Diamond Surface Processing with In-Situ Angle Measurement

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for processing diamond surfaces for optical applications face challenges in achieving high parallelism and low subsurface damage due to the extreme hardness of diamond, which leads to tool wear and introduction of errors during measurement and remounting.

Innovation Solution

A method involving a positioning arm with a holder to process diamond surfaces on a rotating wheel, using a non-contact optical technique like an autocollimator to measure the angle between surfaces in-situ, allowing for iterative polishing without removing the diamond from the holder, thus minimizing subsurface damage and achieving precise parallelism.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If diamond tools are used to process diamond surfaces, then surface flatness and tolerances can be achieved, but tool wear occurs quickly and heat is created causing expansion beyond required tolerances

Engineering Contradiction:

Improvesurface flatness and tolerancesVSAvoidtool life

Core Design Contradiction:

Manufacturing precisionVSDuration of action of stationary object

Solution Approach 1:

The patent uses disposable diamond-impregnated polishing belts that are consumed during the polishing process. These belts are replaced rather than reused, eliminating tool wear issues while maintaining processing precision. The belts are inexpensive enough to be discarded after use, solving the contradiction between achieving tight tolerances and maintaining tool life.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Ease of manufacture

If a very hard tool such as sintered diamond tool is used to process diamond optical part, then processing can be performed, but the diamond optical part sustains high level of sub-surface damage due to hard impact on the brittle material

Engineering Contradiction:

Improveprocessing capabilityVSAvoidsub-surface damage

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the processing parameters by using a soft, compliant polishing belt impregnated with diamond particles rather than a hard sintered diamond tool. This parameter change in tool hardness allows the diamond particles to gently abrade the diamond surface without causing impact damage, thereby maintaining processing capability while eliminating sub-surface damage.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If scaife polishing technique is used to polish diamond, then polishing can be performed, but it is difficult to achieve high degree of parallelism because the rigid arm has a bending moment which introduces a slight angle

Engineering Contradiction:

Improvepolishing capabilityVSAvoidparallelism

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces the rigid arm with a flexible, spring-loaded positioning mechanism that holds the polishing belt. This flexible support eliminates the bending moment problem inherent in rigid arms, allowing the diamond workpiece to be positioned accurately without angular deviations, thereby achieving high parallelism while maintaining polishing capability.

Inventive Principle:

Principle #30Flexible shells and thin films

4Measurement precision

If standard measurement techniques such as interferometer are used, then measurement can be performed, but the diamond part needs to be removed from the holder and remounted, introducing further errors

Engineering Contradiction:

Improveparallelism measurementVSAvoidmeasurement and remounting time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent merges the measurement function with the polishing setup by integrating an autocollimator directly into the polishing apparatus. This allows parallelism measurement to be performed in-situ without removing the diamond workpiece from the holder, eliminating remounting errors and reducing measurement time while maintaining measurement precision.

Inventive Principle:

Principle #5Merging (Combining)

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

This approach enables the production of diamond surfaces with high parallelism and low subsurface damage, achieving surface roughness of less than 1.0 nm and precise angle control, reducing the time and labor required for processing.

Implementation Method 1

processing the first surface on a rotating wheel

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 2

measuring an angle of the first surface relative to the second surface using a non-contact optical technique

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS20250010427A1Method and apparatus for processing diamond surface

Publication Date: 2025.01.09 ELEMENT SIX TECH LTD

AI summary

There is provided a method and apparatus for processing a diamond surface. The method comprises: i. locating a diamond material having a first surface and a second, opposite surface, in a holder, the holder located at the end of a positioning arm; ii. processing the first surface on a rotating wheel; iii. while the diamond material is in the holder, measuring an angle of the first surface relative to the second surface; iv. repeating steps (ii) and (iii) until a desired angle is achieved.