Optical Wedge Assembly via Adhesive Bonding and Indexing
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Solution Overview
Problem
Current prism manufacturing methods are limited by high production costs and inability to achieve precision tolerances below 15 arc seconds, making it impractical to produce high-precision optical wedges and prisms in commercially viable volumes.
Innovation Solution
A method involving the production of pairs of low-cost prisms, indexing, and adhesive bonding to achieve precise angles, allowing for the creation of optical wedge or prism assemblies with tolerances less than 15 arc seconds at reduced costs and increased production volumes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional single-prism production methods are used, then manufacturing precision can reach 1.5 arc minutes, but production cost increases and precision below 15 arc seconds cannot be achieved
Solution Approach 1:
The invention divides a single high-precision prism into multiple lower-precision prism components (first prism wedge and second prism wedge) that are assembled together. Each component can be manufactured with standard 1.5 arc minute tolerance, but when assembled with precise indexing, the final assembly achieves sub-15 arc second precision. This segmentation allows high precision without requiring expensive single-prism manufacturing processes.
Solution Approach 2:
The invention introduces an adhesive bonding process as an intermediary step between prism component fabrication and final assembly. The adhesive not only joins the components but also allows for precise positioning and indexing during curing, enabling sub-15 arc second precision to be achieved through the bonding process itself rather than requiring ultra-precise machining of individual components.
2Productivity
If traditional single-prism production methods are used, then production volume is limited, but precision below 15 arc seconds cannot be achieved
Solution Approach 1:
By segmenting the prism into multiple manufacturable components that can be produced through standard processes, the invention enables higher production volumes. Each component can be manufactured using conventional techniques with 1.5 arc minute tolerance, allowing parallel production and assembly, thus increasing overall productivity while achieving sub-15 arc second precision in the final assembly.
Solution Approach 2:
The invention changes the precision requirement parameter from individual component level to assembly level. Instead of requiring each prism component to be manufactured at sub-15 arc second precision (which limits production), the system allows components at 1.5 arc minute precision and achieves sub-15 arc second precision through assembly indexing and adhesive bonding parameters, thereby enabling higher production volumes.
3Manufacturing precision
If tooling precision is increased 16.8× to produce 5 arc second prisms, then manufacturing precision improves, but tooling cost and complexity increase significantly
Solution Approach 1:
The invention segments the precision requirement across multiple components and assembly steps rather than concentrating it in a single tooling system. Standard tooling with 1.5 arc minute precision can manufacture each component, and the final sub-15 arc second precision is achieved through cumulative assembly and indexing processes, avoiding the need for extremely precise (16.8× more precise) single-step tooling.
Solution Approach 2:
The invention performs preliminary actions of indexing and positioning prism components during the adhesive bonding process before final curing. This preliminary indexing establishes the precise sub-15 arc second geometry early in assembly, allowing standard tooling to be used for component fabrication while achieving high precision through carefully controlled assembly operations rather than requiring ultra-precise production tooling.
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
This method enables the production of precision optical wedges and prisms at significantly lower costs, with reduced skilled labor requirements, higher yields, and increased production outputs, making previously unfeasible components available for existing and new markets.
Implementation Method 1
applying an adhesive to adjacent wedge surfaces of the aligned prism wedges
Data Source
AI summary
A method for producing an optical wedge or prism assembly, including identifying a first prism wedge and a second prism wedge, wherein the first prism wedge includes at least one wedge surface and wherein the second prism wedge includes a wedge surface; indexing the first prism wedge and the second prism wedge such that wedge surfaces of the first prism wedge and the second prism wedge are adjacent to one another; applying an adhesive to adjacent wedge surfaces of the aligned prism wedges; manipulating at least one of the prism wedges relative to the other prism wedge to obtain a desired angle between the outer surfaces of the prism wedges; and allowing the adhesive to cure.