STRENGTHENING GLASS STRUCTURES

Abstract: A method of strengthening materials such as glass, plastic and ceramics enabling strengths to be achieved which are far in excess of what was previously known. Generally, the method comprises the placement of elongated reinforcement members (32, 34) in a molten glass substrate (30, 36, 46, 48) then cooling the substrate to the solid state. The reinforcement members may be pre-stressed in some instances and may assume a variety of arrangements within the glass substrate. The reinforcement members may be of various materials having greater tensile strength than the glass substrate. In one instance, the reinforcement members themselves may be fiber optic bundles composed of glass fibers with an outer glass cladding which melts at lower temperatures than the inner regions. The temperature is raised sufficiently to melt the cladding so as to bond together all of the bundles into an integral structure of optical quality. In another application of non-optical quality, the core may be metallic with an outer glass cladding which melts at a lower temperature than the inner regions. According to yet another embodiment, strengthened plastic members utilizing elongated reinforcing members in a plastic matrix can have an optical quality reflective surface applied by replication.

Description: STRE GTHE Jϋg QLΔZS. BACKGROUND Q∑ R INVENTION i. i±ε±ύ o_£ the Invention This invention relates generally to a method of producing a superior quality of glass resulting in an end product which is substanti lly stronger than conventional glass and exhibits greater strength consistency than was previously known. II. ____£ the. E ±SI Δxi In the past, "tempered" glass was used for strong part requirements. Over the years, a process known variously as "chemical 'tempering", "ion exchange", or "chemical strengthening" came to be employed to do the same thing. These processes render the outside of a glass in compression while the inside is in tension. "Tempering" in glass is not the same as in metals. It merely consists of rapid cooling (actually "quenching") from the melt, or other high temperature, which causes the outside skin to "solidify" first (glass is a technical liquid of nearly infinite viscosity, not a solid). "Chemical" tempering or "ion exchange" or "chemical strengthening" accomplishes the same result by replacing, for example, sodium ions with "fatter" potassium ions in the surface region. This squeezes the surface together, causing compression there. When the glass beam is bent, the tension side first has to lose all the residual compression before going into tension. Either process can result in a part acting as if it could survive between 207 MPa (mega pascals) and 310.5 MPa in tension (instead of just bending, alone). Some parts have approached 414.0 MPa in this way, but in thick section only, and not reliably or repeatedly. The compressive strength of glass is not usually a problem. This is primarily due to the fact that existing flaws and micro cracks in the surface do not propagate under compressive stress. Compressive strengths of 1.725 GPa (1.725 giga pascals) are commonly observed. One problem with the prior art is that it is not reliable statistically. The distribution is skewed, with long tail off in the high strength direction and a sho.rt cutoff at lower values. Thus, one can reliably count on achieving only a fraction of the attainable value in tension. Throughout this disclosure, the term "glass" i . s intended to mean not only those materials commonly known as glass, but also plastics, ceramics, and vitreous materials and other substitutes therefor. It is also intended to include those glass-like materials which have recently been discovered which pour and set at room temperature. SUMMARY CvE TϋE INVENTION It was with recognition of the state of the prior art with regard to glass that the present invention was conceived and has now been reduced to practice. In brief, this invention comprises using several methods of strengthening glass-type materials enabling strengths to be achieved which are far in excess of what was previously known. Generally, the method comprises the placement of elongated reinforcement members in a molten glass substrate, then cooling the substrate to the solid state. The reinforcement members may be pre-stressed in some instances and may assume a variety of arrangements within the glass substrate. The reinforcement members may be of various materials having greater tensile strength than the glass substrate. In one instance, the reinforcement members themselves may be fiber optic bundles composed of glass fibers with an outer glass cladding which melts at a lower temperature than the inner region. The temperature is raised sufficiently to melt the cladding so as to bond together all of the bundles into an integral structure of optical quality. In another application, of non-optically transmissive quality, the core may be metallic with an outer glass cladding which melts at a lower temperature than the inner glass region. According to yet another embodiment, strengthened plastic members utilizing elongated reinforcing members in a plastic matrix can have an optical quality reflective surface or surfaces applied by replication. Most glasses fail prematurely in tension due to some previously known and some previously unknown causes. This invention renders a stronger, more flexible "glass" product which prevents premature failure in tension, or on the tension side of a beam of glass. The invention also provides a wider range of choice of thicknesses than previously available, and allows for a thinner product as well, all without special mill runs of some certain size. The impact of the invention is to render such diverse items as glass mirrors, glass photographic plates, dual wavelength antennas, buried mesh antennas, glass windows of