Integrated Optical Assembly Mold-in-Place Alignment
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Solution Overview
Problem
Current methods for mounting infrared optical elements in optical systems face challenges such as human error in alignment and precision, material mismatch leading to potential damage from temperature changes, and the need for expensive materials like titanium or kovar to match thermal expansion coefficients, as well as the complexity of using epoxies and silicones for secure bonding.
Innovation Solution
An integrated optical assembly is developed, where an opaque tubular optics mount with a transparent optical element is formed through a mold-in-place process, eliminating the need for additional adhesives and retaining elements, and incorporating a second optical element like an aperture stop, which is secured using bonding agents or welding, ensuring precise alignment and thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If epoxies and silicones are used to bond optical elements to mounts, then the optical elements can accommodate thermal expansion differences, but the manufacturing process becomes complex and prone to human error in alignment
Solution Approach 1:
The patent merges the optical element and mount into a single integrated component manufactured via injection molding. The optical element is molded directly within the mount structure, eliminating separate bonding steps and aligning features. This integration maintains thermal expansion accommodation through material selection while removing the complexity of epoxy application, curing, and alignment procedures.
Solution Approach 2:
The injection molding process inherently provides alignment and positioning features through the mold design. The optical element is self-aligned within the mount during molding, eliminating the need for manual alignment and bonding operations. The process serves its own alignment function through geometric constraints built into the mold cavity.
2Strength
If rigid bonding materials are used to match thermal expansion coefficients, then the optical elements remain secure, but expensive materials like titanium or kovar are required
Solution Approach 1:
The patent changes the material parameter from expensive metals (titanium, kovar) to conventional plastics with appropriate thermal expansion properties. The plastic mount material is selected to have a coefficient of thermal expansion that accommodates the optical element while remaining cost-effective. This parameter change maintains bonding strength through integrated molding while dramatically reducing material costs.
Solution Approach 2:
The patent uses composite material properties in the plastic mount, combining materials with specific thermal expansion characteristics. The mount material is engineered to have thermal properties that match or accommodate the optical element, providing secure retention without requiring expensive metal alloys. The composite approach achieves the desired thermal compatibility at lower cost.
3Reliability
If additional parts like retainers and intermediate parts are used to mount optical elements, then thermal expansion is compensated, but the device complexity and manufacturing steps increase
Solution Approach 1:
The patent combines multiple separate components (mount, retainer, intermediate parts) into a single integrated injection-molded structure. The thermal expansion compensation function is built directly into the mount design through material selection and geometric features, eliminating the need for separate retainer and intermediate components. This merger maintains thermal compensation while dramatically improving manufacturing efficiency through single-step production.
Solution Approach 2:
The integrated mount structure performs multiple functions simultaneously: it provides mechanical support, thermal expansion compensation, and optical element retention through its molded geometry. The single component replaces multiple specialized parts, each designed for specific functions. This multi-functionality maintains reliability while streamlining manufacturing and reducing assembly steps.
Data Source
AI summary
An integrated optical assembly comprises an optics mount, an optical element comprising material that is optically transparent, the optical element molded in the optics mount, and an optical aperture wherein the optical aperture is secured in fixed position with respect to the optics mount and the transparent optical element.