Spring Clamp for Optics Thermal Expansion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for aligning optics, such as using epoxy or lock washers, face issues with thermal stress and unpredictable force distribution, leading to misalignment and reduced durability due to coefficient of thermal expansion mismatches and concentration of line contact stress.
Innovation Solution
A spring clamp system comprising a body with a leading edge, an opening for a spring, and a screw to compress the spring, providing a consistent force and reducing line contact stress, allowing for attachment of optics with varying diameters and thermal expansion coefficients, maintaining alignment across a wide temperature range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If epoxy is used to hold the optic in the mount, then the optic is secured in alignment, but thermal stress causes the epoxy to crack and delaminate due to CTE mismatch
Solution Approach 1:
The patent removes the epoxy adhesive from the mounting system entirely, replacing it with a mechanical clamp assembly that secures the optic through direct contact and clamping force, thereby eliminating the thermal expansion mismatch problem that causes epoxy failure
Solution Approach 2:
The clamp assembly acts as an intermediary mechanical element between the mount and the optic, providing a stable mounting mechanism that does not rely on epoxy bonding and is therefore immune to CTE mismatch issues between different materials
2Reliability
If a lock washer is used to clamp the optic, then the optic is held in static alignment, but the force is unpredictable and may damage the optic
Solution Approach 1:
The patent replaces the static, rigid lock washer system with a dynamic spring-based clamp assembly that can adapt its clamping force, providing consistent and controlled pressure on the optic while accommodating thermal expansion and contraction without causing damage
Solution Approach 2:
The spring mechanism allows the clamping force parameter to be adjusted and optimized, ensuring the force remains within a safe and effective range regardless of temperature variations, thereby preventing both optic damage and alignment drift
3Reliability
If a lock washer is used to clamp the optic, then the optic is held in position, but line contact stress concentration reduces the durability of the optic
Solution Approach 1:
The clamp assembly incorporates a contact surface designed to distribute the clamping force across a broader area of the optic, reducing stress concentration while maintaining secure positioning and alignment stability
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 spring clamp system ensures stable optical beam alignment and improved durability by providing a consistent, controllable force and accommodating thermal expansion mismatches, reducing the risk of misalignment and damage from thermal cycling.
Implementation Method 1
The spring may be to dispose a leading edge of the body against the optic
Implementation Method 2
The screw may be to compress the spring. The screw may be to cause the spring to apply a force to the leading edge
Implementation Method 3
The mount, the body, and the optic may be associated with at least two coefficient of thermal expansion (CTE) values that differ by at least 10×10^-6/Kelvin (K)
Data Source
AI summary
An optical device may include an optic disposed in an optical path. The optical device may include a mount to dispose the optic in the optical path. The optical device may include a plurality of spring clamps to attach the optic to the mount. The spring clamp, of the plurality of spring clamps, may include a body, a spring, and a screw. The screw may be to attach to the mount and to compress the spring. The spring may be to dispose a leading edge of the body against the optic. The spring clamp may be to maintain the optic in the optical path for a thermal cycle of at least between approximately −50° C. and approximately 130° C.