Mixer Module for Pulsed Polishing of Optical Surfaces
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Solution Overview
Problem
Conventional polishing methods for high-precision optics are inefficient and prone to tool deformation, limited to polishing high-hardness materials, and struggle with precision on surface edges and large surfaces, while existing hydrodynamic tools cannot interrupt their erosive action without losing stability.
Innovation Solution
A mixer module for deterministic hydrodynamic tools that allows instantaneous interruption of abrasive fluid supply without losing operational stability, enabling pulsed polishing with high internal gas velocities and precise control over abrasive foam dwell time, allowing for pulsed, zonal, and multi-tool polishing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional contact polishing methods are used, then polishing action is continuous and material removal occurs, but the tool cannot be interrupted without losing stability and operational parameters are lost
Solution Approach 1:
The patent applies periodic action by implementing pulsed polishing cycles where the hydrodynamic tool alternates between active polishing phases and inactive recovery phases. During active phases, abrasive fluid is supplied to remove material; during recovery phases, fluid supply is interrupted allowing the tool to restore stability and operational parameters. This periodic on-off operation enables productive material removal while maintaining system reliability through regular stabilization intervals.
2Productivity
If the abrasive fluid supply is interrupted to increase polishing efficiency, then selective material removal is enabled, but the hydrodynamic tool loses stability and operational parameters
Solution Approach 1:
The patent applies preliminary action by ensuring that during each active polishing phase, the tool is fully stabilized and operational parameters are optimized before material removal begins. The system prepares the hydrodynamic tool with proper fluid pressure, flow rate, and positioning before each pulsed operation, ensuring maximum efficiency during the brief active window while minimizing disruption to overall stability.
3Productivity
If continuous polishing is performed, then material removal occurs across the entire surface, but unwanted material removal occurs in areas where correction is not needed
Solution Approach 1:
The patent applies local quality by implementing spatially selective pulsed polishing where different regions of the workpiece receive polishing action at different times and with different pulse characteristics. The control system activates the hydrodynamic tool only at specific locations and time intervals based on the local surface error map, enabling precise material removal only where needed while leaving corrected areas untouched. This localized approach combines high productivity with manufacturing precision.
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 solution enhances polishing efficiency by allowing selective material removal only where necessary, reducing process time, and preventing unwanted material removal, thereby improving the precision and speed of high-precision optical surface polishing.
Implementation Method 1
What is intended is that said abrasive fluid remains inside the polishing tool for less than one millisecond, and once the flow is cut off, high internal velocities of pressurized gases are used to empty said tool.
Implementation Method 2
a first inlet through which pressurized air is injected under control... a second inlet through which a polishing fluid is injected in a controlled manner... wherein said polishing fluid fills a predetermined volume which is then transferred to a mixing zone, and in conjunction with the pressurized air, an abrasive foam is produced
Implementation Method 3
The process is carried out without coming into contact with the surface to be polished, exerting zero force on the work surface
Data Source
AI summary
A hydrodynamically optimized mixer module, to be coupled to a deterministic hydrodynamic tool that allows pulsed polishing of optical surfaces is described. This module allows the supply of abrasive foam or fluid that enters the tool to be interrupted without impairing the operational stability of the polishing process and of said hydrodynamic tool. The mixer module includes at least one interrupter element for switching high-velocity fluids; a first inlet through which air is injected under pressure and in a controlled manner; a second inlet through which a polishing fluid is injected in a controlled manner, said polishing fluid filling a predetermined volume with a hydrodynamically optimized shape and being transferred to a mixing zone where, together with the pressure-injected air, an abrasive foam is produced that is injected into at least one rotational acceleration chamber of the hydrodynamic tool to which the mixer module is coupled.