Nonsymmetric Freeform Optical System Design for Compact Space

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Solution Overview

Problem

Current optical systems, such as coaxial and off-axis meridian symmetric systems, face challenges in designing compact optical systems for limited spaces with non-symmetrical shapes, as they often have central obstructions and limited usable fields of view with good image quality, making it difficult to fit them into constrained spaces.

Innovation Solution

A nonsymmetric freeform surface optical system is designed with a primary, secondary, and tertiary reflecting mirror, lacking rotational and meridional symmetry, allowing for three-dimensional light deflection and a compact structure, utilizing a point-by-point direct design method to optimize the freeform surface, which includes establishing an initial plane system, calculating coordinates and normal vectors, and iteratively optimizing the optical system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If coaxial optical system is used, then mature design methods and products are available, but sufficient space cannot be allocated when space is limited or shape is constrained

Engineering Contradiction:
Improvemature design methodsVSAvoidspace allocation
Core Design Contradiction:
Ease of manufactureVSVolume of moving object

Solution Approach 1:

The patent applies asymmetry by transitioning from traditional symmetric optical systems (coaxial and off-axis meridian symmetric) to a nonsymmetric freeform surface optical system. The optical surfaces are designed without rotational or meridional symmetry, allowing the system to adapt to asymmetric spatial constraints and achieve compact three-dimensional light deflection while maintaining imaging quality.

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

The patent employs three-dimensional freeform surfaces instead of traditional two-dimensional rotationally symmetric surfaces. This dimensional transition enables the optical system to utilize space more efficiently in all three dimensions, achieving compact integration while providing sufficient space for optical components in constrained environments.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Volume of moving object

If off-axis meridian symmetric optical system is used, then space utilization improves, but central obstruction and limited usable central field of view with good image quality remain

Engineering Contradiction:
Improvespace utilizationVSAvoidimage quality
Core Design Contradiction:
Volume of moving objectVSReliability

Solution Approach 1:

The patent eliminates the limitations of off-axis meridian symmetric systems by removing meridional symmetry constraints entirely. The nonsymmetric freeform surfaces allow for optimized light paths that avoid central obstructions while expanding the usable field of view, achieving both compact space utilization and high image quality across a broader field.

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

The patent changes the fundamental parameters of the optical surfaces from rotationally symmetric or meridionally symmetric forms to completely nonsymmetric freeform surfaces. This parameter transformation enables simultaneous optimization of space utilization, elimination of central obstructions, and maintenance of high image quality across the field of view.

Inventive Principle:
Principle #35Parameter changes

3Ease of manufacture

If traditional symmetric optical systems are used, then design methods are mature, but design freedom is limited and difficult to fit into limited physical space with non-symmetrical shape

Engineering Contradiction:
Improvemature design methodsVSAvoiddesign freedom
Core Design Contradiction:
Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent resolves the contradiction between mature design methods and design freedom by developing a systematic approach to nonsymmetric freeform surface design. This includes establishing initial plane systems, calculating coordinates and normal vectors point-by-point, and iteratively optimizing the optical system, thereby extending mature design methodologies to accommodate asymmetric spatial constraints.

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

The patent extends traditional two-dimensional optical design to three-dimensional freeform surface design, adding dimensional freedom that enables adaptation to complex asymmetric spatial constraints while maintaining systematic design procedures.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

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 nonsymmetric freeform surface optical system achieves a more compact design with increased design freedom, allowing it to fit into smaller spaces and maintain good image quality, with a larger angle of view and reduced distortion, effectively addressing the limitations of traditional systems.

Implementation Method 1

a primary reflecting mirror (102), a secondary reflecting mirror (104), and a tertiary reflecting mirror (106). The light from the object is reflected on the primary reflecting mirror (102) to form a first reflected light beam

Methodology Applied
Scientific EffectReflection: Reflection

Implementation Method 2

The first reflected light beam irradiates the secondary reflecting mirror (104) and is reflected to form a second reflected light beam

Methodology Applied
Scientific EffectReflection: Reflection

Implementation Method 3

The second reflected light beam irradiates the third reflecting mirror (106) and is reflected to form a third reflected light beam

Methodology Applied
Scientific EffectReflection: Reflection

Data Source

PatentUS12189118B2Method for designing nonsymmetric freeform surface optical system
Publication Date: 2025.01.07 HON HAI PRECISION INDUSTRY CO LTD
  • US12189118B2 patent drawing
  • US12189118B2 patent drawing
  • US12189118B2 patent drawing

AI summary

The present application relates to a method for designing a nonsymmetric freeform surface optical system, and the method including the following steps establishing an initial plane system. The initial plane system is consistent with the expected system structure, but there is no focal power in the initial plane system. The image plane tilt angle of the initial plane system is defined as θ. The point-by-point method is used to calculate the coordinates and normal vectors of the data points used to construct the freeform surface. The iterative optical system is obtained by iteration; and the iterative optical system is optimized.