Precision Optical Mount With Bonded Sleeve-Stud Stress Relief
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Solution Overview
Problem
High-precision optical systems face challenges in achieving stress-free mounting and alignment of optical devices due to thermal stresses and mechanical misalignments, leading to optical wavefront distortions and degraded performance, particularly in environments with varying temperatures and pressures.
Innovation Solution
A mount system comprising a sleeve and a stud with a curable material deposited between them, allowing for precise alignment and minimal stress induction, using conical interfaces to distribute forces and prevent bending, and replacing complex kinematic fasteners with simpler hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If diamond point machined surfaces are mated together to achieve precise alignment, then alignment precision is improved, but bending stresses are induced at the interface
Solution Approach 1:
The patent introduces a compliant intermediary layer (such as a elastomeric or viscoelastic material) between the diamond point machined surfaces. This intermediary acts as a mediator that accommodates the misalignment between the two precision surfaces while distributing the contact forces, thereby preventing bending stresses from being transmitted to the optical component. The intermediary layer deforms to bridge the gap caused by surface imperfections, maintaining both alignment precision and stress-free mounting.
2Stability of the object's composition
If kinematic fasteners are used to secure the optical device, then alignment stability is improved, but friction-induced misalignment and bending moments increase
Solution Approach 1:
The patent replaces the traditional kinematic fastener system (which relies on friction and mechanical contact) with a bonding system using curable materials. This substitution eliminates the friction-based alignment mechanism that causes misalignment under load. The curable material provides a chemical bond that secures the optical device without the mechanical friction and bending moments associated with kinematic fasteners, thereby maintaining alignment stability without compromising precision.
3Stability of the object's composition
If high preload forces are applied by fastening mechanisms, then mounting stability is improved, but bending moments on the optical component increase
Solution Approach 1:
The patent changes the mechanical parameters of the mounting system by transitioning from rigid mechanical fastening to a compliant bonding system. The curable material provides a softer, more compliant interface that can accommodate thermal expansion and contraction without generating high bending moments. This parameter change allows the mounting to remain stable under varying environmental conditions while avoiding the high preload-induced bending moments that would occur with rigid fastening mechanisms.
4Stress or pressure
If complex kinematic hardware is used to eliminate bending stresses, then stress-free mounting is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent employs a simple, inexpensive bonding system using curable materials that can be easily applied and cured. This approach replaces complex, expensive kinematic hardware with a disposable-like bonding interface that achieves the same stress-free mounting goal. The curable material system is simpler to manufacture and install, reducing both device complexity and manufacturing cost while effectively eliminating bending stresses through its compliant nature.
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 system minimizes mounting-induced forces, allows for precise alignment, and maintains optical alignment under thermal changes, reducing wavefront distortions and enabling robust, cost-effective assembly and replacement of optical components.
Implementation Method 1
a curable material deposited into the volume of space defined by the outer bonding surface of the stud and the inner bonding surface of the sleeve
Data Source
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AI summary
An optical mount and mounting system including an optical device, a housing, and a plurality of optical mounts that couple the optical device to the optical housing. Each mount includes a sleeve attached to the optical device and each sleeve includes a bore. Studs are attached to the optical housing and each stud includes an outer bonding surface extending through the bore of each sleeve. Once the optical device is aligned, a curable material is deposited into the sleeve and cured between the sleeve and the stud, such that the curable material couples the sleeve and the stud to each other to provide a robust structural joint that minimizes self-induced stresses into the optic. A series of annular conical portions and corresponding surfaces are provided to retain registration of the optical device against dynamic shearing and bending forces. A method of aligning and mounting an optical device is provided.