spacecraft and aircarft having a dichroic function (i.e. passing one wavelength and reflecting another) all more durable and bendable by reason of greater strength and greater repeatability or consistency in the product's strength. Additionally, glass optical components can now be employed in formerly unacceptable environments, which were thought to require the use of metals, where the use of non-metallic components would otherwise be desireable. The prior deficiencies of glass have been outlined and explained in an earlier application for patent entitled "Improvements to Glass Structures", Serial No. 868,829, and filed May 29, 1986. In that disclosure, novel methods and means for improvement of those properties are presented. This invention offers other, entirely different, means for improvement of strength in a glass slab, plate, special window, mirror, and the like. The purposes and advantages of this invention are generally the same as those of the earlier disclosure but are accomplished in a new and novel and different manner. Broadly, the goals achieved by the invention include improved strength, impact resistance and surface quality while maintaining the desired transmission, reflectance, and electrical properties needed for each specific application. There are numerous and significant differences between the reinforcement methods disclosed herein and tho'se well known and commonly used reinforcement methods employed, for example, with concrete structures. The following is a partial listing of these differences: (a) concrete is opaque to .J.1 wavelengths, as is the steel reinforcing rod material; "glasses" -and glass fibers are transparent to a wide variety of wavelengths. (b) "glass" with metal fibers is transparent to at least some wavelengths but reflects others (e.g. microwaves) in a dichroic manner. (c) The index of refraction of the glass fibers can even equal the. index of the glass substrate, although having different other properties :. (e.g. tensile strength). Thus, the assembly can pass certain wavelengths without a.nv. optical path difference or bending. (d) The rods in concrete are always drastically different from the concrete, i.e. always steel or other metal. In the present invention, the reinforcement can be the same (i.e. glass) material as the matrix, a different type of glass, or glass in plastic, or glass rods with a metal core rod inside. (e) The coefficient of expansion of glass fibers and glass surround are substantially the same, whereas concrete and steel differ significantly. In metallic fiber reinforcing of glass, the coefficient of expansion of the metal chosen can closely match that of the particular glass used. (f) In some instances, the invention allows for use of the "reinforcing rods" for another purpose entirely, and envisions the use of -ion exchange or surface etch to obtain the necessary tensile strength. One application would be as a dichroic antenna, with the rods as 1/4 wave mesh, for example, or constructed to block passage entirely. (g) The system, or process of the invention often approaches the melting or softening temperature of the "rods", whether they are glass or metal or both, by pouring in a hot matrix that has always been a technical liquid (of infinite viscosity when cold). The material of the invention does not "set up" chemically, but solidifies by becoming more viscous. (h) According to the invention, metal cored rods, or metal alone rods, are sometimes spaced so as to be some fraction of the wavelength of another radiation impinging on the matrix (other than visible or infrared, for example). The metal rods are not spaced for strength alone and, in some instances, are not spaced for strength at all. These applications may be in the microwave or radio region of the spectrum, as far as the "rods" are concerned. Such a construction can be used to augment, focus, enhance, block, or reflect the microwave or radio wave radiation. (i) For purposes of the invention, the fibers or rods can in some cases even be flush with the outer surfaces, or be very close to them, a condition not allowed in concrete applications. According to the invention, rods can also be placed on both top and bottom surfaces for reverse bending. Other and further features, objects, advantages, and benefits of the invention will become apparent from the following description taken in conjunction with the following drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory but are not restrictive of the invention. The accompanying drawings, which are incorporated in and constitute a part of this invention, illustrate some of the embodiments of the invention and, together with the description, serve ' to explain the principles of the invention in general terms. DETAILED DESCRIPTION Q£ T E. DRAWINGS In the Drawings: Figures 1 and 2 are perspective views illustrating two variations of one embodiment of the invention; Figures 3, 4, and 5 illustrate, successively, additional embodiments of the invention; Figure 6A is a perspective view of another embodiment of the invention; Figure 6B is a perspective view of suitable forms of aggregate material which can be incorporated into the embodiment of Figure 6A; Figures 7 and 8 are perspective views, respectively, of different variations of still another embodiment of the invention; Figures 9 and 10 are perspective views of different variations of yet another embodiment of the invention; Figure 11 is a cross section view of a component of still another embodiment of the invention; Figures 12 - 15 diagrammatica1ly illustrate, successively, the steps in a process of prestressing strengthening members according -to the invention; Figures 16 - 18 are perspective views illustrating different variations of still a further embodiment of the invention; and Figures 19 and 20 are diagrammatic representations of a replicating process for obtaining optical quality surfaces on an item constructed in accordance with the invention. DESCRIPTION Q£ THE _E£I _.