Molded Chalcogenide IR Lens with Diffractive Surface
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Solution Overview
Problem
Current IR lens designs with molded chalcogenide glass elements require additional normal lenses for thermal imaging and spectral applications, increasing costs without adequate cost control measures.
Innovation Solution
A novel optical design pattern/method incorporating a molded lens with similar optical power and an aberration correction lens, where the molded lens can be the first or second element, using materials like Germanium, ZnSe, or chalcogenide glass, with various surface configurations to minimize manufacturing costs and correct aberrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a molded chalcogenide glass lens is used for thermal imaging applications, then cost is reduced for volume production, but additional normal lenses are required which increases overall device complexity and cost
Solution Approach 1:
The patent combines the functions of multiple separate lenses (molded chalcogenide glass lens and normal aberration correction lens) into a single integrated lens system. The molded lens incorporates both the primary optical power and aberration correction features, eliminating the need for separate normal lenses and reducing overall system complexity while maintaining cost effectiveness for volume production.
Solution Approach 2:
The molded chalcogenide glass lens is designed to perform multiple functions simultaneously: providing the primary optical power for thermal imaging and incorporating aberration correction capabilities. This multi-functional design eliminates the need for additional specialized lenses, reducing both device complexity and overall cost while maintaining manufacturing efficiency for volume production.
2Manufacturing precision
If additional normal lenses are added to correct aberrations in molded lens systems, then optical performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the aberration correction function into the molded chalcogenide glass lens itself by incorporating specific surface profiles and optical designs within the single molded element. This integration eliminates the need for separate aberration correction lenses, maintaining optical performance while reducing the number of components and overall manufacturing cost for volume production.
3Ease of manufacture
If a single molded lens is used to provide all optical power, then manufacturing cost is reduced, but aberration correction becomes more difficult
Solution Approach 1:
The patent applies local quality by incorporating specific surface profiles and optical features at particular regions of the molded lens. The lens design includes varying curvature, aspheric surfaces, and diffractive structures at specific zones to correct aberrations locally while maintaining the overall molded construction. This allows effective aberration control within a single cost-effective molded element.
Solution Approach 2:
The patent employs composite optical designs within the molded lens, combining different surface types (spherical, aspheric, diffractive) and potentially multiple materials or coatings within a single molded element. This composite approach enables effective aberration correction while maintaining the cost advantages of molded manufacturing for volume production.
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 design significantly reduces the total cost of IR lenses by integrating a cost-effective molded lens with a low-cost aberration correction lens, achieving comparable optical performance at a lower cost for volume production.
Implementation Method 1
an optical element is a molded lens and this molded optical element has an optical power that is almost the same as the optical power of the whole lens
Data Source
AI summary
A lens system for infrared (IR) imaging, including a molded first lens element and an aberration correction second lens element. The first lens element is made of chalcogenide glass and has a first and second surface, one of the first and second surfaces of the first lens element being a diffractive surface. The second lens element has a first and second surface, one of the first and second surfaces being a planar surface and neither of the first and second surfaces being a diffractive surface. The second lens element is of a different material than the second lens element.