Dome-Shaped Optical Component Mounting with Stress-Relief Void
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Solution Overview
Problem
Mounting of substantially hemispherical optical domes is challenging due to minimal edge availability for attachment, making it difficult and costly to form extensions for mounting, which can lead to stress and structural integrity issues.
Innovation Solution
A mounting system featuring a dome-shaped optical component with a recess and a mounting base having a projection, where adhesive material forms upper and lower bands with a void between them, reducing bending stress and incorporating a heater for thermal management and de-icing, along with multiple retention mechanisms for redundancy and environmental tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If extensions are formed on hemispherical optical domes to assist mounting, then mounting capability is improved, but manufacturing complexity and cost increase due to complex geometry
Solution Approach 1:
The mounting system is segmented into distinct functional elements: the optical dome itself, a separate mounting base, adhesive bands for attachment, and a void space for stress relief. This segmentation allows each component to be optimized independently, avoiding the need to modify the optical dome geometry while still achieving secure mounting.
Solution Approach 2:
A mounting base acts as an intermediary element between the optical dome and the mounting structure. Instead of directly modifying the dome to add mounting features, the intermediary base provides the mounting interface, simplifying the dome's geometry while maintaining mounting capability.
2Strength
If adhesive material is applied continuously between optical component and mounting base, then bonding strength is improved, but bending stress at the recess increases
Solution Approach 1:
The continuous adhesive material is segmented into an upper band and a lower band separated by a void. This segmentation maintains bonding strength through the two adhesive bands while the void between them provides stress relief, preventing stress concentration at the recess location.
Solution Approach 2:
The void space is positioned beforehand at the location where bending stress would concentrate at the recess. This pre-positioned void acts as a cushioning element that absorbs and distributes stresses before they can concentrate and cause damage to the optical component.
3Reliability
If multiple retention mechanisms are used to improve reliability, then mounting reliability is improved, but device complexity increases
Solution Approach 1:
The retention system is segmented into multiple independent mechanisms: mechanical engagement features (protrusions and recesses) and adhesive bonding (upper and lower bands). These segmented retention mechanisms work together to provide redundant holding capability, improving reliability while keeping each individual mechanism relatively simple.
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 system provides a reliable, cost-effective, and flight-safe mounting solution that minimizes stress, accommodates thermal expansion, and tolerates environmental loads while being easy to manufacture and using less adhesive material, ensuring the structural integrity and reliability of the optical component.
Implementation Method 1
The void is positioned relative to the recess in the outer surface of the optical component such that a bending stress in the optical component at the recess is less than what the bending stress would be without the void
Implementation Method 2
A heater is thermally coupled to (and typically inside) the optical component
Implementation Method 3
They can accommodate thermal expansion mismatches (e.g., between the optical component and its mounting base)
Implementation Method 4
An adhesive material is between the optical component and the mounting base. The adhesive material forms an upper band and a lower band with a void between the upper band and the lower band
Data Source
AI summary
A system includes a dome-shaped optical component having a substantially circular edge and a mounting base for the optical component. A recess is in an outer surface of the optical component. A projection on an inner surface of the mounting base and is configured to engage the recess. An adhesive material is between the optical component and the mounting base. The adhesive material forms an upper band and a lower band with a void between the upper band and the lower band. The void is positioned relative to the recess in the outer surface of the optical component such that a bending stress in the optical component at the recess is less than what the bending stress would be without the void. A heater is inside and thermally coupled to the optical component.