Reconstruction method of micro curved surface array of optical shaping element

Abstract

The invention provides a reconstruction method of a micro curved surface array of an optical shaping element. The reconstruction method of the micro curved surface array of the optical shaping element comprises the following steps: determining an initial curved surface, dividing the initial curved surface into a plurality of pixel points, and determining the slope of each pixel point; constructing a micro curved surface array model to obtain a micro curved surface array model composed of M * N groups of micro curved surface models; randomly distributing a plurality of pixel points to each micro curved surface model; according to the slopes of the pixel points, regularly arranging the plurality of pixel points in each micro-curved-surface model, so that the slopes of the plurality of pixel points in each micro-curved-surface model are regularly changed; and determining the vector height of each pixel point so as to obtain a final micro curved surface array. According to the invention, the problem that the micro curved surface array of the optical shaping element in the prior art is not beneficial to processing and forming is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of optical equipment, and in particular to a method for reconstructing a micro-curved surface array of an optical shaping element. Background Art

[0002] Optical shaping elements can achieve beam shaping, such as diffusion, and usually have a micro-curved surface array, which is usually composed of multiple micro-curved surface arrays, thereby achieving beam expansion and shaping. Optical shaping elements are thin and light, so they are widely used in miniaturized and lightweight products, such as AR, VR, mobile phones, drones, etc., to match small divergence angle light source applications, such as VCSEL light sources.

[0003] The connection position of the connected micro-curved surfaces of the micro-curved surface array of the current optical shaping element is abrupt, the surface shape changes discontinuously, and the slope is discontinuous. The discontinuous surface shape is difficult to achieve during processing, and the sharp corners will become rounded, thereby changing the beam shaping effect of the element, which is not good for the product.

[0004] That is to say, the micro-curved surface array of the optical shaping element in the prior art has the problem of being difficult to process and shape. Summary of the invention

[0005] The main purpose of the present invention is to provide a method for reconstructing a micro-curved array of an optical shaping element, so as to solve the problem that the micro-curved array of an optical shaping element in the prior art is not conducive to processing and molding.

[0006] In order to achieve the above-mentioned purpose, according to one aspect of the present invention, a method for reconstructing a micro-curved surface array of an optical shaping element is provided, comprising the following steps: determining an initial curved surface, dividing the initial curved surface into a plurality of pixel points, and determining the slope of each pixel point; constructing a micro-curved surface array model to obtain a micro-curved surface array model composed of M×N groups of micro-curved surface models; randomly assigning a plurality of pixel points to each micro-curved surface model; regularly arranging a plurality of pixel points in each micro-curved surface model according to the slope of the pixel points, so that the slopes of the plurality of pixel points in each micro-curved surface model change regularly; determining the vector height of each pixel point, thereby obtaining a final micro-curved surface array.

[0007] Furthermore, the initial curved surface is divided into a plurality of pixel points, and the slope of each pixel point is determined, including: determining the total number of pixel points according to the length and width of the initial curved surface and the pixel size; determining the coordinates of each pixel point; and determining the slope of each pixel point according to the coordinates of each pixel point.

[0008] Further, a micro - surface array model is constructed to obtain a micro - surface array model composed of M×N groups of micro - surface models, including: determining the number of groups M of micro - surface models in the X - axis direction and the number of groups N of micro - surface models in the Y - axis direction of the micro - surface array model according to the length L of the micro - surface array in the X - axis direction, the length W of the micro - surface array in the Y - axis direction, the average value Lx0 of half of the length of a single micro - surface of the micro - surface array in the X - axis direction, and the average value Ly0 of half of the length of a single micro - surface of the micro - surface array in the Y - axis direction, where M = L / Lx0 and N = W / Ly0.

[0009] Further, a plurality of pixel points are randomly assigned to each micro - surface model, including: determining the random assignment quantity of pixel points in each micro - surface model; randomly selecting a random assignment quantity of pixel points from the plurality of pixel points and assigning them to the corresponding micro - surface model.

[0010] Further, determining the random assignment quantity of pixel points in each micro - surface model includes: setting that the random assignment quantity of pixel points in the X - axis direction in the micro - surface models from the 1st group to the (M - 1)th group satisfies: rounding up the value calculated by m / M×(1+(2×rand - 1)×noise); where m is the number of groups of pixel points in the X - axis direction, rand is a random number in the range greater than or equal to 0 and less than or equal to 1, noise is the maximum random fluctuation amount, and 0 < noise < 0.5; and / or setting that the random assignment quantity of pixel points in the Y - axis direction in the micro - surface models from the 1st group to the (N - 1)th group satisfies: rounding up the value calculated by n / N×(1+(2×rand - 1)×noise); where n is the number of groups of pixel points in the Y - axis direction, rand is a random number in the range greater than or equal to 0 and less than or equal to 1, noise is the maximum random fluctuation amount, and 0 < noise < 0.5.

[0011] Further, arranging the multiple pixel points in each micro - surface model according to the slope of the pixel points includes: arranging the slopes of the multiple pixel points in the micro - surface models from the first group to the M - th group in a decreasing or increasing order along the X - axis direction, and arranging the slopes of the multiple pixel points in the micro - surface models from the first group to the N - th group in a decreasing or increasing order along the Y - axis direction, where the first group to the M - th group are arranged along the X - axis direction, and the first group to the N - th group are arranged along the Y - axis direction; inverting the slope change rule of the multiple pixel points along the X - axis direction in the odd - numbered or even - numbered groups of the micro - surface models from the first group to the M - th group, and inverting the slope change rule of the multiple pixel points along the Y - axis direction in the odd - numbered or even - numbered groups of the micro - surface models from the first group to the N - th group, so that the slope change rules of the pixel points in two adjacent micro - surface models are opposite, thereby making the slopes of the pixel points in two adjacent groups of micro - surface models change continuously.

[0012] Further, determining the sag height of each pixel point includes: calculating the sag height of each pixel point by using the point - slope form method, so as to obtain a continuous micro - surface array.

