Optical Component Mounting System with Segmented Pads
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Solution Overview
Problem
Existing optical component mounting systems, such as those for lasers used in ophthalmic procedures, face challenges in maintaining precise alignment and stability due to external factors like temperature, humidity, and vibration, leading to directional drift and misalignment.
Innovation Solution
An optical component mounting system comprising a stack of components with at least three mounting pads providing direct support and adhesive for secure attachment, allowing for precise alignment and stabilization of optical components like laser diodes, beam splitters, and mirrors, using a method that involves curing the adhesive above the expected operating temperature range to ensure stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is used to bond optical components, then components can be securely attached, but alignment stability deteriorates due to thermal expansion and environmental factors causing directional drift
Solution Approach 1:
The bonding interface is segmented into multiple discrete mounting pads (at least three) distributed across the component surface. This segmentation allows each pad to independently bond to the substrate, distributing thermal and mechanical stresses. The segmented structure prevents uniform expansion/contraction that would cause misalignment, while maintaining strong overall bonding through multiple attachment points.
Solution Approach 2:
The mounting pads are designed with specific local properties: they are positioned at strategic locations (at least three non-collinear points) to provide stable triangular support, and their size/shape is optimized for both bonding strength and thermal management. This local quality enhancement at critical bonding points ensures alignment stability without compromising overall bond strength.
2Manufacturing precision
If mounting pads are added to provide direct support, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The mounting pads are merged with the bonding substrate as an integrated structure rather than separate components. The pads are formed directly on the substrate surface, eliminating the need for separate mounting fixtures or complex assembly procedures. This merging achieves high alignment precision through precise pad positioning while keeping the overall device structure simple and manufacturable.
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 effectively maintains the stability of optical components, preventing directional drift and ensuring precise alignment, even under varying environmental conditions, by providing three-point contact and secure adhesion, thus enhancing the reliability of ophthalmic laser systems.
Implementation Method 1
adhesive between the first surface of the first component and the second surface of the second component adhering the first component and the second component together
Data Source
AI summary
Devices and methods are disclosed for an optical component mounting system for supporting an optical component such as a laser. The mounting system comprises a first component comprising a first surface, a second component comprising a second surface facing the first surface, and adhesive between the first surface of the first component and the second surface of the second component, wherein the first component comprises at least three mounting pads extending from the first surface for contacting the second surface of the second component and providing direct support between the first component and the second component. The component comprising the mounting pads may be a lower mount, an upper mount such as an upper clamping mount, or a bonding pad or other component in the stack of components. A method of assembling the stack of components may comprise curing the adhesive at a temperature at or above an upper end of an expected temperature operating range for the optical component mounting system.