Mirror Assemblies with Segmented Miter and Non-Miter Joints
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Solution Overview
Problem
Mirror-based optical assemblies face degradation in optical performance due to thermal contraction and expansion, as existing connection methods are not optimized to manage these effects effectively, leading to issues like surface flatness and beam deviation.
Innovation Solution
The implementation of a mirror-based assembly with multiple connection regions, including miter and non-miter joint regions, to minimize thermal expansion and contraction, featuring a combination of miter joint, pad, and flat or pin joint structures, which allows for more complex integration and stress relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If simple flat connection regions are used to mate mirror panels to support members, then assembly and manufacturing are easier, but thermal expansion and contraction cause degradation of optical performance
Solution Approach 1:
The connection interface is divided into multiple distinct regions: a first connection region with a flat surface for simple mating, a second connection region with a chamfered surface for stress relief, and a third connection region with additional geometric features. This segmentation allows each region to perform its specific function while collectively providing both ease of assembly and thermal stability.
Solution Approach 2:
Different geometric properties are applied to different parts of the connection interface. The flat region provides ease of mating, while the chamfered region with specific angles and dimensions provides stress relief during thermal cycling. This local differentiation of geometric quality optimizes both assembly ease and optical performance stability in their respective zones.
2Reliability
If chamfered surfaces are used to connect mirror panels to support members, then thermal expansion stresses are reduced, but manufacturing complexity increases
Solution Approach 1:
The chamfered stress-relief geometry is confined to a specific second connection region, while the primary first connection region maintains a simple flat surface for easy manufacturing. This segmentation allows the complex chamfered features to be applied only where needed for thermal stress management, rather than across the entire connection interface.
Solution Approach 2:
The chamfered surface with specific angular and dimensional properties is applied locally to the second connection region where stress relief is most needed, while other regions maintain simpler geometries. This localized application of complex geometry minimizes overall manufacturing complexity while providing sufficient thermal stress resistance.
3Ease of manufacture
If a single connection geometry is used between mirror panels and support members, then manufacturing is simpler, but optical performance degrades under thermal effects
Solution Approach 1:
The connection interface is segmented into multiple regions with different geometric properties: a flat first connection region for maintaining surface flatness, and a chamfered second connection region for stress relief. This segmentation allows the system to maintain optical precision while being manufacturable with standard processes.
Solution Approach 2:
Different geometric qualities are applied to different connection regions: the flat region maintains optical surface quality, while the chamfered region provides mechanical stress relief. This local differentiation ensures that optical performance is preserved in critical areas while thermal stresses are managed in structural areas.
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 enhances the optical performance of mirror-based assemblies by effectively managing thermal effects, reducing mechanical stresses, and maintaining beam integrity across temperature changes.
Implementation Method 1
at least three connection regions between the at least one support member and the at least one mirror panel, comprising at least a first connection region comprising a miter joint connection region and at least a second connection region comprising a non-miter joint connection region, wherein the at least the first mirror panel is connected to the at least one support member to minimize thermal expansion or contraction of the at least the first mirror panel
Data Source
AI summary
An improved mirror-based assembly is provided. The mirror-based assembly has at least one mirror panel, at least one support member, and at least three connection regions between the at least one support member and the at least one mirror panel, comprising at least a first connection region comprising a miter joint connection region, at least a second connection region comprising a non-miter joint connection region, and at least a third connection region, wherein the at least one mirror panel is connected to the at least one support member to minimize thermal expansion or contraction of the at least one mirror panel and a method for assembling the same.