[0013] Further, in the step of randomly allocating multiple pixel points to each micro - surface model, it is set that the following is satisfied between half of the maximum length Lx_max of the micro - surface model in the X - axis direction and half of the minimum length Lx_min of the micro - surface model in the X - axis direction: 0.02 < Lx_min / Lx_max < 0.95, and it is set that the following is satisfied between half of the maximum length Ly_max of the micro - surface model in the Y - axis direction and half of the minimum length Ly_min of the micro - surface model in the Y - axis direction: 0.02 < Ly_min / Ly_max < 0.95.

[0014] Further, in the step of determining the sag height of each pixel point, it is set that the following is satisfied between the maximum value h_max of the sag height and the minimum value h_min of the sag height: 0.2 < h_min / h_max < 0.95.

[0015] Further, in the step of determining the sag height of each pixel point to obtain the final micro - surface array, it is set that the following is satisfied between the distance dx between the vertices of two adjacent micro - surfaces in the X - axis direction in the micro - surface array and the sag height h of the micro - surface: 0.3 < dx / h < 6; and / or, it is set that the following is satisfied between the distance dy between the vertices of two adjacent micro - surfaces in the Y - axis direction in the micro - surface array and the sag height h of the micro - surface: 0.3 < dy / h < 6.

[0016] By applying the technical solution of the present invention, a method for reconstructing a micro-curved surface array of an optical shaping element includes the following steps: determining an initial curved surface, dividing the initial curved surface into a plurality of pixel points, and determining the slope of each pixel point; constructing a micro-curved surface array model to obtain a micro-curved surface array model composed of M×N groups of micro-curved surface models; randomly assigning a plurality of pixel points to each micro-curved surface model; regularly arranging a plurality of pixel points in each micro-curved surface model according to the slope of the pixel points, so that the slopes of the plurality of pixel points in each micro-curved surface model change regularly; and determining the vector height of each pixel point, thereby obtaining a final micro-curved surface array.

[0017] The micro-curved surface array obtained by the reconstruction method of the present application is a continuous surface, and can ensure a smooth transition between adjacent micro-curved surfaces, and the slope of the connection position of adjacent micro-curved surfaces is continuous and has no discontinuity, thereby avoiding sharp corners during subsequent processing and molding, which is beneficial to processing and molding, and is beneficial to mold processing and demolding. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The drawings constituting a part of the present application are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0019] Figure 1 A flow chart showing a method for reconstructing a micro-curved array of an optical shaping element according to an optional embodiment of the present invention;

[0020] Figure 2 A schematic structural diagram of an initial curved surface of a method for reconstructing a micro-curved surface array of an optical shaping element of the present invention is shown;

[0021] Figure 3 A schematic structural diagram of a micro-curved surface array according to Example 1 of the present invention is shown;

[0022] Figure 4 A schematic structural diagram of a micro-curved surface array according to Example 2 of the present invention is shown;

[0023] Figure 5 A schematic diagram of the structure of a micro-curved surface array according to Example 3 of the present invention is shown;

[0024] Figure 6 Shows Figure 2 The slope distribution diagram of the profile line of the initial surface in the X-axis direction;

[0025] Figure 7 Shows Figure 5 A distribution diagram of the slope of the profile line of the micro-curved surface array in the X-axis direction;

[0026] Figure 8 Shows Figure 2 Slope statistics of the initial surface in ;

[0027] Fig. 9 Shows Figure 5 Slope statistics of the micro-curved surface array in ;

[0028] Fig.10 A comparison diagram of the profile lines of the initial curved surface and the finally formed micro-curved surface array in the X-axis direction of the present invention is shown;

[0029] Fig.11 A schematic diagram of the structure of a micro-curved surface array according to Example 4 of the present invention is shown;

[0030] Fig.12 A schematic diagram of the structure of a micro-curved surface array according to Example 5 of the present invention is shown;

[0031] Fig.13 Shows Fig.12 A local magnified image of the micro-curved surface array;

[0032] Fig.14 A dimensioning diagram of a micro-curved surface array in one direction of an optional embodiment of the present invention is shown;

[0033] Fig.15 Shows Fig.14 Dimensioning diagram of the micro-surface array in another direction.

[0034] The above drawings include the following reference numerals:

[0035] 10. Initial surface; 20. Micro-curved surface array; 30. Micro-curved surface. DETAILED DESCRIPTION

[0036] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0037] It should be noted that, unless otherwise specified, all technical and scientific terms used in this application have the same meanings as commonly understood by ordinary technicians in the technical field to which this application belongs.

[0038] In the present invention, unless otherwise specified, the directional words used, such as "up, down, top, bottom", usually refer to the directions shown in the drawings, or to the components themselves in the vertical, perpendicular or gravity directions; similarly, for ease of understanding and description, "inside and outside" refer to the inside and outside relative to the outline of each component itself, but the above-mentioned directional words are not used to limit the present invention.

[0039] like Figures 1 to 15As shown, the reconstruction method of the micro-curved surface array of the optical shaping element includes the following steps: determining an initial curved surface 10, dividing the initial curved surface 10 into a plurality of pixel points, and determining the slope of each pixel point; constructing a micro-curved surface array model to obtain a micro-curved surface array model composed of M×N groups of micro-curved surface models; randomly assigning a plurality of pixel points to each micro-curved surface model; regularly arranging a plurality of pixel points in each micro-curved surface model according to the slope of the pixel points, so that the slopes of the plurality of pixel points in each micro-curved surface model change regularly; determining the vector height of each pixel point, thereby obtaining the final micro-curved surface array 20.

[0040] The micro-curved surface array 20 obtained by the reconstruction method of the present application is a continuous surface, and can ensure a smooth transition between adjacent micro-curved surfaces 30, and the slope of the connection position of adjacent micro-curved surfaces 30 is continuous and has no discontinuity, thereby avoiding sharp corners during subsequent processing and molding, which is beneficial to processing and molding, and is beneficial to mold processing and demolding.

