POLARIZING GLASSES HAVING INTEGRAL NON-POLARIZING REGIONS

Abstract: Polarizing glass having localized regions or patterns of non-polarizing glass is disclosed. The non-polarizing regions are formed by use of reducing gas-blocking material, local thermal heating of the glass, or by etching techniques. Figures (1a) - (1b) show the reducing gas-blocking method where a shadow mask (4) or a thin layer of material (6) is formed on the surface of the glass (2) to retard the reduction process and enable the production of color gradients and/or designs or patterns in the glass. The masked glass is exposed to a reducing atmosphere such that the reducible phase in the exposed or unprotected regions (8) is reduced and the non-polarizing region (masked region) (10) is not reduced.

Description: POLARIZING GLASSES HAVING INTEGRAL NON-POLARIZING REGIONS BACKGROUND OF THE INVENTION Hydrogen firing at elevated temperatures to change the color of glasses whose compositions contain reducible ions is well known. A notable commercial application of that technique is found in the Corning Incoφorated eyewear product lines marketed under the SERENGETI ® and CPF ® trademarks. The color changes induced are attributed, to the reduction of a portion ofthe silver and lead ions respectively, in the glass to the atomic state. Several methods have been suggested for making polarizing glasses. For example, one such method is to redraw a glass above its softening temperature. The glass contains a separate phase which is elongated by the redraw process. The thermal treatment which leads to the phase separation is usually carried out before the redraw process. In a particular version of the above process, the separated phase is initially spectrally non- absorbing material such as AgClBr, CuClBr, Agl, Cul or copper/cadmium halides, which must be subsequently modified to create a desired dichroic property necessary for the polarizing effect. This is accomplished by treating the stretched glass in hydrogen gas at elevated temperatures for sufficient time to effect the chemical reduction ofthe spectrally non-absorbing materials to their corresponding metal. The chemical reduction process is a combined process involving both the diffusion of hydrogen in the glass, and the chemical reaction ofthe hydrogen with the halide phase. It is known that the chemical reaction proceeds very fast relative to the hydrogen diffusion which leads to the condition of a shaφ boundary between the reduced region near the surface, and the unreduced region below the surface. The polarizing behaviors derives from the reduced layer. Also, when the polarizing glass is heated to the vicinity of 500 °C for any prolonged period of time, the elongated particles re-spheridize and the polarizing property is lost. That is, the elongated particle returns to its spherical shape. This is explained by the fact that once the glass is soft enough, the interfacial forces act to undo what the redrawing forces had accomplished. For certain applications, it is desirable to have the polarizing properties restricted to localized regions of the glass. Accordingly, it is the object ofthe present invention to provide methods of partially or fully blocking the effect of hydrogen reduction over a portion of a glass surface, or other ways of altering the polarizing state. SUMMARY OF THE INVENTION Briefly, the invention relates to a polarizing glass having an integral non-polarizing region. In one aspect, the invention relates to a method of producing a polarizing glass in which a region on the glass surface is rendered non-polarizing. In a particular aspect, the invention relates to a method of forming a glass having integral polarizing and non-polarizing regions by: (a) providing a glass having an elongated (stretched) reducible phase; (b) protecting or masking a portion ofthe glass by selectively forming a layer of material on the surface of said portion ofthe glass; (c) subjecting the unprotected regions ofthe glass to a reducing gas to reduce the reducible phase in said region; and (d) removing the layer of material from the protected portion to reveal the underlying non-polarizing glass to thereby form a glass having integral polarizing and non- polarizing regions. In still another aspect, the invention relates to a method of forming a non-polarizing region in a polarizing glass by, providing a polarizing glass comprising reducible elongated phase particles; and then subjecting a region ofthe glass surface to thermal heating to re- spheridize the elongated phase and thereby render