Optical Light Guide With Replicated Polymer Lens
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Solution Overview
Problem
Conventional methods for manufacturing optical light guide elements face challenges in minimizing polishing steps, maintaining small dimensions while preserving optical performance, and achieving precise alignment of slanted optics, especially at small scales.
Innovation Solution
The method involves creating optical light guide elements with replicated polymer lenses and reflective surfaces, using a multi-step molding process to form inclined surfaces that redirect light efficiently, and incorporating additional optical elements like lenses, filters, and gratings within the light guide, allowing for precise control of position and angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used for optical light guide elements, then the elements can be produced, but polishing steps are required which increase manufacturing complexity and time
Solution Approach 1:
The mold cavity is pre-formed with the exact optical surface geometry required, including inclined surfaces and curved profiles. This preliminary formation of the optical surface in the mold eliminates the need for subsequent polishing steps, directly resolving the contradiction between achieving high manufacturing precision and reducing process complexity
Solution Approach 2:
The mechanical polishing process is replaced by a molding process where the optical surface is formed directly in the mold cavity. This substitution of the mechanical finishing system with a formative molding system eliminates complex polishing equipment and multi-step procedures while maintaining high surface quality
2Volume of moving object
If the optical light guide element is made small in dimension, then the device size is reduced, but alignment precision of slanted optics becomes more difficult to achieve
Solution Approach 1:
Multiple optical functions including light guidance, slanted surface reflection, and alignment features are merged into a single monolithic molded element. The alignment of slanted optics is achieved by integrating them directly into the molded structure with built-in registration features, eliminating the need for separate assembly and alignment steps that would be particularly difficult at small scales
Solution Approach 2:
The mold cavity incorporates local geometric features such as registration pins, angled surfaces, and precise cavity shapes that ensure correct positioning and orientation of optical elements during molding. These localized quality features in the mold directly transfer precise alignment to the final small-scale component without requiring post-manufacturing adjustment
3Manufacturing precision
If multiple polishing steps are performed to achieve precise optical surfaces, then surface quality is improved, but manufacturing time and cost increase
Solution Approach 1:
The optical surface geometry is preliminarily formed with high precision directly in the mold cavity during the molding process. This preliminary formation of the final surface geometry eliminates the need for subsequent polishing operations, directly resolving the contradiction between achieving high surface quality and maintaining manufacturing efficiency
Solution Approach 2:
The polishing operation is completely extracted from the manufacturing process by forming the optical surface directly in the mold. This extraction of the finishing operation from the production sequence eliminates the time and cost associated with multiple polishing steps while maintaining high optical surface quality
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 minimizes polishing steps, maintains small dimensions without compromising optical performance, and enables precise alignment of slanted optics, effectively reducing the complexity and cost of assembling small-scale optical systems.
Implementation Method 1
the first inclined surface area and said second inclined surface area both comprise a substrate provided with a reflective surface
Implementation Method 2
said first surface area on the optical light guide element which faces the light source comprises a first replicated polymer lens
Data Source
AI summary
The present invention relates to an optical light guide element having a first end section with a light entrance area designed for facing a light source and having a second end section with a light exit area designed for facing a light target area, wherein the light exit area is defined by a second surface area on the optical light guide element which faces a light target area, and wherein the light entrance area is defined by a first surface area on the optical light guide element which faces the light source, wherein the first end section comprises a first inclined surface area which forms an acute angle with the first surface area of the light entrance area, wherein the second end section forms a second inclined surface area which encloses an acute angle with the surface area of the light exit area, characterized in that said first surface area on the optical light guide element which faces the light source comprises a first replicated polymer lens.