__!______£ The invention utilizes techniques for strengthening beams composed of brittle material such as glass, ceramics, or plastics in which the surface is subject to tension, as in beam loading or bending. One novel feature is the use of elongated reinforcing members in substrates or matrices of glass. The reinforcing members provide the required tensile strength, known to be deficient in vitreous products. These members can be either steel wires, glass fiber strands, optical glass fibers themselves, or other appropriate elongated materials. The glassy reinforcing members would preferably be composed of optical fiber quality glass which is known to have superior tensile and bending strengths, far exceeding those strengths of ordinary plate glass. Turn now to the drawings and, initially, to Figure 1 which diagramatically illustrates a melt or pour of glass 30 with a mesh of elongated reinforcing members 32 and 34 near one surface thereof. Plural parallel reinforcing members can extend in one direction only or some can extend transverse to others for increased tensile strength in both directions. In some instances as seen in Figure 2, plural parallel members 32 may be coplanar and separated ' from plural coplanar parallel members 34. In some other instances, as already indicated in Figure 1, the members 32 and 34 can be meshed or interwoven. It is acceptable to heat the glass 30 to the molten state after which the reinforcing members 32 and 34 are introduced to the molten material in a suitable fashion. However, it is also within the purview of the invention for the reinforcing members to be held in a desired configuration, for example, in a parallel, coplanar manner, and then to pour the molten glass into a casting mold so as to completely envelop the reinforcing members. It would also be within the purview of the invention to make up a sandwich, consisting of two slabs of softened (hot) glass pressed together -with the reinforcing members placed between the slabs. This could be a "triple (or more) decker" sandwich as well, with several alternating layers of glass slabs' and reinforcing mats. In any event, the glass material is subsequently cooled to the solid state with the reinforcing members being thereby integrated into the structure of the slab. Preferable materials for the reinforcing members are steel, boron, carbon or nickel alloy, and glass fibers. All of these materials have tensile strengths substantially in excess of that of poured or floated glasses, and some of these materials have more desireable electrical or microwave properties. The intentions of the invention would also be served by employing a "CVD" (chemical vapor deposition) method of burying the supporting reinforcing members. For a complete understanding of the invention, reference may be had to the following materials concerning chemical vapor deposition which are incorporated herein and made a part hereof: -Proceedings of the Sixth International Conference on Chemical Vapor Deposition, 1977, edited by Lee F. Donoghey et al. Proceedings Volume 77-5, The Electrochemical Society, Inc., Princeton, NJ 08540, especially pp. 191, 192, 531, 538; -"Zinc Selenide Blanks for Windows and Lens Elements" (Manufacturing Methods and Technology Program), R.N. Donadio et al, Raytheon Corporation, Research Division, May 1979 (AD Number:A077004) ; "New Advances in Chemical Vapor Deposited (CVD) Infrared Transmitting Materials", R.N. Donadio et al, CVD Inc., Woburn, MA (Conference Paper: Emerging Optical Materials 25-26 Aug. 1981, San Diego, CA) Proc. SPIE Int. Soc. Opt. Eng., Vol. 297, 65-9, 1981; -"New Advances in Chemical Vapor Deposited (CVD) Infrared Transmitting Msaterials", R.N. Donadio et al, CVD, Inc., Woburn, MA; Research and Laser Technology, Inc., Rockport, MA; (Proceedings of the Conference: Emerging Optical Materials August 25, 1981, San Diego, CA) ; Bellington, WA, SPIE - The International Society for Optical Engineering, 1982, p. 65-69. -"Application of the Low-Temperature CVD Process", Bloss, K.H.; Lukas, H; Battelle Inst., Frankfurt am Main (West Germany), 1973. (Available as Document No. 73N19475 from National Technical Institute of- Science, 5285 Port Royal Road, Springfield, VA 22161); and -"Low-Temperature Silicon Epitaxy by Ultrahigh Vacuum/Chemical Vapor Deposition", B.S. Meyerson, IBM Thomas J. Watson Research Center, Yorktown Heights, NY, Applied Physics Letters (ISSN 0003-6951), Vol. 48, March 24, 1986, p. 797-799. In the event chemical vapor deposition is employed to bury the supporting reinforcing members, the surrounding matrix (whether 30, 36, 46, 48 shown in Figs. 1-5) could then be of silicon, zinc sulfide, or zinc selenide, for example. After sufficient build up in the vacuum chamber, the resulting structure could be slab milled or ground to the desired outline overall. When the molten or softened glass has solidified into a slab as indicated at 30, or the silicon or other matrix material has been built up to sufficient depth or thickness in a CVD chamber, the faces of the slabs parallel, to the planes of the reinforcing members 32 and 34 are first ground down and then highly polished. It has been found preferable to grind the faces of the slab until each face exhibits a surface irregularity of approximately 2.59 + 1.27 micrometers. Subsequently, those same faces are polished until each face exhibits a surface irregularity of no greater than .0254 + .0254 micrometers; and a surface roughness (rms) , or smoothness, of no greater than 2.54 x 10 ~4 ± 2.54 x 10~ 4 micrometers. Another embodiment is illustrated in Figure 3. In this embodiment, a slab 36 incorporates elongated, high tensile strength coplanar reinforcing members 38 and substantially coplanar reinforcing members 40. These may be interwoven