Polymer Pin Optical Mount Assembly for Shock-Stable Alignment
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Solution Overview
Problem
Existing optical mounts face challenges with stability under shock and vibration due to competing parameters of stiffness and adjustment resolution, and they inadequately conduct heat, especially in High Energy Laser applications.
Innovation Solution
The use of a polymer pin assembly with cap and cup members, ball bearings, and a rod member, where a polymer material like epoxy is applied between articulated surfaces to 'freeze' the optical mount in place, allowing for removal of adjustment screws and springs, thereby reducing weight and enhancing stiffness and stability independently of adjustment resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spring force is increased to improve stability under shock and vibration, then the optical mount can tolerate larger accelerations without dislodging the mirror cell, but the adjustment screws experience large thread stresses that can strip the threads
Solution Approach 1:
The invention divides the support function into two independent systems: springs provide shock/vibration support while adjustment screws provide precise positioning. This segmentation allows each component to be optimized for its specific function without compromising the other.
Solution Approach 2:
The adjustment screws are used to pre-position the optical element to the desired alignment before the mount is finalized. This preliminary action completes the alignment task before high spring forces are applied, preventing thread stripping during operation.
2Reliability
If spring force is increased to improve stability, then larger accelerations can be tolerated, but fine pitch adjustment screws required for high-resolution adjustments exhibit large thread stresses
Solution Approach 1:
The support function is divided into two independent systems: springs provide shock/vibration support while adjustment screws provide precise positioning. This segmentation allows each component to be optimized for its specific function without compromising the other.
Solution Approach 2:
The adjustment screws are used to pre-position the optical element to the desired alignment before the mount is finalized. This preliminary action completes the alignment task before high spring forces are applied, preventing thread stripping during operation.
3Weight of moving object
If adjustment screws and springs are removed after freezing the optical mount in place, then the structural mass and weight of the optical mount are reduced, but the mount requires a polymer material application process
Solution Approach 1:
The polymer material undergoes a parameter change from liquid to solid state through curing. This transformation allows the material to be injected in a fluid state to fill cavities and bond surfaces, then transforms to a rigid state to provide structural support after the adjustment screws and springs are removed.
Solution Approach 2:
The polymer material acts as an intermediary that temporarily holds the optical element in position during adjustment, then becomes a permanent structural component. It mediates between the need for adjustable components during assembly and the need for a lightweight structure in final operation.
4Temperature
If heat conduction path cross-sectional area is increased to improve heat conduction from the optical lens, then heat transfer rate increases, but the mount structure becomes more complex
Solution Approach 1:
The polymer pin assembly serves multiple functions simultaneously: it provides mechanical support for the optical element, enables heat conduction from the lens to the mount, and maintains structural integrity. This multi-functionality eliminates the need for separate dedicated heat conduction components.
Solution Approach 2:
The support and heat conduction functions are merged into a single integrated polymer pin assembly. The same structural components that provide mechanical support also serve as heat conduction paths, eliminating the need for separate heat sinking components.
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 solution results in an optical mount with very low mass, high stiffness, and stability that does not change under shock or vibration, with improved heat conduction and adjustment resolution, suitable for weight-constrained environments.
Implementation Method 1
a polymer material applied to interior portions of the cap members and applied to interior portions of the cup members after the polymer pin assembly is mounted to the optical mount
Implementation Method 2
two cup members, each cup member being coupled to each respective cap member. The assembly further comprises two ball bearing members, each ball bearing member being disposed within each respective cup member
Implementation Method 3
The rate of conduction heat transfer is proportional to the cross-sectional area of the conduction path. In known optical mounts, the only available conduction path is typically through the springs and the adjustment screws
Data Source
AI summary
There is provided in one embodiment a polymer pin assembly for an optical mount. The assembly comprises two cap members, each cap member having a through opening. The assembly further comprises two cup members, each cup member being coupled to each respective cap member. The assembly further comprises two ball bearing members, each ball bearing member being disposed within each respective cup member. The assembly further comprises a rod member inserted through each cap member and coupled to each ball bearing member. The assembly further comprises a polymer material applied to interior portions of the cap members and applied to interior portions of the cup members after the polymer pin assembly is mounted to the optical mount.