the polarizing glass, non-polarizing in said region. In yet another aspect, the invention relates to a method of forming a non-polarizing region in a polarizing glass by selectively removing the polarizing layer to render the glass in said region, non-polarizing. As used herein: "reducing atmosphere" refers to a gaseous atmosphere in which the chemical potential of oxygen is low. Examples of reducing gases include hydrogen, hydrazine vapor, cracked ammonia, deuterium and forming gas (i.e., a mixture of hydrogen and an inert gas, for example, H 2 /He and H 2 /N 2 ). BRIEF DESCRIPTION OF THE DRAWINGS Figs, la to lc are schematic diagrams illustrating one inventive method of forming a polarizing glass having at least one non-polarizing region; Figs. 2a to 2d are schematic diagrams illustrating another inventive method of forming a pattern of polarizing and non-polarizing glass, by a photolithographic process; Figs.3a and 3b are schematic diagrams illustrating an embodiment ofthe invention, involving, exposing an assembly of polarizing glass and photoresist to light radiation, developing the photoresist to expose the underlying polarizing layer (Figure 3a), etching the exposed region to remove the polarizing layer in said region, and the stripping away the photoresist (Figure 3b). DETAILED DESCRIPTION OF THE INVENTION We have found, and disclose herein, that a polarizing glass having non-polarizing regions can be formed by (1) use of a hydrogen blocking film, (2) local thermal treatment. (3) etching, or (4) a combination of these methods. For ease of discussion, the layer of reducing gas blocking material will be referred to herein as "hydrogen-blocking film" even though it is understood that in addition to hydrogen, other reducing gases such as cracked ammonia, deuterium or forming gas (i.e., a mixture of H 2 with He, N 2 , or Ar) may be used. As contemplated by the present methods, the polarizing glass contains a reducible elongated phase such as, AgCl x Br,. x , CuCl x Br,. x , where x has a value between 0 and 1, or phase separated Pb-borate glass. Other useful reducible phases include, Agl, Cul and Cu/Cd halides. The invention will now be described with reference to the drawings. In the hydrogen blocking method (Figs, la to lc), a thin layer of material 6, preferably a dense film of material such as Cr, Mo or their oxides is formed on the surface of a non-polarizing glass 2 to retard the reduction process and enable the production of color gradients and designs or patterns on the glass. In a particularly useful embodiment using this technique, a non-polarizing region 10 is formed in a glass having a stretched or elongated particles by using a reducing gas and a pattemed film which is capable of retarding penetration ofthe reducing gas. In this embodiment, the non-polarizing region is formed by: 1 ) providing a glass 2 having a layer of reducible elongated phase; 2) protecting a region ofthe glass by forming a layer of blocking material 6 on the surface ofthe region ofthe glass to be protected, the material being capable of blocking or preventing penetration of a reducing gas (Fig. lb); 3) subjecting the unprotected region 8 of the glass to a reducing gas atmosphere to reduce the reducible phase in the unprotected region 8 and thereby render said region polarizing; and 4) removing the layer of blocking material 6 from the protected region to reveal the underlying non-polarizing glass (Fig. lc). The preferred reducing gas can be H 2 , cracked ammonia, forming gas and D 2 . If forming gas is used, then the hydrogen content ofthe forming gas mixture is preferably at least 0.1 %, more preferably, at least 5%, and most preferably, at least 10%. The higher the hydrogen content ofthe forming gas mixture, the lower the pressure and the less the time required to reduce the reducible phase in the glass. The preferred forming gas is H 2 N 3 . The layer of hydrogen- blocking material may be patterned using any method. A particularly useful method of selectively forming the thin film layer is by placing a shadow mask 4 above the glass surface, such that the mask shadows or protects certain regions of the glass (Fig. 1 ). A pattemed layer of blocking material is thereby formed on the unmasked or unprotected regions of the glass through holes or openings in the shadow mask. Another useful method of patterning the thin film blocking layer is by using photolithography (Fig. 2). In this patterning process, (i) a thin film of hydrogen-blocking material 6 is deposited over the entire surface of a reducible glass 2, that