[0041] like Figure 2 As shown, it is a schematic diagram of the structure of the initial curved surface 10. The initial curved surface 10 is a large convex surface or a large concave surface, which can be set according to actual conditions. The beam expansion effect of the initial curved surface 10 needs to meet the design requirements. Micro-curved surfaces of different sizes and sagittal heights can be freely designed according to process capabilities, appearance requirements, etc., without redesigning the micro-curved surface. The initial curved surface 10 can be a free-form surface.

[0042] It should be noted that the above M is the number of groups of micro-curved surface models in the X-axis direction, and N is the number of groups of micro-curved surface models in the Y-axis direction. It can also be understood that the 1st to Mth groups are arranged sequentially along the X-axis direction, and the 1st to Nth groups are arranged sequentially along the Y-axis direction.

[0043] Specifically, the step of dividing the initial curved surface 10 into a plurality of pixel points and determining the slope of each pixel point includes:

[0044] According to the length and width of the initial curved surface 10 and the pixel size, the total number of pixels is determined; the coordinates of each pixel are determined; and according to the coordinates of each pixel, the slope of each pixel is determined.

[0045] The length, width and pixel size of the initial surface 10 are all fixed values ​​and can be set according to actual conditions. For example, the length of the initial surface 10 in the X-axis direction is Ls, the width of the initial surface 10 in the Y-axis direction is Ws, and the pixel size is pizel. According to the formula: m=Ls / pixel, n=Ws / pixel, the total number of pixels m×n is calculated, that is, the initial surface 10 is divided into m×n pixels. The 1st to mth pixels are arranged along the X-axis direction, and the 1st to nth pixels are arranged along the Y-axis direction. Each pixel has a corresponding (x, y, z) coordinate, and the slope of each pixel is calculated according to the coordinates of each pixel. The slope of each row and column pixel is calculated separately, and the calculation formula is: kx i =(x i+1 -x i ) / (z i+1 -z i ),ky i =(y i+1 -y i ) / (z i+1 -z i ), i is a number from 1 to m, or a number from 1 to n, indicating the row or column. kx i is the slope of the 1st to mth pixel points distributed along the X-axis, ky i is the slope of the 1st to nth pixel points distributed along the Y-axis.

[0046] After calculating the slope of each pixel point, the pixel points can be arranged from large to small along the X-axis direction and the Y-axis direction according to the slope, so that the slopes of the pixel points in each row and column are arranged from large to small.

[0047] Specifically, the step of constructing a micro-curved surface array model to obtain a micro-curved surface array model composed of M×N groups of micro-curved surface models includes: determining the number of groups M of micro-curved surface models in the X-axis direction and the number N of micro-curved surface models in the Y-axis direction of the micro-curved surface array model according to the final required length L of the micro-curved surface array 20 in the X-axis direction, the length W of the micro-curved surface array 20 in the Y-axis direction, the mean value Lx0 of half the length of a single micro-curved surface 30 of the micro-curved surface array 20 in the X-axis direction, and the mean value Ly0 of half the length of a single micro-curved surface 30 of the micro-curved surface array 20 in the Y-axis direction, wherein M=L / Lx0, N=W / Ly0. Among them, L, W, Lx0 and Ly0 are all fixed values ​​and can be set according to actual conditions. The calculated M and N are both rounded upwards.

[0048] It should be noted that the above-mentioned micro-curved surface array model and micro-curved surface model are equivalent to a preset framework, and are not the final micro-curved surface array 20 and the micro-curved surface 30 constituting the micro-curved surface array 20.

[0049] Specifically, the step of randomly allocating multiple pixel points to each micro - surface model includes: First, determine the random allocation quantity of pixel points in each micro - surface model, that is, determine the number of pixel points to be allocated in each micro - surface model, and this quantity is random. Then, randomly select the pixel points with the random allocation quantity from the m×n pixel points divided by the initial surface 10 and allocate them to the corresponding micro - surface models. Specifically, randomly select the pixel points with the random allocation quantity from the m×n pixel points and allocate them to the micro - surface models of the 1st group to the Mth group arranged along the X - axis direction, and the micro - surface models of the 1st group to the Nth group arranged along the Y - axis direction.

[0050] Specifically, in the above - mentioned step of determining the random allocation quantity of pixel points in each micro - surface model, it includes:

[0051] Set the random allocation quantity of pixel points in the micro - surface models of the 1st group to the (M - 1)th group in the X - axis direction to satisfy: round up the value calculated by m / M×(1+(2×rand - 1)×noise); where m is the number of groups of pixel points in the X - axis direction, rand is a random number in the range greater than or equal to 0 and less than or equal to 1, noise is the maximum random fluctuation amount, and 0 < noise < 0.5. After determining the allocation quantity of pixel points in the micro - surface models of the 1st group to the (M - 1)th group, the remaining pixel points are allocated to the micro - surface model of the Mth group. Add a random fluctuation amount during the process of determining the quantity of pixel points in the micro - surface models of the 1st group to the (M - 1)th group, so that the quantity of pixel points in the micro - surface models of the 1st group to the (M - 1)th group is random. When the calculation result of m / M×(1+(2×rand - 1)×noise) is not an integer, just round it up. For example, if the calculation result is 3.82, then take 4. The sum of the pixel points of the micro - surface models of the 1st group to the (M - 1)th group is m 1至M-1 , and the number of pixel points in the micro - surface model of the Mth group is m - m 1至M-1 .

[0052] The number of randomly allocated pixels in the micro - surface models of the 1st group to the (N - 1)th group in the Y - axis direction satisfies: rounding up the value calculated by n / N×(1+(2×rand - 1)×noise); where n is the number of groups of pixels in the Y - axis direction, rand is a random number in the range greater than or equal to 0 and less than or equal to 1, noise is the maximum random fluctuation amount, and 0 < noise < 0.5. By adding a random fluctuation amount in the process of determining the number of pixels in the micro - surface models of the 1st group to the (N - 1)th group, the number of pixels in the micro - surface models of the 1st group to the (N - 1)th group is random. When the calculation result of n / N×(1+(2×rand - 1)×noise) is not an integer, just round it up. For example, if the calculation result is 3.82, then take 4.

