Prism Ridge Flat Face Design for Breakage Prevention
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Solution Overview
Problem
Existing prism manufacturing methods, such as press molding, result in sharp ridges that are prone to breakage and chipping during handling and mounting, leading to low performance and yield in optical equipment.
Innovation Solution
A prism with a polygonal column shape, where at least one ridge is formed into a flat face and the joint parts between adjacent faces are R-planes, preventing breakage and chipping by facilitating accurate mounting and reducing the risk of damage during handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If press molding method is used to manufacture prism, then manufacturing efficiency is improved, but ridge strength deteriorates causing breakage and chipping
Solution Approach 1:
The invention applies preliminary action by forming the ridge into a flat face shape during the press molding process itself, rather than adding a separate chamfering step after molding. This preliminary structural modification prevents breakage and chipping from occurring in the first place, while maintaining the efficiency of the press molding method.
2Strength
If post treatment (chamfering) is added to prevent ridge breakage, then ridge strength is improved, but manufacturing complexity increases
Solution Approach 1:
The invention merges the ridge strengthening function into the primary press molding process by designing the mold to directly form the ridge as a flat face. This combines what would otherwise be separate operations (molding and chamfering) into a single integrated process, reducing manufacturing complexity while maintaining ridge strength.
3Manufacturing precision
If ridges are kept sharp for precision, then manufacturing precision is improved, but reliability deteriorates due to breakage risk
Solution Approach 1:
The invention applies local quality by modifying only the ridge region into a flat face shape, while keeping the rest of the prism surfaces sharp and precise. This localized modification provides the strength needed to prevent breakage at the vulnerable ridge area without compromising the overall manufacturing precision and optical quality of the prism.
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 solution effectively prevents breakage and chipping of the prism, ensuring high-quality performance and accurate positioning in optical equipment, while also allowing for compact and high-strength designs with improved optical characteristics.
Implementation Method 1
The prism body is arranged so that incident light to the prism body is reflected by the inclined side face toward the light receiving element
Implementation Method 2
a generally-called press molding method is known in which a material to be molded is heated and pressed and then is cooled
Implementation Method 3
a generally-called press molding method is known in which a material to be molded is heated and pressed and then is cooled
Implementation Method 4
a generally-called press molding method is known in which a material to be molded is heated and pressed and then is cooled
Data Source
AI summary
A prism 30 includes a prism body 31 formed into a polygonal column. At least one ridge 35 of a plurality of ridges 35 of the prism body 31 is formed into a flat face 37. A joint part 38 between the flat face 37 and at least one 32, 33 of the faces 32, 33 of the prism body 31 which are adjacent to each other with the ridge 35 in the flat face 37 interposed is formed into an R-plane.