High-strength laminated sheet for optical applications

• US 7,514,149 B2
• Filed: 04/04/2003
• Issued: 04/07/2009
• Est. Priority Date: 04/04/2003
• Status: Expired due to Fees

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Chen, David, Tammaro, David A., Gillberg, Gunilla E., Bocko, Peter L., Edwards, Victoria A., Cook, Glen B., Vaddi, Butchi R., Lapp, Josef C., Coppola, Frank T., Rhoads, Randy L.
• Primary Examiner(s): Speer; Timothy M
• Application Number:
  US10/406,965
• Publication Number:
  US 20040197575A1
• Time in Patent Office: 2,195 Days
• Field of Search: None
• US Class Current: 428/426
• CPC Class Codes: B32B 17/06 comprising glass as the main or only constituent of a layer, next to another layer of a specific material
• CPC Class Codes: C03B 17/02 Forming molten glass coated with coloured layers; Forming molten glass of different compositions or layers; Forming molten glass comprising reinforcements or inserts
• CPC Class Codes: C03B 17/061 by lateral drawing or extrusion
• CPC Class Codes: C03B 17/062 combined with flowing onto a solid or gaseous support from which the sheet is drawn
• CPC Class Codes: C03B 17/064 by the overflow downdraw fusion process; Isopipes therefor
• CPC Class Codes: C03B 19/12 by liquid-phase reaction processes
• CPC Class Codes: Y10T 428/26 Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension

Abstract

A laminated sheet includes a surface layer having an optical surface that is of fire-polished quality and a core layer having a higher modulus than the surface layer to increase an overall stiffness or fracture toughness of the laminated sheet.

Claims

1. A laminated sheet, comprising:

a surface layer having an optical surface of fire-polished quality and a thickness less than about 1 mm; and

a core layer attached to the surface layer, the core layer having a higher elastic modulus than the surface layer to increase an overall stiffness of the laminated sheet, wherein the core layer is separable from the surface layer, the core layer being made of a foam material or an annealed glass;

wherein the surface layer is made of a material selected from the group consisting of glasses and glass-ceramics and the core layer is more soluble than the surface layer in a selected solvent.

2. The laminated sheet of claim 1, wherein the optical surface is a fusion-formed surface.

3. The laminated sheet of claim 1 having a cross-draw dimension of greater than about 4 feet.

4. The laminated sheet of claim 1, wherein the surface layer comprises a glass.

5. The laminated sheet of claim 1, wherein the optical surface is coated with a coating material.

6. The laminated sheet of claim 5, wherein the coating material acts as a barrier to the environment.

7. The laminated sheet of claim 5, wherein the coating material enhances selected optical properties of the surface layer.

8. The laminated sheet of claim 5, wherein the coating material comprises a conductive material.

9. The laminated sheet of claim 5, wherein the coating material comprises a semiconductive material.

10. The laminated sheet of claim 1, wherein the core layer is optically enhanced.

11. A laminated sheet consisting of:

a surface layer having an optical surface that is of fire-polished quality and a thickness less than about 1 mm, said surface layer consisting of glass;

a core layer having a higher elastic modulus than the surface layer to increase an overall stiffness of the laminated sheet, said core layer consisting of glass-ceramic; and

a sacrificial layer removably coupling the surface layer to the core layer;

wherein the sacrificial layer is more soluble than the surface layer in a selected solvent.

12. The laminated sheet of claim 11, wherein the optical surface is a fusion-formed surface.

13. The laminated sheet of claim 11, wherein the surface, core, and sacrificial layers are each made of a viscoelastic material.

14. The laminated sheet of claim 11, wherein the core layer is optically enhanced.

15. A laminated sheet consisting of:

a surface layer having an optical surface that is of fire-polished quality and a thickness less than about 1 mm, said surface layer consisting of glass, wherein the optical surface is coated with a coating material;

a core layer having a higher elastic modulus than the surface layer to increase an overall stiffness of the laminated sheet, said core layer consisting of glass-ceramic; and

a sacrificial layer removably coupling the surface layer to the core layer;

wherein the sacrificial layer is more soluble than the surface layer in a selected solvent.

16. The laminated sheet of claim 15, wherein the coating material acts as a barrier to the environment.

17. The laminated sheet of claim 15, wherein the coating material enhances selected optical properties of the surface layer.

18. The laminated sheet of claim 15, wherein the coating material comprises a conductive material.

19. The laminated sheet of claim 15, wherein the coating material comprises a semiconductive material.

20. A laminated sheet comprising:

a surface layer having an optical surface that is of fire-polished quality and a thickness less than about 1 mm, said surface layer consisting of glass;

a core layer having a higher elastic modulus than the surface layer to increase an overall stiffness of the laminated sheet, said core layer consisting of glass-ceramic; and

a sacrificial layer removably coupling the surface layer to the core layer, said sacrificial layer being more soluble than the surface layer in a selected solvent;

wherein said surface layer, core layer, and sacrificial layer form a surface layer/sacrificial layer/core layer structure.