[0053] Generate the number of pixels in each micro - surface model by adding a random variation amount, so that the size of each micro - surface model is random. After determining the number of pixels in each micro - surface model, since the size of each pixel is determined, the size of each micro - surface model in the X - axis direction and Y - axis direction is also determined. In this way, the sizes of each micro - surface model and the subsequent determined sagittal height are different, and the positions also deviate from the regular arrangement, which is beneficial to light mixing.

[0054] Specifically, the step of regularly arranging multiple pixels in each micro - surface model according to the slope of the pixels can be divided into two steps, including:

[0055] First, arrange the slopes of multiple pixels in the micro - surface models of the 1st group to the Mth group according to the changing rule of from large to small or from small to large along the X - axis direction, and arrange the slopes of multiple pixels in the micro - surface models of the 1st group to the Nth group according to the changing rule of from large to small or from small to large along the Y - axis direction. Among them, the 1st group to the Mth group are arranged along the X - axis direction, and the 1st group to the Nth group are arranged along the Y - axis direction.

[0056] In an optional embodiment of the present application, the slopes of multiple pixel points in the micro-curved surface models of the first to the Mth groups are arranged according to a rule of change from large to small along the X-axis direction, and the slopes of multiple pixel points in the micro-curved surface models of the first to the Nth groups are arranged according to a rule of change from large to small or along the Y-axis direction. This arrangement makes it possible for the slopes of multiple pixel points in the micro-curved surface models of the first to the Mth groups to be arranged according to a rule of change from large to small along the X-axis direction, so that the rule of change of the slopes of multiple pixel points in two adjacent groups of micro-curved surface models is from large to small along the X-axis direction, so that the slopes corresponding to the connection positions of the two adjacent groups of micro-curved surface models are respectively the minimum slope and the maximum slope, thereby forming a mutation, so that the slopes of the connection positions of the two adjacent groups of micro-curved surface models are discontinuous. The adjacent micro-curved surface models in the first to the Nth groups also have this problem.

[0057] In another optional embodiment of the present application, the slopes of multiple pixel points in the micro-curved surface models of the first to the Mth groups are arranged according to a rule of change from small to large along the X-axis direction, and the slopes of multiple pixel points in the micro-curved surface models of the first to the Nth groups are arranged according to a rule of change from small to large along the Y-axis direction. This arrangement makes it possible for the slopes of multiple pixel points in the micro-curved surface models of the first to the Mth groups to be arranged according to a rule of change from small to large along the X-axis direction, so that the rule of change of the slopes of multiple pixel points in two adjacent groups of micro-curved surface models is from small to large along the X-axis direction, so that the slopes corresponding to the connection positions of the two adjacent groups of micro-curved surface models are respectively the maximum slope and the minimum slope, thereby forming a mutation, so that the slopes of the connection positions of the two adjacent groups of micro-curved surface models are discontinuous. The adjacent micro-curved surface models in the first to the Nth groups also have this problem.

[0058] Therefore, after the above steps, it is necessary to invert the slope change rules of multiple pixel points in the odd or even groups of micro-curved surface models from the 1st to the Mth group along the X-axis direction, and invert the slope change rules of multiple pixel points in the odd or even groups of micro-curved surface models from the 1st to the Nth group along the Y-axis direction, so that the slope change rules of the pixel points in the two adjacent groups of micro-curved surface models are opposite, so that the slopes of the pixel points in the two adjacent groups of micro-curved surface models change continuously.

[0059] In an optional embodiment of the present application, the slope variation rule of multiple pixel points in the micro-curved surface models of the odd groups in the 1st to the Mth groups along the X-axis direction is inverted, and the variation rule of the even groups remains unchanged; so that the slope variation rule of the pixel points in the two adjacent groups of micro-curved surface models in the 1st to the Mth groups arranged along the X-axis direction is opposite, so that the slopes of the pixel points in the two adjacent groups of micro-curved surface models change continuously. The slope variation rule of multiple pixel points in the micro-curved surface models of the odd groups in the 1st to the Nth groups along the Y-axis direction is inverted, and the variation rule of the even groups remains unchanged, so that the slope variation rule of the pixel points in the two adjacent groups of micro-curved surface models in the 1st to the Nth groups arranged along the Y-axis direction is opposite, so that the slopes of the pixel points in the two adjacent groups of micro-curved surface models change continuously.

[0060] In another optional embodiment of the present application, the slope variation rule of multiple pixel points in the micro-curved surface models of the even groups in the 1st to the Mth groups along the X-axis direction is inverted, and the variation rule of the odd groups remains unchanged; so that the slope variation rule of the pixel points in the two adjacent groups of micro-curved surface models in the 1st to the Mth groups arranged along the X-axis direction is opposite, so that the slopes of the pixel points in the two adjacent groups of micro-curved surface models change continuously. The slope variation rule of multiple pixel points in the micro-curved surface models of the even groups in the 1st to the Nth groups along the Y-axis direction is inverted, and the variation rule of the odd groups remains unchanged, so that the slope variation rule of the pixel points in the two adjacent groups of micro-curved surface models in the 1st to the Nth groups arranged along the Y-axis direction is opposite, so that the slopes of the pixel points in the two adjacent groups of micro-curved surface models change continuously.

[0061] It should be noted that the above inversion refers to changing the law of change from large to small to the law of change from small to large, or changing the law of change from small to large to the law of change from large to small. The law of change from large to small is opposite to the law of change from small to large.

[0062] After completing the above steps, the slope values ​​of the pixels in the micro-curved surface model from the 1st group to the Mth group can be sequentially connected to the complete slope distribution. The total number of pixel groups is still m, and the slope value is not changed, only the slope arrangement order is changed. Similarly, the slope values ​​of the pixels in the micro-curved surface model from the 1st group to the Nth group are sequentially connected to the complete slope distribution. The total number of pixel groups is still n, and the slope value is not changed, only the slope arrangement order is changed. The slope change rule after completion can be referred to Figure 7 As shown in the figure, it can be seen that the curvature change of the micro-curved surface model after the slope is rearranged is continuous and without mutation, and the slopes at the connection positions of two adjacent groups of micro-curved surface models are connected and transitioned sequentially.

