Refractive Optical Component Scattering Reduction via Layered Index Modulation
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Solution Overview
Problem
Existing additive manufacturing processes for refractive optical components often result in undesirable scattering effects, negatively impacting their optical properties.
Innovation Solution
A refractive optical component with a base body manufactured via 3D printing, featuring optical layers with specific thickness, orientation, and a modulated refractive index profile to minimize scattering, using a 3D printing process that controls droplet size and application density for precise layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional lens production methods are used, then manufacturing precision and surface quality are maintained, but material waste is high and production time is long
Solution Approach 1:
The patent changes the manufacturing approach from subtractive (milling) to additive (3D printing) processes. This fundamental parameter change in production methodology enables near-net-shape manufacturing of lens blanks, dramatically reducing material waste while maintaining optical surface quality through controlled deposition and curing processes
Solution Approach 2:
The patent performs preliminary shaping of lens blanks using additive manufacturing before final precision processing. By pre-forming the bulk geometry through 3D printing, the subsequent polishing and finishing operations require less material removal, thereby reducing both material waste and processing time while preserving surface quality
2Productivity
If conventional lens production methods are used, then manufacturing precision is maintained, but production time and cost are high
Solution Approach 1:
The patent performs preliminary shaping of lens blanks using additive manufacturing before final precision processing. By pre-forming the bulk geometry through 3D printing, the subsequent polishing and finishing operations require less material removal, thereby reducing both material waste and processing time while preserving surface quality
Solution Approach 2:
The patent changes the manufacturing approach from subtractive (milling) to additive (3D printing) processes. This fundamental parameter change in production methodology enables near-net-shape manufacturing of lens blanks, dramatically reducing material waste while maintaining optical surface quality through controlled deposition and curing processes
3Adaptability or versatility
If freeform surfaces are produced using conventional methods, then design flexibility is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent changes the manufacturing approach from subtractive (milling) to additive (3D printing) processes. This fundamental parameter change in production methodology enables near-net-shape manufacturing of lens blanks, dramatically reducing material waste while maintaining optical surface quality through controlled deposition and curing processes
Solution Approach 2:
The patent performs preliminary shaping of lens blanks using additive manufacturing before final precision processing. By pre-forming the bulk geometry through 3D printing, the subsequent polishing and finishing operations require less material removal, thereby reducing both material waste and processing time while preserving 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
The solution significantly reduces scattering losses by more than 50%, providing improved optical properties and flexibility in manufacturing refractive optical components.
Implementation Method 1
The incident light rays are deviated by the refractive optical component 1 onto the retina 2
Data Source
Figure 1~3
Figure 4
AI summary
A refractive optical component (1) has a main body (10) with a plurality m of optical layers (5i) extending between a front side (2) and a back side (3), each layer having a thickness (di) in the direction parallel to the principal axis, wherein each of the layers (5i) extends over a region common to all layers (5i) in directions perpendicular to the principal axis, said common region being greater than the maximum thickness (dimax) of the respective layer (5i) by at least a factor of 10, wherein the thickness (di) of the layers (5i) varies over the extent thereof transversely to the principal axis, and wherein the main body (10) has a refractive index curve (n = n(x, y, z)), modulated at least in the direction parallel to the principal axis, with a plurality of maxima and minima, a distance between adjacent maxima and minima ranging between 0.5 µm and 100 µm and a refractive index difference Δn between adjacent maxima and minima ranging between 10-4 and 0.3, wherein a number of maxima in the refractive index curve within a given layer (5i) is less than 20 in directions transversely to the principal axis.