or spaced apart as described above, and are positioned centrally of the opposed surfaces of the slab 36, that is, the reinforcing members 38 and 40 are positioned near to the neutral axis in planes generally equidistant from the opposed surfaces thereof. As with the embodiment of Figures 1 and 2, when the slab 36 returns to the solid state and/or is cooled to room temperature, it is desirable to grind and polish the surfaces as in the previous embodiment. This can be accomplished at any depth desired, or total thickness required, down to the region of the reinforcing members. Whereas the slab 30 is strongest in tension when the surface nearest the reinforcing members 32 and 34 is put in tension, the slab 36 exhibits equally strong characteristics in tension regardless of which surface assumes a convex shape, the largest values of which occur as the slab is ground down and polished closest to the region of the reinforcing fibers or members. In Figure 4, elongated reinforcing members 42 and 44 are positioned near both opposed surfaces of a slab 46. With subsequent grinding and polishing of the opposed surfaces in the manner generally as described above, the slab 46 can accommodate reverse bending in the same manner as the slab 36, but with a greater thickness of the glass than is possible with the Figure 3 embodiment. Figure 5 illustrates a slab 48 with transversely directed elongated reinforcing members 50 and 52. The slab 48, then, is similar to the slab 30 of Figures 1 and 2 except that, in this instance, the grinding and polishing operation has proceeded to the reinforcing members themselves so that they are, at least partially, flush with the surface of the slab 48. In such an instance, if 'an optical quality of reflecting - surface is desired in the finished part, it has been found desirable to employ optical quality glass fibers as the materials for the reinforcing members because of their superior optical qualities, equal to that of the surface glass matrix. For optical quality applications requiring transmission, use of optical quality glass fibers having an index equal to the surrounding glass or plastic is required. If clad, then the cladding is restricted to the same index as well. In another embodiment of the invention as depicted in Figures 6A and 6B, the melt resulting in a slab 54 is "doped" with particles 56 as illustrated in Figure 6B. The particles 56 can be of a variety of shapes and compositions, and can be, for example, ground diamonds, steel balls, microba 11 oons , birefringent crystal fragments, unusual expansion coefficient materials, and the like. Although the use of an aggregate population as provided by the particles 56 solves many problems in providing an improved optical structure, it may offer little improvement in tensile strength unless the arrangement of parts is such that the glass serves as a glue for particles having superior mechanical properties. Of course, it will be appreciated that the structure sense can be reversed such that the particles could be made of the glass and the matrix made of a substance of much less strength, for example, optical grade plastic, cast or CVD silicon. In Figure 7, a slab 58 is illustrated which comprises glass as a matrix filled continuously with layers of mesh formed of interwoven reinforcing members 60 and 62, that is throughout the thickness of the slab. A slab 64, as illustrated in Figure 8, is similar to the slab 58 of Figure 7 except that transversely extending ' reinforcing members 66 and 68 are not interwoven. Instead, the reinforcing members 66 of a layer are all coplanar and similarly the reinforcin . g members 68 are all coplanar with layers of the reinforcing members 66 separating layers of reinforcing members 68, and vice versa. In each of the above disclosed embodiments, it is highly desirable to utilize compatible materials for the matrix and for the elongated reinforcing members. Examples of preferred combinations are the use of titanium for the elongated reinforcing members while using a matrix of glass; molybdenum for the reinforcing members and pyrex for the matrix; and invar for the reinforcing members with fused silica for the matrix. In this manner, the coefficient of expansion of the respective materials can be matched to allow for wide ranges of temperature in the working environment. The consideration of reinforcing member "show-through", i.e., flush with the slab surface, as discussed with respect to the slab 48 of Figure 5, and problems with extremely thin beams or slabs 36 as illustrated in Figure 3, give rise to the embodiments of Figures 9 and 10. In these embodiments, the reinforcing members and the substrate are essentially identical, comprising a lay up of optical quality glass fibers. Graphite fiber/epoxy constructions employ graphite fibers having superior mechanical properties to epoxy, as well as a very low coefficient of expansion. The overall expansion coefficient and the overall strength is thus changed for the better over epoxy alone, as in the construction of tennis racquets, for example. Similarly, the use of metallic wire fibers for the reinforcing members of the constructions illustrated in Figures 1 - 8 serve the purposes of the invention very well. However, drawn glass fibers used in communications optics have even better strength and uniform properties, approaching and even exceeding 0.69 GPa in tension. This property is due to the pristine nature of their manufacture, which can be maintained by burying them in the matrix as in Figures 1-8. These types of optical glass fibers are often laid up in a matrix (by themselves) for encoding (non aligned), transferring information (match plates), or focal plane repeating. However, what is presently proposed is laying them up in a beam or slab formation, or parallel, and bonded together in a unitary fashion, so as to gain strength, not