Optics element for insertion into an optical apparatus, optical apparatus, method for producing an optics element, and method for producing an optical apparatus

Abstract

The invention relates to an optics element (100) for insertion into an optical apparatus, the optics element comprising an optical element (110) that has at least one optical property that has a deviation from a default value. With regard to the insertion of the optics element (100) into the optical apparatus, the deviation causes adjustment of the optics element (100) relative to the optical apparatus. The optics element (100) also comprises at least one adjustment element (120) that is joined to the optical element (110) by a generative manufacturing process. The at least one adjustment element (120) is produced on the basis of the deviation. The at least one adjustment element (120) is designed to function as a passive adjustment structure for compensating for the deviation during insertion of the optics element (100) into a holding device of the optical apparatus.

Description

[0001] Optical element for insertion into an optical device, optical device, method for producing an optical element and method for producing an optical device

[0002] The invention is based on a device or a method according to the class of the independent claims.

[0003] Optical elements usually require adjustment before being inserted into optical devices so that the overall system can achieve the predefined specifications. Typically, machining or turning processes that require removal of material, such as turning or milling, can be used for adjustment. Microtechnical processes such as laser ablation are also conceivable, as described, for example, in DE 10 2018106468 Ai. Furthermore, DE 10 2016101928 Ai describes a method for manufacturing an optoelectronic sensor consisting of a lens and a detector. The method consists in particular in that, in a first step, both components are brought into a desired position relative to one another, whereby they are temporarily held mechanically. In the second step, material is applied around the components using additive manufacturing (3D printing) in such a way that they permanently remain in the pre-adjusted position.

[0004] Disclosure of the invention

[0005] Against this background, the approach presented here provides an improved optical element for insertion into an optical device, an improved optical device, an improved method for producing an optical element, and an improved method for producing an optical device according to the main claims. The measures listed in the dependent claims enable advantageous refinements and improvements of the device specified in the independent claim.

[0006] The described approach enables simple yet highly precise passive alignment of an optical element within an optical device. For this purpose, dimensionally accurate reference surfaces or alignment elements can be created on the optical element using additive manufacturing for use in passive alignment.

[0007] An optical element for insertion into an optical device comprises the following features: an optical element having at least one optical property that exhibits a deviation from a specified value, wherein, with regard to the insertion of the optical element into the optical device, the deviation necessitates an adjustment of the optical element with respect to the optical device; and at least one adjustment element that is attached to the optical element by a generative manufacturing process, wherein the at least one adjustment element is generated as a function of the deviation, wherein the at least one adjustment element is designed to function as a passive adjustment structure for compensating for the deviation when the optical element is inserted into a holding device of the optical device.

[0008] An optical device can be understood as an optical system. The optical device can be designed to generate, guide, redirect, and additionally or alternatively modify a light beam. The optical element can be designed to generate, guide, redirect, and additionally or alternatively modify a light beam. A generative manufacturing process can also be referred to as an additive manufacturing process. With regard to the insertion of the optical element into the optical device, the deviation can require an adjustment, in particular of the optical element with respect to the optical device.

[0009] The at least one optical property can be a position of the optical axis, a centering error, a center thickness, or a modulation transfer function. The position of the optical axis can be defined with respect to an outer circumference or outer surfaces of the optical element.

[0010] Furthermore, the optical element can be a passive or active optical element. In particular, the optical element can be a lens, an objective, or a laser diode. The optical element can be rotationally symmetrical, with another type of symmetry, or asymmetrical. Thus, a very broad range of applications for the concept mentioned herein is possible.

[0011] An optical device comprises the following features: at least one example of an embodiment of an optical element mentioned herein; and a holding device for holding the at least one optical element, wherein the at least one optical element is adjusted by passive adjustment by means of the at least one adjustment element in a state held by the holding device.

[0012] By using at least one optical element as presented herein, a passive adjustment can be carried out for the optical device in a simple and precise manner, particularly during final assembly.

[0013] The optical device can be a lens or a camera. This results in a broad and diverse range of applications for the concept mentioned here.

[0014] The holding device can also be a mount or a tube. The holding device can be designed to fix at least one specimen or piece of an embodiment of the optical element mentioned herein.