is, a glass having a layer of stretched or elongated particles; (ii) a thin photoresist layer 12 is then applied to the surface of the hydrogen-blocking material 6 (Fig. 2a); (iii) the photoresist is lithographically pattemed using a mask and developed (Fig. 2b); (iv) the pattemed photoresist image is then transferred into the layer of blocking material by an etching process (dry or wet); and (5) the photoresist is removed leaving a pattemed film blocking material (Fig. 2c). To form a region of non-polarizing glass, the assembly of Fig. 2c is exposed to a reducing gas atmosphere as above to render the glass polarizing in the unprotected region. Then the blocking material is removed to form a glass having polarizing 8 and non-polarizing 10 regions as shown in Fig. 2d. We have found that the particular method used to deposit the thin layer of material is a key aspect ofthe invention. In particular, to avoid the formation of pinholes in the layer, the film is deposited, preferably in a Class 1000 (or better) clean room environment, by sputtering or other suitable methods. The choice ofthe blocking material and its deposited thickness is made on the basis of how deep a reduced layer in the glass is required for any given application. In other words, the property ofthe deposited film, through the combined property of density and thickness, must be sufficient to retard the diffusion of H 2 for the time/pressure/temperature required to produce a sufficient reduced depth in the glass, in turn, providing the desired contrast. For example, the depth to which the silver or copper halide phase is chemically reduced to silver, or copper (i.e., the thickness ofthe polarizable layer), determines the contrast ofthe polarizer. It has been shown that the reduced depth is proportional to the square root ofthe H 2 pressure and the time of treatment, as well as an exponential function ofthe temperature. The contrast is defined as the ratio of the transmittance in the passing direction (peφendicular to the stretched direction, T 0 ) to the transmittance in the absorbing direction (parallel to the stretching direction). One can mathematically express this in terms ofthe thickness of the polarizing layer by the equation, contrast = T 0 /exp(-αd) where d is the polarizing film thickness. The coefficient, , depends on the wavelength of light and the degree to which the glass was stretched. For a given application, α, and T 0 are determined experimentally, and the thickness ofthe polarizing film can be determined for any desired contrast. In one particularly useful embodiment, at a wavelength of 640 nm, a thickness of 28 μm is required to achieve a contrast of 100. The particular choice of a material for use in the blocking of hydrogen, such as, Cr, Mo, Ta, Zn, W, may depend on the method used to form the thin layer and the related deposition variables. Other useful hydrogen blocking materials include the noble metals such as Au, Rh, Pd, Pt, and Ir. For example, where the layer is formed by film deposition method, the relevant variables may include the porosity of the deposited film, which depends on the specific deposition method and system, the film adherence, and how it varies with thickness, the thermal mismatch, and how it relates to thickness. These latter issues relate to the quality ofthe film that is produced, pinholes, cracks, and other features that would allow H 2 to penetrate through the film. A summary of illustrative results using several hydrogen blocking materials films is shown in Table 1. For this particular case the high contrast was desired at a wavelength of 640nm. In another embodiment, localized heating is used to render a portion of a polarizing glass, non-polarizing. In the local heating method, a non-polarizing region is formed in a polarizing glass by subjecting a region of the glass surface to thermal heating to re- spheridize the elongated phase and thereby render the polarizing glass, non-polarizing in the region of thermal contact. The object is to locally heat the glass to above about 450°C, preferably, above about 500 °C in a manner appropriate for forming the desired pattem. In the heated region, the elongated phase will be re-spheroidized and rendered nonpolarizing. An important point to realize is that one need only to heat the relatively thin surface polarizing layer to above 450° C, which means the amount of heat required can be quite small. This can be achieved by a number of ways. One way to easily localize the heated regions is to use a light source, such as laser, at a wavelength