optical advantage. The choice of glass for core and/or clad is for thermal and mechanical properties. They can be either of the clad or unclad variety, depending on required physical and optical (that is, polishability) , transmissive, and index of refraction properties. As illustrated in Figure 9, a plurality of optical glass fiber strands 70 provided with an outer cladding 72 are laid up in a known fashion in a parallel relationship. Then they are squeezed together into a generally hexagonal formation as seen in cross section. Preferably, the outer cladding 72 has a melting temperature which is lower than that of the glass fiber strands 70. The temperature of a slab 74 composed of the glass fibers strands 70 and outer cladding 72 is then raised above the melting point for the outer cladding so that the strands become unified. Such optical quality glass fibers can be made so as to have miniaturized dimensions (that is, having diameters of thousandths of an inch). The physical bond achieved is excellent and when the opposed surfaces are ground and polished as described above, the outer surfaces of the slab 74 exhibit equally superior reflective optical qualities whether the strands 70 are flush with the surface or not. Simultaneously, the slab or beam 74 would also exhibit excellent bending strength parallel to the optical fiber layup direction * The contribution of highly polishing the surfaces, and even the edges and corners, is discussed in the copending application Serial No. 868,829 noted above. A slab 76 illustrated in Figure 10 is similar to the slab 74 in that a plurality of glass fiber strands 78 having an outer cladding 80 are aligned in a mutually parallel arrangement, then squeezed together, into a solid, hexagonal formation. However, in this instance, the longitudinal axis of the fiber strands 78 are transverse, and preferably perpendicular to a plane of the slab 76. When opposite surfaces of the slab 76 are ground and polished in the manner described above, the outer surfaces of the slab 76 also exhibit excellent reflective optical properties while simultaneously possessing high strength characteristics parallel to the fiber layup direction, in this case transverse to the principal ' surfaces (and not parallel to them). he present invention is further practiced if a slab 64, as in Figure 8, were to contain alternating layers of fiber bundles, each like Figure 9, so that each layer was perpendicular to the adjacent one. In this manner bi-directional bending strength would be achieved. In such arrangements as Figures 9, 10, or Figure 8 (built up of a series of alternating and perpendicular layers of the type illustrated in Figure 9), there would also be possible the transmission of coherent or incoherent light through the fibers employed for strength purposes, as well as incoherent light transmission through the beam itself (from surface to surface, perpendicular to the fiber layup directions). In another embodiment of the invention which is a variation on the constructions illustrated in Figures 8, 9, and 10, is that illustrated in Figure 11. The slabs 74 and 76 utilize glass fiber strands having great strength characteristics surrounded by outer protective cladding glass having less stringent but beneficial properties (i.e. reduced melting temperature, less strength, and no requirement on index unless simultaneous transmission through the reinforcing fibers themselves is desired). In the alternative, a reinforcing member 82 could be utilized in a slab in which inner cor-e material 84 is of a high strength steel or other elongated metallic substance having high tensile strength, an outer core material 85 is an optical quality glass fiber, surrounded by a relatively thin and flexible protective cladding 86. The cladding 86 serves as a temporary or permanent protective layer as well as improving the eventual bonding of the reinforcing members 82 together when the resulting slab is of the solid nature as illustrated in Figures 8, 9, and 10 or when the reinforcing members 82 are embedded in a matrix or substrate as illustrated in Figures 1 - 5 and 7 - 8. In those instances in which reinforcing members are employed, especially when the reinforcing members are composed of steel, nickel, boron, or carbon, prestressing can be employed to obtain even greater strength characteristics for those instances in which the finished product is subjected to bending stresses. As illustrated in Figure 12, a reinforcing member 88 is diagrammatically illustrated as being held at its opposite ends by suitable grippers 90 and 92. These grippers draw the member 88 in opposite directions so that it is stretched beyond rest to a tension of some fraction of its yield strength, for example, 30%. As shown in Figure 13, a plurality of such stretched reinforcing members 88 would then be suitably placed on a mold box 94 in the stil1-tensioned condition. Thereafter, a glass or plastic matrix or substrate 96 is poured into the mold box and allowed to solidify. After solidification, the grippers 90 and 92 are released (see Fig. 14), thereby imparting compressive stresses in a resulting slab 98. The benefit thereby derived resides in the fact ' that this initial compression in the slab must be overcome before any tensile stress appears in the matrix or substrate. The effect is similar to the process of chemical tempering which occurs in ion exchanged glass, but here the compressive stress extends down to the core of the entire part instead of being mostly a near surface phenomenon. A further appl ication of the invention, regar ding prestressed members , may empl oy the CVD process wherein a vapor deposited matrix or substrate is imposed on and around the prestressed rods. This would incl ude such mater ia l s as si l icon, z inc sul fide , z inc selenide, and vapor deposited (smoked) fused silica. By way of example, in