[0015] A method for manufacturing an embodiment of an optical element mentioned herein comprises the following steps:

[0016] Determining the deviation of the at least one optical property of the optical element from the specified value; and

[0017] Generating the at least one adjustment element as a function of the deviation by a generative manufacturing process on the optical element.

[0018] By carrying out the method, an embodiment of an optical element mentioned herein can be advantageously produced. Advantageously, both the determining step and the generating step can be carried out automatically.

[0019] According to one embodiment, in the production step, the at least one adjustment element can be produced on the optical element true to size with respect to the holding device of the optical device. For this purpose, a direct, true-to-size application of material can thus be carried out. According to another embodiment, the method can comprise a step of generating a true-to-size replication template of the holding device. In this case, in the production step, the at least one adjustment element can be produced on the optical element relative to the replication template. Furthermore, the method can comprise a step of removing the optical element from the replication template. The replication template can also be referred to as a master. This results in a targeted molding of a master of the structure, which is designed to fix or hold the optical element in the optical device.

[0020] A method of manufacturing an embodiment of an optical device mentioned herein comprises the following step:

[0021] Arranging the at least one optical element in the holding device, wherein a passive adjustment of the at least one optical element is carried out by means of the at least one adjustment element.

[0022] By carrying out the method, an embodiment of an optical device mentioned herein can be advantageously produced. The arranging step can advantageously be carried out automatically.

[0023] Examples of the approach presented here are illustrated in the drawings and explained in more detail in the following description. It shows:

[0024] Fig. i is a schematic representation of an embodiment of an optical element;

[0025] Fig. 2 is a schematic representation of an embodiment of an optical device;

[0026] Fig. 3 is a schematic representation of an embodiment of an optical element in a replication template;

[0027] Fig. 4 is a schematic representation of an embodiment of an optical element in a replication template;

[0028] Fig. 5 is a schematic representation of an embodiment of an optical element; Fig. 6 is a schematic representation of an embodiment of an optical device;

[0029] Fig. 7 is a flowchart of an embodiment of a method for producing an optical element; and

[0030] Fig. 8 is a flowchart of an embodiment of a method for manufacturing an optical device.

[0031] In the following description of advantageous embodiments of the present invention, the same or similar reference numerals are used for the elements shown in the various figures and having a similar effect, whereby a repeated description of these elements is omitted.

[0032] Fig. i shows a schematic representation of an embodiment of an optical element 100. The optical element 100 is intended for insertion or use in an optical device, as will be described in more detail with reference to the following figures.

[0033] The optical element 100 comprises an optical element 110, here for example a lens, and at least one adjustment element 120, here only as an example three adjustment elements 120, which are additively attached to the optical element 110.

[0034] The optical element 110 has at least one optical property that exhibits a deviation from a specified value. The optical property is such that, with respect to the insertion of the optical element 100 into the optical device, the deviation causes an adjustment of the optical element, more precisely of the optical element 110, with respect to the optical device. The position of the optical axis A is shown here as an example of such an optical property.

[0035] The at least one adjustment element 120 is attached to the optical element 110 by an additive or generative manufacturing process. The at least one adjustment element 120 is generated as a function of the aforementioned deviation in the optical property. The at least one adjustment element 120 is thus designed to function as a passive adjustment structure for compensating for the deviation when the optical element is inserted into a holding device of the optical device. In addition to the position of the optical axis A, a centering error, a center thickness, or a modulation transfer function are also examples of the at least one optical property of the optical element 110. According to one embodiment, the optical element 110 is a passive optical element. According to another embodiment, the optical element 110 is an active optical element.In particular, the optical element 110 is designed as a lens, as an objective or as a laser diode.

[0036] Fig. 2 shows a schematic representation of an embodiment of an optical device 200. The optical device 200 comprises at least one optical element 100 and a holding device 230. The optical element 100 corresponds to or is similar to the optical element from Fig. 1. Thus, the optical element 100 here also comprises the optical element 110, here for example a lens, and the at least one adjustment element 120, here merely by way of example three adjustment elements 120, which are additively attached to the optical element 110. The holding device 230 is designed to hold or fix the at least one optical element 100. In a state held by the holding device 230, the at least one optical element 100 is adjusted by means of the at least one adjustment element 120 by passive adjustment.

[0037] The optical device 200 is, for example, a lens or a camera. The holding device 230 is designed as a mount or a tube.

