Monolithic Reflective Beam Conditioner With Passive Alignment
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Solution Overview
Problem
Existing reflective beam conditioner systems face challenges in achieving optimal alignment and stability of optical surfaces, particularly in maintaining alignment over temperature changes and requiring costly active alignment methods.
Innovation Solution
A reflective beam conditioner system with a monolithic body featuring integrated alignment features, allowing for precise alignment and fabrication of optical surfaces in a single setup, which reduces the need for additional alignment adjustments and maintains stability across temperature variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate optical components are used in reflective beam conditioner systems, then flexibility and adjustability are improved, but alignment stability and manufacturing precision deteriorate due to cumulative tolerance errors and sensitivity to temperature changes
Solution Approach 1:
The patent merges multiple separate optical components (mirrors, beam expander elements) into a single monolithic body with integrated optical surfaces. This eliminates the interfaces between separate components, removing cumulative tolerance errors and improving alignment precision while maintaining the optical functionality through precisely machined surfaces on the monolithic structure.
Solution Approach 2:
The monolithic body is designed with distinct functional zones and integrated alignment features that segment the optical paths while remaining part of a unified structure. This allows different optical functions (beam expansion, reflection, alignment reference) to be distributed across the monolithic body with precise geometric relationships, achieving both flexibility and precision.
2Manufacturing precision
If active alignment methods are used to maintain optical surface alignment, then alignment precision is improved, but system complexity and cost increase
Solution Approach 1:
The monolithic body with integrated alignment features provides self-aligning capability through built-in geometric references (alignment planes, reference surfaces) that passively maintain optical surface alignment. The system serves its own alignment needs through the inherent geometric relationships in the monolithic structure, eliminating the need for external active alignment mechanisms, sensors, or control systems.
Solution Approach 2:
The patent extracts and eliminates the complex active alignment subsystems (motors, sensors, control electronics) by incorporating alignment functionality directly into the monolithic body structure itself. The alignment features are built-in rather than added as separate active systems, reducing overall system complexity while maintaining alignment precision.
3Ease of operation
If multiple adjustment axes are provided for aligning optical surfaces, then ease of operation is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The monolithic body is manufactured with pre-established geometric relationships and integrated alignment features that define the optimal optical paths and surface orientations during the manufacturing process itself. The alignment references are built-in beforehand, allowing final assembly and operation to be simplified while the manufacturing process incorporates the precision alignment requirements into the monolithic structure.
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 system achieves precise and stable alignment of optical components, optimizing beam quality and reducing the need for costly active alignment methods, while maintaining alignment accuracy across temperature changes.
Implementation Method 1
The two or more mirrors are configured such that, in use, a beam reflects once sequentially off of each of the mirrors
Data Source
AI summary
A reflective beam conditioner includes a monolithic body having two or more mirrors and at least one alignment feature. The at least one alignment feature has a predetermined orientation or position with respect to at least one of the two or more mirrors. The two or more mirrors are configured such that, in use, a beam reflects once sequentially off of each of the mirrors. A method of manufacturing such a reflective beam conditioner includes providing a monolithic body. The method further includes restraining the monolithic body to a machining fixture. The method further includes forming a first mirror, a second mirror, and an alignment feature in the monolithic body with the monolithic body restrained in the machining fixture.