a typical instance, the reinforcing member 88 may be subjected by the grippers 90 and 92 to a tensile stress of 207 MPa. When the matrix or substrate solidifies and the grippers 90 and 92 are removed, as illustrated in Figure 14, the tensile stress in each member is partially transferred to the slab 98 in a form of a compressive stress of, for example, 138 MPa. When the reinforcing member 88 is "relaxed", as illustrated in Figure 14, a certain amount of residual tensile stress remains in the reinforcing member itself, for example, 103.5 MPa. If, then, the slab 98 is bent as illustrated in Figure 15, by a force of 207 MPa acting centrally from beneath, a convex surface 100 will exhibit a stress of 69.0 MPa in tension (that is, 207 MPa applied tensile stress minus 138 MPa initial compressive stress). Similarly, a concave surface 102 exhibits a compressive stress of 345.0 MPa (that is, 207 MPa applied compressive stress plus 138 MPa initial compressive stress). Since conventional glass customarily fails at approximately 69.0 MPa in tension, and 690 MPa in compression, the slab 98 employing a plurality of prestress reinforcing members 88 can well survive the 30,000 psi force to which it is subjected, by way of example. As for the reinforcing member 88 itself, if it is positioned within the slab 98 midway between the surfaces 100 and 102, it will continue to exhibit the tensile stress of 103.5 MPa to which it had "relaxed" following solidification of the substrate or matrix 96 and release of the grippers 90 and 92, being on the neutral "axis" of the beam. Departure from this central position wil l cause sl ight curvature to ari se in the member 88. If not done deliberately, such curvature can be ground and polished away if desired. Additional embodiments ' of structures for producing a superior quality of "glass" with exceptional strength characteristics are il lustrated in Figures 16 - 18. In Figure 16 , an optical fiber bundl e 104 i s shown buried inside a pl astic sur round 106. The composition of the pl astic surround 106 may be, for example acrylic or polystyrene. This construction results in a beam 108 of exceptional strength with the glass optical fiber 104 being permanently protected from damage by air, or gas , or moisture intrusion. A beam was made up according to Figure 16, wherein the fiber of optical glass- was about. 510 micrometers in diameter and the plastic surround was about 1,114 micrometers in diameter. A stress of 1.725 GPa was handled in repeated bending as a "beam" without failure of the glass fiber, or crazing of the plastic surface, or set of the part from any possible yielding. While the surround 106 is illustrated in Figure 16 as being circular, it may also be square in cross section as illustrated by a surround 106A in Figure 17 and resulting in a beam 108A. Indeed, as illustrated in Figure 18, a plurality of generally parallel fiber bundles 104 may be embedded in a plastic "board" or flat 110 which can be used for a large sized articles and which can be cut, lumber style, to accommodate particular shapes or sizes of an end product. One unfortunate drawback of the construction described with respect to Figures 16 - 18 relates to those applications in which an optical quality surface is required. That is, it would previously have been required that the surfaces of the beams 108, 108A or of the boards 110 be polished. However, the polishing of plastic has always presented problems since it is usually a relatively soft material. This aspect has primarily made the plastic surround less attractive as compared to glass surrounds. However, this problem is overcome by reason of the already known invention according to which optical surfaces can be replicated onto any strengthened items 116 constructed in accordance with Figures 16 - 18. The replicating process is generally illustrated in Figures 19 and 20. According to this process, a complimentary or negative glass master 112 is provided with a contoured outer surface 114 having generally the configuration of an item 116 (Figure 20) whose surface 118 is to be rendered optical quality. In preparation for receiving the item 116 which may have been constructed in accordance with Figures 16-18, or even Figures 12-15, or Figures 1-11, on the outer surface 114, the outer surface 114 is first figured and highly polished to the extent discussed previously and in a known manner. Thereafter, the contoured surface is coated, in sequence, with layers of a suitable parting agent 120 (which is usually proprietary to the user); a suitable overcoating (for the part-to-be) 122 such as silicon monoxide; a suitable reflecting material 124 such as gold, silver, or aluminum; and a suitable bonding agent 126 to attach the optical surface to the substrate 116. The bonding agents commonly used are: Armstrong A-12 or Narmco epoxies, silicon cements such as RTV, and Uralane 5753. The choice of bonding agent is determined by coefficient of expansion considerations and/or the end application of the replicated part. The bond can even be layered or built up of several components. Some are chosen to slightly contract or expand upon curing. Some are chosen for rigidity or flexibility considerations . The purpose of the bonding agent 126 is to assure integrity of the various layers with the item 116 being coated. The parting agent 120 serves to assure that the coated item 116 can be readily removed from the outer surface 114 of the glass master 112 without damage to the reflecting material 124. The purpose of the overcoating 122 is to protect the reflecting material 124 but without diminishing its optical quality. It is noteworthy that the bonding agent 126 can also be chosen as to generally match the thermal properties of the surround of plastic or other material in the item 116 to assure that often occurring problem's with temperature excursions in use will not