Solid State Lenses via Powder Compression Molding
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Solution Overview
Problem
Traditional lens manufacturing processes struggle to produce aspheric lenses efficiently due to the difficulty in achieving precise non-spherical surfaces, especially in materials that are limited in infrared and ultraviolet spectral transmission, and are costly and time-consuming for high-volume production.
Innovation Solution
A solid-state method involving the compression of deformable powder particles into cohesive monolithic solids at low temperatures, using suitable optical materials and host matrix materials like potassium bromide to form lenses with low absorption and scattering, allowing for the creation of aspheric lenses and components that transmit ultraviolet, visible, and infrared light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional lens grinding and polishing methods are used to create aspheric surfaces, then precise non-spherical surfaces can be achieved, but the manufacturing process becomes extremely difficult, time-consuming, and expensive
Solution Approach 1:
The patent changes the physical state of the optical material from solid (requiring grinding and polishing) to powder form that can be compressed and molded. This parameter change allows aspheric surfaces to be formed through molding rather than subtractive machining, dramatically easing manufacturing while maintaining precision
Solution Approach 2:
The patent utilizes phase transition by converting optical materials into powder form and then compressing them into cohesive monolithic solids at low temperatures. This phase transition enables the material to be shaped into precise aspheric surfaces through molding, avoiding the difficulties of traditional grinding and polishing methods
2Productivity
If thermoplastic optical polymers are used for injection or compression molding of aspheric lenses, then high-volume production becomes feasible, but infrared transmission is severely limited to wavelengths less than 1.7 microns
Solution Approach 1:
The patent creates composite optical materials by combining powder particles of deformable optical materials with host matrix materials such as potassium bromide. This composite approach enables high-volume production through molding while achieving broad spectral transmission including infrared wavelengths, overcoming the limitations of pure thermoplastic polymers
3Reliability
If exotic crystals and alloys are ground and polished for use as lenses, then broad infrared and ultraviolet spectral transmission can be achieved, but the materials are not suitable for volume manufacture by molding and are expensive
Solution Approach 1:
The patent changes the form factor and processing method by converting exotic optical materials into powder form that can be compressed and molded. This allows volume manufacture of lenses from materials like potassium bromide that previously could only be processed by slow grinding and polishing, while maintaining their excellent spectral transmission properties
Solution Approach 2:
The patent replaces the mechanical grinding and polishing system with a compression molding system. By applying high pressure to powder particles in a mold, precise aspheric lens surfaces are formed directly, eliminating the need for slow subtractive machining while enabling high-volume production
4Manufacturing precision
If computer-numerical-control diamond surface cutting or grinding is used for aspheric optical components, then precise non-spherical surfaces can be manufactured, but the process is too slow and expensive for economical high-volume production
Solution Approach 1:
The patent utilizes phase transition by converting optical materials into powder form and then compressing them into cohesive monolithic solids at low temperatures. This enables precise aspheric surfaces to be formed through molding in a single step, achieving both high precision and high production speed
Solution Approach 2:
The patent applies preliminary action by pre-forming the aspheric surface geometry in the mold cavity before compression. This eliminates the need for subsequent precision machining or CNC grinding, enabling both high precision and economical high-volume production
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 method enables the economical and efficient production of lenses with precise non-spherical surfaces, overcoming the limitations of traditional methods by allowing for the formation of lenses at room temperature, reducing production costs, and improving spectral transmission across a broader range.
Implementation Method 1
A solid-state method involving the compression of deformable powder particles into cohesive monolithic solids at low temperatures
Implementation Method 2
compression of deformable powder particles into cohesive monolithic solids
Data Source
AI summary
Solid state lenses, lens blanks, and lens components formed of compressible mixed powders of two or more optical substances where the mixing ratio has been deliberately varied from place to place within the volume of the optical component to produce optically useful variations in the local refractive. The compressible mixed powders are ground as fine powders having mechanical properties that make them capable of being formed into cohesive monolithic masses that are low in scattering. The fine powders may be admixtures of host matrix materials and others which, when combined, provide preferred optical properties such as index and dispersion. Parts possessing transmission from within the range from the ultraviolet to the infrared are possible. The materials are suited to low temperature formation of aspheric lenses transmissive in the near and far IR.