Impact resistant and tempered optical elements

• US 4,995,684 A
• Filed: 04/20/1989
• Issued: 02/26/1991
• Est. Priority Date: 06/18/1986
• Status: Expired due to Term

• Current Assignee: Raytheon Company (Rtx Corporation)
• Original Assignee: Raytheon Company (Rtx Corporation)
• Inventors: diBenedetto, Bernard, Montanari, Dennis, Varitimos, Thomas, Tustison, Randal W.
• Primary Examiner(s): Arnold, Bruce Y.
• Assistant Examiner(s): PARSONS, DAVID
• Application Number:
  US07/342,605
• Time in Patent Office: 677 Days
• Field of Search: 65/61, 428/908.8, 350/1.6, 350/164, 350/166, 350/1.1, 427/163
• US Class Current: 359/359
• CPC Class Codes: G02B 1/105 Protective coatings
• CPC Class Codes: G02B 1/14 Protective coatings, e.g. hard coatings

Abstract

An impact resistant anti-reflection coating for an optical element mounted on an airborne system which mitigates damage to the optical element when the airborne system is flown through a high velocity droplet impact medium is described. In a first embodiment, the coating comprises a material having a relatively high modulus of elasticity deposited to a thickness equal to an odd multiple of a quarter of a wavelength of the wavelength radiation to be transmitted through the optical element. In accordance with a further aspect of the invention, the high modulus of elasticity layer may comprise a homogeneous mixture of a pair of high modulus elasticity materials as well as a composite layer comprising a first layer of a high modulus elasticity material and a second layer of a second modulus of elasticity material. In a second embodiment, the outer surface of an infrared material is strengthened by single diamond point turning the outer surface of the material to introduce into the surface a compressive layer. The compressive layer is characterized as having a plurality of furrows or grooves being spaced by compressed regions of material and having disposed under said furrows or grooves a compressed region of material.

Claims

1. An optical element comprising:

a base comprising a first material having an index of refraction at 10 microns in the range of about 2.2 to 3.3, a predetermined optical transmissivity over at least portions of a band of at least about 2 μ

m to 30 μ

m and a predetermined resistance to damage caused by high velocity water droplet impact;

means optically transparent over said portion of said band and disposed over said base for increasing the resistance of the base to damage caused by water droplet impact, comprising a second material having an index of refraction less than 2.0 at 10 microns and a physical thickness related to ((2[n]N+1)λ

/4)/n_c, when N is an integer, λ

is a selected wavelength in the band, and N_c is the refractive index of the second material at the wavelength λ

.

2. The optical element as recited in claim 1 wherein said means further comprises a compressed region of said first material disposed on said base, with said second material disposed over said compressed region of first material.

3. The optical element as recited in claim 2 wherein the compressed layer includes a plurality of furrows disposed in a surface portion of said layer having disposed under said furrows a compressed layer of said first material and having disposed between adjacent furrows compressed regions of the first material.

4. The optical element as recited in claim 3 wherein the first material comprises a material selected from the group consisting of zinc sulfide, zinc selenide, gallium arsenide, gallium phosphide, mercury cadmium telluride, cadium telluride and a ternary sulfide having the general chemical formula MN₂ S₄ where M is a cation selected from the Group 1A elements, N is a cation selected from the lanthanide rare earth series elements, and S is the sulfide anion S^2-.

5. The optical element as recited in claim 4 wherein the furrows have a depth in the range of 10 A to 10,000 A and have a width generally in the range of 0.01 to 0.02 mm.

6. The optical element as recited in claim 1 wherein said first material has a first predetermined modulus of elasticity and wherein said second material has a second, higher modulus of elasticity than the modulus of elasticity of the first material and is disposed on said base to provide the increased impact resistance to the base.

7. The optical element as recited in claim 6 wherein the modulus of elasticity of the second material is at least twice the modulus of elasticity of the first material.

8. The optical element as recited in claim 7 wherein the first material comprising the base layer is selected from the group consisting of zinc sulfide, zinc selenide, gallium arsenide, gallium phosphide, mercury cadium telluride, and cadium telluride and a ternary sulfide having the general chemical formula MN₂ S₄ where M is a monovalent cation selected from the Group 1A elements, N is a cation selected from the lanthanide rare earth series elements and S is the sulfide anion S_2- ;

and

wherein the second material is selected from the group consisting of yttrium oxide, scandium oxide, or mixtures of yttrium oxide, scandium oxide and magnesium oxide.

9. The optical element as recited in claim 1 wherein the first material has a first predetermined modulus of elasticity and wherein the means comprises a first layer of the second material disposed on said base said second material having a second, higher modulus of elasticity than the modulus of elasticity of the first material and a second layer of a third material disposed on said first layer having a modulus of elasticity higher than the modulus of elasticity of the first material and the second material, and having an index of refraction greater than 2.0.

10. The optical element as recited in claim 9 wherein the physical thickness of the second layer and third layer is given by t=(2N+1)λ

/4/n_c where N is an integer 0,1,2,3, . . . , λ

is a particular wavelength of interest and n_c is the index of refraction of the second and third layers.