occur, such as in cryogenic applications. When the item 116 has been received on the glass master 112 in a customary manner and for a proper length of time for curing and set up, the item 116 is then removed with the reflecting material 124 and overcoating 122 still intact. It will be appreciated that this same procedure can be used in preparing optical surfaces for the previously described embodiments. The procedure is particularly beneficial for that situation illustrated in Figure 5 in which the slab 48 has been ground and polished to the extent that the reinforcing members 50 and 52 are actually visible at one surface thereof. Experience has also shown that polishing with water, previously a primary lubricant used for polishing actually causes propagation of microcracks in any vitreous matrix thereby impairing optical quality as well as substantially reducing the strength of the item. By using the replicating procedure just described and as diagr amat ica 1 ly illustrated in Figures 19 and 20, an exceptional optical surface can be achieved without the need to grind and polish each individual item, and without diminution of strength. The following table presents various of the embodiments disclosed with preferred usages for each embodiment: Embodiment Preferred usage Metal fibers, or unequal 1. Radio or radar antenna index glass fibers, or (i.e. formed dish), glass surrounded metal fibers 2. Dichroic window for infrared and radar/ microwave separation. 3. Dichroic window for visible and radar/ radio separation. Glass fibers of equal 4. Clear windows of index to surround appropriate wave length, contoured shapes, (i.e. dishes, lenses, domes) for appropriate wavelengths. 5. Mirror applications, any wave length. 6. Non-coherent window (shower door, floors, walls) . 5, 6, 15. Visible and infrared dichroic. Concentric glass fibers, 4, 5, 15. i.e. core and clad: both of equal index to each other and surround (unequal melt tempera¬ tures and strengths allowed) As above, but with un¬ 1, 5, 6. equal index matches metal core, glass clad glass index not equal to surround Metal core, glass clad;. 1, 2 glass and any outer clad to it of equal index to surround "Rods " i n ou te r par ts 8. Bi stress beams applica of beam, or rods crossed tions (reverse bending) . (compound) in outer parts 9. Pre stressed beams, or bistress and prestress. "Rods" in center or on 9. neutral axis of part, single or compound Rods inside one 7. Beams with single dire surface, single or tensile stress. compound 10. Prestressed, single dir ion tensile stress. Surround doped with ind. I, 4, 5, 6 diamond "dust", metal II. Complete reflectors for • particles, bi-refringent non infra red .or visible rays crystals (aligned), par¬ 12. Super strong interiors w ticles having unusual glassy surfaces. properties (i.e. super- 13. Unusual elastic or exp¬ strong, unusual expansion ansive properties in an coefficients or elastic (otherwise) glassy part. moduli) , particles 14. Polaroid or bi-refringent having no self coherence filters of high strength and/ or adhesion with themselves or integrity in a hostile environment . While preferred embodiments of the invention have been disclosed in detai l , it should be understood by those ski lled in the art that var ious modif ications may be made to the il lustrated and described embodiments without departing f rom the scope of the invention as described in the specification and defined in the appended claims.

Claims: CLAI&Z 1. A method of strengthening items composed of a vitreous material comprising the steps of: heating a slab of vitreous material to the molten state; laying into the molten material a first plurality of generally parallel, coplanar elongated reinforcing members having a tensile strength substantially greater than that of the vitreous material; cooling the vitreous material to the solid state whereby the reinforcing members are integrated into the structure of the slab. 2. A method as set forth in Claim 1 including the step of laying into the molten material a second plurality of generally parallel, coplanar elongated reinforcing members similar to the first plurality and extending in a direction transverse to that of the first plurality. 3. A method as set forth in Claim 2 wherein the slab has substantially parallel planar opposed faces and wherein the first and second plurality of reinforcing members are positioned nearer one of the opposed faces than the other. 4. A method as set forth in Claim 2 wherein the elongated reinforcing members of the first plurality are interwoven with those of the second plurality to form a reinforcement fabric. 5. A method as set forth in Claim 2 wherein the slab has substantially parallel planar opposed faces and wherein the first and second plurality of reinforcing members are positioned to lie in planes substantially equidistant from the opposed faces. 6. A method as set forth in Claim 1 wherein he material of the reinforcing members is selected from the group consisting of glass fibers, steel, boron, carbon, nickel and alloys thereof. 7. A method as set forth in Claim 5 including the steps of; grinding the faces of the slab until each face exhibits a surface irregularity of approximately 2.54 ± 1.27 micrometers; and polishing the faces of the slab until each face exhibits a surface irregularity of no greater than 2.54 x 10~ 2 ± 2.54 x 10 ~2 micrometers, and a surface roughness of no greater than 254 + 254 picometers. 8. A method as set forth in Claim 2 wherein the slab has substantially parallel planar opposed faces and wherein one reinforcement fabric is positioned in a plane parallel with and proximate to one of the faces and wherein another reinforcement fabric is positioned in a plane parallel with and proximate to the other of the faces. 