Spherical Optical Mount for Precision Alignment
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Solution Overview
Problem
Current optical component mounting techniques for concentric optical systems require complex and costly precision alignment with multiple degrees of freedom, often involving specialized equipment and being prone to issues like decentration and tilt, which can misalign optical components and affect performance, especially under temperature variations.
Innovation Solution
An optical mount with spherical mating surfaces that extend beyond the usable aperture of the primary optical element, allowing for five degrees of freedom adjustment and adhesive bonding without additional bond-gap tolerance, using single-point diamond turning for precise fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional spider support with machined flanges and pilot diameters is used for mounting secondary mirror, then alignment precision can be achieved, but manufacturing complexity and cost increase due to special measurement equipment and tolerance requirements
Solution Approach 1:
The patent replaces traditional flat machined flanges and pilot diameters with spherical seating surfaces. The secondary mirror mount features a spherical seating surface that interfaces with a corresponding spherical surface on the primary mirror, eliminating the need for complex machining and special measurement equipment while maintaining precise alignment through the natural geometry of spherical contacts.
Solution Approach 2:
The spherical seating surfaces are designed to self-align during assembly. The curvature of the spherical surfaces automatically guides the secondary mirror into the correct position relative to the primary mirror, eliminating the need for technician adjustment and specialized alignment equipment while ensuring repeatable precision.
2Ease of operation
If adjustment mechanisms and fasteners are used for optical component alignment, then centering and tilt adjustment capability is provided, but parasitic motion and alignment instability occur
Solution Approach 1:
The patent removes traditional adjustment mechanisms and fasteners from the optical mounting system. Instead of providing adjustable components, the design uses fixed spherical seating surfaces that provide permanent, stable alignment. The spherical geometry inherently provides the necessary degrees of freedom for alignment while eliminating movable parts that could introduce parasitic motion.
3Ease of manufacture
If conventional mounting methods are used for concentric optical components, then component mounting is achieved, but centering and tilt alignment require trained technicians and interferometer instrumentation
Solution Approach 1:
The spherical seating surfaces provide inherent alignment guidance through their geometry. The secondary mirror naturally seats on the spherical surface of the primary mirror at the correct concentric position, eliminating the need for interferometer measurements and technician expertise. The spherical geometry encodes the alignment information directly in the physical form.
Solution Approach 2:
The mounting system is designed to be self-aligning during assembly. The spherical interfaces automatically guide the components into proper alignment without requiring external measurement equipment or skilled operators, making the manufacturing process simpler and more accessible.
4Manufacturing precision
If fasteners and adjustment mechanisms are used for device alignment, then alignment is achieved, but thermal expansion differences jeopardize alignment under temperature extremes
Solution Approach 1:
The patent eliminates fasteners and adjustment mechanisms that would be susceptible to thermal expansion effects. By using a fastenerless mounting system with spherical seating surfaces, the design removes the components most vulnerable to temperature-induced dimensional changes, thereby maintaining alignment stability under thermal extremes.
Data Source
AI summary
An optical apparatus has a primary optical element having a primary spherical optical surface with a primary center of curvature, wherein the primary spherical optical surface has a peripheral portion that extends outside a usable aperture of the optical apparatus, and a secondary optical element. A mount suspends the secondary optical element spaced apart from the primary optical element, wherein the mount comprises a number of leg sections, each leg section extending between the primary and secondary optical elements. Each leg section terminates in a spherical mating surface that rests against the peripheral portion of the primary optical element. The spherical mating surface has a mating surface center of curvature that is substantially concentric with the primary center of curvature.