Off-Axial Three-Mirror System With Integrated Freeform Mirrors

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Solution Overview

Problem

Off-axial three-mirror systems face limitations in degrees of freedom and difficulty in assembling and aligning separate mirrors, which affect their performance and image quality.

Innovation Solution

Designing an off-axial three-mirror system where the primary and tertiary mirrors are formed as one piece with freeform surfaces, such as XY polynomial or Zernike polynomial surfaces, and integrating them within a bulk structure to enhance assembly precision and alignment, while allowing for more degrees of freedom to improve imaging performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If separate mirrors are used in the off-axial three-mirror system, then the system structure is simpler to manufacture individually, but the assembly and alignment difficulty increases

Engineering Contradiction:
Improvemanufacturability of individual mirrorsVSAvoidassembly and alignment complexity
Core Design Contradiction:
Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges the primary mirror and tertiary mirror into a single integrated component with a freeform surface. This combination eliminates the need for separate assembly and alignment of these two mirrors, directly resolving the contradiction by reducing assembly complexity while maintaining the optical functionality of both mirrors. The integrated design allows the system to benefit from simpler manufacturing of the combined structure while avoiding the alignment difficulties that would arise from using separate mirrors.

Inventive Principle:
Principle #5Merging (Combining)

2Ease of manufacture

If traditional spherical or conicoid mirrors are used, then the manufacturing process is well-established, but the degrees of freedom for optimizing imaging performance are limited

Engineering Contradiction:
Improvemanufacturing process maturityVSAvoiddegrees of freedom for imaging optimization
Core Design Contradiction:
Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent employs a freeform surface described by mathematical polynomials (such as Zernike or XY polynomials) for the integrated mirror. This allows continuous adjustment of surface parameters and coefficients to optimize imaging performance across multiple fields of view. The freeform surface provides numerous adjustable parameters that enable fine-tuning of optical paths, thereby increasing degrees of freedom for imaging optimization while remaining manufacturable through precision polishing and measurement techniques.

Inventive Principle:
Principle #35Parameter changes

3Manufacturing precision

If multiple separate mirrors are used, then each mirror can be optimized independently, but the overall system alignment precision decreases

Engineering Contradiction:
Improveindividual mirror optimizationVSAvoidsystem alignment precision
Core Design Contradiction:
Manufacturing precisionVSMeasurement precision

Solution Approach 1:

By integrating the primary and tertiary mirrors into a single component, the patent eliminates alignment errors that would occur between separate mirrors. The integrated design ensures that the optical surfaces are precisely positioned relative to each other during manufacturing, achieving higher system alignment precision. At the same time, the freeform surface allows independent optimization of different regions of the mirror to maintain individual mirror optimization benefits.

Inventive Principle:
Principle #5Merging (Combining)

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 approach increases the system's degrees of freedom, simplifies assembly and alignment, and enhances image quality by maintaining high modulation transfer function values close to the diffraction limit, thereby improving overall performance.

Implementation Method 1

The secondary mirror 104 is located on a reflective optical path of the primary mirror 102. The tertiary mirror 106 is located on a reflective optical path of the secondary mirror 104.

Methodology Applied
Scientific EffectReflection: Reflection

Data Source

PatentUS8975571B2Off-axial three-mirror system
Publication Date: 2015.03.10 HON HAI PRECISION INDUSTRY CO LTD
  • US8975571B2 patent drawing
  • US8975571B2 patent drawing
  • US8975571B2 patent drawing

AI summary

An off-axial three-mirror system includes a primary mirror, a secondary mirror, a tertiary mirror, and an image sensor. The secondary mirror is located on a reflective optical path of the primary mirror. The tertiary mirror is located on a reflective optical path of the secondary mirror. The image sensor is located on a reflecting optical path of the tertiary mirror. The primary mirror and the tertiary mirror are formed as one piece. The surface type of both the primary mirror and the tertiary mirror is a freeform surface. The primary mirror is a convex mirror, and the tertiary mirror is a concave mirror.