9. A method as set forth in Claim 8 including the steps of: grinding the faces of the slab until each face exhibits a surface irregularity of approximately 2.54 ± 1.27 micrometers; and polishing the faces of the slab until " each face exhibits a surface irregularity of no greater than 2.54 x 10~ 2 ± 2.54 x 10 "2 micrometers and a surface roughness of no greater than 2.54 x 10 "4 ± 2.54 x 10 "4 micrometers. 10. A method as set forth in Claim 2 wherein the slab has a substantially planar face and wherein the first and second plurality of reinforcing members are positioned adjacent the face,including the steps of: grinding the faces of the slab until each face exhibits a surface irregularity of approximately 2.54 ± 1.27 micrometers; and polishing the faces of the slab until each face exhibits a surface irregularity of no greater than 2.54 x 10~ 4 ± 2.54 x 10 ~4 micrometers. 11. A method as set forth in Claim 2 including the step of laying into the molten material successive layers of the first plurality and of the second plurality of reinforcing members 12. A method as set forth in Claim 4 including the step of laying into the molten material successive layers of the interwoven reinforcing members. 13. A method as set forth in Claim 1 wherein the vitreous material is glass and wherein the material of the reinforcing members is selected from the group consisting of titanium and alloys of titanium. 14. A method as set forth in Claim 1 wherein the vitreous material is pyrex and wherein the material of the reinforcing members is selected from the group consisting of molybdenum and alloys of molybdenum. 15. A method as set forth in Claim 1 wherein the vitreous material is fused silica and wherein the material of the reinforcing members is invar. 16. A method of strengthening items composed of a vitreous material comprising the steps of: laying up in a casting mold a plurality of generally parallel, coplanar elongated reinforcing members having a tensile strength substantially greater than the vitreous material; pouring molten vitreous material into the casting mold so as to completely envelop the reinforcing members; and cooling the vitreous material to the solid state thereby forming a slab of reinforced vitreous material. 17. A method as set forth in Claim 16 wherein the reinforcing members are positioned closer to one surface of the mold than to an opposing surface. 18. A method as set forth in Claim 16 wherein the reinforcing members are positioned so as to lie equidistant from opposed surfaces of the mold. 19. A method as set forth in Claim 16 wherein the material is poured into the mold at substantially room temperature and then cured at room temperature. 20. " A method as set forth in Claim 16 wherein curing of the vitreous material takes place at a temperature which is elevated relative to the pouring temperature. 21. A method as set forth in Claim 20 wherein curing of the vitreous material takes place at a temperature which is less than the pouring temperature. 22. A method as set forth in Claim 16 including the step of prestressing the reinforcing members prior to pouring and solidification of the vitreous material. 23. A method of strengthening items composed of a vitreous material comprising the steps of: heating opposed surfaces of a pair of slabs of vitreous material to a softened state; inserting between the opposed surfaces a plurality of elongated reinforcing members having a tensile strength substantially greater than that of the vitreous material; pressing the slabs together in a sandwich structure so that the reinforcing members are embedded in the softened surfaces of the slabs; and cooling the opposed surfaces of the slabs to the solid state. 24. A method as set forth in Claim 23 wherein the slabs are of unequal thickness. 25. A method as set forth in Claim 23 including the step of prestressing the reinforcing members prior to cooling of the two slabs. 26. A method of producing high strength optical quality reflectors without the need to grind and polish them comprising the steps of: embedding in a plastic matrix a plurality of elongated reinforcing members having a tensile strength substantially greater than that of the plastic matrix to form a strengthened plastic member; shaping the strengthened plastic member to a desired form; coating a highly polished glass master having generally the form of the strengthened plastic member, in sequence, with layers of: (a) a parting agent; (b) an overcoating; (c) a reflecting- material ; and (d) a bonding agent; pressing the strengthened plastic member against the coated glass master for a predetermined length of time to cure the bonding agent; and removing from the glass master the strengthened plastic member with a replicated reflecting surface ' thereon. 27. A method as set forth in Claim 26 wherein the matrix is a vitreous material produced by any one of the processes of casting, melting, or chemical vapor deposition. 28. A method as set forth in Claim 26 wherein the composition of the plastic matrix is selected from the group consisting of polycarbonate, acrylic, or polystyrene. 29. A method as set forth in Claim 26 wherein the elongated reinforcing members are glass fibers. 30. A method as set forth in Claim 26 wherein the elongated reinforcing members are metallic. 31. A strengthened item composed of a vitreous material having embedded in its structure a plurality of elongated reinforcing members having a tensile strength substantially greater than that of the vitreous material. 32. A method as set forth in Claim 16, wherein the casting mold is placed in a chamber and the vitrerous material is introduced by chemical vapor deposition.

Inventors: BAGBY JOHN P, OTIS ROBERT J, SEERY CRAIG W, YANATOVIC STEVEN C, BAGBY, JOHN, P., OTIS, ROBERT, J., SEERY, CRAIG, W., YANATOVIC, STEVEN, C.
Applicants: HUGHES AIRCRAFT CO, HUGHES AIRCRAFT COMPANY
Application year: 1987
Main classification: C03B19
IPC codes: C03B13, C03B19, C03B37, C03C14, C03C27