where the effective absoφtion depth, usually defined as the reciprocal of the absoφtion coefficient, is approximately equal to the polarizing film thickness. In this way the light is primarily absorbed in the layer to be heated. In this embodiment, care must be taken to avoid possible overheating, and the physical damage that may result from such overheating. The power input must be sufficiently controlled to maintain a safe temperature and avoid any possible damage. An example of a light source that satisfies the above stated conditions is a CO 2 laser. The intensity distribution ofthe beam is important in that it will influence the temperature profile and, therefore, affect the nature of the transition from the non-polarizing to polarizing region. One can influence this by using a mask in a scanning mode, or a multimode laser with a flat intensity profile. In one embodiment, a CO 2 laser source is focused on a region of polarizing glass to heat the glass in said region and thereby render the glass non-polarizing by re-spheroidizing the elongated phases as described above. Another way to provide local heating is to use a polarized light source whose polarization direction is oriented in the absorbing orientation ofthe polarizing material. The wavelength ofthe light is chosen to correspond to the high contrast spectral region. Another way to provide local heating in the thin polarizing layer is to use a high current of an energetic beam, such a electrons or ions, either focused or in conjunction with a suitable mask. The beam would locally heat the polarized surface layer. Another useful method of forming a non-polarizing region by local thermal treatment, is by thermal contact. In one such embodiment, heated tips or ridges are brought in contact with the polarized layer ofthe glass to heat the contact region, and thereby effect re-spheroidization. In using the thermal contact method, care must be taken to avoid thermal shock which may result due to the rapid heating and cooling. One possible disadvantage ofthe thermal heating methods is the residual birefringence that may result from the rapid heating and cooling. This can be mitigated by careful annealing. In this embodiment, it is not necessary to directly contact the polarizing glass with the heat source, as effective heating can be achieved without direct contact. Thus, it may be sufficient to bring the heat source to the proximate region ofthe glass to be heated, since it is the heat radiation, rather than the heat source itself that is required to achieve the objective of this method. The etching method (Figs. 3a and 3b), relies on the selective removal of the polarizing layer by any number of etching techniques. In this method, parts of the polarizing layer 8, is protected by use of a film or layer of metal or photoresist 16. The unprotected layer of polarizing glass is then etched to remove the polarizing layer and thereby form a polarizing glass having an integral non-polarizing region 20 (Fig. 3b). The protected region restricts the removal of the polarized surface layer. Preferably, the thickness of the polarizing layer is in the range of 10-50 microns, depending on the polarizing property required. The selective removal or etching away ofthe polarizing layer may be done by either wet or dry etching techniques. This method may produce a phase front alteration to a beam because light passing through it may have different optical paths in the etched and non-etched areas. This front alteration may be undesirable for certain applications. EXAMPLES 1. Hydrogen Blocking a) A Mo film of the order of 1 μm thick was deposited through a pattemed shadow mask onto a stretched glass surface. The mask was maintained in intimate contact with the sample. The metal pattemed sample was then treated in pure H 2 atmosphere at 420° C, 1 atm, for 17 hours. A polarizing layer having a depth of about 30μm was formed in the unmasked region, while the masked region remained non-polarizing. The Mo film was then removed by a suitable acid. If a single sided pattemed polarizing effect is desired, the entire back side can be covered with Mo to protect it. If desired, a two-sided product may be produced by apply the same or a different pattem on the opposite side ofthe glass. In this example, the hydrogen-blocking material was applied by sputtering, in a Class 1000 clean room environment. b) Same as above except that the hydrogen-blocking material was Cr, having a thickness of about O.