[0038] In other words, Fig. 1 and Fig. 2 show a direct application of reference surfaces, as is also provided according to an exemplary embodiment of a method explained in more detail below. Fig. 1 shows the application of dimensionally accurate reference points or reference surfaces, or the optical element 110 with dimensionally accurate applied adjustment elements 120. Fig. 2 shows the insertion of the optical element 100 into a mount or a tube, or the optical element 100 inserted into the holding device 230. The at least one adjustment element 120 is produced on the optical element 110 dimensionally accurate with respect to the holding device 230 of the optical device 200.

[0039] Fig. 3 shows a schematic representation of an embodiment of an optical element 100 in a replication template 330. The optical element 100 corresponds to or is similar to the optical element from one of the figures described above, with the exception that the additively or generatively manufactured adjustment elements 120 of the optical element 100 in Fig. 3 are produced by molding. For this purpose, the optical element 110, here also designed as a lens, for example, is arranged in the replication template 330, which can also be referred to as a replication tool or molding master. The replication template 330 is generated dimensionally true to the holding device of the optical device, for example, relative to the holding device from Fig. 2 and / or Fig. 6. The adjustment elements 120 are additively or generatively produced on the optical element 110 relative to the dimensionally true replication template 330.

[0040] Fig. 3 shows the optical element 100 and the replication template 330 in a top view. It can be seen that the adjustment elements 120 adjust the lateral position or orientation of the optical element 110 relative to the replication template 330.

[0041] Fig. 1 shows a schematic representation of an embodiment of an optical element 100 in a replication template 330. Here, the optical element 100 and the replication template 330 correspond to those of Fig. 3, wherein the optical element 100 and the replication template 330 are shown in a cross-sectional view in the illustration of Fig. 1. It can be seen that a vertical or axial position or alignment of the optical element 110 relative to the replication template 330 is set by the adjustment elements 120.

[0042] Fig. 5 shows a schematic representation of an embodiment of an optical element 100. The optical element 100 corresponds to the optical element from Fig. 3 and / or Fig. 4. The optical element 100 is removed from the replication template shown in Fig. 3 and Fig. 4. The adjustment elements 120 or reference surfaces for passive adjustment are thus additively attached and subsequently molded.

[0043] Fig. 6 shows a schematic representation of an embodiment of an optical device 200. The optical device 200 corresponds to the optical device from Fig. 2 with the exception that the optical element 100 is manufactured in the manner illustrated in Figs. 3 to 5. In other words, the optical element 100 in Fig. 6 comprises the adjustment elements 120 that are additively or generatively attached and mounted or molded as explained in Figs. 3 to 5. The optical element 100 is also inserted into a holding device 230. The holding device 230 is, for example, the mount of a lens, which is, for example, the optical device 200.

[0044] Fig. 7 shows a flowchart of an embodiment of a method 700 for manufacturing an optical element. The manufacturing method 700 can be executed to produce the optical element from one of the figures described above or a similar optical element. The manufacturing method 700 includes a determining step 704 and a generating step 706.

[0045] In the determining step 704, the deviation of the at least one optical property of the optical element from the specified value is determined. Subsequently, in the generating step 706, the at least one adjustment element is generated on the optical element using a generative manufacturing process, depending on the determined deviation.

[0046] According to one embodiment, in step 706 of generating, the at least one adjustment element is generated on the optical element true to size with respect to the holding device of the optical device. A procedure according to this embodiment is illustrated in Figures 1 and 2.

[0047] According to another exemplary embodiment, the method 700 for generating also includes a step 702 of generating a true-to-size replication template of the holding device of the optical device. Such a replication template is shown, for example, in Figures 3 and 4. Then, in step 706 of generating, the at least one adjustment element is generated on the optical element relative to the replication template. Furthermore, the method 700 for generating also includes a step 708 of removing the optical element from the replication template. A procedure according to this exemplary embodiment is illustrated in Figures 3 to 6.

[0048] Fig. 8 shows a flow diagram of an embodiment of a method 800 for manufacturing an optical device. The method 800 for manufacturing can be carried out to manufacture the optical device from one of the figures described above or a similar optical device. The method 800 for manufacturing includes a step 805 of arranging.

