Optical Assembly Production with Integrated Reference Structures

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Solution Overview

Problem

Existing methods for producing optical arrangements with multiple optical functional surfaces on a common support structure face challenges in achieving precise shape and positional accuracy, particularly with aspherical mirrors, as they require iterative processes that can be time-consuming and prone to systematic errors.

Innovation Solution

A method involving a processing machine to form and position optical functional surfaces in sequence or simultaneously, with the inclusion of a reference structure for precise measurement and iterative correction, allowing for the reduction of shape and positional deviations, ensuring accurate alignment without further adjustment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If iterative production processes are used to achieve precise shape and position of optical functional surfaces, then manufacturing precision is improved, but production time increases

Engineering Contradiction:

Improveshape and position accuracy of optical functional surfacesVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent applies preliminary action by producing reference structures with defined positions on the support structure before producing the optical functional surfaces. This allows the processing machine to use these reference structures as targets for automated measurement and iterative correction, eliminating the need for separate measurement and alignment steps that would otherwise be required. The reference structures serve as pre-established benchmarks that guide the subsequent production process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements feedback by measuring the produced optical functional surfaces against the reference structures using the processing machine's measurement device, determining deviations from target positions, and using this information to correct the production process in iterative cycles. The measurement results feed back into the production control, allowing automatic adjustment of machine parameters to reduce deviations and improve precision without manual intervention.

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If reference structures are produced and measurement steps are repeated iteratively, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improveposition accuracy of optical functional surfacesVSAvoidcomplexity of production process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies universality by designing the processing machine to perform multiple functions: it can both produce the optical functional surfaces and measure them against the reference structures. The same processing machine serves as the measurement device, eliminating the need for separate measurement equipment and reducing overall system complexity. This multi-functional approach integrates production and verification into a single system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If multiple optical functional surfaces are produced on a common support structure, then alignment accuracy is improved, but production difficulty increases

Engineering Contradiction:

Improverelative position accuracy of multiple functional surfacesVSAvoidease of producing multiple surfaces

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies segmentation by dividing the production process into distinct process steps: producing reference structures, producing optical functional surfaces, measuring surfaces against references, and correcting deviations. This segmented approach allows each step to be optimized independently and makes the complex task of producing multiple precise surfaces manageable through systematic, repeatable cycles rather than attempting to accomplish everything in a single complex operation.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentEP2470328B1Method for producing an optical assembly having at least two optical functional surfaces, an optical device and unit for carrying out the method

Publication Date: 2018.01.10 FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV

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AI summary

The invention relates to a method for producing an optical assembly, comprising at least two optical functional surfaces (5, 6) arranged in a fixed positional relationship to one another on a common supporting structure (9), wherein by means of a processing machine (15), in various process steps, at least two optical functional surfaces (5, 6) and at least one reference structure (13) having a defined and measurable relative position to the optical functional surfaces (5, 6) are produced. The supporting structure (9) remains rigidly connected to the processing machine (15) until said process steps have been completed, and wherein the optical functional surfaces (5, 6) are then measured relative to the at least one reference structure (13), and any deviation from a target shape and target position is determined, after which said process steps are repeated at least once with modified actuation of the processing machine (15). The invention further relates to an optical device comprising an optical assembly produced in this way and to a unit for carrying out such a method.