Symmetrical Lens Array Molded Polymer Assembly
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Solution Overview
Problem
Conventional rod lens arrays for high-resolution imaging are expensive to manufacture due to the high cost of GRIN fiber optic glass, require complex precision steps, and have limited resolution and environmental concerns related to lead-containing glass, with suppliers being limited and manufacturing processes being difficult.
Innovation Solution
A lens array assembly where multiple lens faces are molded into polymer bars, simplifying manufacturing and alignment, using inexpensive materials, and allowing for increased resolution without significant cost increases, comprising identical lens sections and covers with a middle holder to block scattered light and enhance focus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If GRIN fiber optic rod lenses are used for high-resolution imaging, then imaging resolution is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent replaces expensive GRIN fiber optic rod lenses with inexpensive molded polymer lenses that can be mass-produced through injection molding. The polymer lenses achieve sufficient optical performance for the application while dramatically reducing material costs and eliminating the need for expensive precision manufacturing processes.
Solution Approach 2:
The patent changes the material parameter from GRIN glass to polymer and modifies the lens geometry parameters (spheroidal shape with specific refractive index distribution) to achieve the desired optical performance. By adjusting the molding parameters and lens geometry, the system achieves high-resolution imaging without requiring expensive GRIN materials.
2Measurement precision
If the number of rod lenses is increased to improve resolution, then imaging resolution is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple individual rod lens functions into a single integrated molded polymer lens array. Instead of assembling many separate precision-aligned rod lenses, the invention molds multiple lens elements directly into a single polymer component, reducing assembly complexity while maintaining the necessary resolution through the array configuration.
Solution Approach 2:
The patent segments the imaging function into multiple smaller lens elements arranged in an array within the molded polymer structure. This segmentation allows high resolution to be achieved through the collective action of multiple elements while the molding process integrates them into a single manageable component rather than requiring separate handling of each lens.
3Ease of manufacture
If flat ends of rod lenses are used for simplicity, then ease of manufacture is improved, but imaging resolution is limited
Solution Approach 1:
The patent employs spheroidal lens surfaces in the molded polymer lenses instead of flat ends. The curved spheroidal surfaces provide the necessary optical focusing capability for high-resolution imaging while the entire lens structure is formed through molding, maintaining ease of manufacture. The spherical geometry is inherently optimized for optical performance unlike flat surfaces.
4Ease of manufacture
If conventional rod lens arrays are used, then manufacturing is simplified, but environmental harm increases due to lead-containing glass
Solution Approach 1:
The patent changes the material composition parameter from lead-containing glass to lead-free polymer. This substitution eliminates the environmental harm associated with lead while maintaining the manufacturing simplicity of molding processes. The polymer material can be molded using similar techniques to glass but without the toxic components.
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 reduces manufacturing complexity and costs, allows for adjustable resolution, and improves image quality with enhanced depth of field and reduced ghosting, while using environmentally friendly materials.
Implementation Method 1
A lens array for high-resolution imaging of a surface comprises a plurality of lenses having optical axes that are substantially parallel to one another and that are substantially equidistantly spaced
Implementation Method 2
The fiber optic rod lenses 110 are typically made from GRIN (graduated index) fibers, with the refractive index of the glass carefully controlled during manufacture to have a graduated refractive index that decreases radially from the central axis to the edge
Data Source
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AI summary
A symmetrical lens array (200) comprises two identical covers (210A,210B), two identical lens sections (220A,220B), and a middle holder (230). Each lens section comprises a plurality of lenses (223A,223B,224A,224B) disposed on the top and bottom of the lens section. The lens array is assembled with the middle holder positioned between the two lens sections. The two covers are positioned so that one cover is on the top of the upper lens section and one cover is positioned on the bottom of the lower lens section. Mating elements of the covers, lens sections, and the middle holder mate to allow the components to attach and be held together. Since each lens section is identical and each cover is identical the same lens section tooling is used for all lens sections and the same cover tooling is used for all covers.