Etalon Fabrication via Concave Plate Deformation
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Solution Overview
Problem
The manufacturing of etalons with high finesse is costly and time-consuming due to the need for extremely flat and parallel optical surfaces, which are difficult to achieve with traditional methods, especially for thin plates, and the use of expensive materials like quartz.
Innovation Solution
The method involves optical contact bonding of spacers to a first optical plate and deforming a concave surface of a second optical plate to a flat shape, allowing for the creation of a monolithic etalon with relaxed surface flatness tolerances and the use of less expensive materials like borosilicate glass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional polishing methods are used to achieve extremely flat surfaces (surface figure less than λ/20), then high finesse is achieved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-forming the optical plates with sufficiently flat surfaces through controlled deformation processes before final assembly. The plates are deformed to achieve the required surface figure during manufacturing rather than relying on time-consuming post-polishing operations, thus reducing total manufacturing time while maintaining the required surface flatness for high finesse
Solution Approach 2:
The patent utilizes parameter changes by controlling the deformation parameters (force, temperature, pressure) during the forming process to achieve the desired surface figure. By adjusting these parameters, the optical plates can be deformed to meet the surface flatness requirements without requiring traditional extensive polishing operations
2Manufacturing precision
If traditional polishing methods are used to achieve extremely flat surfaces, then high finesse is achieved, but manufacturing cost increases significantly
Solution Approach 1:
The patent applies preliminary action by pre-forming the optical plates with sufficiently flat surfaces through controlled deformation processes before final assembly. The plates are deformed to achieve the required surface figure during manufacturing rather than relying on time-consuming post-polishing operations, thus reducing total manufacturing time while maintaining the required surface flatness for high finesse
Solution Approach 2:
The patent utilizes parameter changes by controlling the deformation parameters (force, temperature, pressure) during the forming process to achieve the desired surface figure. By adjusting these parameters, the optical plates can be deformed to meet the surface flatness requirements without requiring traditional extensive polishing operations
3Stability of the object's composition
If thick optical plates are used to achieve sufficient surface figure and avoid bending, then manufacturing stability is improved, but material cost and device weight increase
Solution Approach 1:
The patent utilizes parameter changes by controlling the deformation parameters (force, temperature, pressure) during the forming process to achieve the desired surface figure. By adjusting these parameters, the optical plates can be deformed to meet the surface flatness requirements without requiring traditional extensive polishing operations
Solution Approach 2:
The patent replaces the traditional mechanical approach of using thick plates to prevent bending with a controlled deformation process. By applying specific forces and constraints during manufacturing, thin plates can be deformed into the correct shape and maintained in that shape, substituting the need for excessive material thickness with a controlled manufacturing process
4Stability of the object's composition
If thick optical plates are used to achieve sufficient surface figure, then manufacturing stability is improved, but material cost increases
Solution Approach 1:
The patent utilizes parameter changes by controlling the deformation parameters (force, temperature, pressure) during the forming process to achieve the desired surface figure. By adjusting these parameters, the optical plates can be deformed to meet the surface flatness requirements without requiring traditional extensive polishing operations
Solution Approach 2:
The patent replaces the traditional mechanical approach of using thick plates to prevent bending with a controlled deformation process. By applying specific forces and constraints during manufacturing, thin plates can be deformed into the correct shape and maintained in that shape, substituting the need for excessive material thickness with a controlled manufacturing process
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 reduces manufacturing costs and time by allowing for etalons with sufficient finesse using less expensive materials and thinner plates, while maintaining optical performance and accommodating thermal changes.
Implementation Method 1
deforming the concave surface to provide a deformed surface... Deforming the concave surface to provide the deformed surface may comprise forcing the second optical plate toward the first optical plate
Implementation Method 2
optical contact bonding a plurality of spacers to a flat surface of a first optical plate; optical contact bonding a second surface of a second optical plate to the plurality of spacers
Data Source
AI summary
A method for manufacturing an etalon is disclosed. The method comprises arranging a plurality of first spacers between a flat surface of a first optical plate and a concave surface of a second optical plate. For each of the spacers, the flat surface bears on a first abutment surface of the spacer and the concave surface bears on a second abutment surface of the spacer. The concave surface is deformed to be parallel to the second abutment surfaces. For each of the spacers, the flat surface is bonded to the first abutment surface and the concave surface is bonded to the second abutment surface.