SOL-GEL COATING FACILITY CONCEPTUAL DESIGN REVIEW

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SOL-GEL COATING FACILITY CONCEPTUAL DESIGN
REVIEW

• October 19, 2005

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Purpose

• Develop the ability to dip coat large optics with
  sol-gel solution in conjunction with our vacuum
  coating facility.
• Design parameters.
• Maximum size optic 44 diameter, 4 thick, 4,600
  cu. in. volume (44 dia X 3 thick)
• Ability to vacuum coat than sol-gel coat in a
  clean environment
• Initial sol solution TEOS, provide for an
  additional solution type
• Locate facility in upper astronomy shop optics
  lab.
• Initial Goal
• Coat ADC prisms with MgF2 and Sol-gel
• ADC prisms are 41 dia. wedges approx 7/8 X 2
  7//8 thick

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DESIGN

• Dip coat facility in clean room environment
• Optic handling equipment for ADC optics.
• Handling equipment optic specific in general
• Interface with vacuum tank facility

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CLEAN ROOM

• Erect clean room in optics lab to include vacuum
  Sol-gel coating
• Initial quote for a 25 X 25 X 8class 1000 room
  including HEPA filters fans 16,000

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ADC OPTIC HANDLING
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ADC OPTIC HANDLING

• Use a frame with Teflon pads instead of band
  strap
• A U-shaped frame with interchangeable upper cross
  members
• One for general lifting turning optic over
• One for Sol-gel dip
• One for hardening (not shown)
• Optic restraint for general lifting turning
  over is provided by 4 U shaped Teflon pads
• Optic constraint for Sol-gel dip is provided by 3
  U shaped Teflon pads
• Might be able to support optic by bevels with
  flat part of U being for safety

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Transport between stations on cart with 4 swivel
wheels
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• Uprights (Item 3) slide into frame channels,
  bottom frame channel sets on beam
• This supports optic vertically to move around and
  to change top bars
• Bottom of cart is generic for most large optics
• Uprights are specific to ADC optic
• Remove frame for vacuum coating
• Load into vacuum chamber with stand used
  for previous coating
• Revise mounting in vacuum tank to work
  without band used last time
• Sol-gel fixture is equipped with a ½ ton crane
  and trolley on a beam
• Garment supplier can provide fabric covers
  for hoists
• To load optic into Sol-gel fixture
• Push optic into enclosure on cart
• Lift optic with ½ ton crane
• Roll trolley back to lift fixture
• Lower optic onto lift fixture

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SOL-GEL FIXTURE
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SOL-GEL FIXTURE

• Two dip tanks and a cleaning station
• Dip tanks 54 X 8 X 50 high, inside
• Sides supported by steel frame (not shown)
• Lid opens in 2 halves with shield at ends to
  provide extension of vapor height to 6
• Pneumatic opener on lid to operate remotely
• Stainless steel or polypropylene (poly quote
  940)
• Cleaning station design TBD
• Include CO2 snow and N2 blow off, operated
  remotely

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• Compensator to hold Sol-gel level constant in dip
  tank
• Provides constant vapor height in dip tank
• Prevents plating of tank sides
• Connection to tank 1 dia. Teflon tube
• Overflow to be provided on sol-gel tank in
  case of compensator malfunction
• (volume to compensator volume)
• Tanks compensator mounted on a carriage
• Moves from position shown to Sol-gel dip
  position
• Steel rollers
• Manual drive with stops for positive
  location
• Lift mechanism to raise lower optic at
  programmed rates
• Single ball screw 2 ball slides almost
  identical to ADC mechanism
• Ball Screw 40 mm dia. by 5 mm pitch NSK
• Bayside 101 gearbox
• Pitman motor driven by Galil controller
• Encoder on motor
• NSK quote for ball screw and ball slides
  5,000
• (not including end bearing mounts for
  ball screw)

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• Hoist hoist beam to load optic onto lift
  mechanism
• Structure mounted on vibration isolators TBD
• Probably Barry mounts (same as profilometer)
• Base vibration requirement on size of
  meniscus photographed
• while pulling microscope slide in NC mill

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COMPENSATOR
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COMPENSATOR

• Shown as stainless steel, quote on 20 X 12 X ¾
  wall dia. polypropylene tube 600
• Volume to be 21 gal. Min.
• Height not above top of fluid level in tank
• NSK ball slide and ball screw quote 4,600 (not
  including end bearings)
• Ball screw 32 mm dia X 5 mm pitch
• Ball nut held stationary at top of cylinder
• Ball screw and motor / gearbox move up down
  guided by ball slide
• Additional rod to prevent piston rotation
• Bayside gearbox and Pitman motor controlled by
  Galil controller
• Bleed in piston not shown
• Piston relieved at end to allow it to go to
  bottom of tank without restricting output

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STRUCTURE

• Steel weldment
• Start with Deimos rails
• Epoxy paint

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ENCLOSURE

• 2 X 2 X 1/8 wall steel tube welded frame
• Clad with 1/8 thick plexiglass
• ¼thick plexiglass doors on front, open from
  center
• HEPA filters fans on side near top

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HARDENING / HMDS TANK

• Use existing tank
• Improve insulation
• Load optic from cart under overhead crane

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SOFTWARE

• Control for 2 stage axis
• One on lift mechanism requires lift and constant
  rate
• One on compensator has varying rate depending on
  optic geometry