Surgical Headlight Optical Assembly for Uniform Light Without Doublets
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Solution Overview
Problem
Existing surgical headlights suffer from poor light uniformity, unacceptable color separation at the edge of the beam, and are often heavy or uncomfortable due to the use of doublet lenses, leading to clinician discomfort during prolonged procedures.
Innovation Solution
A headlight design featuring a housing with an optical assembly comprising three singlet lenses - a first singlet lens, a second bi-convex lens, and a third plano-convex lens - positioned to provide a uniform light beam, with each lens centered on an optical axis and spaced apart to enhance comfort and light intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a doublet lens is used in the headlight, then light uniformity is improved, but the headlight becomes heavier and causes head and neck discomfort
Solution Approach 1:
The patent divides the optical system into multiple singlet lenses (first singlet lens, second singlet lens, and third singlet lens) positioned at specific distances from each other. This segmentation replaces the traditional single doublet lens while achieving similar or superior light uniformity through the combined effect of multiple simpler optical elements, thereby reducing overall weight.
Solution Approach 2:
Each singlet lens in the optical assembly has specific local optical properties optimized for its position in the light path. The first singlet lens is positioned close to the LED, the second singlet lens is positioned at an intermediate distance, and the third singlet lens is positioned at the distal end, with each lens contributing differently to the overall light uniformity while maintaining lightweight construction.
2Illumination intensity
If the doublet lens is positioned at the distal opening of the housing, then light uniformity is improved, but the lens diameter becomes relatively large
Solution Approach 1:
The optical function previously handled by a single large doublet lens is segmented across three smaller singlet lenses positioned at different locations in the optical path. This segmentation allows each lens to have a smaller diameter while collectively achieving the desired light uniformity across the beam.
Solution Approach 2:
Instead of achieving light uniformity through a single large lens element, the patent distributes the optical function across multiple smaller lenses arranged in sequence along the optical axis. This dimensional redistribution allows the system to achieve the same uniformity effect with smaller individual lens diameters.
3Illumination intensity
If a singlet lens is positioned between the LED and doublet lens, then light uniformity is improved, but the overall device complexity increases
Solution Approach 1:
The patent further segments the optical system into three singlet lenses instead of using a doublet lens with an additional singlet. This segmentation simplifies the optical assembly by using identical or similar lens elements (all singlet lenses) rather than combining different lens types (doublet and singlet), reducing manufacturing complexity while maintaining light uniformity.
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 design achieves a more uniform light beam with greater intensity, reducing weight and discomfort, making it more comfortable for medical professionals during extended surgical procedures.
Implementation Method 1
an optical assembly at least partly in the passage of the housing, the optical assembly comprising: a first singlet lens proximate the second end and defining an optical axis; a second singlet lens disposed between the light source and the first singlet lens; and a third singlet lens disposed between the light source and the second singlet lens
Data Source
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AI summary
A headlight (12) of the type worn by medical and dental professionals includes a housing (20) having an opening therein. A housing (20) defines opposing ends and a passage. A light source (32), such as a LED, is proximate the first end. An optical assembly (30) is in the passage of the housing (20) and includes a first singlet lens (60), a second singlet lens (62) disposed between the light source (32) and the first singlet lens (60), and a third singlet lens (64) disposed between the light source (32) and the second singlet lens (62). Each of the second singlet lens (62) and the third singlet lens (64) are centered on the optical axis (38) and the second singlet lens (62) and the third singlet lens (64) are spaced apart by a separation distance.