Optical Resonator Assembly with Aligned Contact and Laser Welding
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Solution Overview
Problem
Existing methods for assembling optical resonators, such as optical contacting and ultrashort-pulse laser welding, face challenges in achieving reliable connections that withstand environmental stresses and allow miniaturization, particularly under aerospace conditions, due to low resistance to climatic loads, thermal shock, and mechanical stresses, and the inability to join components with different surface shapes.
Innovation Solution
A multi-step process involving cleaning and optical contacting of mirrors and a spacer, followed by provisional alignment and verification, and then permanent bonding using ultrashort-pulse laser welding, where the laser beam is focused on the interface formed by optical contacting to create a strong, stable connection without additional pressure tools, allowing for the formation of annular or spatially limited weld paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If optical contacting is used to join mirrors and spacer, then the connection is formed without additional connecting materials, but the resistance to climatic loads, thermal shock, and mechanical stresses is low
Solution Approach 1:
The patent combines optical contacting and laser welding into a single integrated process. The optical contacting provides initial alignment and positioning, while the laser welding subsequently creates a permanent, stress-resistant bond. This merging of two joining methods resolves the contradiction by maintaining the material-free advantage of optical contacting while adding the environmental resistance of laser welding.
Solution Approach 2:
The patent applies preliminary optical contacting to achieve precise alignment and positioning of the mirrors on the spacer before performing the final laser welding. This preliminary action ensures that the components are correctly positioned and aligned before the permanent bond is formed, resolving the contradiction by separating the alignment function (optical contacting) from the bonding function (laser welding).
2Strength
If ultrashort-pulse laser welding is used to permanently bond components, then the connection strength and stability are high, but the process complexity increases due to multiple steps required
Solution Approach 1:
The patent merges optical contacting and laser welding into a single integrated process flow. The optical contacting and laser welding are performed in sequence without removing or repositioning the components, which simplifies the overall process despite using multiple joining methods. This merging approach maintains high connection strength while minimizing process complexity.
Solution Approach 2:
The optical contacting step serves a dual function: it provides the preliminary bonding needed for alignment and also creates the interface that facilitates subsequent laser welding. The initial optical contact prepares the surfaces for the laser welding process, reducing the need for additional preparation steps and simplifying the overall process.
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 process ensures high mechanical strength and stability, maintaining high finesse and resistance to environmental stresses, enabling miniaturization of optical resonator components while ensuring the connection is irreversible and maintains the initial alignment state.
Implementation Method 1
The at least two mirrors are optically contacted by their joining regions to the joining surfaces so as to form an interface
Implementation Method 2
permanently joining the joining regions to the joining surfaces by laser welding with a laser beam of an ultrashort-pulse laser
Implementation Method 3
permanently joining the joining regions to the joining surfaces by laser welding with a laser beam of an ultrashort-pulse laser
Data Source
AI summary
A multiple-step process for assembling and joining an optical resonator and to an optical resonator. With the process according to the invention, the mirrors of a resonator are connected to the spacer thereof after being aligned relative to one another by optical contacting via a provisional connection in which the aligned position is fixed. After checking the resonator, the provisional connection is fixed conclusively by laser welding or the provisional connection is disconnected and after aligning once again is optically contacted and checked again.