Devices and processes for fabricating multi-component optical systems

Abstract

The present disclosure relates to devices and processes for fabricating a multi-component optical system. A device is an integral mold comprising an attachment portion and a cup portion having a cavity, and the mold further comprises a first optical component. The cavity of the mold contains additional optical components to form a multi-component optical system blank. Another device is a multi-component optical system blank. A process for fabricating a multi-component optical system blank comprises providing an integral mold comprising a first optical component, adding at least a second optical component, shaping the mold after addition of an optical component, and shaping the resultant blank into an optical system. A further device is a multi-component optical system produced in a process disclosed herein.

What is claimed is: 
     
         1 . A mold for fabricating a multi-component optical system blank comprising:
 a cup portion, wherein the cup portion comprises an inner wall and a first cavity defined by the inner wall; and   an attachment portion;   wherein the mold comprises a first optical component, and   wherein the mold comprises a portion of the blank.   
     
     
         2 . The mold of  claim 1 , further comprising a reference surface. 
     
     
         3 . The mold of  claim 1 , wherein the cup portion further comprises a bottom wall and a first axial wall. 
     
     
         4 . The mold of  claim 3 , wherein the inner wall is concave. 
     
     
         5 . The mold of  claim 3 , the inner wall further comprising a first bottom surface and a first axial surface. 
     
     
         6 . The mold of  claim 1 , wherein the first cavity contains a second optical component. 
     
     
         7 . The mold of  claim 6 , wherein the first cavity contains an nth optical component. 
     
     
         8 . The mold of  claim 7 , wherein at least one optical component is selected from a group consisting of polarization filters, refractive lenslets, diffractive lenslets, selective chromatic filters, bandpass filters, circular polarizing filters, linear polarizer filters, gray attenuator filters, birefringent filters, zone plates, mirrors, electronic circuits, electronic devices, microdisplays, sensors, antennas, and nanowires. 
     
     
         9 . The mold of  claim 8 , wherein the inner wall is shaped to specification. 
     
     
         10 . The mold of  claim 9 , wherein the first cavity further comprises:
 a second cavity defined by a second axial wall and a second bottom surface within the first cavity, and   a third cavity defined by the second axial wall and a third bottom surface within the first cavity.   
     
     
         11 . The mold of  claim 9 , wherein the first cavity further comprises a second cavity defined by a second axial surface and a second bottom surface within the first cavity. 
     
     
         12 . The mold of  claim 9 , wherein the first cavity further comprises a second cavity defined by a second axial surface, a third axial surface, and a second bottom surface within the first cavity. 
     
     
         13 . The mold of  claim 10 , wherein the second cavity and the third cavity contain separate optical components. 
     
     
         14 . The mold of  claim 1 , wherein the attachment portion is configured for fastening in a collet and comprises a reference surface. 
     
     
         15 . A process for fabricating a multi-component optical system blank comprising:
 adding a second optical component to an integral mold comprising a first optical component,   wherein the integral mold comprises:   a cup portion, wherein the cup portion comprises a cavity defined by an inner wall, and   an attachment portion; and   wherein the second optical component is added in the cavity of the integral mold.   
     
     
         16 . The process of  claim 15 , further comprising adding an nth optical component in the cavity of the integral mold. 
     
     
         17 . The process of  claim 16 , wherein at least one optical component is selected from a group consisting of polarization filters, bandpass filters, selective chromatic filters, circular polarizing filters, linear polarizer filters, gray attenuator filters, birefringent filters, refractive lenslets, diffractive lenslets, pinhole apertures, zone plates, mirrors, electronic circuits, electronic devices, microdisplays, sensors, antennas, and nanowires. 
     
     
         18 . The process of  claim 17 , wherein the cup portion further comprises a bottom wall and a first axial wall. 
     
     
         19 . The process of  claim 18 , wherein the inner wall is concave. 
     
     
         20 . A multi-component optical system comprising at least two optical components having differing properties,
 wherein during a manufacturing process of the multi-component optical system a first optical component serves as a mold for at least a second optical component,   wherein during the manufacturing process the at least two optical components are shaped into the multi-component optical system by a material removal step, and   wherein the at least two optical components are in predetermined locations in the multi-component optical system.