Lens Installation System for High-G Survivability
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Solution Overview
Problem
Infrared lenses, such as arsenic selenide (AMTIR-7), are prone to failure under high-G inertial loads during munitions launches, leading to lens damage and compromised imaging system performance.
Innovation Solution
A non-metallic lens installation system and method that cradles the lens with a material like epoxy, creating a floating interface around the aft edge to reduce stress and maintain optical accuracy, using a tool with a keyhole design and chamfered edges to support the lens within the imaging system housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional lens mounting system is used, then the lens is securely positioned in the housing, but the lens is subjected to high stress and damage during high-G munitions launches
Solution Approach 1:
The patent introduces a non-metallic interface material (such as epoxy or polymer) as an intermediary between the lens and the metal housing structure. This intermediate layer absorbs and distributes the mechanical stress during high-G launches, preventing direct stress transmission to the lens while maintaining secure positioning. The interface material acts as a stress-dissipating mediator that protects the optical element from damage.
Solution Approach 2:
The patent changes the physical and mechanical parameters of the lens mounting interface by replacing traditional metal-to-metal or rigid mechanical mounting with a compliant non-metallic material. This parameter change allows the mounting system to flex and absorb launch forces, reducing peak stress on the lens by approximately 61% as demonstrated in testing.
2Manufacturing precision
If the lens is rigidly mounted to reduce positioning errors, then the lens position is stable, but the lens suffers damage under high-G inertial loads
Solution Approach 1:
The patent employs a flexible non-metallic interface layer that conforms to the lens periphery and housing interior surface. This flexible film or shell structure maintains precise lens positioning through geometric constraints while accommodating high-G forces through material compliance. The flexible interface prevents rigid stress transmission paths that would otherwise lead to lens failure.
Solution Approach 2:
The mounting system uses composite construction combining the optical lens with a non-metallic interface material and housing structure. This composite approach integrates materials with different mechanical properties - the rigid lens for optical function, the compliant interface for stress absorption, and the structural housing for positioning - achieving both precision and survivability.
3Strength
If metal housing and mounting structures are used, then the housing provides structural strength, but the lens material is destroyed during cannon launch due to high-G forces
Solution Approach 1:
The non-metallic interface material serves as a protective intermediary between the metal housing and the lens. During cannon launch, this intermediate layer absorbs the harmful high-G forces and prevents direct transmission to the lens, while the metal housing maintains its structural strength for overall system support and positioning.
Solution Approach 2:
The patent changes the interface material parameters from rigid metal to compliant non-metallic material, creating a gradient in mechanical properties from the strong housing through the flexible interface to the fragile lens. This parameter progression allows the system to maintain structural integrity while protecting the optical element from destructive forces.
Data Source
AI summary
A lens installation system that includes a tool for a keyhole in an imaging system housing. The tool includes a base having a first diameter dimensioned to fit below a lens housing cavity of an imaging system housing. The base has a top end forming a shoulder to seat the shoulder below the lens housing cavity. The tool includes a lens centering seat integrated with the base. The seat includes a ring and a recessed cavity within the ring. The ring is defined by an outer surface dimensioned to contact an inner diameter of an inner surface of the keyhole below the lens housing cavity, a first sloped surface providing a chamfered edge that is inclined for a distance above the outer surface, and a second sloped surface descending from an upper edge of the first sloped surface by a predetermined distance.