Optically Contacting Scale Bonding for Carrier Attachment
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Solution Overview
Problem
Direct bonding of scales to carriers is prone to disturbances from impurities and air bubbles, requiring precise even joining surfaces, which is challenging especially for large-area scales, limiting its acceptance for highly accurate position measuring.
Innovation Solution
The method involves creating an optically contacting bond between the scale and carrier at multiple spaced surface regions with projections, allowing for local separation and using an adhesive joint to enhance retention, while channels facilitate media escape and capillary action introduces adhesive agent for additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If direct bonding is used to attach the scale to the carrier, then strong bonding is achieved, but the connection is easily disturbed by impurities or air bubbles and requires very even joining surfaces
Solution Approach 1:
The patent divides the bonding interface into multiple discrete optical contacting points instead of a continuous large-area bond. This segmentation allows local failures at individual points without compromising the overall bonding reliability, while still achieving strong cumulative bonding strength across multiple contact regions.
Solution Approach 2:
The patent creates different surface regions with distinct functions: some regions are optimized for optical contacting (high flatness, clean surfaces) while other regions serve as channels for impurity removal. This local differentiation allows each region to perform its specific function optimally without compromising the other.
2Area of stationary object
If large-area scales are used for position measuring, then measurement range is improved, but the risk of contamination and bonding failures increases
Solution Approach 1:
By segmenting the large-area scale into multiple smaller optical contacting regions, the patent maintains bonding reliability across the entire large area. Each small contact region is less susceptible to contamination, and failures in one region do not propagate to other regions, ensuring overall system reliability.
Solution Approach 2:
The patent extracts and removes harmful factors (impurities, air bubbles) through dedicated channel regions that are separated from the bonding surfaces. This active removal process prevents contamination from compromising the bonding reliability of large-area scales.
3Reliability
If optically contacting bond surfaces are separated by channels, then local separation due to contamination is limited, but the complexity of the bonding structure increases
Solution Approach 1:
The channel structures serve multiple functions: they act as separation barriers between bonding regions, provide pathways for impurity and bubble removal, and potentially serve as alignment features. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in overall structural complexity.
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 minimizes separation due to contamination, maintains flatness, and provides strong bonding with reduced risk of material splintering, achieving precise and stable attachment suitable for large-area scales in position measuring applications.
Implementation Method 1
producing an optically contacting bond between the scale and the carrier at a plurality of surface regions
Implementation Method 2
capillary action introduces adhesive agent for additional support
Implementation Method 3
disruptive media may escape through the at least one channel leading to the outside
Data Source
AI summary
A scale is attached to a carrier by optically contacting. The optically contacting bonds are formed by raised surface regions of the scale set apart from each other. Additional measures, such as the provision of adhesive surfaces, provide a rigid and vibration-resistant joint.