11. The optical element as recited in claim 9 wherein:

the base comprises a material selected from the group consisting of zinc sulfide, zinc selenide, gallium arsenide, gallium phosphide, mercury cadmium telluride and cadmium telluride and a ternary sulfide having the general chemical formula MN_s S₄ where M is a cation selected from the Group 1A elements, N is a cation selected from the lanthanide rare earth series elements and S is the sulfide anion S^2- ;

wherein the second material is selected from the group consisting of yttrium oxide, scandium oxide, and a mixture of yttrium oxide, scandium oxide and magnesium oxide; and

wherein the third material is selected from the group consisting of hard carbon, cerium oxide, titanium oxide and zirconium oxide.

12. The optical element as recited in claim 1 wherein the first material of the base has a first predetermined modulus of elasticity and wherein the means further comprises:

a compressed region of said second material and a layer of a third material having a second, higher modulus of elasticity than the material of the first layer.

13. The optical element as recited in claim 1 wherein said means further comprises:

a compressed region of the first material disposed in the base and a composite layer comprising a layer of said second material layer of a third material disposed on the layer of second material.

14. The optical element as recited in claim 13 wherein the modulus of elasticity of the third material is at least twice that of the material of the base.

15. The optical element as recited in claim 14 wherein the first material is selected from the group consisting of zinc sulfide, zinc selenide, gallium arsenide, gallium phosphide, mercury cadmium telluride, and cadmium telluride and a ternary sulfide having the general chemical formula MN₂ S₄ when M is a group 1A element N is a lanthanide rare earth element and S is the sulfide anion S^2- said second material is selected from the group consisting of yttrium oxide, scandium oxide, magnesium oxide or mixture of yttrium oxide, scandium oxide and magnesium oxide;

and said third material is selected from the group consisting of hard carbon cerium oxide, titanium oxide and zirconium oxide.

16. An optical element comprising

a base comprising a first material having an index of refraction between about 2.2 and 3.3 at 10 microns, a predetermined optical transmissivity over the range of 8 μ

m to 12 μ

m and a predetermined modulus of elasticity;

a layer of a second, different material selected from the group consisting of yttrium oxide, scandium oxide, or homogeneous mixtures of yttrium oxide, scandium oxide and magnesium oxide disposed on said base, transparent over said optical wavelength range and having a modulus of elasticity at least about twice the modulus of the material of the base, an index of refraction less than 2.0 at 10 microns and a physical thickness related to ((2N+1)λ

/4)/n_c, where λ

is a wavelength in the range of 8 λ

m to 12 λ

m, and N is an integer, and n_c is the refractive index of the second material at the wavelength λ

to protect such element from water droplet impact and to anti-reflect correct the optical element.

17. The optical element as recited in claim 16 wherein the base comprises a material selected from the group consisting of zinc sulfide, zinc selenide, galliuarsenide, gallium phosphide, mercury cadmium telluride, cadmium telluride and a ternary sulfide having the general chemical formula MN₂ S₄ where M is a monovalent cation from the Group 1A elements, N is a cation selected from the lanthanide rare earth series elements and S is the sulfide anion S^2-.

18. The optical element as recited in claim 17 wherein the layer of second material is yttrium oxide.

19. An optical element comprising

a base comprising a material having an index of refraction between about 2.2 and 3.3 at 10 microns, a predetermined optical transmissivity over a predetermined range of wavelengths, a first predetermined modulus of elasticity;

and

a composite coating disposed over at least a portion of said base comprising;

(1) a first layer comprising yttrium oxide having a modulus of elasticity of at least twice the modulus of elasticity of said base material and having an index of refraction less than the index of refraction of the material of said base;

(2) a second layer comprising a second high modulus of elasticity material having a modulus of elasticity of at least twice the modulus of elasticity of said base material and having an index of refraction greater than 2.0.

20. The combination as recited in claim 19 wherein:

the base comprises a material selected from the group consisting of zinc sulfide, zinc selenide, gallium arsenide, gallium phosphide, mercury cadmium telluride and cadmium telluride and a ternary sulfide having the general chemical formula MX₂ S₄ where M is a monovalent ion selected from the Group 1A elements, X is a divalent ion selected from the lanthanide rare earth series elements and S is the sulfide anion S^2- ; and

wherein the second high modulus material is selected from the group consisting of hard carbon, cerium oxide, titanium oxide and zirconium oxide.

21. The combination as recited in claim 20 wherein the first layer has a physical thickness t given by t=((2N+1)λ

/4)n_c1 where N is an integer 0,1,2,3, . . . , is a particular wavelength of interest and n_c1 is the index of refraction of the material of the first layer; and

wherein the physical thickness of the second layer is given by t=((2N+1)λ

/4)/n_c where n_c2 is the index of refraction of the material of the second layer.

22. A method of protecting a region of an optical element comprised of a first material having a first modulus of elasticity and a predetermined optical transmissivity over a wavelength range of about 8 μ

m to 12 μ

m from impact damage encountered in a high velocity droplet environment comprises the step of;

providing a layer of a second material selected from the group consisting of yttrium oxide and scandium oxide over the region to be protected having a modulus of elasticity at least twice the modulus of elasticity of said first material having a predetermined optical transmissivity over said range and which is resistant to debonding from the first material in response to sheer stress causes by radial outflow during water droplet impact.

