Three-dimensional universal mounting component system for optical breadboards

A three-dimensional Universal Mounting Component (UMC) system of UMC blocks provides general mounting for use in optical research in constructing layouts for experiments and breadboard-type prototypes. In such optical layouts laser beams or other light beams are directed about complex paths, often on several planes or levels. Use of the invention overcomes the problem of creating three-dimensional optical layouts with less standardized, and much more expensive, mounting adapters and posts. An economical, standardized set of UMC blocks, each with a number of holes in grid configurations, enables users to construct custom three-dimensional optical layouts. Each UMC block is a right rectangular solid of substantial standardized thickness sufficient to support it on edge. Each UMC block has a set of smooth counterbored holes from front to back and has another set of such holes from back to front. These holes allow the UMC blocks to be bolted to each other and to optical breadboards with full recessing of mounting bolts for flush connections. Each UMC block also has a set of tapped holes extending through from front to back to accommodate the direct mounting of optical components. Each UMC block also has at least one set of tapped edge holes for accepting connecting bolts in L- and T-configurations to matching counterbored holes in another appropriately sized UMC block.

TECHNICAL FIELD 
This invention relates to optical table auxiliary hardware, and, more 
particularly, relates to a three-dimensional universal mounting component 
system for optical breadboards. 
BACKGROUND ART 
Optical tables are well-known in optical research as bases for building up 
optical setups for experiments and breadboard-type prototype constructions 
using laser beams or other light beams, which must be precisely controlled 
or steered around complex paths. Such optical tables resemble oversize 
billiard tables, with steel tops having a regular grid pattern of tapped 
holes. Optical tables or benches are manufactured by various producers, 
and optical components from various manufacturers can be mounted to these 
tables because the hole patterns have been standardized. The inch or 
"standard" optical table features an array of 1/4-inch Unified Coarse 
Series threaded holes (1/4-20 UNC-2B) on 1-inch (25.4 mm) centers. The 
metric optical table, on the other hand, features M6 threaded holes on 25 
mm centers. Although the hole dimensions for these two systems are very 
close (25.4 mm versus 25.0 mm), and 1/4-20 threads are very close to the 
metric M6 standard, the two systems are generally incompatible and 
mounting hardware must thus be designed for either one or the other, or 
adapter plates must be used. 
It is often convenient to have subassemblies of complex optical layouts 
mounted on smaller breadboards. Smaller, auxiliary tapped-hole breadboard 
plates may be used for such purposes. These smaller plates also may be 
mounted to the optical table as an extension or as a higher surface plane, 
to carry additional auxiliary hardware. (The terminology "breadboard" is 
used for both optical table and auxiliary mounting plates.) Optical 
components interface with the breadboard through their mounts by having 
their mountings provided with 1/4 inch holes (6 mm holes for metric 
systems) on integral inch (or 25 mm) unit intervals, or by a commonly used 
system of stand-off posts and post-holders. Socket head cap screws are 
most commonly used to securely bolt these components to the breadboards. A 
socket head cap screw has a hex socket in its cylindrical, flat-bottomed 
head and provides good lock-down when passed through a counter-bored hole 
or slot and threaded into a tapped hole. 
Optical researchers in the United States have widely accepted breadboard 
arrays of 1/4-20 UNC tapped holes on 1 inch centers as the de facto 
standard; but metric arrays are also sometimes used. Most optical 
component and mount manufacturers design their products to mount directly 
to one of these standard breadboards. Since these breadboards are 
essentially two-dimensional, less standardized and more expensive 
right-angle adapters must be used to create three-dimensional or 
multilayer optical layouts. These adapters are usually machined castings, 
which are considerably more expensive than the essentially two-dimensional 
mounting plates and posts. Thus, while current methods of mounting optical 
components work satisfactorily, their disadvantages include high cost and 
insufficient standardization of mounting hardware. 
The need has been long felt for a more standardized and economical way of 
building three-dimensional optical layouts. As described above, this need 
stems from: 
the convenience of mounting subassemblies of complex optical layouts on 
smaller breadboards; 
the need for mounting optical components and hardware at right angles or at 
different heights; 
the expense of maintaining an inventory of specialized hardware; 
the need for greater functionality of mounting hardware at reduced cost. 
DISCLOSURE OF INVENTION 
It is the object of the invention to provide a novel set of universal 
mounting component (UMC) blocks which are inexpensive and easily assembled 
into a great number of three-dimensional configurations. 
Another object of the invention is to eliminate the need to purchase and 
store a large number of more specialized items of mounting hardware in 
favor of universal mounting component (UMC) blocks. 
A feature of the invention is the use of rectangular blocks of metal with a 
minimum number of tapped or counter-bored holes, to provide an optimum 
cost/functionality ratio. 
Another feature of the invention is the use of a single thickness of block 
for components regardless of size. 
An advantage of the invention is the versatility of the new components: 
numerous three-dimensional mounting configurations can be quickly realized 
with a set of basic universal mounting components. 
Another advantage of the invention is that it significantly reduces the 
need for different right-angle mounting fixtures. 
Other objects, features and advantages of the invention will be apparent 
from the following written description, claims, abstract and the annexed 
drawings.

