Optical composite and method of making same

Abstract

A method for making an optical composite composed of glass and plastic is disclosed. The method can be used to create a photochromic lens of high optical and refractive quality that is both scratch resistant and of high impact resistance. The method can also be used to create a strong sheath and/or cladding for an optic fiber. The method can also be used to create a scratch resistant coating for polycarbonate material, such as bulletproof glass. Vacuum pressure and optical contacting are used to hold the glass and plastic portions together. A flexible, peripheral seal, whose kinetic reaction strength has been enhanced with microwave radiation, is used maintain the vacuum adhesion of the glass and the plastic. This structural seal is located in a peripheral, non-optical portion of the optical composite to minimize any interference the seal may have with the optical function of the composite.

1 . A glass and plastic composite comprising: 
 a glass having a shape, a center, a margin;    a plastic having a shape essentially adapted to receive the shape of the glass, a center, a margin; and    a sealant disposed between the margin of the glass and the margin of the plastic, whereby the center of the glass and the center of the plastic are devoid of the sealant.    
     
     
         2 . The composite of  claim 1  wherein the glass contains a microwave absorbent compound selected from the group consisting of a metallic salt and a ferrite.  
     
     
         3 . The composite of  claim 2  wherein the glass is photochromic.  
     
     
         4 . The composition of  claim 1  wherein the plastic is selected from the group consisting of polycarbonate, polyurethane, polystyrene, fluorocarbon and polymethylmethacrylate.  
     
     
         5 . The composition of  claim 1  wherein the sealant is selected from the group consisting of silicones, shellac, lacquer, silane coupling agents, disilyl crosslinker compounds, epoxy resins, crosslinkable polyethylene vinylacetate terpolymer, polyvinyl butyral and polysulfide.  
     
     
         6 . The composite of  claim 1  wherein the glass and plastic are transparent and refractive.  
     
     
         7 . The composite of  claim 1  wherein the margin of the glass has at least one appendage and the margin of the plastic defines an aperture shaped for receiving the appendage of the glass.  
     
     
         8 . The composite of  claim 1  wherein the percentage of glass in the composite is between about 0.01 to 99.99%.  
     
     
         9 . The composite of  claim 1  wherein the percentage of plastic in the composite is between about 0.01 to 99.99%.  
     
     
         10 . The composite of  claim 1  wherein the margin of the plastic has at least one appendage and the margin of the glass defines an aperture shaped for receiving the appendage of the plastic.  
     
     
         11 . A microwave-transparent spring-loaded vice adapted to hold together the glass and plastic of  claim 1 .  
     
     
         12 . The vice of  claim 11  wherein the spring tension is between about 0.01 to 200 foot pounds.  
     
     
         13 . A microwave-transparent, weighed vice adapted to hold together the glass and plastic of  claim 1 .  
     
     
         14 . The vice of  claim 11  wherein the vice's holding weight is between about 0.01 to 100 foot pounds.  
     
     
         15 . A method of making a glass and plastic optical composite comprising: 
 forming a glass with a rigid nature having a center and a margin to a particular shape;    forming a plastic with a plastic nature having center and a margin to a shape essentially adapted to receive the shape of the glass; and    applying microwave radiation for a time effective to optically correct the formed plastic and optically contact the formed plastic to the formed glass.    
     
     
         16 . (cancelled)  
     
     
         17 . The method of  claim 15  wherein the microwave radiation is applied at about between 10 watts to 100,000 watts and a frequency of about between 3 Ghz to 3000 Ghz.  
     
     
         18 . The method of  claim 15  wherein the microwave radiation is applied for between about 0.01 minutes to 100 minutes.  
     
     
         19 . A method of making a glass and plastic composite comprising: 
 forming a glass having a center and a margin to a particular shape;    forming a plastic having a margin and a center to a shape essentially adapted to receive the shape of the glass; and    applying microwave radiation for a time effective to optically correct the formed plastic and to affix the formed glass and the formed plastic together; and    applying sealant only to the margin of the glass and the margin of the plastic, whereby the center of the glass and the center of the plastic are devoid of the sealant.    
     
     
         20 . canceled  
     
     
         21 . The method of  claim 19  wherein the microwave radiation is applied for between about 0.01 minutes to 100 minutes.  
     
     
         22 . The method of  claim 19  wherein the microwave radiation is applied at between about 10 watts to 100,000 watts and at a frequency of about between 3 Ghz to 3000 Ghz.  
     
     
         23 - 33 . (cancelled)  
     
     
         34 . A glass and plastic composite made according to the method of  claim 15 .  
     
     
         35 . (cancelled)  
     
     
         36 . The method of  claim 15  wherein the margin of the plastic is formed with a notch adapted to interlockingly receive the margin of the glass.  
     
     
         37 . The method of  claim 19  wherein the margin of the plastic is formed with a notch adapted to interlockingly receive the margin of the glass.  
     
     
         38 - 39 . (cancelled)  
     
     
         40 . The method of  claim 15  wherein a sealant is applied only to the margins of the glass and the margin of the plastic after the microwave radiation has optically corrected the formed plastic and optically contacted the formed plastic to the formed glass, whereby the center of the glass and the center of the plastic remain devoid of sealant.  
     
     
         41 . The method of  claim 40  wherein the sealant is capable of being cured by exposure to air.  
     
     
         42 . The method of  claim 40  wherein the sealant is exposed to microwave radiation for a time effective to enhance the strength of the sealant.  
     
     
         43 . The method of  claim 19  wherein the sealant is capable of being cured by exposure to air.  
     
     
         44 . The method of  claim 19  wherein the sealant is exposed to microwave radiation for a time effective to enhance the strength of the sealant.  
     
     
         45 . A method of making a glass and plastic composite comprising: 
 forming a glass having a center and a margin to a particular shape;    forming a plastic having a margin and a center to a shape essentially adapted to receive the shape of the glass;    applying sealant only to the margin of the glass and the margin of the plastic, whereby the center of the glass and center of the plastic are devoid of the sealant; and    applying microwave radiation for a time effective to enhance the reaction kinetics of the sealant and optically correct the formed plastic and optically contact the formed plastic to the formed glass.    
     
     
         46 . The method of  claim 45  wherein the sealant is capable of being cured by exposure to air.  
     
     
         47 . The method of  claim 45  wherein the microwave radiation is applied for between about 0.01 minutes to 100 minutes.  
     
     
         48 . The method of  claim 45  wherein the microwave radiation is applied at between about 10 watts to 100,000 watts and at a frequency of about between 3 Ghz to 3000 Ghz.  
     
     
         49 . The method of  claim 45  wherein the margin of the plastic is formed with a notch adapted to interlockingly receive the margin of the glass.  
     
     
         50 . A glass and plastic composite made according to the method of  claim 19 .  
     
     
         51 . A glass and plastic composite made according to the method of  claim 45.