Process of making high speed multifaceted polygonal scanners

Claim 2

A process of making a high speed multifaceted polygonal scanner comprising providing a die cavity having a geometry which includes a plurality of facet shaped surfaces, placing an aluminum member into said cavity, said aluminum member being sized so as to provide a gap for a suitably dimensioned injected material having suitable mechanical and optical properties for high speed scanning applications, and injection molding acrylic into the gap between the aluminum member and the die cavity, an injected molded acrylic scanner comprising the injected molded acrylic having a plurality of facets on one surface thereof and an aluminum member thereby being formed, removing said injected molded acrylic scanner from said die cavity, coating the facets of said acrylic scanner with magnesium fluoride, and then applying a mirrorlike finish of aluminum to the surface of said magnesium fluoride coated acrylic scanner to provide a high speed multifaceted polygonal scanner, said magnesium fluoride enhancing the adherence of said aluminum finish to said acrylic scanner.

Claim 3

The process as defined in claim 1 wherein a protective coating is applied to the finished aluminum coating.

Claim 4

The process as defined in claim 2 wherein said protective coating comprises silicon monoxide.

Claim 5

The process as defined in claim 1 wherein the aluminum hub comprises an aluminum alloy 7075-T651 having the following properties: ______________________________________ Nominal Chemical Composition ______________________________________ Zinc 5.6% Magnesium 2.5% Copper 1.6% Chromium 0.3% Aluminum Balance (incl. normal impurities) Typical Tensile Strength, psi 83,000 Mechanical Yield Strength, psi 73,000 Properties Elongation, % in 2" 11 Shear Strength, psi 48,000 Brinell Hardness 10/500 150 Typical Density, Lbs./Cu. In. 0.101 Physical Melting Range, approx. ° F 890-1180 Properties Electrical Conductivity, % IACS at 20° C (68° F) 33 Thermal Conductivity, btu at 25° C (77° F) 900 Average Coefficient of Thermal Expansion at 68° to 212° F 0.0000131 ______________________________________

Claim 6

A process of making a high speed, multifaceted polygonal scanner comprising providing an aluminum member which is capable of accepting an acrylic material on its periphery, providing an injection molded acrylic material having a first surface which comprises a plurality of facets and a second surface sized so as to conform to the periphery of said aluminum member, cementing said acrylic material to the periphery of said aluminum member, coating the facets of said acrylic material with magnesium fluoride and then applying a mirrorlike finish of aluminum to the surface of said magnesium fluoride coated facets to provide the high speed multifaceted polygonal scanner, said magnesium fluoride enhancing the adherence of said aluminum finish to said acrylic material.

Claim 7

A process of making a high speed, multifaceted polygonal scanner comprising providing an aluminum member which is capable of accepting an acrylic material on its periphery, providing an injection molded acrylic material having a first surface which comprises a plurality of facets and a second surface sized so as to conform to the periphery of said aluminum member, cementing said acrylic material to the periphery of said aluminum member, coating the facets of said acrylic material with magnesium fluoride and then applying a mirrorlike finish of aluminum to the surface of said magnesium fluoride coated facets to provide the high speed multifaceted polygonal scanner, said magnesium fluoride enhancing the adherence of said aluminum finish to said acrylic material.

Claim 8

The process as defined in claim 5 wherein a protective coating is applied to the aluminum surface.

Claim 9

The process as defined in claim 6 wherein said protective coating comprises silicon monoxide.

Claim 10

The process as defined in claim 5 wherein the aluminum hub comprises an aluminum alloy designated as 7075-T651 having the following properties: ______________________________________ Nominal Chemical Composition ______________________________________ Zinc 5.6% Magnesium 2.5% Copper 1.6% Chromium 0.3% Aluminum Balance (incl. normal impurities) Typical Tensile Strength, psi 83,000 Mechanical Yield Strength, psi 73,000 Properties Elongation, % in 2" 11 Shear Strength, psi 48,000 Brinell Hardness 10/500 150 Typical Density, Lbs./Cu. In. 0.101 Physical Melting Range, approx. ° F 890-1180 Properties Electrical Conductivity, % IACS at 20° C (68° F) 33 Thermal Conductivity, btu at 25° C (77° F) 900 Average Coefficient of Thermal Expansion at 68° to 212° F 0.0000131 ______________________________________