Deformable mirror with variable curvature and associated method of manufacturing a mirror
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Solution Overview
Problem
Existing deformable mirrors for adaptive optics require a large number of actuators, leading to complexity, high manufacturing costs, fragility, and difficulty in precision, making them expensive and prone to downtime due to actuator malfunctions and complex connections.
Innovation Solution
A deformable mirror design featuring a plate with primary and secondary portions of varying stiffness, where secondary portions are interposed between primary portions, and a limited number of actuators are used to exert force on the hidden face, allowing for precise deformation and correction of optical aberrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large number of actuators are used to deform the mirror plate, then the deformation precision is improved, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The mirror plate is segmented into multiple zones with different thickness profiles, allowing each zone to be independently controlled by fewer actuators. This segmentation enables precise deformation control while reducing the total number of actuators required, as each actuator controls a specific radial zone rather than requiring one actuator per mirror surface point.
Solution Approach 2:
Different regions of the mirror plate are given different local properties through variable thickness design. The plate has varying thickness from center to periphery, with specific thickness profiles in different radial zones that allow targeted deformation control. This local quality variation enables precise optical correction with minimal actuators by exploiting the different mechanical responses of different plate regions.
2Manufacturing precision
If multiple actuators with complex connections are used, then the deformation control is improved, but the reliability decreases due to more connection points and potential failure modes
Solution Approach 1:
The invention extracts and eliminates the complex connection network between multiple actuators and the mirror plate by reducing the actuator system to a single actuator with simple central connection. This extraction of unnecessary complexity maintains deformation control capability while significantly improving reliability by removing multiple potential failure points in the connection system.
Solution Approach 2:
The mirror plate's own structural properties (variable thickness profile) are utilized to enable self-deformation control. The plate's geometry is designed such that a single actuator applying force at the center can induce controlled deformation patterns across the entire plate surface, making the system self-regulating and eliminating the need for complex multi-actuator coordination systems.
3Manufacturing precision
If a particular thickness profile according to complex mathematical formulas is used, then the optical precision is improved, but the manufacturing difficulty and cost increase
Solution Approach 1:
The invention changes the manufacturing parameters from requiring ultra-precise complex mathematical thickness profiles to using simpler, piecewise thickness variations that can be manufactured with standard techniques. The thickness profile is defined in discrete radial zones rather than as a continuous complex function, making it manufacturable with conventional precision while maintaining optical performance.
Solution Approach 2:
The invention accepts that the mirror plate may need replacement rather than investing in extremely complex and expensive manufacturing processes. By using simpler manufacturing methods that produce good enough (not perfect) thickness profiles, the system becomes more cost-effective, allowing economical replacement if needed rather than requiring flawless single-unit manufacturing.
4Manufacturing precision
If the plate thickness is precisely reduced according to radius, then the optical performance is improved, but the manufacturing time and scrap rate increase
Solution Approach 1:
The continuous thickness variation is segmented into discrete radial zones with stepwise thickness changes. This segmentation allows manufacturing using standard stepped machining or molding techniques rather than requiring continuous precision material removal, dramatically reducing manufacturing time and increasing yield by avoiding the scrap associated with complex precision thickness profiling.
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 solution results in a reliable, compact, and cost-effective deformable mirror that is easy to install and adapt, capable of precise focusing or defocusing of optical beams with reduced actuator requirements, enhancing optical system performance and reducing manufacturing complexities.
Implementation Method 1
at least one actuator intended to exert a force on said hidden face to deform said plate
Data Source
Figure 1
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AI summary
The invention relates to a deformable mirror (1) comprising: - on the one hand, a plate (2) having a reflective face (4) and an opposite hidden face (5) and whose shape has a center (C) and radii (r), and - on the other hand, at least one actuator for exerting a force on said hidden face (5) to deform said plate (2), characterized in that said plate (2) comprises a plurality of primary (6) and secondary (7) portions, said secondary portions (7) being interposed between said primary portions (6), each of said primary portions (6) extending substantially locally along and on either side of a respective radius (r') among said radii (r), and having a stiffness different from that of said secondary portions (7) adjacent to it. The deformable mirror according to the invention is particularly intended for introducing or correcting optical aberration in a light beam.