Acoustic Optical Integrity Detection on Contoured Surfaces
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Solution Overview
Problem
Traditional methods for detecting the optical integrity of geometric optics, such as resistive or capacitive safety traces, are unreliable on contoured surfaces due to lithograph patterning limitations and thermal expansion issues with traditional lens array materials.
Innovation Solution
Acoustic integrity detection using piezoelectric transducers to transmit ultrasonic waves along or through optical surfaces, detecting impurities or discontinuities by measuring attenuation, redirection, or reflection of the waves, and determining their location based on time-of-flight techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional resistive or capacitive safety traces are used for integrity detection, then the detection method is simple to implement, but the detection reliability is poor on contoured surfaces due to lithograph patterning limitations and thermal expansion issues
Solution Approach 1:
The patent replaces traditional electrical safety traces (resistive or capacitive) with acoustic wave-based detection. Acoustic transducers generate and detect acoustic waves that propagate through the optical component, eliminating the need for lithograph patterning on contoured surfaces and avoiding thermal expansion issues associated with traditional materials.
Solution Approach 2:
The patent introduces acoustic waves as an intermediary medium for integrity detection. The acoustic waves interact with impurities or discontinuities in the optical component, providing a reliable detection mechanism that works on contoured surfaces without requiring direct electrical contact or complex patterning.
2Measurement precision
If direct or indirect optical/imaging detection is used, then the detection can be performed during active illumination usage, but the imaging resolution is insufficient and additional system cost is significant
Solution Approach 1:
The patent replaces optical/imaging detection systems with acoustic wave-based detection. This substitution achieves superior measurement precision for impurity detection without requiring complex imaging equipment, reducing both system complexity and cost while maintaining the ability to detect during active illumination usage.
3Ease of manufacture
If lithograph patterning is applied on multidimensional surfaces with curved/sharp transitions, then the safety traces can be formed, but the patterning reliability is poor due to geometric limitations
Solution Approach 1:
The patent replaces lithograph patterning with acoustic transducer-based detection. This eliminates the fundamental geometric limitations of lithography on contoured surfaces, as acoustic waves can propagate through and interact with impurities regardless of surface curvature or complexity, greatly improving both manufacturability and reliability.
4Ease of manufacture
If traditional lens array materials are used, then the materials are readily available, but thermal expansion causes detection inaccuracies
Solution Approach 1:
The patent replaces thermal-based detection methods with acoustic wave-based detection. This substitution eliminates thermal expansion issues that plague traditional materials, as acoustic wave propagation is not significantly affected by thermal expansion, thereby maintaining measurement precision while working with readily available materials.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively evaluates the optical integrity of geometric optics on contoured surfaces, enabling reliable detection of impurities and ensuring compliance and performance, while also controlling light emission in illumination systems.
Implementation Method 1
Acoustic integrity detection can utilize one or more transducers, such as piezoelectric transducers, to transmit ultrasonic waves along an optical surface and/or through the thickness of an optical component
Implementation Method 2
As the wave propagates along the optical surface, one or more impurities or discontinuities (e.g., scratches, liquid ingress, etc.) in contact with or integral to the optical surface can interact with the transmitted wave causing attenuation, redirection and/or reflection
Implementation Method 3
Position of an impurity or discontinuity touching or integral to an optical surface can be determined using time-of-flight (TOF) techniques
Data Source
AI summary
Acoustic optical integrity detection system architectures and methods can be used to detect optical integrity of an optical component by detecting a discontinuity on and/or in the optical component (e.g., on the optical surface and/or within the bulk of the optical component). In some examples, integrity detection can be used to ensure safety compliance of an optical system, optionally including a laser. Acoustic integrity detection can utilize transducers (e.g., piezoelectric transducers) to transmit ultrasonic waves along an optical surface and/or through the thickness of an optical component. A discontinuity of the optical surface can interact with the transmitted wave causing attenuation, redirection and/or reflection of at least a portion of the transmitted wave. Portions of the transmitted wave energy after interaction with the discontinuity can be measured to determine discontinuity location, type, and/or severity.