US 12,265,214 B2
Method of manufacturing monolithic optical systems
Frank Ravizza, Livermore, CA (US)
Assigned to Lawrence Livermore National Security, LLC, Livermore, CA (US)
Filed by Lawrence Livermore National Security, LLC, Livermore, CA (US)
Filed on Dec. 29, 2021, as Appl. No. 17/565,314.
Prior Publication US 2023/0204936 A1, Jun. 29, 2023
Int. Cl. G02B 23/02 (2006.01); B29D 11/00 (2006.01); C01B 33/158 (2006.01); C01B 33/16 (2006.01); G02B 7/18 (2021.01); G02B 7/182 (2021.01); G02B 7/183 (2021.01); G02B 17/08 (2006.01); B29K 105/00 (2006.01)
CPC G02B 23/02 (2013.01) [B29D 11/00596 (2013.01); B29D 11/00865 (2013.01); C01B 33/1585 (2013.01); C01B 33/16 (2013.01); C01B 33/163 (2013.01); G02B 7/181 (2013.01); G02B 7/182 (2013.01); G02B 7/183 (2013.01); G02B 17/0808 (2013.01); B29K 2105/0061 (2013.01); C08J 2205/026 (2013.01)] 17 Claims
OG exemplary drawing
 
1. A method of manufacturing an optical system, the method comprising:
applying a reflective coating to at least a portion of a surface of a mandrel;
placing the mandrel in a tank and subsequently filling the tank with aerogel to a predetermined depth below a top of the mandrel;
adding a separation layer to the tank on top of the aerogel at the predetermined depth, and catalyzing the separation layer into a solid;
adding aerogel on top of the separation layer filling the tank with aerogel above a height of the mandrel;
removing the aerogel and mandrel from the tank;
drying the aerogel into a solid aerogel structure;
catalyzing the reflective coating to bond the reflective coating with the aerogel; and
removing the mandrel from the solid aerogel structure to produce a hollowed-out aerogel structure.