[0063] Specifically, the steps of determining the sag height of each pixel point include calculating the sag height of each pixel point by using the point-slope method, that is, zi = zi-1 + kxi × pixel, (where zi-1 is the sag height of the previous known pixel point and zi is the sag height of the pixel point to be determined). After determining the sag height of each pixel point, the surface shape of each micro-surface 30 can be obtained, and then a continuous micro-surface array 20 can be obtained. Use the point-slope method to calculate the z' value in the coordinates of each pixel point in turn, and keep the x and y values unchanged to obtain a new sag height distribution. Since the slopes of each pixel point are continuous, a continuous and smooth micro-surface array 20 composed of M×N groups of micro-surfaces 30 is formed.

[0064] Through the above method, it can be ensured that the reconstructed micro-surface array 20 has the same slope distribution as before reconstruction, and the surface shape of the micro-surface array 20 is continuous without mutation. There are no breaks or sharp corners at the connection positions of the connected micro-surfaces 30, which is beneficial to mold processing and demolding. The consistent slope value with that before reconstruction can ensure that the light homogenization effect is the same as that of the initial surface 10. The random sizes and morphologies of each micro-surface 30 can improve the light homogenization effect, making the light homogenization effect more uniform and the light spot smoother.

[0065] Specifically, reference can be made to Fig.14 and Fig.15 As shown in, in the step of randomly assigning multiple pixel points to each micro-surface model, it is satisfied that between half of the maximum length Lx_max of the micro-surface model in the X-axis direction and half of the minimum length Lx_min of the micro-surface model in the X-axis direction: 0.02 < Lx_min / Lx_max < 0.95, and it is satisfied that between half of the maximum length Ly_max of the micro-surface model in the Y-axis direction and half of the minimum length Ly_min of the micro-surface model in the Y-axis direction: 0.02 < Ly_min / Ly_max < 0.95. In the specific embodiments of the present application, the sizes and sag heights of each micro-surface model are random. By limiting these two ranges, it is beneficial that the sizes and intensities of the light spots emitted by each micro-surface 30 are not equal, which is beneficial to light mixing. Lx1 and Lx2 in the figure are respectively half of the maximum lengths of two different micro-surfaces 30 in the X-axis direction, and Ly1 and Ly2 are respectively half of the maximum lengths of two different micro-surfaces 30 in the Y-axis direction.

[0066] Specifically, in the step of determining the sag height of each pixel point, it is satisfied that between the maximum value h_max of the sag height and the minimum value h_min of the sag height: 0.2 < h_min / h_max < 0.95. By reasonably planning this ratio, it is beneficial to ensure that the sag heights of each micro-surface 30 are not too large or too small, which is beneficial to ensuring dimensional rationality, ensuring processing feasibility, and then ensuring the light mixing effect.

[0067] Specifically, in the step of determining the sagittal height of each pixel point to obtain the final micro - surface array 20, it is set that the distance dx between the vertices of two adjacent micro - surfaces 30 in the X - axis direction in the micro - surface array 20 and the sagittal height h of the micro - surface 30 satisfy: 0.3 < dx / h < 6; and the distance dy between the vertices of two adjacent micro - surfaces 30 in the Y - axis direction in the micro - surface array 20 and the sagittal height h of the micro - surface 30 satisfy: 0.3 < dy / h < 6. Such a setting is beneficial to ensuring that the spot sizes and intensities emitted by each micro - surface 30 are not equal, thereby increasing the light - mixing effect.

[0068] It should be noted that the micro - surface 30 is formed by randomly grouping and collapsing and reconstructing the initial surface 10 according to the slope. After reconstruction, the slopes of all micro - surfaces 30 are combined and statistically analyzed, and the distribution is consistent with the slope distribution of the initial surface 10 before reconstruction. All concave and convex surfaces are randomly grouped and collapsed and reconstructed according to the slope. There is no direct relationship between the concave and convex micro - surfaces 30 in terms of surface shape and size. The consistent slope distribution ensures that the beam - expanding performance after reconstruction remains unchanged. After randomly grouping the slopes and reconstructing the surface shape, concave and convex surfaces with random sizes and shapes can be constructed, which can improve the light - mixing effect and make the spot transition smoother.

[0069] In summary, the reconstruction method of the micro - surface array of the optical shaping element provided by the present invention collapses and groups the initial surface 10, so that the slopes of the reconstructed micro - surface array 20 change continuously and are optimized to a G1 surface, and the adjacent micro - surfaces 30 of the micro - surface array 20 are continuous without breakpoints. It is applicable to a continuous - surface optical shaping element for shaping the beam of a small - angle light source. There are no sharp corners on the designed element, and the processability is greatly improved.

[0070] The present invention also provides an optical shaping element, including a micro - surface array 20. The micro - surface array 20 is composed of M×N groups of micro - surfaces 30, where M and N are both positive integers. There is a smooth transition between two adjacent groups of micro - surfaces 30, and the slopes of two adjacent groups of micro - surfaces 30 change continuously; the difference between the maximum slope value and the minimum slope value of a single - group micro - surface 30 and the distance between the point with the maximum slope value and the point with the minimum slope value of the micro - surface 30 are set in a linear proportion.

[0071] The first to the Mth groups of micro-curved surfaces 30 are arranged in sequence along the X-axis direction, and the first to the Nth groups of micro-curved surfaces 30 are arranged in sequence along the Y-axis direction. There is a smooth transition between two adjacent groups of micro-curved surfaces 30, and the slope of the two adjacent groups of micro-curved surfaces 30 changes continuously. This setting is conducive to ensuring that the surface shape at the connection position between the two adjacent groups of micro-curved surfaces 30 is continuous and smooth, and the slope is also continuous, which is conducive to ensuring the stability of subsequent processing, ensuring that there will be no shape difference at the connection position of adjacent micro-curved surfaces 30 during processing, and is conducive to ensuring processing accuracy and shaping effect. By setting the difference between the maximum slope and the minimum slope of a single group of micro-curved surfaces 30 and the distance between the point of the maximum slope and the point of the minimum slope of the micro-curved surface 30 in a linear proportion, it is conducive to ensuring the rationality of the slope and size of each micro-curved surface 30, so as to control the uniform light effect of each micro-curved surface 30, ensure the sufficiency of light mixing, and ensure the reliability of the use of the optical shaping element.

