Corner Cube Retroreflector Alignment Fixtures
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Solution Overview
Problem
Assembling corner cube mirrors requires precise alignment and attachment of components, which is challenging due to the need for accurate angular relationships and potential alterations in alignment during the attachment process, affecting the structural integrity and reflective properties of the retroreflecting device.
Innovation Solution
The use of supporting members made from the same material as the mirror substrates, providing increased contact surface area and bracing, along with adjustable alignment fixtures and adhesives that minimize volume change during curing, facilitates precise alignment and strengthens the structure of the corner cube mirror assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional attachment methods are used to join corner cube mirror components, then the components can be assembled, but the alignment precision deteriorates due to alignment alterations during and after attachment
Solution Approach 1:
The patent implements preliminary alignment using adjustable fixtures and alignment lasers before attachment. The components are precisely positioned and aligned in the fixture, with alignment verified through laser reflection patterns, before the attachment process begins. This preliminary action ensures that alignment is established prior to any attachment-induced disturbances.
Solution Approach 2:
The patent introduces a rigid fixture as an intermediary structure that holds all corner cube mirror components during alignment and attachment. This fixture serves as a stable reference frame that maintains component positions and angles throughout the assembly process, preventing alignment alterations that would occur with direct component-to-component attachment.
2Ease of manufacture
If multiple components are assembled to form corner cube mirrors, then the retroreflecting device can be constructed, but the structural integrity deteriorates due to potential misalignment and weak attachment
Solution Approach 1:
The patent combines multiple attachment methods including mechanical fastening, adhesive bonding, and supporting members into a unified attachment system. This multi-modal approach ensures that components are securely joined with redundant attachment mechanisms, thereby strengthening the overall structure while maintaining assembly feasibility.
Solution Approach 2:
The rigid fixture acts as an intermediary that distributes mechanical stresses and forces across all attached components uniformly. By providing a stable mounting structure, the fixture prevents stress concentration at individual attachment points, thereby enhancing structural integrity without complicating the assembly process.
3Stability of the object's composition
If adhesive is used to attach mirror components, then permanent fixation is achieved, but the alignment precision deteriorates due to volume change during curing
Solution Approach 1:
The patent performs complete alignment and positioning of all components within the rigid fixture before applying adhesive. Alignment is verified and locked in place through the fixture's mechanical constraints prior to adhesive application, ensuring that no alignment adjustments are needed during the curing process even if volume changes occur.
Solution Approach 2:
The rigid fixture serves as a compensating intermediary that absorbs and isolates the effects of adhesive volume change. The fixture's rigid structure maintains component positions and angles independently of adhesive curing shrinkage or expansion, thereby preserving alignment accuracy while achieving permanent fixation.
Data Source
AI summary
Corner cube retroreflector apparatus. At least one of the illustrative embodiments is an apparatus with three plates, each with a face, each adjoined substantially perpendicular and substantially normal to each other; an alignment device coupled to the first plate face with an adjustable plate substantially parallel to the first plate face and movably coupled to the first plate, and adjustable with respect to an angular relationship with the second and third plates; a second alignment device coupled to the second plate face with an adjustable plate substantially parallel to the second plate face and movably coupled to the second plate, and adjustable with respect to an angular relationship with the first and third plates; attachment appurtenances on both alignment devices which holds components of the retroreflective device onto the alignment devices during assembly; and apertures through which portions of the retroreflective device are accessible during assembly.