Originally posted by photoptimist These hot-spots are almost certainly an interaction between the hot-mirror (which is reflecting near-IR & IR) and the 720 nm Hoya R72 (which also strongly reflects near-IR around 720 nm). The light from the scene is passing through the filter, being focused by the lens, hitting the hot-mirror, reflecting back through the lens, hitting the backside of the Hoya, and being bounced back. (You can do a back-of-the-envelope ray tracing to see how this works.)
Hot spots like this will be a problem with "high quality" IR filters that using thin-film technology to create a sharp bandpass. Cheaper filters that use a bulk material that absorbs visible light (and passes IR) will have much less problems although these absorptive filters still need good AR coatings to avoid all problems with reflections between the IR-Filter and hot mirror............
Are you sure about this? I have a Hoya R72 in front of me and it's a dye type filter - no thin films. Not doubting your theory, but the light would have to be reflected off the glass housing the filter material - it doesn't appear that the Hoya is coated to reduce reflections so that could be a source of unwanted reflections. If I look at this filter in IR (with my IR camera), it appears to be pretty transparent, not showing much reflection but the glass reflects just as it would for visible light.
I think some of these "hot spot" issues have to do with how lens coatings interact with IR since they are designed to reduce reflections of visible light, their IR performance can be quite different, and they could be reflective at IR wavelengths.
Most IR filters that I'm familiar with (for photographic use) are the dye type. Dichroic (thin film) filters are expensive to make and the narrow transmission bands they provide aren't needed for normal IR photography. It's pretty easy to make a dye that's opaque to visible light and transmits IR - most non-pigmented black printer ink has this property, so it's generally cost effective to make IR filters using dyes.
You could check this theory out by using a flat wall that shows a hot spot. If the IR filter is removed and the wall is illuminated with IR light (darkness needed otherwise), the hot spot should disappear if the filter is at fault. If it is still there, the lens/camera system is causing it. Putting the filter back on should produce the hot spot if it's at fault.