[0072] Specifically, the plurality of micro-curved surfaces 30 include a plurality of convex surfaces and concave surfaces, and the convex surfaces and concave surfaces of the micro-curved surface array 20 are alternately arranged along the X-axis direction, and the convex surfaces and concave surfaces of the micro-curved surface array 20 are alternately arranged along the Y-axis direction. That is to say, the plurality of groups of micro-curved surfaces 30 arranged along the X-axis direction of the micro-curved surface array 20 are alternately arranged with convex surfaces and concave surfaces, so that the surface shapes of two adjacent groups of micro-curved surfaces 30 in the plurality of groups of micro-curved surfaces 30 arranged along the X-axis direction are different, namely, convex surfaces and concave surfaces. Similarly, the plurality of groups of micro-curved surfaces 30 arranged along the Y-axis direction of the micro-curved surface array 20 are alternately arranged with convex surfaces and concave surfaces, so that the surface shapes of two adjacent groups of micro-curved surfaces 30 in the plurality of groups of micro-curved surfaces 30 arranged along the Y-axis direction are different, namely, convex surfaces and concave surfaces. Such an arrangement is conducive to forming a wavy micro-curved surface array 20, and is conducive to ensuring that the surface shape is continuous without breakpoints and sharp corners, and is easy to process and form.

[0073] Of course, in an optional embodiment of the present application, the micro-curved surface 30 may be columnar, that is, the micro-curved surface 30 only in the X-axis direction or only in the Y-axis direction is an alternating arrangement of convex surfaces and concave surfaces.

[0074] Specifically, the radius of curvature of the central area of ​​the convex surface is greater than 0.01mm and less than 1mm; the radius of curvature of the central area of ​​the concave surface is greater than 0.01mm and less than 1mm. If the radius of curvature is too large, the center of the light spot will be too strong, and it is easy to form a bright spot. If the radius of curvature is too small, the surface will be too sharp, difficult to process and easy to damage. By rationally planning the central curvature radius of the micro-curved surface 30 within this range, it is helpful to ensure the surface reliability of each micro-curved surface 30 and ensure the mixed light effect.

[0075] In this application, the length of the micro-curved surface 30 in the X-axis direction, the length of the micro-curved surface 30 in the Y-axis direction, and the sagittal height of the micro-curved surface 30 all vary randomly. That is to say, the sizes and heights of the multiple micro-curved surfaces 30 in the micro-curved surface array 20 are all random. The lengths of the multiple micro-curved surfaces 30 in the X-axis direction are partly equal and partly unequal, without any pattern. The lengths of the multiple micro-curved surfaces 30 in the Y-axis direction are partly equal and partly unequal, without any pattern. The sagittal heights of the multiple micro-curved surfaces 30 include various equal and unequal ones. This randomness of size and height is beneficial to increasing the sufficiency of light mixing and ensuring the uniformity of the brightness of the outgoing light spot.

[0076] As Fig.14 and Fig.15 shown, the following relationships are satisfied between half of the maximum length Lx_max of the micro-curved surface 30 in the X-axis direction and half of the minimum length Lx_min of the micro-curved surface 30 in the X-axis direction: 0.02 < Lx_min / Lx_max < 0.95; the following relationships are satisfied between half of the maximum length Ly_max of the micro-curved surface 30 in the Y-axis direction and half of the minimum length Ly_min of the micro-curved surface 30 in the Y-axis direction: 0.02 < Ly_min / Ly_max < 0.95. The following relationship is satisfied between the maximum sagittal height h_max of the micro-curved surface 30 and the minimum sagittal height h_min of the micro-curved surface 30: 2 < h_min / h_max < 0.95. By reasonably planning the sizes and sagittal heights of the respective micro-curved surfaces 30, when the sizes and sagittal heights of the respective micro-curved surfaces 30 are unequal, the sizes and intensities of the light spots emitted by the respective micro-curved surfaces 30 are all unequal, which is beneficial to light mixing. Fig.15 Lx1 and Lx2 in

[0077] are respectively half of the maximum lengths of two different micro-curved surfaces 30 in the X-axis direction, and Ly1 and Ly2 are respectively half of the maximum lengths of two different micro-curved surfaces 30 in the Y-axis direction.

[0078] Specifically, the maximum slope k of the micro-curved surface 30 satisfies: tan(-80°) < k < tan(80°). By reasonably planning the maximum slope k within this range, it is beneficial to ensure that the slope of the micro-curved surface 30 satisfies the distribution of a smooth surface type and at the same time meets the light mixing effect.

[0079] In this application, the vertices of the multiple micro-curved surfaces 30 of the micro-curved surface array 20 include various types of regular arrangements and irregular arrangements. The distance dx between the vertices of two adjacent micro-curved surfaces 30 in the X-axis direction in the micro-curved surface array 20 and the sagittal height h of the micro-curved surface 30 satisfy: 0.3 < dx / h < 6; the distance dy between the vertices of two adjacent micro-curved surfaces 30 in the Y-axis direction in the micro-curved surface array 20 and the sagittal height h of the micro-curved surface 30 satisfy: 0.3 < dy / h < 6. When the micro-curved surface 30 is columnar, it is not restricted by 0.3 < dx / h < 6 or 0.3 < dy / h < 6. If dx / h or dy / h is too large, the beam expansion effect of the micro-curved surface array 20 is not obvious and bright spots are likely to form at the center of the light spot. If dx / h or dy / h is too small, the slope of the micro-curved surface 30 is too large, which is not easy to process with a mold and the structure is prone to deformation during demolding. Constraining such a range is beneficial to controlling the distribution density of the micro-curved surface 30. At the same time, the distribution density and the sagittal height are constrained, which is beneficial to ensuring the surface type stability, and then ensuring the continuity and feasibility of the surface type, and at the same time ensuring the reliability of light mixing.

