Anamorphic Projection Optics for High-Resolution Laser Imaging
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Solution Overview
Problem
Current laser imaging systems face challenges in achieving high resolution and high power imaging across large areas in a single pass due to limitations in optical performance, such as image field curvature and differential aging of LED arrays, which restricts their application in high-speed printing and cutting processes.
Innovation Solution
A homogenous light generator combined with a spatial light modulator and an anamorphic optical system that modulates and focuses light to create a high power, narrow scan line image, allowing for scalable high resolution and high speed imaging without the need for high intensity light sources passing through spatial light modulators, using commercially available low-cost devices like DMD chips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single laser head motorized x-y flatbed architecture is used for large area coverage, then the imaging area is improved, but the imaging speed deteriorates and becomes too slow for high speed printing processes
Solution Approach 1:
The patent divides the imaging system into multiple stationary laser heads, each responsible for a specific region. This allows parallel imaging across large areas without requiring mechanical movement, thereby maintaining high imaging speed while achieving large area coverage.
Solution Approach 2:
The patent replaces the mechanical x-y scanning system with a static array of laser heads combined with optical scanning. This eliminates mechanical movement limitations and enables high-speed parallel imaging across large areas by using optical paths instead of mechanical positioning.
2Measurement precision
If laser ROS is used to achieve high resolution imaging, then the image resolution is improved, but the lateral extent of the scan line is limited and optical performance deteriorates at the extremes
Solution Approach 1:
The patent divides the scan line into multiple segments, each handled by a separate laser head. This allows high resolution to be maintained across each segment while extending the total lateral coverage by combining multiple segments in parallel.
Solution Approach 2:
The patent combines multiple laser heads to form a unified imaging system that covers a wide lateral extent. By merging the output of multiple high-resolution laser heads, the system achieves both high resolution and large area coverage simultaneously.
3Power
If high power light sources are used to achieve high power imaging, then the imaging power is improved, but the light intensity required for spatial light modulators increases causing device damage or reduced lifespan
Solution Approach 1:
The patent divides the high power requirement into multiple lower power laser heads, each operating within safe intensity limits for spatial light modulators. This allows the system to achieve high total power output while maintaining reliability of individual components.
Solution Approach 2:
The patent combines multiple moderate-power laser sources to achieve high total imaging power. By merging the output of multiple reliable low-to-moderate power sources, the system achieves high power capability without requiring any single spatial light modulator to handle extreme intensities.
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
This solution enables the production of high power scan lines with gray-scale capabilities and variable resolution, facilitating seamless stitching of images across large areas without mechanical interference, suitable for applications like high-speed printing and lithographic marking.
Implementation Method 1
anamorphic optical system that focuses the modulated light to a form a narrow scan line image
Implementation Method 2
spatial light modulator that modulates the homogenous light according to predetermined scan line image data
Data Source
AI summary
Substantially one-dimensional scan line images at 1200 dpi or greater are generated in response to predetermined scan line image data. A substantially uniform two-dimensional homogenous light field is modulated using a spatial light modulator in accordance with the predetermined scan line image data such that the modulated light forms a two-dimensional modulated light field. The modulated light field is then anamorphically imaged and concentrated to form the substantially one-dimensional scan line image. The spatial light modulator includes light modulating elements arranged in a two-dimensional array. The light modulating elements are disposed such that each modulating element receives an associated homogenous light portion, and is individually adjustable between an “on” modulated state and an “off” modulated state, whereby in the “on” modulated state each modulating element directs its received light portion onto a corresponding region of the anamorphic optical system, and in the “off” state blocks or diverts the light portion.