Multi-Component Optical System Fabrication via Integral Mold Alignment
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Solution Overview
Problem
Current methods for manufacturing multi-component optical systems face issues with adhesive failures and alignment problems, leading to optical distortions and reduced performance due to the use of adhesive assembly processes.
Innovation Solution
A mold-based process for fabricating multi-component optical systems, where a cup portion with a cavity and an attachment portion is used to integrate optical components, eliminating the need for adhesive layers by allowing components to be accurately configured and aligned within the mold itself.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive assembly process is used to join optical components, then components can be connected, but optical distortions and adhesive failures occur due to inhomogeneities in adhesive layers
Solution Approach 1:
The patent merges the bonding function and the optical component into a single integrated structure. The adhesive layer is not merely a joining medium but becomes an integral part of the optical system with a defined refractive index, eliminating the interface between separate components and reducing optical inhomogeneities.
Solution Approach 2:
The patent introduces a carefully controlled adhesive layer with specific optical properties (refractive index matching) as an intermediary between optical components. This mediator minimizes optical distortions while maintaining mechanical bonding, transforming the adhesive from a potential source of defects to a functional element of the optical system.
2Ease of manufacture
If traditional cutting and assembly methods are used, then manufacturing flexibility is maintained, but alignment problems and adhesive failures increase
Solution Approach 1:
The patent applies preliminary action by pre-configuring the adhesive layer with optimal thickness and refractive index properties before final assembly. The mold cavity is designed with precise dimensions and surface treatments that ensure proper adhesive distribution and bonding, preventing alignment problems before they occur.
Solution Approach 2:
The patent utilizes parameter changes by controlling the refractive index, thickness, and optical homogeneity of the adhesive layer. By adjusting these parameters, the adhesive layer achieves both mechanical bonding strength and optical transparency, eliminating the trade-off between manufacturing ease and assembly reliability.
3Device complexity
If multiple optical components are assembled using adhesives, then system complexity is reduced, but optical inhomogeneities such as bubbles and de-adhesion occur
Solution Approach 1:
The patent applies local quality by optimizing the adhesive layer properties specifically at the interface between optical components. The adhesive is formulated with local characteristics (refractive index matching, controlled viscosity, bubble-free application) that address the specific requirements of optical bonding while maintaining overall assembly simplicity.
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3A~3B
AI summary
The present disclosure relates to devices and processes for fabricating a multi-component optical system. A device is an integral mold comprising an attachment portion and a cup portion having a cavity, and the mold further comprises a first optical component. The cavity of the mold contains additional optical components to form a multi-component optical system blank. Another device is a multi-component optical system blank. A process for fabricating a multi-component optical system blank comprises providing an integral mold comprising a first optical component, adding at least a second optical component, shaping the mold after addition of an optical component, and shaping the resultant blank into an optical system. A further device is a multi-component optical system produced in a process disclosed herein.