or I. 
     The expected effect of AgI crystallographic structure transition during the cooling of this crystal after its growth from the melt was surprisingly suppressed by limiting the content of AgI to less then 5% of the AgCl-AgBr matrix. 
     It was also determined that the concentration of double valent cations (Hg, Cd, Pb, etc.) needs to be restricted to less than 0.001% probably due to the substantial physical difference between them and the host cations of the lattice matrix. 
     The positive effect of the doping of the silver halide crystals on the transmission stability of the fibers can be observed with any chosen fiber structure (for examples, core only with gas as lower index surrounding, core with polymer cladding, core/clad fiber with silver halide core and lower refractive index silver halide compositions, cladding or graded index silver halide fiber). 
     It was observed that the grain structure in the finished fiber can be influenced by pretreating the preform used for the fiber extrusion. If the preform is carefully deformed by exerting pressure to its lateral surface by preextrusion or by other methods with a low extent of deformation (&lt;2) a texture with elongated grains is achieved. The texture is finer at the outside of the deformed preform while larger crystalline grains are prevailing at the inner core area. We have observed that fibers extruded from above described preforms exhibit similar texture and show improved transmission and stability. It is assumed that the fiber with a texture of superfine (0.01 to 0.2 μm) ellipsoidally shaped crystalline grains, elongated along the fiber axis and decreased in size in the peripherical fiber layers, deforms more elastically and with less defect formation when multiple bending of the fiber occurs, than a fiber with conventional, round shaped grain structure. Furtheron, the essentially longitudinal directed radiation rays pass over fewer grain boundaries and defects, which may further explain the enhanced transmission properties. 
     Referring now to FIG. 1, a conventional prior art extrusion process is shown for a step-index type preform. This involves applying pressure with a plunger 1 and heat with heater 3 in high pressure chamber 2 to the crystalline preform comprising preform core 4 and cladding preform 5 to force the material in the direction of the applied force and to afterwards deform it through the orifice of a die 6 to obtain a fiber 7 with the desired diameter. 
     FIG. 2 shows a cut cross section of fiber 7 from the method shown in FIG. 1. It is observed, unfortunately, that the resulting fiber 7 shows pronounced deformations of the geometry of core 9 and clad 8 and shows intermeshing of core 9 and clad 8 materials. This rough core-cladding interface frequently causes high scattering losses in the fiber. 
     We attributed this shortcoming of the extrusion process to the friction of the material on the cylindrical chamber surface and to the related turbulences in the material flow. We have found, however, that by inversing the plunger movement (movement of the plunger in a direction opposite to the fiber movement) the problem can be essentially overcome and the fiber geometry remarkably improved. Thus, FIG. 3 shows one present invention method with apparatus 21. 
     In FIG. 3, high pressure chamber includes heater 23, core preform 24, and cladding preform 25. However, here, plunger 29 is below the preforms and moves upwardly, i.e. against the flow. Cap 27 holds the preforms in place and, as plunger 29 moves die 28 upwardly, fiber 30 is extruded downwardly therefrom. 
     FIG. 4 shows a cross-sectional cut of fiber 30 from the present invention FIG. 3 process, wherein clad 31 and core 32 have a smooth, consistent interface with a relatively consistent clad thickness and core shape. 
     The main advantage of this method is probably the fixed position of a preform in the chamber which eliminates the friction at the lateral surface of the preform and, therefore, also eliminates the release of friction energy. The inhomogeneous deformation of complex step-index or gradient-index preforms due to friction-caused turbulence is practically inhomogeneous. The intermeshing between core and cladding layers is remarkably reduced. 
     But even with the above described extrusion process, some residual irregularities for the starting stage of the extrusion may be observed. FIG. 5 shows a further advance. Here, the same equipment as shown in FIG. 3 is used, with like parts identically numbered. However, to reach the laminar flow geometry faster, additional cladding material 35 can be inserted not only at the side but also below the cylindrical core preform 36, as shown as base 37. 
     Further, by keeping the plunger diameter marginally smaller than the preform diameter, surface contamination from the chamber surface or preform surface defects are effectively excluded from entering the finished fiber. In this way, our claimed extrusion process for silver halide fiber production shows additional benefits also for core-only or plastic clad/core fiber manufacturing. 
