Infrared Aperture Printing on Optical Elements

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Solution Overview

Problem

The high cost and complexity of producing high-performance infrared cameras are hindered by the expensive and difficult-to-manufacture infrared imaging sensors, limiting their use to specialized applications, and there is a need for a cost-effective and durable aperture component that can withstand various environmental conditions.

Innovation Solution

A method of creating a light stop aperture using opaque, paintable or printable materials applied to transparent or reflective optical elements, such as lenses, using pad printing or other automated processes, ensuring high reflectivity and durability while reducing manufacturing complexity and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional mechanical aperture components are used, then manufacturing precision and reliability are improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improveaperture positioning accuracyVSAvoidaperture component complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical aperture components with a direct printing method where the aperture pattern is formed by depositing opaque material directly onto the optical element surface. This eliminates the need for separate mechanical aperture components and assembly processes, reducing device complexity while maintaining positioning accuracy through direct patterning on the optical element.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent merges the aperture function with the optical element by directly forming the aperture pattern on the optical element surface itself. This consolidation eliminates the need for separate aperture components and their associated mounting mechanisms, thereby reducing overall device complexity while maintaining manufacturing precision through integrated fabrication.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If high-performance infrared imaging sensors are used, then optical performance is improved, but manufacturing cost and complexity increase

Engineering Contradiction:

Improveoptical performanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent employs a cost-effective printing method that can be easily replicated for mass production. The opaque material used in the aperture formation is inexpensive and the printing process itself is cost-efficient, enabling mass production of infrared cameras at lower unit costs while maintaining reliable optical performance through the durable aperture structure.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the manufacturing approach from traditional mechanical fabrication to a printing-based process, fundamentally altering how the aperture is created. This parameter change in the manufacturing method enables cost-effectiveness while maintaining the required optical performance through controlled material deposition and pattern formation.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If durable aperture materials are used, then reliability is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveaperture durabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical aperture fabrication processes with a direct printing method that deposits durable opaque material onto the optical element. This substitution simplifies the manufacturing process while ensuring the aperture material achieves the required durability through proper material selection and deposition techniques.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes composite material structures where opaque materials are deposited onto the optical element surface to form the aperture. These composite structures provide both the required durability and the optical blocking function, achieving reliable performance without complicating the manufacturing process through integrated material deposition.

Inventive Principle:

Principle #40Composite 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

This approach results in a cost-effective, durable aperture that can withstand environmental stresses and simplifies manufacturing, enabling mass production of infrared cameras with improved optical performance and reduced unit costs, suitable for consumer-oriented devices.

Implementation Method 1

The ink provides for adequate durability and dimensional stability over time and is used commercially in challenging applications such as on automotive windshields and cosmetically critical applications such as on branded sunglass lenses

Methodology Applied

Scientific EffectAbsorption (EM radiation): Absorption (EM radiation)

Implementation Method 2

In a particular embodiment, the aperture is pad printed onto the element, typically the lens itself, and the loading, printing and unloading may be fully automated

Methodology Applied

Scientific EffectPad printing:

Data Source

PatentUS9684153B2System and method for producing an aperture on an optical element of an infrared optical system

Publication Date: 2017.06.20 SEEK THERMAL

AI summary

A system and method for producing an optical aperture for an optical element of an infrared optical system includes placing the optical element in a printer and applying ink in an image of the optical aperture to a curved surface of the optical element.