Optical Mirror Assembly With Gap-Based Angular Adjustment

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Solution Overview

Problem

Existing optical assemblies with mirror parts face challenges in maintaining a narrowly tolerated angle between mirror parts in a stable manner, often leading to stress imbalances and manufacturing inefficiencies.

Innovation Solution

An optical assembly with at least two mirror parts that utilize an adjustment gap and a gap body to precisely adjust and fix the angle between mirror surfaces, ensuring equal stress distribution and long-term stability, using methods such as diffusion welding and insertion of wedges or rods into grooves.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If mirror parts are joined directly without adjustment mechanism, then manufacturing is simpler, but angular position tolerance cannot be adjusted and stability is poor

Engineering Contradiction:

Improveangular position toleranceVSAvoidassembly structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The optical assembly is divided into separate mirror parts that can be independently adjusted and positioned, allowing precise angular alignment without requiring complex pre-grinded contact surfaces. Each mirror part can be separately mounted and adjusted to achieve the desired angular relationship.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The assembly includes adjustment mechanisms that allow the angular position of mirror parts to be dynamically adjusted during assembly or maintenance. This dynamic adjustment capability enables precise angular positioning while simplifying manufacturing requirements compared to static pre-aligned designs.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If adjustment mechanism is added to change angle between mirror parts, then angular flexibility is improved, but long-term stability of adjusted position cannot be guaranteed

Engineering Contradiction:

Improveangular adjustment flexibilityVSAvoidadjusted position stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The adjustment mechanisms are designed to set and lock the angular position of mirror parts during the assembly process. Once the desired angular relationship is achieved, the positioning is fixed through mechanical locking or bonding, ensuring long-term stability of the adjusted configuration.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Adjustment elements such as wedge-shaped inserts or adjustable mounting brackets serve as intermediaries between the mirror parts and the housing. These intermediaries enable precise angular adjustment while maintaining stable positioning when properly secured.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If reflection prism is used to reflect light beam, then angular position is permanently maintained and space is compact, but manufacturing is complex, weight is high, and transmission is reduced

Engineering Contradiction:

Improveangular position maintenanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of using a single monolithic reflection prism, the optical system employs separate mirror parts that can be individually manufactured and assembled. This segmentation simplifies manufacturing by allowing each mirror to be produced independently with standard techniques, while achieving the same optical function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces the traditional glass prism mechanical structure with separate mirror components mounted on adjustable supports. This substitution reduces weight, simplifies manufacturing, and improves light transmission while maintaining the angular reflection function through careful positioning of the mirror surfaces.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution achieves a stable, precisely adjusted angle between mirror parts, reducing manufacturing costs and ensuring long-term stability without stress imbalances, offering a compact and cost-effective alternative to traditional reflective prisms.

Implementation Method 1

using methods such as diffusion welding and insertion of wedges or rods into grooves

Methodology Applied

Scientific EffectDiffusion welding: Diffusion Welding

Implementation Method 2

The depth of the adjustment gap equal to the thickness of the cemented second mirror part is a mandatory requirement in order to tilt the mirror surface of the first mirror part towards that of the second mirror part by spreading the adjustment gap apart by pressing in the wedge

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Implementation Method 3

Optical assembly for changing the direction of light beams with at least two mirror sections

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentEP3528027B1Optical assembly for changing the direction of light beams with at least two mirror sections

Publication Date: 2025.07.02 ERNST ABBE HOCHSCHULE JENA

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Figure 3a~3b

AI summary

Optical assembly for changing the direction of light rays with at least two mirror parts (1, 2) arranged relative to each other such that two mirror surfaces (1.1, 2.1) enclosing a predetermined first angle (α) and forming an edge (3) with a length (I), are adjacent to each other and a slit body (4) arranged in the optical assembly, projecting along a line of action (5) into the optical assembly to a depth (t), with which the angle (α) was adjusted.