Monolithic Optical Bench for Athermal Reflex Sight Alignment
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Solution Overview
Problem
Existing weapon sights, particularly reflex and laser sights, require time-consuming alignment adjustments for windage and elevation, and plastic lenses are not widely used due to thermal expansion issues, increasing manufacturing costs.
Innovation Solution
A monolithic optical bench structure formed via additive manufacturing, incorporating flexures for adjustment and thermal stability, which supports both reflex and laser sight components, including a plastic reflex lens with embedded iron sight and adjustable laser emitters, allowing for coalignment and athermalization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic lenses are used instead of glass lenses, then manufacturing costs are reduced, but thermal expansion issues arise due to higher coefficient of thermal expansion
Solution Approach 1:
The patent changes the material parameter from glass to plastic lens, accepting the higher thermal expansion coefficient in exchange for lower manufacturing cost. The design accommodates this parameter change through the monolithic structure that can absorb thermal deformation.
Solution Approach 2:
The patent segments the sight system into a monolithic optical bench structure that can independently accommodate lens thermal expansion without affecting other components. This segmentation allows the plastic lens to expand/contract freely while maintaining overall system stability.
2Ease of operation
If traditional alignment adjustment methods are used, then sight alignment can be adjusted, but the process is time-consuming
Solution Approach 1:
The patent incorporates preliminary alignment features directly into the monolithic optical bench structure during manufacturing. The flexures and mounting features are pre-configured to provide automatic alignment, eliminating the need for time-consuming field adjustments.
Solution Approach 2:
The monolithic structure with integrated flexures provides self-aligning capabilities that automatically maintain sight alignment without requiring manual intervention. The structure serves its own alignment needs through its inherent design features.
3Ease of manufacture
If multiple separate components are used in the optical bench, then manufacturing flexibility is maintained, but the structure becomes complex with bonded or bolted joints
Solution Approach 1:
The patent merges multiple separate optical bench components into a single monolithic structure manufactured via additive manufacturing. This consolidation eliminates bonded or bolted joints, reducing structural complexity while maintaining manufacturing flexibility through the additive process.
Solution Approach 2:
The patent changes the manufacturing approach from traditional subtractive or assembly-based methods to additive manufacturing. This parameter change enables the creation of complex monolithic structures that would be difficult or impossible to manufacture using conventional techniques.
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 solution enables efficient adjustment and maintenance of sight alignment, accommodates thermal expansion of plastic lenses, and reduces manufacturing costs by providing a single-piece structure with no bonded or bolted joints, enhancing performance in high-shock environments.
Implementation Method 1
Because plastic lens materials have a higher coefficient of thermal expansion than glass, plastic lenses have not been widely adapted for use in reflex sights. The optical bench structure includes one or more flexures for optothermal stability of optical assemblies.
Data Source
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AI summary
An optical bench for supporting a reflex sight in a weapon-mounted sight assembly includes a reflex sight mounting portion having a first surface for receiving a reticle light source and a first reticle lens mounting arm spaced apart from a second reticle lens mounting arm. The first and second reticle lens mounting arms are attached to the reflex sight mounting portion and the first and second reticle lens mounting arms are configured to engage opposite sides of a reticle lens to support the reticle lens in an optical path of the reticle light source. The first and second reticle lens mounting arms are sufficiently resilient to accommodate thermal expansion and contraction of the reticle lens. In further aspects, a weapon sight assembly employing an optical bench and a method for manufacturing an optical bench are provided.