Deflection Mirror Groove Formation in Light Waveguides
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Solution Overview
Problem
Existing methods for forming deflection mirrors in light waveguides using dicing blades with V-shaped or wedge-shaped cutting ends result in blade damage, fluctuation, and inaccurate grooves due to excessive wearing and deviation during the cutting process.
Innovation Solution
A dicing blade with a flat top cutting face and at least one slanted side cutting face is used to cut the light waveguide, limiting the groove depth to the width of the flat top cutting face for enhanced strength and accuracy, and incorporating sub-steps for precise depth control and abrasive granules for smoothening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a dicing blade with V-shaped or wedge-shaped cutting end is used to cut the light waveguide surface, then the groove can be formed, but the blade is susceptible to damage and fluctuation during rotation, resulting in excessive wearing and inaccurate grooves
Solution Approach 1:
The dicing blade cutting end is designed with asymmetric geometry consisting of a flat top cutting face and slanted side cutting faces, replacing the symmetric V-shaped or wedge-shaped designs. This asymmetric structure provides a stable platform for cutting while distributing mechanical stress, preventing blade fluctuation and excessive wearing during rotation, thereby simultaneously improving groove accuracy and blade durability
Solution Approach 2:
The cutting end geometry is optimized with a flat top cutting face that provides a stable, non-fluctuating platform during rotation. The flat surface area distributes cutting forces evenly, preventing the blade from vibrating or deviating, which ensures both accurate groove formation and prolonged blade service life
2Manufacturing precision
If the dicing blade is placed perpendicular to the light waveguide surface, then the cutting can be performed, but the deflection mirror easily deviates from the intended position due to cutting depth variation
Solution Approach 1:
The asymmetric cutting end design with flat top and slanted side faces allows the blade to be positioned at an optimized angle relative to the light waveguide surface. The flat top face provides a stable reference for maintaining consistent cutting depth, while the slanted side faces facilitate smooth material removal. This geometric configuration reduces sensitivity to depth variations and ensures the deflection mirror forms at the intended position
Solution Approach 2:
The cutting process incorporates preliminary actions to establish a stable cutting depth before forming the final groove. The flat top cutting face first establishes a reference plane, and then the slanted side faces complete the groove formation. This staged approach ensures precise control over the deflection mirror position while maintaining ease of operation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process ensures prolonged blade durability, maintains groove accuracy, and allows for precise positioning of deflection mirrors, reducing wear and deviation, while abrasive granules and energy beam irradiation or resin coating further enhance smoothness and reflectivity.
Implementation Method 1
a dicing blade having a cutting end with a flat top cutting face and at least one slanted side cutting face... cutting step of cutting a surface of the light waveguide
Implementation Method 2
the dicing blade includes in its surface abrasive granules having an abrasion scale of 4500 to 6000 according to the Japanese Industry Standard R6001 for smoothening the deflection mirror
Data Source
AI summary
A process of forming a deflection mirror in a light waveguide with a use of a dicing blade having a cutting end with a flat top cutting face and at least one slanted side cutting face. The process includes a cutting step of cutting a surface of the light waveguide to a depth not greater than a width of the flat top cutting face, thereby forming a groove in the surface of the light waveguide. The groove has a slanted surface which is formed by the slanted cutting face to define the deflection mirror in the waveguide.