όμm. The H 2 treatment was at 420° C, at 1 atm, for 3 hours. The resulting polarizing layer had a depth of about 15μm. c) Same as above except that the hydrogen-blocking layer was 1 μm of ZnO. The H 2 treatment was 420° C for 3 hours, at 1 atm. Thickness ofthe polarizing layer was 15μm In a similar experiment, we found that Mo film having a thickness as low as 0.5 μm can be treated in a hydrogen environment at 1 atm, 420°C for 16 hours without any bleed through. That is, the hydrogen did not penetrate through the Mo film into the underlying glass. We have found that the higher the pressure, the more likely the hydrogen is to bleed through the film. Also, the denser the film the less likely the hydrogen is to bleed through the film. For a given hydrogen-blocking material, the optimal reducing gas treatment conditions (time, temperature, pressure) necessary to minimize or reduce bleed through can be determined by experimentation. For example, if a forming gas mixture having low hydrogen content is used, then the reducing gas treatment can be carried out at high pressure with minimal effect from any resulting bleed through. 2. Local heating a) A glass sample having a reducible elongated phase was exposed to a hydrogen environment as described above to form a polarized glass. A 4W cw CO 2 laser was focused to a 1.5mm spot on the polarized glass sample for a fraction of a second using a shutter. The exposed spot was yellow in color, and non-polarizing corresponding to the condition ofthe respheroidization ofthe elongated silver particles. b) The same as above, but the sample was exposed to the CO 2 laser before the H 2 treatment. This heat treatment respheroidized the metal halide particle in the region exposed to the laser. The sample was then treated in a H 2 atmosphere as described above to develop the polarizing layer. Because the heated area only contained spherical particles, no polarizing property was developed in the exposed area. 3. Etching a) A glass sample having a stretched or elongated layer was coated with 0.2μm of Cr and then coated with photoresist. The sample was exposed to light through a mask containing the desired pattem as shown in Fig. 2. The resist was then developed to expose the underlying Cr layer in the unmasked region, and the Cr layer was etched away. The remaining photoresist material was then stripped leaving a pattem of metal-covered and uncovered regions, (Fig. 3a). Using a wet chemical etching technique, the sample was then dipped in dilute HF for a sufficient time to dissolve the glass in the uncoated region to a thickness corresponding to the polarizing layer. The Cr layer was then stripped to obtain a polarizing glass, having an integral non-polarizing region, (Fig. 3b). b) The same as above, except that a dry etching process (reactive ion etching) was used to remove the polarizing glass layer at a rate of about 3μm per hour. THE PREFERRED EMBODIMENT In the preferred embodiment, the metal films used to inhibit the H 2 penetration were delineated using a shadow mask. Samples were prepared using two dense metal - Cr and Mo. Thin layers ofthe hydrogen-blocking metal were deposited using either a CVC DC sputtering system or a MRC in-line sputter system, both in a Class 1000 clean room. If desired, a film ofthe reducing gas blocking material may also be applied to the other surface to the polarizing glass prior to the hydrogen treatment. The deposition conditions were as follows: Cr Mo P Prreessssuurree ((iittiiTT)) 1 10 Power (W) 1000 1000 Deposition Rate (A/s) 3.5 15 Rotation number 5.0 Belt speed (in/min) 10 Passes 6 The glass used in all cases was Polarcor™ (available from Coming Incoφorated), with a 680 nm center peak wavelength. The samples were ground and polished to a thickness of 0.5 mm before hydrogen treatment. The results are summarized in the table below. TABLE 1 H 2 - Thickness block. of H 2 block, H 2 treatment Polarizing film Mafl material Temp/time/pressure Thickness 5 (μm) (°C/hours/atm) (μm) Cr 0.4-0.6 415/3/1 15 Mo 1.0 415/16/1 30 n υ Mo 1.0 415/7/1 20 Mo 1.0 415/17/1 30 5 Mo 1.0 415/3/1 8 ZnO 1.0 415/4/1 15 Mo 1.0 350/1.25/5 30