[0049] In step 805 of arranging, the at least one optical element is arranged in the holding device. In this case, a passive adjustment of the at least one optical element is performed using the at least one adjustment element. The passive adjustment advantageously results from the at least one adjustment element being attached to the optical element using a generative or additive process.

[0050] With reference to the figures described above, the exemplary embodiments, backgrounds of exemplary embodiments, and advantages of exemplary embodiments, the invention is briefly summarized below. In particular, a method for producing reference surfaces or alignment elements 120 on optical elements 110 by additive manufacturing is presented. This can be used in the alignment processing of optics and / or the production of assembled optical components and / or cameras.

[0051] According to exemplary embodiments, for example, limitations that are often associated with conventionally used methods of alignment machining can be advantageously avoided. The production of reference surfaces on mounts by means of machining, so-called alignment turning, for the assembly of lenses is conventionally practiced. However, not every material can be machined precisely, and there are also application cases in which the optics cannot be clamped rigidly enough to enable precise machining, particularly in micro-optics. Last but not least, if the optical material itself cannot be machined, the optics should be mounted in a mount that is suitable for machining. This can be disadvantageous in applications with limited installation space. In some cases, therefore, the production of reference surfaces is required without the optical element being able to be inserted into a mount that can then be machined.This can be achieved by embodiments wherein the optical element 110 can be arranged in an optical device 200 by means of the adjustment elements 120 by means of passive adjustment.

[0052] Traditionally, additional requirements arise, particularly due to the need for assembly in a clean room. For this reason, for example, an active alignment and assembly of lenses in the lens was developed. The lens is moved into the target position by a hexapod and fixed there using UV-curing adhesive. However, this approach can encounter economic limitations, particularly if the application does not allow for UV adhesive, as is the case in many military applications, because the hexapod is intended to hold the lens in position until the adhesive cures. If the lens could be positioned using reference surfaces in the mount, the bonding to the mount would no longer depend on active alignment and would be independent of the type of adhesive. This can be achieved according to exemplary embodiments.

[0053] Thus, machining processes such as turning, milling, and the like, which require a mount that can be machined, can be dispensed with for the adjustment of optics. Other known processes, such as laser ablation, also remove material from the optical element, which must be removed from the processing zone to prevent the optical element from becoming contaminated. The known processes can be complex and may not be compatible with certain manufacturing methods, e.g., due to a lack of cleanroom compatibility. In particular, according to exemplary embodiments, the disadvantages frequently associated with adjustment turning can be avoided, because the optics do not need to be mounted if the optics are generally not machinable, and cleanroom compatibility can also be achieved.Furthermore, according to exemplary embodiments, the disadvantages frequently associated with active alignment and assembly can be avoided, since a restriction on the use of a certain range of adhesives can be eliminated. Thus, many of the aforementioned process-related disadvantages of conventional methods can be avoided by generatively or additively manufacturing the alignment elements 120 on the optical element 110 before insertion into the holding device 230 of the optical device 200.

[0054] According to exemplary embodiments, reference surfaces or alignment elements 120 are produced on these optical elements 110 by additive manufacturing, particularly for the assembly of passive and active optical elements 110. For this purpose, the optical properties of an optical element 110, especially the centering error or the position of the optical axis A, but also the center thickness and other properties, are measured. Material for the alignment elements 120 is then applied in relation to these measured values ​​in such a way that the added material can be used as a reference point for passive alignment.

[0055] Thus, according to exemplary embodiments, in the context of aligning optical elements 110, especially lenses, via reference surfaces or adjustment elements 120 through passive adjustment, the following advantages in particular can be offered: The optical element 110, for example the lens, no longer needs to be mounted separately or glued into a mount. The technique for attaching reference surfaces or adjustment elements 120 is cleanroom compatible. The technique for attaching reference surfaces or adjustment elements 120 is not tied to rotationally symmetric lenses or optical elements 110, unlike with adjustment rotation.

[0056] According to exemplary embodiments, two different approaches are conceivable: first, the direct, dimensionally accurate application of material; second, the targeted molding of a master. Both are illustrated, for example, by the lateral alignment of the optical axis A of a lens as optical element 110 to a mount or a tube as holding device 230. However, the application is not limited to this and can be applied to other references as well.

