Diffuser Plate With Irregular Concave Depths For Laser Light
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Solution Overview
Problem
Existing optical devices using laser light sources face inefficiencies in light diffusion due to regular arrangements of microlenses, leading to insufficient correction of intensity distribution and increased diffraction, while existing methods for introducing irregularity are either inefficient or prone to defects during processing.
Innovation Solution
The development of optical devices with concaves or convexes on a base material surface, where the positions of the bottoms or tops are irregularly arranged in the depth or height direction, respectively, to create a diffuser plate that efficiently diffuses light within a predetermined angular range, using wet etching to form these structures and ensuring high light use efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a regular microlens array is used to diffuse light, then the intensity distribution can be corrected, but diffraction effects increase and light use efficiency decreases
Solution Approach 1:
The patent applies asymmetry by introducing irregularity in the depth direction of microlens structures. Specifically, the distance from the light incident surface to the bottom of each microlens is varied irregularly rather than being uniform, which suppresses diffraction effects while maintaining light diffusion capability. This asymmetric depth configuration prevents constructive interference that causes diffraction, thereby improving light use efficiency while still correcting intensity distribution.
Solution Approach 2:
The patent transitions from two-dimensional regular arrangement to three-dimensional irregular arrangement by controlling the depth position of microlens bottoms. This dimensional change allows the microlens array to maintain regular spacing in the plane while introducing irregularity in the depth direction, achieving both intensity correction and diffraction suppression simultaneously.
2Object-generated harmful factors
If irregularity is introduced to reduce diffraction, then diffraction effects decrease, but manufacturing precision becomes more difficult
Solution Approach 1:
The patent changes the parameter of microlens depth position from a fixed uniform value to a controlled irregular distribution. By defining specific constraints on the depth variation (such as maintaining average depth within certain ranges and controlling depth differences between adjacent microlenses), the invention enables manufacturing with conventional precision while achieving diffraction suppression. This parameter change approach balances manufacturing feasibility with optical performance.
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
The solution effectively reduces diffraction effects and maintains high light use efficiency by irregularly arranging the positions of the concaves or convexes, preventing intense light from being directed in specific directions and ensuring uniform light distribution, thus enhancing the performance of optical devices and projectors.
Implementation Method 1
optical devices that keep the diffusion of light within a predetermined range by a refraction effect
Data Source
AI summary
An optical device includes a base material including a surface on which multiple concaves are formed. The concaves include respective curved surfaces. The concaves are formed so that the bottoms of the concaves are at two or more different positions in a depth direction. In the optical device, 2/7≤|(n1−n2)×Δd|/λ≤10 holds, where n1 is the refractive index of the base material, n2 is the refractive index of a medium around the concaves, λ is the wavelength of a beam flux that enters the base material, and Δd is a range of the positions of the bottoms in the depth direction.