     FIG. 6 illustrates a cross-section of a preform successively deformed of its periphery consisting of a core 74 and a crystalline cladding 75, a layer of polymer lubrication 72 and a protective coating 73 of metal or polymer. This preform is particularly advantageous for the present inventive method. The enhanced quality of the core/cladding boundary in step-index fibers and the improved symmetry in gradient index fibers can also be realized by applying isotropic pressure through gaseous or liquid media. Thus, FIG. 8 illustrates a cross section of present system which includes chamber 92, fluid inlet 90, heater 94, die 95, preform 93 and pressurized fluid 91, to produce fiber 96. A lubricant, which could be used to reduce friction, can also serve as the liquid medium. Silicon oil or liquid flouropolymers could be used for this purpose. Argon or other inert gases seem particularly suitable for gas extrusion purposes. 
     The core/clad preform being subjected to extrusion by a plunger moving in a direction opposite to the fiber flow or to liquid or gas extrusion may also be surrounded by an additional layer of relatively soft metal. This metal layer can then be extruded together with the core/clad (or gradient index) crystalline preform to form a fiber already protected by an external metal sheath against light, stresses or contamination. 
     The above described types of essentially friction free extrusion substantially suppress lateral surface friction-one of the main causes of macrostructure defects and turbulence intermeshing at the core/cladding boundary. 
     The present invention is further illustrated by the following examples, but is not limited thereby: 
     EXAMPLE I 
     A crystal of solid solution of silver halide with a 50/50 ratio of chlorine and bromine, i.e. AgCl 0 .5 :Br 0 .5 was grown with a Hg ++  dopant (concentration 0.0003%) by known silver halide crystal growing methods and prepared as an extrusion billet in cylindrical form (15 mm in diameter and 40 mm long). The billet was extruded into a fiber with 1 mm diameter by the present invention friction free process as shown in FIG. 3 and described above, i.e. by moving the plunger of 14 mm in diameter in the direction opposite to the fiber flow at about 200° C. The optical losses measured in the fiber by the cut-back method at 10.6 μm were 0.2 dB/m immediately after the extrusion and 0.5 dB/m 1 year later. For comparative purposes a fiber of equal diameter was manufactured at the same temperature from a crystal of AgCl 0 .5 :AgBr 0 .5 solid solution by conventional extrusion in FIG. 1 above. Its optical losses were measured as 1 dB/m right after the extrusion and 2.4 dB/m 1 year later. Both fibers were stored in black loose polymer tubes at controlled laboratory conditions to avoid environmental damages. 
     EXAMPLE II 
     The preform of a structure such as is shown in cross-section in FIG. 6. Structure 73 was formed from a AgCl 0 .5 :AgBr 0 .5 core rod (diameter 15 mm), and a AgCl 0 .7 :AgBr 0 .3 cladding tube (15/18 mm diameter), a polyethylene coating tube (18/19 mm diameter) and a OFHC-copper ductile tube (19/20 mm diameter) with a bottom part in a form, suitable for laminar extrusion. Two successive extrusions of this preform through the raw of conical dies were realized with silicon oil as outer lubricant, and the diameters of the orifices were successively decreased from 17 mm to 15 mm. A final friction free extrusion using the FIG. 3 method was realized to obtain 1 mm diameter fiber. The optical losses in the fiber were 1.5 dB/m at 10.6 μm. The tensile strength was remarkably high (120 MPa). Structure investigations of chemically etched fiber samples revealed a texture similar to that shown in FIGS. 7a and 7b, showing a fiber 50 with a core 51 and cladding 54. Note that large, elongated grains 52 are formed toward the center and smaller elongated grains are formed toward and in the cladding, such as grains 53. 
     It was observed that the fiber could withstand significantly more and several bend cycles than fibers produced directly from non-predeformed crystals described above. 
     EXAMPLE III 
     A step-index type fiber was produced by the method illustrated in FIG. 3 from a predeformed preform (as shown in FIG. 5). The extrusion billet (15 mm diameter and 40 mm long) consisted of a single crystalline rod of AgCl 0 .24 :Br 0 .76 solid solution (10 mm diameter and 38 mm long) being inserted in a hollow cylinder cladding of AgCl 0 .5 :Br 0 .5 solid solution (inner diameter 10 mm, outer diameter 15 mm, length 38 mm) and a disk of cladding material was placed at the bottom (diameter 15 mm and 2 mm thickness). The billet was hot extruded (at about 200° C.) by friction free extrusion into a fiber of 0.7 mm outside diameter and 0.47 mm core diameter. Good quality of the core-cladding boundary was observed over the length of about 10 m. 
     Without the insertion of the extra cladding material at the bottom (near the die) much smaller yield was observed due to several meters of start up loss. 
     While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from its spirit and scope. 
     Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.