Monolithic Optical Bench Flexures for Thermal Lens Alignment
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Solution Overview
Problem
Existing weapon sights, particularly reflex and laser sights, face challenges in alignment adjustments due to thermal expansion issues with plastic lenses and require time-consuming processes for bore sighting, which is exacerbated by changes in target distance, ammunition types, and firing positions.
Innovation Solution
A monolithic optical bench structure formed via additive manufacturing, incorporating flexures for adjustment of elevation and windage, and optothermal stability, which supports both reflex and laser sight assemblies, including a plastic reflex lens with an embedded iron sight, allowing for thermal expansion compensation and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic lens is used in a reflex sight, then manufacturing costs are reduced, but thermal expansion causes alignment instability
Solution Approach 1:
The patent changes the physical parameters of the mounting structure by introducing flexures with specific geometric designs that allow controlled movement. These flexures are engineered with predetermined flexibility characteristics that enable them to accommodate thermal expansion of the plastic lens while maintaining optical alignment, thus resolving the contradiction between using cost-effective plastic lenses and maintaining alignment stability.
Solution Approach 2:
The patent transitions from a rigid mounting structure to a dynamic one by incorporating flexures that can adaptively move in response to thermal changes. This dynamic structure allows the lens mounting to self-adjust during temperature variations, maintaining alignment stability while using plastic lenses, thereby resolving the contradiction between manufacturing cost and alignment stability.
2Manufacturing precision
If traditional alignment adjustment methods are used, then alignment precision can be achieved, but the process is time-consuming
Solution Approach 1:
The patent incorporates preliminary action by pre-configuring the flexure structures during manufacturing with built-in adjustment capabilities. The flexures are designed with preliminary geometric features that allow for quick alignment adjustments without requiring complex manual procedures, thus achieving both alignment precision and reduced adjustment time.
Solution Approach 2:
The patent implements self-service through flexures that can be easily adjusted by the user without requiring specialized tools or expertise. The self-adjusting mechanism allows operators to perform alignment corrections independently and quickly, reducing both time loss and maintaining precision, thereby resolving the contradiction between alignment precision and adjustment time.
3Ease of repair
If multiple separate components are used in the optical bench, then ease of repair is improved, but manufacturing complexity and assembly time increase
Solution Approach 1:
The patent applies segmentation by dividing the optical bench into distinct functional modules, each with its own flexure-based mounting structure. This modular design allows individual components to be replaced or repaired independently while maintaining the overall integrated structure, thus achieving both ease of repair and controlled complexity through systematic segmentation of the optical bench.
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 alignment and maintenance of laser coalignment, accommodates thermal expansion, and reduces manufacturing costs by using a single-piece structure with no bonded or bolted joints, facilitating quick adjustments and reliable performance across varying conditions.
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 first and second reticle lens mounting arms are sufficiently resilient to accommodate thermal expansion and contraction of the reticle lens.
Implementation Method 2
The first and second reticle lens mounting arms attached to the reflex sight mounting portion and configured to engage opposite sides of the reticle lens. The resiliency of the lens assembly flexures allows for compensation for the expansion of the lens assembly induced by heat.
Implementation Method 3
the optical bench structure is monolithic, formed via an additive manufacturing processes
Data Source
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.