Passive Optical Assembly Jig for Rapid Bonding
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Solution Overview
Problem
Current methods for fabricating optical instruments, such as those using adjustable mounts and pick-and-place assembly, are costly, slow, and not suitable for demanding environments due to high capital expenditures and maintenance costs, and are inefficient for complex optical devices with extreme temperature and vibration requirements.
Innovation Solution
A jig system with shaped apertures and alignment bumps is used to precisely place and secure optical components on an optical bench, allowing simultaneous bonding and verification, eliminating the need for active alignment and reducing the complexity of the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional pick-and-place assembly methods are used, then assembly precision can be maintained, but assembly time is excessive and capital expenditure is high
Solution Approach 1:
The patent implements preliminary action by pre-configuring the jig with precisely positioned apertures and alignment features before the assembly process. The jig is designed with predetermined locations for each optical component, including alignment bumps and positioning features that are prepared in advance. This allows components to be quickly placed and secured without requiring time-consuming active alignment during assembly, thus maintaining precision while dramatically reducing assembly time from days to minutes.
Solution Approach 2:
The patent introduces a jig as an intermediary device that mediates between the operator and the optical components. The jig serves as a passive alignment tool with pre-defined apertures, alignment bumps, and positioning features that guide component placement. This intermediary structure eliminates the need for complex active alignment systems and pick-and-place machinery, achieving both high precision and rapid assembly through its carefully designed geometric features.
2Adaptability or versatility
If adjustable mounts are used for optical components, then alignment flexibility is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the alignment function from complex adjustable mounts and concentrates it into a simple, passive jig structure. Instead of using sophisticated adjustable mounting mechanisms for each component, the alignment capabilities are taken out and embedded into the jig itself through precisely machined apertures, alignment bumps, and positioning features. This extraction eliminates the need for complex adjustable mounts while maintaining alignment flexibility through the jig's predetermined geometric constraints.
Solution Approach 2:
The patent employs a simple, inexpensive jig that can be easily manufactured and replaced compared to expensive adjustable mount systems. The jig is a relatively simple fixture with apertures and alignment features that does not require complex mechanisms or high capital expenditure. While the jig may need to be redesigned for different optical configurations, each individual jig is low-cost and straightforward to fabricate, reducing overall device complexity and cost.
3Productivity
If passive bonding with jigs is used, then assembly speed increases, but alignment precision may be compromised
Solution Approach 1:
The patent resolves this contradiction by performing preliminary action in the jig design phase rather than during assembly. The apertures, alignment bumps, and positioning features are precisely configured in advance to define exact component locations and orientations. During assembly, components are simply placed into these pre-configured positions, achieving both rapid assembly and high alignment precision without requiring active alignment adjustments.
Solution Approach 2:
The patent replaces complex mechanical alignment systems with a passive geometric constraint system. Instead of using adjustable mounts or active alignment mechanisms, the jig employs carefully designed apertures, alignment bumps, and positioning features that mechanically constrain components to precise locations through simple geometric relationships. This substitution maintains alignment precision while enabling rapid passive bonding assembly.
Data Source
AI summary
Techniques are disclosed for fabricating optical instrumentation. The techniques can be used, for instance, to populate an optical bench with several optics that can be simultaneously bonded and simultaneously verified to precise assembly, and without the use of adjustable mounts or active alignment. The techniques may be embodied, for instance, in a jig designed for operatively coupling to a given optical bench. The jig includes cut-outs that identify placement locations for the various optical components on the underlying optical bench. Thus, once the jig is secured to the optical bench, precise placement of the optical components is simplified. In some such embodiments, the jig further includes a clamping assembly for each cut-out, so that once an optical component is placed on the optical bench via that cutout, the clamping assembly can be engaged to hold that optical component in place while a deposited bonding agent is cured.