Solar Reflector Mirror Assembly With Adjustable Rigid Joining Elements
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Solution Overview
Problem
The existing methods for manufacturing mirror reflectors with mobile support structures face challenges in achieving high manufacturing tolerances without compromising the mechanical strength and optical properties, often requiring large glue blocks that can cause deformation and increase manufacturing complexity.
Innovation Solution
A method involving the use of rigid metallic or ceramic joining elements that are adjusted during the positioning process to secure the mirror to the support structure, eliminating the need for large glue blocks and allowing for higher manufacturing tolerances, improved mechanical strength, and enhanced optical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If large volume blocks of glue are used to compensate for high manufacturing tolerances, then the manufacturing precision requirement is relaxed, but the mechanical strength of the mirror on its structure deteriorates and local deformation occurs
Solution Approach 1:
The patent divides the connection system into multiple rigid joining elements distributed across the mirror surface, replacing a single large glue block. This segmentation allows each joining element to be small and rigid, maintaining mechanical strength while accommodating high manufacturing tolerances through the distributed arrangement.
Solution Approach 2:
The patent changes the material parameter from soft, deformable glue to rigid metallic or ceramic joining elements. This parameter change enables the use of high manufacturing tolerances without requiring large connection volumes, as the rigid material itself provides the necessary mechanical strength and dimensional stability.
2Ease of manufacture
If blocks of glue are heated to soften them for assembly, then the positioning step is enabled, but additional manufacturing constraints and residual shape defects are generated
Solution Approach 1:
The patent replaces the thermal field (heating) with a mechanical adjustment system. Rigid joining elements are mechanically positioned and adjusted during assembly without thermal softening, eliminating the harmful thermal effects that cause residual shape defects while maintaining ease of manufacture through mechanical adjustability.
3Manufacturing precision
If very low manufacturing tolerances are required for direct mirror contact with support structure, then the optical properties are maintained, but the manufacturing cost increases significantly
Solution Approach 1:
The patent introduces rigid joining elements as intermediary components between the mirror and support structure. These intermediaries absorb the manufacturing tolerance deviations, allowing the mirror and support structure to be manufactured with high tolerances while maintaining the necessary optical alignment and mechanical connection.
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3A~3C
AI summary
The invention relates to a method for manufacturing a reflector (6) including a mirror (16) supported by a support structure (18), said method including a step of positioning the mirror relative to the structure by means of the relative movement of a mold (30) supporting the mirror in relation to said structure. According to the invention, the method also includes a step of adjusting a plurality of elements (20) for linking the mirror and the structure together, said step being carried out during the mirror-positioning step and/or thereafter, and causing the movement of at least some of the linking elements relative to the structure (18).