Modular Optical Filter Assembly with Clamp Mounting
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Solution Overview
Problem
Current filter assemblies for small satellites, such as CubeSats, are complex, costly, and inflexible, failing to effectively withstand mechanical loads during launch while allowing for multi-spectral observations in different spectral bands.
Innovation Solution
A compact filter assembly design featuring a frame-shaped base part and clamp parts made from rigid materials, allowing for the secure and interchangeable placement of multiple planar optical filters, including those with different thicknesses, using clamping instead of gluing for flexibility and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If integrated filter assemblies are designed for small satellites, then the device complexity is reduced, but the manufacturing cost increases to over 25 k€ per unit
Solution Approach 1:
The filter assembly is divided into separate modular components: individual planar filters, a frame structure with mounting features, and separate securing mechanisms. This segmentation allows each component to be manufactured independently using standard processes, avoiding the high cost of monolithic integrated assemblies while maintaining structural integrity and functionality.
Solution Approach 2:
The frame structure is designed with universal mounting features that can accommodate different filter configurations and spectral bands. The same basic frame design can be used across multiple satellite missions by simply changing the filter inserts, eliminating the need for custom-designed expensive integrated assemblies for each specific application.
2Ease of manufacture
If filter assemblies are designed with fixed configurations, then manufacturing is simplified, but flexibility for filter replacement is lost
Solution Approach 1:
The filter assembly incorporates removable and replaceable filter elements within a stable frame structure. The dynamic aspect is the ability to swap filters in and out, while the static frame provides consistent mounting geometry. This allows the assembly to be manufactured once with a fixed frame design but adapted for different spectral requirements by simply changing the filter inserts.
Solution Approach 2:
The frame structure is pre-manufactured with standardized mounting features, alignment pins, and securing mechanisms before the filters are installed. This preliminary preparation of the frame allows filters to be easily swapped later without requiring complex reassembly or customization, maintaining manufacturing simplicity while enabling future flexibility.
3Stability of the object's composition
If optical filters are secured using traditional mounting methods, then the assembly is stable, but the footprint and complexity increase
Solution Approach 1:
The mounting features, alignment pins, and securing mechanisms are integrated directly into the frame structure as a unified design. Rather than using separate complex mounting brackets and fastening systems, the frame itself incorporates all necessary elements, reducing overall complexity while maintaining stable filter positioning through the combined structural features.
Data Source
AI summary
A filter assembly comprises a planar first optical filter, a planar second optical filter, a frame-shaped base part for accommodating the first and second optical filters, wherein the base part comprises a support part for supporting edge portions of lower surfaces of the first and second optical filters, and a wall part for laterally enclosing at least part of the first and second optical filters, and one or more clamp parts for securing the first and second optical filters against the base part when the first and second optical filters are inserted into the base part, by contacting upper surfaces of the first and second optical filters and pressing the first and second optical filters towards the support part. The disclosure further relates to a method of manufacturing such filter assembly.