Passive Optical Alignment Compensation Using a Material Sample

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Solution Overview

Problem

Alignment-critical systems, such as EO systems, suffer from performance errors due to movement of their components caused by thermal changes, hygroscopic shrinkage, and material-related growth, which are typically compensated by expensive and complex electronically controlled motors and actuators.

Innovation Solution

A passive displacement compensator is used to maintain alignment by applying pushing or pulling forces on optical components in response to material changes, compensating for variations in the support structure's geometric dimensions, eliminating the need for active motor and actuator systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If electronically controlled motors and actuators are used to compensate for component movement, then alignment precision is improved, but device complexity and cost increase

Engineering Contradiction:

Improvealignment precisionVSAvoiddevice complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces electronically controlled motors and actuators with a passive mechanical compensation system. The support structure itself is designed to mechanically compensate for dimensional changes through its inherent properties, eliminating the need for active electronic control systems while maintaining alignment precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The support structure is designed to automatically compensate for component movement caused by thermal changes and other environmental factors. The system serves itself by using the support structure's material properties and geometric design to maintain alignment without requiring external electronic control or active intervention.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If electronically controlled motors and actuators are used to compensate for component movement, then alignment precision is improved, but cost increases

Engineering Contradiction:

Improvealignment precisionVSAvoidcost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent replaces expensive electronically controlled motors and actuators with a cost-effective passive mechanical compensation system. The support structure is designed to inherently compensate for dimensional changes, eliminating the need for costly electronic components while maintaining alignment precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses a simple, inexpensive support structure design that provides alignment compensation through its inherent mechanical properties rather than relying on expensive electronic components. This approach reduces manufacturing cost while achieving the desired alignment precision.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Stability of the object's composition

If the support structure material is made stable against environmental changes, then dimensional stability is improved, but adaptability to environmental conditions worsens

Engineering Contradiction:

Improvedimensional stabilityVSAvoidadaptability to environmental changes

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent deliberately designs the support structure to utilize thermal expansion and other environmental-responsive material properties. Rather than using materials that resist environmental changes, the support structure is configured to adaptively compensate for dimensional changes caused by thermal changes, humidity, and other environmental factors, transforming potential instability into a useful compensation mechanism.

Inventive Principle:

Principle #37Thermal expansion

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 approach provides stable and consistent system focus without requiring periodic recalibration, ensuring high-quality data output by maintaining optical component alignment despite environmental changes.

Implementation Method 1

thermal changes growing/shrinking hardware

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

composites 'drying out' (hygroscopic shrinkage)

Methodology Applied

Scientific EffectHygroscopic shrinkage: Absorption (physical)

Data Source

PatentUS20260003152A1Passive actuation to correct for error contributors in an alignment-critical system through use of a sample material

Publication Date: 2026.01.01 EAGLE TECHNOLOGY LLC

AI summary

Systems and methods for operating a system. The systems comprise: at least two optical components; a support structure configured to structurally support the at least two optical components in a spaced apart arrangement (the support structure comprising a material having at least one geometric dimension that varies throughout a lifespan of the system); and a displacement compensator disposed between the support structure and at least one optical component of the at least two optical components, and configured to passively and/or actively maintain an alignment of the at least two optical components, despite variations of the at least one geometric dimension of the support structure; wherein the displacement compensator is configured to apply pushing forces or pulling forces on the optical component(s) responsive to physical changes of a material sample formed of a same material as the support structure.