[0080] Specifically, the slope of the profile line in each direction of the micro-curved surface array 20 is continuously set. That is to say, the lines formed by any cross-section intercepted along the direction perpendicular to the micro-curved surface array 20 are all continuous curves, and the slopes are also continuously distributed. The smaller the arrangement distance between adjacent micro-curved surfaces 30, the faster the slope changes. The slope change amount (k_max - k_min) / t of a single micro-curved surface 30 satisfies: 100 < (k_max - k_min) / t < 2000; where k_max is the maximum value of the slope of the micro-curved surface 30, k_min is the minimum value of the slope of the micro-curved surface 30, and t is the vertical distance between the point with the maximum slope value and the point with the minimum slope value of the micro-curved surface 30. Such a setting is beneficial to ensuring the slope continuity of a single micro-curved surface 30 and ensuring the curvature continuity. Curvature continuity is beneficial to improving the smoothness of the micro-curved surface 30 and making it a G1 or G2 surface; (k_max - k_min) / t is related to the size of the micro-curved surface 30. The larger (k_max - k_min) / t is, the smaller the micro-curved surface 30 is, and it is not conducive to processing when the micro-curved surface 30 is too small.

[0081] It should be noted that M=L / Lx0, N=W / Ly0. Among them, L is the length of the micro-curved surface array 20 in the X-axis direction, W is the length of the micro-curved surface array 20 in the Y-axis direction, Lx0 is the average of half the length of a single micro-curved surface 30 of the micro-curved surface array 20 in the X-axis direction, and Ly0 is the average of half the length of a single micro-curved surface 30 of the micro-curved surface array 20 in the Y-axis direction. M and N can be odd or even numbers. In order to make multiple products continuous after being arranged in a row, M and N are preferably even numbers. According to the size of the target micro-curved surface array 20, the number of groups M and N is determined so that the number of micro-curved surfaces 30 can be conveniently and freely adjusted.

[0082] The present application is described below with reference to specific examples and drawings.

[0083] In an optional embodiment of the present application, the length L of the micro-curved surface array 20 in the X-axis direction is 4 mm, the length W of the micro-curved surface array 20 in the Y-axis direction is 3.6 mm, the vector height h of the initial curved surface 10 is 2.3 mm; k_min=0, k_max=tan(54.23°), and different groups can be allocated for reconstruction, and the corresponding parameters are shown in Table 1 below:

[0084] Table 1

[0085]

[0086] Figure 3 A schematic structural diagram of the micro-curved surface array 20 of Example 1 is shown. Figure 4 A schematic diagram of a micro-curved surface array 20 of Example 2 is shown. Figure 5 The schematic diagram of the structure of the micro-curved surface array 20 of Example 3 is shown. Since there are too many pixels in the micro-curved surface array 20, in order to avoid too many horizontal and vertical lines in the figure, which appear black and cannot show the surface, a view that can be clearly displayed is reasonably used for display.

[0087] Figure 6 A schematic diagram of the slope distribution of the profile line of the initial curved surface 10 in the X-axis direction is shown. Figure 7 The schematic diagram of the slope distribution of the cross-section line of the micro-curved surface array 20 in the X-axis direction of Example 3 is shown. By comparison, it can be seen that the slope of the micro-curved surface array 20 in Example 3 is continuous and has no endpoints, and the slope changes from small to large and from large to small from left to right, without abrupt rises and falls, which is conducive to ensuring that the surface of the micro-curved surface array 20 is smooth and continuous.

[0088] Figure 8 A graph of the slope statistics of the initial surface 10 is shown. Fig. 9The slope statistics of the micro-curved surface array 20 of Example 3 is shown. By comparison, it can be seen that the slope statistics of the micro-curved surface array 20 of Example 3 is similar to the slope statistics of the initial surface 10, indicating that the micro-curved surface array 20 formed by the reconstruction method of the present application does not change the slope quantity distribution of the original initial surface 10, so as to ensure that the uniform light performance is unchanged compared with the initial surface 10, and ensure that the uniform light effect of the micro-curved surface array 20 of Example 3 meets the effect required by the initial surface 10 setting, and ensure consistency.

[0089] Fig.10 Schematic diagram of the cross section line of the initial curved surface 10 in the X-axis direction and schematic diagram of the cross section line of the micro-curved surface array 20 in the X-axis direction of Example 3 are shown in FIG. It can be seen from the figure that the cross section line of the micro-curved surface array 20 in the X-axis direction is continuous and has no sharp corners.

[0090] This application also provides Example 4 and Example 5.

[0091] In Example 4, Fig.11 As shown, M=8, N=8, the micro-curved surface array 20 composed of M×N groups of micro-curved surfaces 30 is used as a basic unit, and then based on the basic unit, an integrated micro-curved surface array 20 formed by 2×2 basic units is formed. Fig.11 (a) and (b) show the structural schematic diagram and top view of a basic unit respectively. Fig.11 (c) and (d) respectively show a schematic diagram and a top view of the structure of the integrated micro-curved surface array 20. As can be seen from the figure, the surface continuity of the integrated micro-curved surface array 20 formed in this way is better.

[0092] In Example 4, Fig.12 As shown, M=7, N=7, the micro-curved surface array 20 composed of M×N groups of micro-curved surfaces 30 is used as a basic unit, and then based on the basic unit, an integrated micro-curved surface array 20 formed by 2×2 basic units is formed. Fig.12 (a) and (b) show the structural schematic diagram and top view of a basic unit respectively. Fig.12 (c) and (d) respectively show the structural schematic diagram and top view of the integrated micro-curved surface array 20. It can be seen from the figure that the surface continuity of the integrated micro-curved surface array 20 formed in this way is better. However, in this example, the splicing positions of adjacent basic units are prone to sharp corners and small rounded corners, which is not conducive to sample preparation. This is a defect caused by M and N being odd numbers, so M and N are preferably even numbers.

[0093] Obviously, the above-described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0094] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0095] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the numbers used in this way can be interchanged where appropriate, so that the embodiments of the present application described herein can be implemented in an order other than those illustrated or described herein.