23. The method as recited in claim 22 wherein the material comprising the optical element is selected from the group consisting of zinc sulfide, zinc selenide, gallium arsenide, gallium phosphide, mercury cadium telluride and cadmium tellurid.

24. The method as recited in claim 22 further comprising the step of:

providing a layer of a third material over the layer of second material, said third material having a modulus of elasticity at least twice the modulus of elasticity of said first material and an index of refraction greater than the index of refraction of the second material.

25. The method as recited in claim 24 wherein the third material is selected from the group consisting of hard carbon, cerium oxide, titanium oxide and zirconium oxide.

26. A method of bonding a layer of hard carbon to a base comprising a material selected from the group consisting of a Group II-V or Group III-V material comprising the step of:

providing a first layer comprising a material selected from the group consisting of yttrium oxide, scandium oxide and magnesium oxide between the base and the hard carbon layer.

27. The method of claim 26 wherein the Group II-VI material is selected from the group consisting of zinc sulfide, zinc selenide, mercury cadmium telluride, cadmium telluride and the Group III-V material is selected from the group consisting of gallium arsenide and gallium phosphide.

28. The method as recited in claim 27 wherein the first layer is yttrium oxide and the material of the base is selected from the group consisting of zinc selenide and zinc sulfide and wherein the base, the first layer of yttrium, and hard carbon layer provide an optical element having a high percent transmittance over the wavelength range of at least 8 μ

to 12 μ

.

29. The method as recited in claim 28 wherein the first layer has a physical thickness (t) related to t=(2N+1)λ

/4/n_c [t=(2N+1)/4/n_c ] where μ

is a wavelength of interest, n_c is the refractive index of the material of the first layer at λ and

N is an integer 0,1,2,3, . . . .

30. An optical element comprising:

a base comprising a material having a predetermined optical transmissivity, with a surface portion of said optical material being in compression, said compressed surface portion having a plurality of furrows disposed in said surface potion having underlying said furrows and disposed between adjacent, ones of said furrows compressed regions of the material of said base.

31. The optical element as recited in claim 30 wherein said base compress a material selected front he group consisting of zinc sulfide, zinc selenide, germanium, gallium arsenide, gallium phosphide, mercury cadmium telluride, cadmium telluride, and a ternary sulfide having the general chemical formula MN₂ S₄ where M is a monovalent cation selected from the group 1A elements, N is cation selected front he lanthanide rare earth series elements and S is the sulfide anion S₂ -.

32. The optical element of claim 31 wherein said compressed region of material has a thickness of about three microns.

33. A method of providing a tempered, strengthened surface to an optical element, comprised of a first material having an initial predetermined fracture strength, comprising the step of converting a surface portion of said material into a compressed surface portion layer of said material, to provide said surface portion layer having a high fracture strength than the initial fracture strength of the material, by single point turning the outer surface of the optical element to introduce onto such outer surface the compressed surface portion of said optical element.

34. The method as recited in claim 33 wherein said turning step is accomplished with a single diamond point tool.

35. The method as recited in claim 34 wherein the turning step comprises the steps of first turning the optical element to remove a surface layer portion having a thickness of at least 1 mil from said outer surface;

and

then turning said optical element to remove a surface portion of at least 0.01 mils thick from said outer surface to provide on said outer surface of said optical element furrows in said surface portion, said furrows spaced by regions of the compressed material.

36. The method of claim 35 wherein said optical element is selected from the group consisting of a dome, a lens, a plate and a window.

37. The method as recited in claim 36 wherein said material of the optical element is selected from the group consisting of zinc sulfide, zinc selenide, mercury cadium telluride, cadium telluride, germanium, gallium arsenide and gallium phosphide.

38. The method as recited in claim 37 wherein said material is selected from the group consisting of zinc selenide and zinc sulfide.

39. An optical element having an antireflection, impact resistant optical coating, comprising:

a base comprised of a material selected from the group consisting of zinc sulfide and zinc selenide said base having a predetermined thickness in the range of about 0.05 inches to 0.5 inches and said selected material having a predetermined percent transmissivity to optical energy having a wavelength in the range of about 2 μ

m to 12 μ

m;

a coating of a material selected from the group consisting of scandium oxide and yttrium oxide having an optical thickness equal to about a quarter of a wavelength, said wavelength being selected within said wavelength range.

40. The element of claim 39 wherein said wavelength is in the range of 8 to 12 microns.

41. The element of claim 40 where said single quarter wavelength coating is yttrium oxide.

42. An optical element, comprising

a base of optically transmissive material selected from the group consisting of zinc sulfide and zinc selenide having a surface portion of said material being disposed in compression relative to the base portion of the material and a predetermined percent transmission measured through said surface portion over the wavelength range of 2 μ

to 12 microns.

43. The optical element of claim 42 wherein said compressed surface portion of said optical material has a thickness of about three microns.