Monolithic Optical Flexure Mount for Thermal and Vibration Stability
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Solution Overview
Problem
Current optical alignment and mounting mechanisms in optical systems suffer from suboptimal performance due to thermal and physical mass, variability in assembly, and vulnerability to shock and vibration, leading to alignment issues and system instability.
Innovation Solution
A monolithic optical flexure made from materials like Titanium grade 5 (Ti6Al4V) or 17-4 stainless steel, with a split clamp design that is slightly undersized and secured by a screw, allowing for precise clamping force control and minimal mass, combined with integrated flexure arms and adjustment screws for precise alignment and reduced thermal mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional mounting designs use adhesives to secure optical elements, then assembly is simplified, but thermal cycling performance deteriorates and assembly challenges increase
Solution Approach 1:
The patent replaces adhesive bonding with a mechanical clamping system consisting of a split ring and screw assembly. The split ring mechanically grips the optical element holder, eliminating the need for adhesives while providing secure attachment that withstands thermal cycling without degradation.
Solution Approach 2:
The mounting mechanism is segmented into distinct components: a split ring divided into two halves, a screw for actuation, and an optical element holder. This segmentation allows for easy assembly and disassembly while maintaining secure mechanical attachment during operation.
2Ease of manufacture
If a split ring is circumferentially tightened around an optical element, then mounting is simplified, but local deformation of the optical element occurs and tightening variability affects performance
Solution Approach 1:
The patent introduces an optical element holder as an intermediary component between the split ring and the optical element. The holder receives the clamping force from the split ring and transfers it to the optical element in a controlled manner, preventing direct deformation of the optical element while maintaining secure attachment.
Solution Approach 2:
The clamping force is applied locally at specific points through the holder rather than uniformly around the optical element. The holder's geometry and material properties are optimized to distribute forces appropriately, preventing deformation while maintaining secure mounting.
3Reliability
If radial spring elements or jacket sleeves are used to achieve stable connection, then connection stability improves, but device complexity, cost, and thermal mass increase
Solution Approach 1:
The patent extracts and eliminates unnecessary components from the mounting system. By using a simple split ring and screw mechanism, it removes the need for radial spring elements, jacket sleeves, and other complex components, achieving stable connection with minimal parts.
Solution Approach 2:
Instead of using active elements like springs that push outward, the patent uses a passive mechanical advantage system where the screw converts rotational motion into linear clamping force. The split ring's elasticity provides the necessary compliance without requiring additional spring components.
4Manufacturing precision
If high-precision positioning mechanisms with rails and roller bearings are used, then alignment precision improves, but device complexity and mass increase
Solution Approach 1:
The patent extracts and removes complex positioning mechanisms such as rails, roller bearings, and multi-component adjustment assemblies. It replaces them with a simplified flexure-based mechanism that achieves comparable or superior precision through elastic deformation and geometric design.
Solution Approach 2:
The patent employs flexures—thin, elastic components that bend and deform elastically to provide precise positioning. These flexures replace rigid mechanical assemblies with flexible elements that achieve fine adjustment through controlled elastic deformation, reducing complexity while maintaining precision.
5Manufacturing precision
If alignment mechanisms with multiple components are used, then adjustment precision improves, but thermal mass and physical mass increase, affecting dynamic response
Solution Approach 1:
The patent merges multiple separate components into integrated, monolithic structures. The optical element holder, flexures, and mounting features are combined into single pieces, eliminating the need for multiple discrete parts and reducing total mass and thermal mass while maintaining alignment precision.
Solution Approach 2:
The patent utilizes materials with optimized properties, such as low thermal expansion coefficients and high strength-to-weight ratios. By selecting appropriate materials for the flexures and holder, it achieves precise alignment and stable thermal performance with minimal mass.
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 solution provides superior stability, precision, and resilience to transport and manufacturing variations, minimizing thermal and physical mass while enhancing mechanical and thermal performance.
Implementation Method 1
a first flexure arm, wherein tightening of the first fastener against the first flexure arm causes a second flexure arm to pivot around a flexure element and increase a size of the bore
Data Source
AI summary
A compact optical mount optimized for stability in physically and thermally dynamic applications is disclosed. An example optical mount apparatus includes a body. The body includes a bore for an optical element, a first opening for a first fastener, and a first flexure arm. Tightening of the first fastener of the optical mount apparatus against the first flexure arm causes a second flexure arm to pivot around a flexure element and increase a size of the bore.