[0096] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A method for reconstructing a micro-curved surface array of an optical shaping element, characterized in that: The method includes the following steps: Determine an initial surface (10), divide the initial surface (10) into a plurality of pixel points, and determine the slope of each pixel point; Construct a micro-surface array model to obtain the micro-surface array model composed of M×N groups of micro-surface models; Randomly allocate a plurality of the pixel points to each of the micro-surface models; Regularly arrange the plurality of pixel points in each of the micro-surface models according to the slope of the pixel points, so that the slopes of the plurality of pixel points in each of the micro-surface models change regularly; Determine the sagittal height of each pixel point, thereby obtaining a final micro-surface array (20).

2. The method for reconstructing a micro-curved array of an optical shaping element according to claim 1, characterized in that: The step of dividing the initial surface (10) into a plurality of pixel points and determining the slope of each pixel point includes: Determine the total number of the pixel points according to the length and width of the initial surface (10) and the pixel size; Determine the coordinates of each pixel point; Determine the slope of each pixel point according to the coordinates of each pixel point.

3. The method for reconstructing a micro-curved array of an optical shaping element according to claim 1, characterized in that: The step of constructing a micro-surface array model to obtain the micro-surface array model composed of M×N groups of micro-surface models includes: Determine the number of groups M of the micro-surface models in the X-axis direction and the number of groups N of the micro-surface models in the Y-axis direction of the micro-surface array model according to the length L of the micro-surface array (20) in the X-axis direction, the length W of the micro-surface array (20) in the Y-axis direction, the average value Lx0 of half of the length of a single micro-surface (30) of the micro-surface array (20) in the X-axis direction, and the average value Ly0 of half of the length of a single micro-surface (30) of the micro-surface array (20) in the Y-axis direction, wherein M = L / Lx0, N = W / Ly0.

4. The method for reconstructing a micro-curved array of an optical shaping element according to claim 1, characterized in that: The step of randomly allocating a plurality of the pixel points to each of the micro-surface models includes: Determine the random allocation quantity of the pixel points in each of the micro-surface models; Randomly select the random allocation quantity of the pixel points from the plurality of pixel points and allocate them to the corresponding micro-surface models.

5. The method for reconstructing a micro-curved array of an optical shaping element according to claim 4, characterized in that: The step of determining the random allocation quantity of the pixel points in each of the micro-surface models includes: Set that the random allocation quantity of the pixel points in the micro-surface models from the 1st group to the (M−1)th group in the X-axis direction satisfies: round up the value calculated by m / M×(1+(2×rand−1)×noise); where m is the number of groups of the pixel points in the X-axis direction, rand is a random number in the range greater than or equal to 0 and less than or equal to 1, noise is the maximum random fluctuation amount, and 0 < noise < 0.5; and / or, Set that the random allocation quantity of the pixel points in the micro-surface models from the 1st group to the (N−1)th group in the Y-axis direction satisfies: round up the value calculated by n / N×(1+(2×rand−1)×noise); where n is the number of groups of the pixel points in the Y-axis direction, rand is a random number in the range greater than or equal to 0 and less than or equal to 1, noise is the maximum random fluctuation amount, and 0 < noise < 0.

5.

6. The method for reconstructing a micro-curved array of an optical shaping element according to claim 1, characterized in that: Regularly arranging a plurality of pixel points in each of the micro - surface models according to the slope of the pixel points includes: Arranging the slopes of a plurality of pixel points in the micro - surface models from the first group to the M - th group in a changing rule of decreasing or increasing from large to small along the X - axis direction, and arranging the slopes of a plurality of pixel points in the micro - surface models from the first group to the N - th group in a changing rule of decreasing or increasing from large to small along the Y - axis direction, wherein the first group to the M - th group are arranged along the X - axis direction, and the first group to the N - th group are arranged along the Y - axis direction; Inverting the changing rule of the slopes of a plurality of pixel points along the X - axis direction in the odd - numbered groups or even - numbered groups from the first group to the M - th group, and inverting the changing rule of the slopes of a plurality of pixel points along the Y - axis direction in the odd - numbered groups or even - numbered groups from the first group to the N - th group, so that the changing rules of the slopes of pixel points in two adjacent micro - surface models are opposite, thereby making the slopes of pixel points in two adjacent groups of micro - surface models change continuously.

7. The method for reconstructing a micro-curved array of an optical shaping element according to claim 1, characterized in that: Determining the sagittal height of each of the pixel points includes: Calculating the sagittal height of each of the pixel points by using the point - slope method, thereby obtaining the continuous micro - surface array (20).

8. The method for reconstructing a micro-curved surface array of an optical shaping element according to any one of claims 1 to 7, characterized in that: In the step of randomly distributing a plurality of the pixel points to each of the micro - surface models, it is set that between half of the maximum length Lx_max of the micro - surface model in the X - axis direction and half of the minimum length Lx_min of the micro - surface model in the X - axis direction: 0.02 < Lx_min / Lx_max < 0.95, and it is set that between half of the maximum length Ly_max of the micro - surface model in the Y - axis direction and half of the minimum length Ly_min of the micro - surface model in the Y - axis direction: 0.02 < Ly_min / Ly_max < 0.

95.

9. The method for reconstructing a micro-curved array of an optical shaping element according to any one of claims 1 to 7, characterized in that: In the step of determining the sagittal height of each of the pixel points, it is set that between the maximum value h_max of the sagittal height and the minimum value h_min of the sagittal height: 0.2 < h_min / h_max < 0.

95.

10. The method for reconstructing a micro-curved surface array of an optical shaping element according to any one of claims 1 to 7, characterized in that: In the step of determining the sagittal height of each of the pixel points to obtain the final micro - surface array (20), It is set that between the spacing dx in the X - axis direction between the vertices of two adjacent micro - surfaces (30) in the micro - surface array (20) and the sagittal height h of the micro - surface (30): 0.3 < dx / h < 6; and / or, It is set that between the spacing dy in the Y - axis direction between the vertices of two adjacent micro - surfaces (30) in the micro - surface array (20) and the sagittal height h of the micro - surface (30): 0.3 < dy / h < 6.

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