[0057] For the direct attachment of reference surfaces or alignment elements 120, the position of the optical axis A is measured. Material is then applied to the circumference or at discrete points of the optical element 110 such that the circumference or the discrete points are at the same distance from the optical axis A. If the lens or optical element 110 is now joined to the references or alignment elements 120, the alignment of the optical axis A to the mount or holding device 230 is achieved by passive adjustment. Depending on the tolerance requirements, active adjustment may no longer be necessary.

[0058] The molding or creation of the reference surfaces or adjustment elements 120 by molding requires the replication template 330 or a master having an inner diameter and, if applicable, bearing surfaces that correspond to the later inner diameter on the lens or the holding device 230 of the optical device 200. To prevent the lens or the optical element 110 from sticking to the master or the replication template 330, the master is made of a material such that the applied material does not adhere or can at least be easily removed again, e.g., by pressing it out. The optical axis A is then measured, and the lens or the optical element 110 is aligned relative to this master or the replication template 330 such that the optical axis A is centered on the master. The lens is positioned laterally and axially, and the material for producing the reference surfaces or adjustment elements 120 is applied.The lens is then separated from the master and now has reference surfaces or adjustment elements 120 that are aligned to the optical axis A.

[0059] It is also conceivable that reference structures or alignment elements 120 are attached to complete lenses as optical elements 110 according to an MTF (modulation transfer function) or wavefront measurement. This allows an existing process to be broken down into the measurement and alignment of the camera by attaching references and the bonding of the camera to the sensor chip. This can be useful in certain circumstances if the camera chip cannot be contacted.

[0060] When adjusting laser diodes as optical elements 110, the application of reference surfaces or adjustment elements 120 can also serve to align the laser beam in order to compensate for manufacturing tolerances in the production of laser diodes.

Claims

Patent claims 1. An optical element (100) for insertion into an optical device (200), the optical element (100) having the following features: an optical element (110) having at least one optical property that exhibits a deviation from a specified value, wherein, with regard to the insertion of the optical element (100) into the optical device (200), the deviation necessitates an adjustment of the optical element (100) with respect to the optical device (200); and at least one adjustment element (120) that is attached to the optical element (110) by a generative manufacturing process, the at least one adjustment element (120) being produced as a function of the deviation, the at least one adjustment element (120) being designed to function as a passive adjustment structure for compensating for the deviation when the optical element (100) is inserted into a holding device (230) of the optical device (200).

2. Optical element (100) according to claim 1, wherein the at least one optical property is a position of the optical axis (A), a centering error, a center thickness or a modulation transfer function.

3. Optical element (100) according to one of the preceding claims, wherein the optical element (110) is a passive or active optical element, in particular a lens, an objective, or a laser diode. . Optical device (200), wherein the optical device (200) has the following features: at least one optical element (100) according to one of the preceding claims; and a holding device (230) for holding the at least one optical element (100), wherein the at least one optical element (100) is adjusted by passive adjustment by means of the at least one adjustment element (120) in a state held by the holding device (230).

5. Optical device (200) according to claim , wherein the optical device (200) is a lens or a camera.

6. Optical device (200) according to one of claims 1 to 5, wherein the holding device (230) is a mount or a tube.

7. A method (700) for producing an optical element (100) according to any one of claims 1 to 3, wherein the method (700) comprises the following steps: Determining (704) the deviation of the at least one optical property of the optical element (110) from the specified value; and Generating (706) the at least one adjustment element (120) as a function of the deviation by a generative manufacturing process on the optical element (110).

8. The method (700) according to claim 7, wherein in the step (706) of producing, the at least one adjustment element (120) is produced on the optical element (110) true to size with respect to the holding device (230) of the optical device (200).

9. The method (700) according to claim 7, comprising a step (702) of generating a dimensionally accurate replication template (330) of the holding device (230), wherein in the step (706) of generating the at least one adjustment element (120) is generated on the optical element (110) relative to the replication template (330), and comprising a step (708) of removing the optical element (100) from the replication template (330).

10. A method (800) for manufacturing an optical device (200) according to any one of claims 4 to 6, wherein the method (800) comprises the following step: Arranging (805) the at least one optical element (100) in the holding device (230), wherein a passive adjustment of the at least one optical element (100) is carried out by means of the at least one adjustment element (120).

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