Concave Optical Lens Fabrication via Uniform Vacuum Pressure
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Solution Overview
Problem
Conventional methods for fabricating concave optics, such as compressing silicon crystal wafers between dies, result in residual stresses and aberrations due to non-uniform stress distribution, leading to poor performance and increased costs.
Innovation Solution
A system and method using a support member with a precision-cut out filled with slow-drying epoxy to create a vacuum seal, applying uniform vacuum pressure to achieve the desired curvature of the optical lens, eliminating the need for forceful bending and reducing residual stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If compressive force is applied to bend the silicon crystal wafer between dies, then the desired concave curvature is achieved, but non-uniform stress distribution and residual stresses occur leading to poor optical performance
Solution Approach 1:
Instead of applying compressive force from the convex side to bend the crystal into a concave shape, the invention applies vacuum pressure from the concave side to pull the crystal into the desired concave curvature. This inversion of the bending approach ensures uniform stress distribution across the crystal surface, eliminating residual stresses and improving optical performance while achieving the same concave shape.
2Shape
If forceful bending is applied to achieve curvature, then the concave optics shape is formed, but residual stresses and aberrations increase leading to non-coherent images
Solution Approach 1:
The invention replaces the mechanical compressive bending system with a vacuum pressure system. By using vacuum pressure applied uniformly across the crystal surface, the crystal is gently pulled into the desired curvature without the localized high-stress regions that cause residual stresses and aberrations. This substitution maintains the necessary shape while ensuring image coherence and optical reliability.
3Productivity
If standard compressive techniques are used for fabrication, then the concave optics are produced, but production costs increase due to poor performance and rework
Solution Approach 1:
The vacuum pressure system allows the crystal to self-form into the desired concave shape through uniform pressure application, eliminating the need for complex die systems and multiple adjustment steps. This self-service approach reduces manufacturing complexity, minimizes rework, and lowers production costs while improving overall productivity and ease of manufacture.
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
The method produces optical lenses with substantially uniform surface stresses, reducing production costs and improving optical performance by eliminating non-coherent images and aberrations, making them suitable for advanced applications like X-ray detectors and high-resolution focusing systems.
Implementation Method 1
A vacuum pump is connected to the support member for providing a set vacuum level to produce a curvature in the focusing optical lens
Implementation Method 2
The set vacuum level is continued until the epoxy has hardened and the focusing optical lens has achieved its final curvature
Data Source
AI summary
A system and method are provided for implementing enhanced optics fabrication for making a concave focusing optical lens with a selected material of a crystal or an amorphous material and a support member. A cut-out is formed in the support member with a depth based upon the final, desired curvature of the concave focusing optical lens. The cut-out is partially filled with an epoxy and the selected crystal or amorphous material is placed on top thereby creating a quasi-vacuum seal. A vacuum pump is connected to the support member, providing a set vacuum level until the epoxy has hardened and the selected crystal or amorphous material has achieved its final curvature. Vacuum pressure is substantially uniformly applied to the crystal, providing substantially uniform stresses on the surface of the final concave focusing optical lens.