Seamless Optical Element with Slanted Surfaces
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Solution Overview
Problem
Current optical elements in manufacturing processes face challenges in reducing manufacturing load and achieving high value-added optical characteristics, particularly in providing seamless connections and efficient light transmission while maintaining optical accuracy and heat dissipation.
Innovation Solution
The optical element comprises a first and second light transmissive optical portion connected by a seamless, light transmissive connection region, with surfaces designed to minimize reflection and absorption losses, and a gap for improved heat dissipation, allowing for enhanced optical characteristics and reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple optical portions are connected to form a complex optical element, then optical functionality is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple optical portions (first optical portion and second optical portion) into a single integrated optical element with a unified structure. The connection region integrates these portions seamlessly, eliminating the need for separate assembly processes and reducing manufacturing complexity while maintaining enhanced optical functionality.
Solution Approach 2:
The optical element is designed as a multi-functional component where the first optical portion, second optical portion, and connection region work together as an integrated system. This universal design allows the single element to perform multiple optical functions that would otherwise require separate components, simplifying the manufacturing process.
2Ease of manufacture
If optical portions are connected with traditional methods, then manufacturing is simpler, but connection seamless and light transmission quality deteriorates
Solution Approach 1:
The connection region acts as an intermediary structure that seamlessly joins the first optical portion and second optical portion. This intermediate zone is specifically designed to maintain optical continuity and minimize reflection, providing high-quality light transmission while being integrated into the single-piece manufacturing process.
Solution Approach 2:
The connection region employs gradual parameter changes in its refractive index and physical dimensions to bridge the optical portions. This gradual transition minimizes optical discontinuities and reflection losses, achieving high manufacturing precision for connection quality while maintaining ease of manufacture through additive manufacturing.
3Ease of manufacture
If optical surfaces are made perpendicular to light direction, then manufacturing is easier, but reflection and absorption losses increase
Solution Approach 1:
The optical surfaces are designed with asymmetric orientations relative to the light propagation direction. Instead of being perpendicular, the surfaces are angled to reduce reflection losses. This asymmetric design is integrated into the additive manufacturing process, allowing optimized optical performance without significantly increasing manufacturing complexity.
4Manufacturing precision
If optical portions are made as single piece, then manufacturing precision is improved, but heat dissipation capability deteriorates
Solution Approach 1:
While manufactured as a single piece, the optical element is functionally segmented into distinct regions (first optical portion, connection region, second optical portion) with different thermal management characteristics. The connection region serves as a thermal interface that facilitates heat dissipation between portions, maintaining optical precision while improving heat management through functional segmentation.
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 configuration results in a highly value-added optical element with improved optical performance, reduced manufacturing load, and efficient heat dissipation, enabling accurate mounting and effective light utilization with minimal reflection and absorption losses.
Implementation Method 1
The first connection region connects at least a portion of an end of the first optical portion and at least a portion of an end of the second optical portion, and provides a seamless connection to the first optical portion and the second optical portion. The first connection region is light transmissive.
Implementation Method 2
At least one of the first surface or the second surface includes a portion slant to a plane perpendicular to a first direction from the second optical portion toward the first optical portion.
Data Source
AI summary
An optical element includes first and second optical portions, and a first connection region. The first optical portion has first and second surfaces opposed each other. The first optical portion is light transmissive. The second optical portion has a third surface opposing the first surface and separated from the first surface, and a fourth surface on an opposite side to the third surface. The second optical portion is light transmissive. The first connection region connects at least a portion of an end of the first optical portion and at least a portion of an end of the second optical portion, and provides a seamless connection to the first and second optical portions. The first connection region is light transmissive. At least one of the first or second surfaces includes a portion slanted to a plane perpendicular to a first direction from the second optical portion toward the first optical portion.