Brittle Optical Component Mounting via Monolithic Reference Surfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The current methods for assembling optical systems with brittle-hard materials, such as glass or ceramic, face challenges in achieving precise positioning and mounting due to the complex processing technologies and high thermal expansion coefficients, leading to inefficiencies in system integration and increased assembly efforts.
Innovation Solution
A method involving ultra-precision machining to produce reference and mounting surfaces on optical components, allowing for precise measurement and correction of optical functional surfaces, enabling simplified assembly by creating a high-precision coordinate system for accurate mounting within the optical system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mounting techniques are used for brittle mirror materials, then assembly is simplified, but positional alignment accuracy deteriorates to tolerances an order of magnitude higher than micromachined references
Solution Approach 1:
The patent merges the optical component with micromachined reference and support structures into a single monolithic body made of brittle material. This integration eliminates the need for separate mounting operations and external support structures, achieving sub-micrometer positional alignment accuracy while simplifying the overall assembly process. The reference surfaces and support structures are created directly on the optical component through precision machining in a single clamping setup.
2Manufacturing precision
If ultra-precision machining is used to achieve sub-micrometer positional alignment, then manufacturing precision improves, but the process complexity and time increase
Solution Approach 1:
The patent performs all necessary machining operations including reference surfaces, support structures, and mounting interfaces in a single clamping setup before final assembly. This preliminary action eliminates the need for subsequent reclamping or disassembly operations that would compromise positional accuracy. The complete machining process is completed upfront, ensuring sub-micrometer accuracy is maintained through the entire manufacturing and assembly cycle.
3Stability of the object's composition
If brittle materials like glass ceramics are used for mirror bodies, then thermal and mechanical stability improves, but machining complexity increases compared to metallic materials
Solution Approach 1:
The patent replaces traditional multi-step machining processes for brittle materials with ultra-precision machining techniques that can machine all features in a single setup. This substitution of machining methodology eliminates the need for complex reclamping and repositioning operations, making brittle materials like glass ceramics as manufacturable as metals while maintaining their superior thermal and mechanical stability properties.
Data Source
Figure 1A~1B
Figure 2~3
Figure 4
AI summary
A method for producing an optical system with an optical component (1) made of a hard brittle material is described, said method comprising the steps of: - producing at least one optical functional surface (2) on the optical component (1), - placing the optical component (1) onto a processing machine (10) and producing a plurality of reference surfaces (14) and mounting surfaces (5') on the optical component (1), or on at least one insert body (5) connected permanently to the optical component (1), by means at least one machine tool (11, 12) of the processing machine (10), - measuring the shape and position of the optical functional surface (2) in a coordinate system (3) relating to the reference surfaces (14), - performing corrective processing at least once, in which corrective processing the deviation in shape and position of the optical functional surface (2) relative to the reference and mounting surfaces (5', 14) is reduced, and - installing the optical component (1) in a housing structure (19) of the optical system at the mounting surfaces (5')