Optical Component Dovetail Mounting Against Adhesive Failure

Solution Overview

Problem

Existing methods for mounting optical components in free-space optics modules, such as adhesive bonding, are prone to failure due to temperature changes, impacts, and vibrations, leading to potential misalignment and overheating of laser systems, especially in high-power diode and fiber lasers, and require costly mechanical clamps for stability.

Innovation Solution

An opto-mechanical mounting system using a dovetail groove and adhesive combination, where the adhesive is wedged in a recess with a wider base than top, providing a secure six-dimensional interlock even if the adhesive bond fails, preventing movement or rotation of the optical component.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If adhesive bonding is used to mount optical components, then the mounting process is simple and low-cost, but the mounting is prone to failure under temperature changes, impacts, and vibrations

Engineering Contradiction:

Improvemounting process simplicityVSAvoidmounting stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent combines adhesive material with a mechanical interlocking structure (recess with undercut geometry) to create a composite mounting system. The adhesive provides chemical bonding while the undercut recess provides mechanical interlocking, creating a hybrid mounting solution that leverages both bonding mechanisms for enhanced reliability under thermal and mechanical stress

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The recess features an undercut geometry where the lower portion is wider than the upper portion, creating a wedge-shaped or tapered structure. This geometric curvature prevents adhesive extrusion and provides mechanical interlocking by anchoring the adhesive and optical component assembly within the recess, resisting displacement forces

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Reliability

If mechanical clamps are used to ensure stability, then mounting reliability improves, but device complexity and cost increase

Engineering Contradiction:

Improvemounting stabilityVSAvoidmounting structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The undercut recess structure is self-contained and self-locking. Once the adhesive is inserted and the optical component is positioned, the wider lower portion of the recess automatically prevents extrusion and provides mechanical interlocking without requiring additional clamps, fasteners, or adjustment mechanisms. The structure serves its own retention function

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent merges the adhesive bonding function with the mechanical retention function into a single integrated recess structure. Instead of using separate adhesive application and mechanical clamping systems, the undercut geometry combines both functions in one feature, reducing overall device complexity while maintaining reliability

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If adhesive is used without mechanical interlocking, then device complexity is low, but the optical component may move or rotate under stress

Engineering Contradiction:

Improvemounting structure simplicityVSAvoidoptical component position stability

Core Design Contradiction:

Device complexityVSStability of the object's composition

Solution Approach 1:

The recess features an undercut geometry where the lower portion is wider than the upper portion, creating a wedge-shaped or tapered structure. This geometric curvature prevents adhesive extrusion and provides mechanical interlocking by anchoring the adhesive and optical component assembly within the recess, resisting displacement forces

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent combines adhesive material with a mechanical interlocking structure (recess with undercut geometry) to create a composite mounting system. The adhesive provides chemical bonding while the undercut recess provides mechanical interlocking, creating a hybrid mounting solution that leverages both bonding mechanisms for enhanced reliability under thermal and mechanical stress

Inventive Principle:

Principle #40Composite materials

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 ensures robust and cost-effective retention of optical components, preventing misalignment and overheating by maintaining the optical component's position and stability in the event of adhesive failure, enhancing the reliability and longevity of laser systems.

Implementation Method 1

the adhesive is wedged in a recess with a wider base than top, providing a secure six-dimensional interlock

Methodology Applied

Scientific EffectMechanical interlocking: Mechanical Force

Data Source

PatentUS20230273391A1OPTO-mechanical mounting for optical components

Publication Date: 2023.08.31 NLIGHT INC

AI summary

An optical component has a bottom part located in an opening defined by a surface, wherein a distance between a sidewall of the bottom part of the optical component and a sidewall of the opening is non-uniform in which a width of a first section of the opening or a first section of the bottom part of the optical component is narrower than a width of a second lower section of the opening or a width of a second lower section of the bottom part of the optical component; and an adhesive is located in the opening between sidewalls.