3D Printed Strut Spacers for Lens Air Gap Stability
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Solution Overview
Problem
Existing three-dimensional optical structures, such as lens assemblies, face challenges in maintaining optical quality and stability under external forces due to the reduction of air gaps caused by deformation, and conventional spacer elements are visible, introduce optical aberrations, and are difficult to produce in small sizes using three-dimensional printing.
Innovation Solution
Incorporating three-dimensionally printed strut structures as spacers within the air gap between optical elements, which are produced using additive manufacturing techniques, allowing for precise control of size and placement to maintain the air gap stability and optical quality without introducing noticeable patterns or aberrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional spacer elements are used to maintain air gap distance, then the air gap stability is improved, but the optical quality deteriorates due to visible patterns and optical aberrations
Solution Approach 1:
The patent applies local quality by making the spacer structures optically invisible through specific geometric design. The struts are configured with dimensions and shapes that minimize light scattering and refraction, making them substantially invisible from the front and back surfaces of the lens assembly while maintaining their mechanical spacing function.
Solution Approach 2:
The patent changes the physical parameters of the spacer elements by producing them in extremely small sizes (micrometer scale) using additive manufacturing. This parameter change allows the spacers to maintain air gap stability while becoming optically imperceptible and minimizing optical aberrations.
2Ease of manufacture
If additive manufacturing is used to produce spacer elements, then manufacturing flexibility is improved, but the manufacturing precision deteriorates due to droplet size limitations
Solution Approach 1:
The patent segments the spacer structure into multiple thin layers, each deposited by the additive manufacturing process. By building the spacer incrementally layer by layer, the system achieves precise control over the final dimensions, overcoming the inherent droplet size limitations of the manufacturing process.
Solution Approach 2:
The patent transitions from conventional two-dimensional patterning to three-dimensional structured spacers with controlled height, width, and shape. This dimensional approach allows precise control of optical properties by adjusting the vertical and lateral dimensions independently, achieving manufacturing precision that compensates for droplet size limitations.
3Volume of moving object
If the air gap is reduced to minimize lens thickness, then the compactness is improved, but the optical quality deteriorates due to increased element contact under external forces
Solution Approach 1:
The patent applies preliminary action by pre-positioning multiple spacer structures at strategic locations within the air gap before the lens assembly is subjected to external forces. These spacers act as preventive measures that maintain the air gap distance even when compression forces are applied, preventing element contact and preserving optical quality.
Solution Approach 2:
The patent uses composite construction by integrating the spacer structures as integral parts of the lens assembly, made from the same or compatible materials. This composite approach ensures that the spacers and optical elements work together as a unified structure, maintaining reliability under external forces while minimizing overall thickness.
Data Source
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AI summary
A three-dimensional optical structure, in particular a lens assembly, is proposed, wherein the optical structure comprises a first element, a second element and an air gap arranged between the first element and the second element, characterized in that the first element and/or the second element comprises on a surface thereof facing the air gap a plurality of three-dimensionally printed strut structures for spacing the first element and the second element from each other.