BEST MODE FOR CARRYING OUT THE INVENTION 
This invention allows for the construction of three-dimensional optical 
layouts using standard mounting breadboards as the base. It minimizes the 
need for expensive right angle brackets, pedestals and posts for most 
applications by employing a small number of universal mounting component 
(UMC) blocks which can be mounted to standard breadboards, and to each 
other, either lying flat or standing on edge. Such edge mounting is 
facilitated by two appropriately tapped holes in one side of each UMC 
block. Other holes, on both front and back of each UMC block, are 
counter-bored to allow for mounting in any of several orientations without 
the problem of obtruding bolt heads. It is this arrangement of edge holes 
and oppositely counter-bored holes which makes the UMC block system so 
versatile. 
FIGS. 1 and 2 show the design and function of the smallest component of the 
set of eight UMC blocks. (The entire system is shown in FIG. 3.) The front 
4, left 5, and back 6 of the 2.times.2 UMC block are shown. The 2.times.2 
UMC block is preferably anodized aluminum, but may be of other suitable 
material, and has the following holes located on chosen intersections of a 
quarter-unit grid (where the unit is either one inch for standard or 25 mm 
for metric) on the front, back and at least one edge, as follows: 
a) two counter-bored holes dimensioned to accommodate standard 1/4-20 
socket head cap screws from the front 7; 
b) two identical counter-bored holes from the back 8; 
c) three 1/4-20 UNC tapped through holes 9 for mounting; and 
d) two blind 1/4-20 UNC tapped holes from the left 10 for building up 
three-dimensional configurations 
NOTE: (To design this part for the metric standard, all tapped holes only 
need to be changed to M6 and located on corresponding quarter of 25 mm 
grid intersections.) 
FIG. 2 shows how the 2.times.2 components may be attached in pairs to 
2.times.2 clones, and to a standard breadboard base, to form 
three-dimensional right angle mounting structures. 
FIG. 3 shows front views of a set of eight components of varying sizes, all 
of which have the same thickness (preferably 1/2 inch). Any two having a 
compatible side length can be combined into right angle structures similar 
to those illustrated in FIG. 2. 
The subset of eight UMC blocks is designed to minimize the number of holes 
that need to be drilled in the bulk material of the UMC blocks and to keep 
the cost of manufacture, inventory and delivery low. At the same time, the 
number and position of useful tapped mounting holes is optimized. 
Additionally, all "standard" UMC blocks can be mounted on standard 1/4-20, 
inch center breadboards, If a metric breadboard is to be used, a subset of 
metric UMC blocks is similar but with a slightly altered measurement unit. 
Furthermore, in making the UMC blocks, outer dimensions of each UMC block 
are specified and toleranced so that UMC blocks may be mounted side by 
side on an optical table with a small clearance (i.e., no interference) 
between adjacent blocks. 
Use of the UMC blocks facilitates the process of building up optical setups 
in a number of ways. In particular, the UMC blocks may be mounted to the 
table and also to each other in T-shaped and L-shaped configurations. 
Optical components may then be mounted to the UMC blocks. Because the UMC 
blocks have strategically placed counter-bored holes 7 and 8 and tapped 
holes 10, the bolts that are used to connect UMC blocks to each other are 
fully recessed. Thus, there is no interference with a flat-to-flat planar 
fit of a base UMC block to a breadboard, since the orthogonal UMC block is 
held by fully recessed bolts. Such subassemblies of UMC blocks may be used 
to mount optical components at right angles or at different heights. The 
placement of sets of counter-bored through-holes 7 and 8 on opposing faces 
of each UMC block adds to the utility of T-shaped and L-shaped 
configurations. As shown in FIG. 2, for example, even when UMC blocks are 
connected, at least one set of counter-bored through-holes is available on 
a base block to enable the user to bolt the T-shaped or L-shaped 
configuration to the table. Furthermore, the oppositely counter-bored sets 
of through-holes 7 and 8 allow the user to flip over the blocks in order 
to find the optimal way in which to connect blocks to each other or to 
other optical components. In addition, since the UMC blocks are right 
rectangular solids, they can be built up at right angles into larger 
structures. 
Thus, the invention satisfies a need for economical optical mounting 
hardware that can be used in a wide variety of configurations to 
facilitate the set-up, precision and reproducibility of three-dimensional 
optical layouts. 
INDUSTRIAL APPLICABILITY 
The invention is capable of being used by optical researchers and system 
designers for mounting optical elements for experiments and 
breadboard-type prototype constructions using laser beams or other light 
beams which must be steered about complex paths. Because the invention 
comprises a set of UMC blocks which are capable of being assembled into a 
great number of three-dimensional configurations, the invention provides a 
more standardized and economical inventory of hardware for building 
three-dimensional optical standoffs. The very simplicity of the design is 
useful, not only because of the number of customized configurations in 
which the component parts may be assembled, but also because the invention 
obviates the need for users to invest in and store a large number of more 
specialized items of mounting hardware.