Laser Finishing and Vacuum Coating of Optical Components
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Solution Overview
Problem
Current methods for finishing and coating optical components are labor-intensive and inefficient, leading to high scrap rates and prolonged processing times, especially when trying to achieve precise surface finishes and coatings on diverse optical components.
Innovation Solution
A finishing and coating apparatus that integrates a laser engine with a beam delivery system and a vacuum chamber, allowing for precise laser finishing and subsequent coating of optical components within the same housing, utilizing a combination of heating and ablation to improve surface quality and reduce imperfections, while also employing electron guns and ion guns for enhanced coating deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mechanical polishing processes are used, then surface finish can be achieved, but the process is labor-intensive and time-consuming
Solution Approach 1:
The patent replaces traditional mechanical polishing systems with a laser-based finishing system. The laser engine with beam delivery apparatus directs energy onto the optical component surface, eliminating the need for mechanical contact and manual operation while achieving superior surface finish and significantly reducing processing time.
Solution Approach 2:
The patent changes the physical state and parameters of the optical component surface through controlled laser heating. By adjusting laser power, pulse duration, and scanning speed, the system transforms the surface material properties to achieve desired finish quality without mechanical contact, thereby improving both precision and productivity.
2Manufacturing precision
If multiple separate processes are used for finishing and coating, then each process can be optimized, but the overall processing time increases
Solution Approach 1:
The patent merges the laser finishing process and the coating deposition process into a single integrated chamber. The optical component undergoes laser surface treatment and subsequent coating application without removal from the chamber, eliminating transfer time and enabling continuous processing, thus reducing total processing time while maintaining quality.
Solution Approach 2:
The laser finishing process is performed as a preliminary action before coating deposition within the same vacuum chamber. This sequence prepares the surface optimally for coating adhesion and eliminates the need for separate handling and transfer operations, reducing overall processing time while ensuring surface quality.
3Reliability
If manual polishing and inspection processes are used, then quality control can be achieved, but scrap rates increase and efficiency decreases
Solution Approach 1:
The patent replaces manual polishing and inspection operations with automated laser-based systems. The laser engine with programmable beam delivery provides consistent, repeatable surface treatment, while integrated sensors and control systems monitor the process in real-time, reducing human error and scrap rates while improving productivity.
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 integrated approach significantly reduces processing time, minimizes scrap rates, and achieves high-quality surface finishes and coatings on a variety of optical components, including mirrors, lenses, and prisms, by allowing for efficient laser finishing and coating in a single apparatus, improving surface quality and reducing the need for manual inspection and mechanical polishing.
Implementation Method 1
The laser can be used to heat and/or ablate the surface
Implementation Method 2
allowing surface material to flow to fill imperfections in the surface
Implementation Method 3
the electron gun, the electron gun configured to bombard the coating body to transform a portion of the coating body to a vapor phase to coat the one or more optical components
Implementation Method 4
A vacuum pump system is provided to create a vacuum within the chamber
Implementation Method 5
the ion gun, the ion gun configured to direct ions at the sputtering target to eject material from the sputtering target to coat the one or more optical components
Implementation Method 6
the ion gun, the ion gun configured to direct ions at the sputtering target to eject material from the sputtering target to coat the one or more optical components
Data Source
AI summary
A finishing and coating apparatus combines finishing and coating optical components into one vacuum apparatus. The apparatus includes a vacuum system, a substrate holder, a finisher including a laser engine and a beam delivery apparatus, and a coating source. The finisher is configured to finish the optical components prior to coating the optical components. The finisher includes a laser engine and a laser beam delivery apparatus configured to direct a beam from the laser engine toward each of the optical components.