胶合棱镜工艺.docx
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胶合棱镜工艺.docx
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胶合棱镜工艺
TheBondingofOpticalElements
TechniquesandTroubleshooting
by
SummersOptical
ADivisionofEMSAcquisition,Inc.
POBox380-1560IndustryRoad
Hatfield,PA19440
Tel#:
215-412-8380-Fax#:
215-412-8450
E-Mail:
SGKCCK@AOL.COM
Thiswritingisanattempttopreventmanyofthecommonerrorsandfailuresthatoccurwhenanopticianortechnicianbeginsbondingopticswithsyntheticadhesives.Inmanyplacestheexperiencedopticaltechnicianwillbestrainedtoendurewhattohimseemonlycommonsense.Intheseinstancespatienceisrequested.Itisexperiencethathaspromptedthiswriting.Manyduplicationsoferrorshaveoccurredovertheyearsbecausewhatwastakenforgrantedbysomewastotallynewandunexpectedbyothers.Thereisalsothechancethatthereareafewnewaspectstobelearnedbytheexperienced.Designersmayafterreading,beabletodesignoutsomeoftheproblemsmentionedbeforetheyreachthecementingdepartment.
InformationRequirements
Priorto1946opticalelementswerebondedwithpurified,filteredCanadabalsam.Balsamwaseasytoapplyandinmostcasesanopticallycompatiblebondingmediumexceptthatithadlittlethermalorsolventresistance.Thewarandadvancesinaviationunderlinedtheselimitationsandsoasyntheticresinadhesivewasdeveloped.Thisadhesiverequiredveryhightemperaturesandlongcuringtimes,soresearchwasconductedbyDRs.SourenSadjianandMarcoPetroniotodevelopaloworroomtemperature,catalystcuredadhesive.TheresearchwasdoneundertheauspicesoftheU.S.GovernmentattheFrankfordArsenalinPhiladelphia.Theresultofthatresearchwasatwocomponentpolyesterresinbasedcementthatmanyopticalcompaniesusetoday.
Sincethen,privateadhesivemanufacturershavedevelopedamyriadofpolyester,epoxyandurethanebasedsingleandtwocomponentadhesivesforbondingopticalelements.Alloftheseadhesivesaremorecomplexthanbalsamanddemandathoroughknowledgeofwhatthefinishedopticswillexperienceinordertochoosethecorrectone.Beforechoosing,thetechnicianmusttakeintoaccountphysicalaspectsoftheelementsaswellastheopticalpropertiesandtheenvironmentalconditionsthefinishedopticswillbeexpectedtowithstand.
Listedbelowissomebutperhapsnotalloftheinformationthatmustbeknowntocorrectlychoosetheadhesivetobondanopticalelement.
PHYSICAL
1.Dotheelementshavechamfers?
2.Depthandradiusofcurvature.
3.Willtherebepostcementingprocessing?
(CuttingorGrinding)
4.Typesofmaterialstobebonded.
5.Coefficientsofthermalexpansion.
6.Bondlineconfiguration.
7.Surfaceareavscementviscosity.
OPTICAL
1.Refractiveindicesoftheelements.
2.Transmissionoftheelements.
3.Toleranceofinternalreflectionandabsorption.
ENVIRONMENTAL
1.Workingtemperatureextremes.
2.MechanicalShockrequirements.
3.Chemicalresistancerequirements.
4.Pre-bondingchemicalandsubstanceexposure.
Alloftheitemslistedmustbeknownbythebondingtechnicianandperhapscommunicatedtotheadhesivemanufacturerinordertocorrectlychoosethecementtobeused.However,evenwiththisdone,witnesspiecesorsamplesoftheelementsshouldbetriedandtestedpriortoproduction.Itwillbemadeevidentinthefollowingsectionswhytheyareimportantandhowtheycanadverselyaffectthefinishedopticsifoverlooked.
Wewillfirstdiscussbondingasimplecrownandflintdoubletwithatwocomponentadhesiveinordertoestablishtheproperpreparationofthistypeofadhesiveandalsotoestablishatechniqueforapplyingacementwhetheritbeofthesingleortwocomponentvariety.Wewillalsodiscussthepreparationoftheelementsthemselves.AsectionisdevotedtoUVcuringadhesivestoshowtheiradvantagesaswellassomeoftheproblemsthatcanarisewiththeiruse.Becauseofthedifficultyintryingtoitemizeallpreventativemeasuresthatshouldbetakentoavoidbondfailures,asectiononbondfailuresthemselvesisdiscussedincludingthecausesandpreventativemeasures.Finallyanoverviewonperhapssomeoftheequipmentacementingdepartmentshouldhavetoinsuresuccessfulbonding.
Substrateand
CementPreparation
Correctpreparationisthekeytothesuccessfulbondingofopticalelements.Thoroughcleaningoftheelementsandcareful,accuratepreparationofthecementisabsolutelyessential.
Preparationof
theOptical
Elements
Thetwomajorconsiderationsinpreparingelementsforbondingarepropercleanlinessoftheelementsaswellastheequipmenttobeusedincementing,andorientingtheelementssothatthematchingsurfacesgotogetherthefirsttimewithouthavingtoremovetheupperelementbecauseitwasmistakenlyinvertedduringthefinalcleaningprocess.
Onecannotbondopticalelementsthatarenotclean.Residuesleftfromthe
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