Optically Measurable Mounting Structure for Precision Alignment
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Solution Overview
Problem
Existing semi-kinematic mounts face limitations due to errors in flatness and coplanarity of mounting pads, leading to misalignment and distortion in mounted objects, and mechanical measurement methods restrict tolerance and precision.
Innovation Solution
An optically measurable mounting structure with smooth, highly reflective surfaces on mounting pads and connecting surfaces, allowing for precise measurement using optical inspection systems like interferometers, enabling tighter tolerances and accurate alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical measurement methods are used to measure mounting pads, then the measurement process is simple and direct, but the measurement precision and manufacturing tolerances are limited
Solution Approach 1:
The patent replaces mechanical measurement methods with optical measurement methods. The mounting pads are equipped with optically measurable features (such as reflective surfaces or encoded patterns) that can be measured by optical instruments like interferometers or laser scanners. This substitution enables measurement precision beyond the limitations of mechanical contact measurement, achieving tighter tolerances without proportionally increasing device complexity.
Solution Approach 2:
The patent changes the measurement parameter from mechanical displacement to optical properties (such as light reflection, interference patterns, or laser time-of-flight). By transforming the physical quantity being measured, the system achieves higher precision. The mounting pads incorporate optical features that convert positional information into optical signals, enabling more accurate measurement of pad positions and orientations.
2Manufacturing precision
If tighter manufacturing tolerances are implemented for mounting pads, then alignment precision improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces mechanical measurement and alignment procedures with optical measurement systems. This allows for the verification and adjustment of mounting pad positions with sub-micron precision, enabling tighter manufacturing tolerances to be achieved and maintained. The optical measurement capability provides real-time feedback that guides the manufacturing process, making tight tolerances more achievable.
Solution Approach 2:
The patent incorporates optically measurable features directly into the mounting pad design during the manufacturing process. These features (such as reflective markers or encoded surfaces) are prepared in advance, allowing for precise measurement and adjustment before final assembly. This preliminary preparation of measurement references enables tighter tolerances to be built in during manufacturing rather than requiring costly post-processing adjustments.
3Reliability
If mechanical fasteners or restraints are used to secure mounted elements, then the mounting is secure and stable, but loads and torque from fasteners may affect the final position and optical figure of the mounted element
Solution Approach 1:
The patent separates the functions of mechanical support and precise positioning. The mounting structure is divided into support elements (that provide mechanical strength and stability) and precision positioning elements (the optically measurable mounting pads). This segmentation allows the support structure to bear loads and torques without compromising the positional accuracy of the mounting pads, as the pads are designed to be insensitive to such mechanical stresses.
Solution Approach 2:
The patent introduces optically measurable features as intermediaries between the mechanical mounting structure and the alignment verification process. These features serve as a buffer that decouples the mechanical stresses from the positional measurement. The measurable features are designed to maintain their geometric relationship to the mounting pads even under load, allowing accurate measurement without being affected by the mechanical fastening forces.
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 allows for tighter manufacturing tolerances and improved precision in aligning optical elements, reducing distortions and misalignment, and enabling faster, non-contact measurement without damaging softer materials.
Implementation Method 1
The connecting surface and mounting pads may be a highly reflective or mirror-like surface
Implementation Method 2
The surface may have an optical finish that can be analyzed with an optical inspection system, such as an interferometer
Data Source
AI summary
A mount between an optical element and a housing includes an optical element that has an optical element mount with plural optical element mounting pads and an optical element connecting surface that links the optical element mounting pads together. The housing includes a housing mount that has plural housing mounting pads and a housing connecting surface that links the housing mounting pads together. The optical element mount and the housing mount are mounted to one another such that the only contact between the optical element and the housing is between the mounting pads of each respective element.