Sintered Polycrystalline Diamond Mirror for Laser Scanning
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Solution Overview
Problem
Existing mirror technologies, such as those using highly oriented diamond, are expensive and complex to manufacture, and there is a need for improved diamond mirrors with higher stiffness and cost-effectiveness in laser systems and scanning applications.
Innovation Solution
The development of mirrors fabricated partially from sintered polycrystalline diamond (PCD) with a reflective surface, where the PCD body is sintered at high pressure and temperature, and optionally coated with reflective materials, providing high stiffness and low surface roughness for efficient electromagnetic energy reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If highly oriented diamond segments are joined together to obtain a larger planar surface area, then the mirror surface area is increased, but the manufacturing cost increases significantly
Solution Approach 1:
The patent combines multiple diamond segments into a single integrated mirror substrate using a bonding layer, eliminating the need for separate joining operations. This merging approach maintains the large surface area while reducing manufacturing complexity and cost compared to assembling multiple segments.
Solution Approach 2:
The patent uses a composite structure consisting of diamond segments bonded to a substrate through a bonding layer. This composite material approach allows the mirror to achieve large surface area with reduced cost by combining diamond's optical properties with a more cost-effective substrate material.
2Speed
If the mirror substrate is made thinner to reduce mass, then the speed and responsiveness improve, but the stiffness and structural integrity decrease
Solution Approach 1:
The patent employs a composite substrate structure that combines materials with different properties to achieve both thinness for speed and sufficient stiffness for structural integrity. The bonding layer and substrate combination provides the necessary mechanical strength while maintaining a thin overall profile.
Solution Approach 2:
The patent applies different material properties to different regions of the mirror substrate. The diamond segments provide local optical quality and stiffness where needed, while the bonding layer and substrate provide structural support, allowing the mirror to be thin overall while maintaining local strength where required for rapid response.
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 PCD mirrors offer enhanced stiffness and reduced material volume, enabling thinner designs with improved performance and cost-effectiveness in laser systems and other scanning applications, while maintaining high reflectivity and thermal properties.
Implementation Method 1
sintering a plurality of diamond particles in the presence of a material at a pressure of at least 4.0 GPa and a temperature of at least 1000° C. to form a sintered PCD body
Implementation Method 2
The reflective surface exhibits a surface roughness of less than about 50 nm Rms... configured to reflect electromagnetic energy
Data Source
AI summary
Mirrors for a deflection unit in a scanning system, scanning systems using such mirrors, and methods of manufacturing such mirrors are disclosed. In an embodiment, a mirror for a deflection unit in a laser system includes a sintered polycrystalline diamond body including a plurality of randomly oriented diamond grains defining a plurality of interstitial regions. At least a portion of the interstitial regions includes a material disposed interstitially therein. The mirror includes a reflective surface formed at least partially from the sintered polycrystalline diamond body or provided thereon. The reflective surface exhibits a surface roughness of less than about 50 nm Rrms.