Claims: CLAIMS: 1. A polarizing glass having an integral non-polarizing region. 2. The polarizing glass of claim 1 , wherein the glass comprises a reducible elongated phase. 3. The polarizing glass of claim 2, wherein the reducible elongated phase is selected from the group consisting of AgCl x Br,. x , CuCl x Br,.,,, where x has a value between 0 and 1, Pb-borate, Agl, Cul and Cu/Cd halides. 4. A method of forming a non-polarizing region in a polarizing glass by the steps of: a) providing glass having a layer of reducible elongated phase; b) forming a protected region in the glass by applying a layer of reducing gas- blocking material on the surface of said region to form a patte of protected and unprotected regions in the glass, c) subjecting the glass to a reducing gas environment to reduce the reducible phase in the unprotected region, and render the glass polarizing in said region; and d) removing the layer of reducing gas-blocking material from the protected region to reveal the underlying non-polarizing glass. 5. The method of claim 4, wherein the reducible phase comprises an elongated separated phase selected from the group consisting of AgCl x Br,. x , CuCl x Br,. x , where x has a value between 0 and 1 , Pb-borate, Agl, Cul and Cu/Cd halides 6. The method of claim 4, wherein the reducing gas is selected from the group consisting of H 2 , D 2 , cracked ammonia, and forming gas. 7. The method of claim 4. wherein the thin layer is formed by a method selected from the group consisting of sputtering, thermal evaporation, and chemical vapor deposition. 8. The method of claim 4, wherein the layer of material is selected from the group consisting of dense metal, oxide, and semiconductor. 9. The method of claim 8, wherein the layer of material is a metal selected from the group consisting of Cr, Mo, Ta, W, Zn, Au, Rh, Pd, Pt, and Ir. 10. The method of claim 8, wherein the layer of material is an oxide selected from the group consisting ofthe oxides of Cr, Mo. Ta, W, Zn, Au, Rh, Pd, Pt, and Ir. 1 1. The method of claim 8, wherein the layer of material has a thickness in the range of 0.01 to 5 μm. 12. The method of claim 4, wherein the polarizing glass is subjected to the reducing gas at a temperature of about 350 to 425 °C, and at a pressure in the range of 1 -200 atm. 13. The method of claim 4, wherein the layer of hydrogen-blocking material is deposited onto the glass through a shadow mask. 14. The method of claim 4, wherein the layer of reducing gas-blocking material is formed by the steps of: a) forming a layer of photoresist on the surface of the reducing gas-blocking material; b) masking and exposing the photoresist to light radiation such that the masked region is not exposed to said light radiation; c) developing the photoresist to thereby reveal the underlying reducing gas- blocking material in said region; d) etching the underlying reducing gas-blocking material and remove photoresist. e) exposing the glass to a reducing gas atmosphere; and f) removing the layer of reducing gas-blocking material from said region to reveal the underlying non-polarizing glass in said region. 16. A method of forming a non-polarizing region in a polarizing glass by: (a) providing a glass having reducible elongated phase particles; and (b) selectively subjecting a region ofthe glass surface to thermal heating to reduce the elongated phase and thereby render the glass in said region polarizing. 17. The method of claim 16, wherein the glass is subjected to said thermal heating for a sufficient temperature and time to re-spheroidize the elongated phase particles in said region. 18. The method of claim 16, wherein the glass is subjected to said thermal heating at a temperature of at least 450 °C. 19. The method of claim 16, wherein the local heating is achieved by contacting the surface ofthe glass with a heating element. 20. The method of claim 16, wherein the heating is produced from a source selected from the group consisting of a laser, electron beam, and ion beam. 21. A method of forming a non-polarizing region in a polarizing glass having a polarizing layer by selectively removing the polarizing layer in a region of the glass to render the glass in said region, non-polarizing. 22. The method of claim 21, wherein the polarizing layer is removed by a method selected from the group consisting of laser ablation, sand blasting, laser scribing, electron beam bombardment, wet etching, and dry etching. 23. The method of claim 21 , wherein prior to selectively removing the polarizing layer, the regions ofthe polarizing glass which are to remain polarizing are protected by a mask to prevent removal ofthe polarizing layer in said regions.

Inventors: BORRELLI NICHOLAS F, MOORE CHAG B, SACHENIK PAUL A, BORRELLI, NICHOLAS, F., MOORE, CHAG, B., SACHENIK, PAUL, A.
Applicants: BORRELLI NICHOLAS F, CORNING INC, MOORE CHAG B, SACHENIK PAUL A, BORRELLI, NICHOLAS, F., CORNING INCORPORATED, MOORE, CHAG, B., SACHENIK, PAUL, A.
Application year: 1997
Main classification: C03B27
IPC codes: C03B27, C03C14, C03C15, C03C17, C03C19, C03C23