Optical Assembly Alignment via Adjustable Flexure and Vacuum Chuck
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge lies in accurately aligning the optical axes of lenses in optical assemblies, such as doublets or triplets, during manufacturing, which is difficult due to the need for precise alignment tolerances and can result in stress and birefringence when using conventional adhesive curing methods.
Innovation Solution
An alignment apparatus featuring a rotatable chuck with an adjustable flexure assembly and vacuum support, allowing for precise alignment of lenses using flexible webbing and low-force adjustments, enabling alignment of optical axes without stressing the adhesive, and allowing the adhesive to cure once alignment is achieved.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional adhesive curing methods are used to align lenses, then the lenses can be bonded together, but stress and birefringence occur due to force disturbances during alignment
Solution Approach 1:
The patent performs alignment actions before the adhesive fully cures, while the adhesive is still in a semi-cured state that allows for adjustment. This preliminary alignment prevents stress and birefringence by completing positioning before final bonding occurs.
Solution Approach 2:
The patent changes the physical state parameter of the adhesive from fully cured to semi-cured during the alignment process. This parameter change allows the adhesive to be more pliable and less prone to stress during alignment, reducing birefringence effects.
2Manufacturing precision
If rigid alignment methods are used to achieve precise optical axis alignment, then alignment precision improves, but stress and deformation increase in the optical components
Solution Approach 1:
The patent changes the mechanical property parameter of the adhesive from rigid to pliable by controlling the curing state. This allows precise alignment to be achieved without applying excessive force that would cause stress or deformation in the optical components.
Solution Approach 2:
The semi-cured adhesive acts as an intermediary medium that transmits alignment forces gently rather than rigidly. This intermediary state allows for precise positioning while distributing forces evenly, preventing stress concentration in the optical components.
3Strength
If alignment adjustments are made after adhesive curing, then permanent bonding is achieved, but alignment precision decreases due to adhesive rigidity
Solution Approach 1:
The patent performs the alignment action before the adhesive reaches full curing strength. By completing alignment while the adhesive is still pliable, the system achieves both high alignment precision and strong permanent bonding without the trade-off.
Solution Approach 2:
The patent exploits the dynamic transition of the adhesive from pliable to rigid state. During alignment, the adhesive remains dynamic and adjustable; after alignment, it transitions to a static, rigid bonded state, achieving both precision and strength.
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 method ensures precise alignment of optical axes with reduced stress and birefringence, improving the optical quality and performance of the assembly by minimizing force disturbances during the alignment process.
Implementation Method 1
the chuck includes a vacuum channel, and the optical assembly is supported on the chuck by vacuum pressure provided through the vacuum channel
Implementation Method 2
a flexible webbing coupling the fixed portion to the sliding portion... flexing the flexible webbing and adjusting the position of the flexure
Data Source
Figure 1A~1B
Figure 2A
Figure 2B
AI summary
An alignment apparatus for aligning components of an optical assembly include a chuck configured to support the optical assembly thereon, and an adjustable flexure assembly disposed around the chuck. The adjustable flexure assembly includes a plurality of flexures. The plurality of flexures are positioned relative to the chuck such that each of the plurality of flexures contact the optical assembly when the optical assembly is positioned on the chuck. Adjustment of a position of one or more flexures of the plurality of flexures adjusts an alignment of an optical axis of an optical component of the optical assembly when the optical assembly is positioned on the chuck, wherein the alignment apparatus is configured to align optical axes of the optical component to an angle of deviation of less than about 1,000 µrad and provide an extinction ratio within the optical assembly of greater than or equal to 1000:1.