Sharp-Edge Lens Opto-Mechanical Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing opto-mechanical devices struggle to produce small lenses with diameters less than 2 mm for miniaturized imaging systems, as conventional manufacturing methods like edge grinding are costly and time-consuming, and alternative methods like molding and lithography are limited in producing lenses with high index of refraction and short radius of curvature for high-volume, low-cost production.
Innovation Solution
The development of an opto-mechanical assembly using sharp-edged lenses with first and second polished surfaces intersecting at the periphery, which eliminates the need for edge grinding and allows for self-centering and easy integration with image sensors or coherent fiber bundles, enabling high-volume, low-cost production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional edge grinding is used to manufacture small lenses with diameters less than 2 mm, then manufacturing precision can be achieved, but production time increases and manufacturing cost increases
Solution Approach 1:
The patent extracts the edge grinding step from the lens manufacturing process by using pre-formed lenses with edges already ground to the correct diameter. This eliminates the time-consuming edge grinding operation while maintaining the required manufacturing precision, thereby significantly increasing production volume and reducing manufacturing costs.
Solution Approach 2:
The patent applies preliminary action by pre-grounding the lens edges during lens formation rather than after. Lenses are manufactured with edges already ground to the specified diameter and alignment, so that when the lenses are mounted in the opto-mechanical assembly, no further edge grinding is needed. This preliminary preparation of the lens edges enables high-volume production without sacrificing precision.
2Manufacturing precision
If edge grinding is used to align optical and mechanical axes, then alignment precision is achieved, but manufacturing time increases
Solution Approach 1:
The patent removes the edge grinding alignment step by using pre-aligned lenses. The lenses are manufactured with their optical and mechanical axes already aligned, eliminating the need for time-consuming post-manufacturing alignment operations while maintaining the required axis alignment precision.
Solution Approach 2:
The patent performs axis alignment as a preliminary action during lens manufacturing rather than as a separate post-processing step. Lenses are produced with pre-established optical and mechanical axis alignment, so that when mounted in the assembly, the axes are already aligned without requiring additional grinding or adjustment operations.
3Ease of manufacture
If plastic lenses are used for small diameters, then manufacturing cost decreases, but image resolution deteriorates
Solution Approach 1:
The patent uses composite construction by combining glass lenses with plastic or metal housings. The glass lenses provide the necessary optical quality and image resolution for small diameters, while the plastic housing enables cost-effective high-volume manufacturing through molding techniques. This composite approach allows the use of glass optics without the high costs associated with traditional glass lens manufacturing methods.
4Volume of moving object
If lens diameter is reduced to less than 2 mm for miniaturization, then device size decreases, but manufacturing complexity increases
Solution Approach 1:
The patent extracts the complex edge grinding and alignment operations from the miniaturized lens manufacturing process by using pre-formed, pre-aligned lenses. This eliminates the steps that would otherwise become increasingly complex and difficult to perform at sub-2mm scales, thereby reducing manufacturing complexity while maintaining the miniaturized form factor.
Solution Approach 2:
The patent performs all difficult manufacturing operations (edge grinding, axis alignment) as preliminary actions during lens fabrication rather than as post-processing steps. Lenses are manufactured at their final small dimensions with all necessary edge preparations and alignments already completed, eliminating the need for complex miniaturized machining and alignment operations.
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 solution enables the manufacture of opto-mechanical assemblies with small glass lenses that can interface with image sensors or coherent fiber bundles at reasonable production costs and high volumes, suitable for disposable instruments, while maintaining image quality and reducing manufacturing time and costs.
Implementation Method 1
a lens having first and second polished surfaces that intersect in a sharp edge at the periphery
Data Source
AI summary
An opto-mechanical device, such as a lens cell, includes a housing having an axially extending chamber and an intermediate internal spacer that positions a sharp-edged lens in the chamber. The sharp-edged lens has first and second optical surfaces that intersect in a circumferential sharp edge. The housing positions an image sensor proximal to the sharp-edged lens for processing light therefrom.