Flat-Top Laser Diffuser With Random Lens Overwrite
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flat top diffusers using micro-lens arrays suffer from high frequency diffracted orders and low frequency diffraction patterns, which affect optical quality and aesthetic appearance, particularly when used with coherent light sources.
Innovation Solution
The introduction of randomly placed lenses (RPLs) and a light shaping diffuser (LSD) pattern overwrites the micro-lens array (MLA) to create a homogenized image, reducing high frequency diffraction and enhancing aesthetic appeal by camouflaging the diffuser from human view.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a regularly spaced micro-lens array (MLA) is used to achieve high optical efficiency and uniform light distribution, then light shaping performance is improved, but high frequency diffracted orders and low frequency diffraction patterns are generated affecting optical quality
Solution Approach 1:
The optical surface is divided into multiple layers: a base MLA layer for light shaping, a middle RPL layer to disrupt diffraction patterns, and a top LSD layer for fine homogenization. Each layer performs a specific function, collectively eliminating diffraction while maintaining uniform light distribution.
Solution Approach 2:
The patent combines three different micro-optic structures (MLA, RPL, LSD) into a composite multi-layer diffuser. This composite structure leverages the strengths of each component: MLA for efficiency, RPL for diffraction suppression, and LSD for uniformity, achieving superior overall performance.
2Productivity
If a micro-lens array structure is used to achieve flat top light distribution, then optical efficiency is improved, but aesthetic visual appearance deteriorates due to visible diffraction patterns
Solution Approach 1:
The solution adds the dimension of depth by creating a multi-layer structure with vertical stacking. The RPL and LSD layers are positioned at different depths from the MLA, allowing optical functions to be separated in the vertical dimension while presenting a uniform appearance from the front viewing dimension.
Solution Approach 2:
Different regions of the optical element have different functions: the MLA regions provide high efficiency light shaping, the RPL regions provide diffraction disruption, and the LSD regions provide fine uniformity control. Each local region is optimized for its specific function while contributing to the overall aesthetic appearance.
3Object-affected harmful factors
If randomly placed lenses (RPLs) are introduced to reduce diffraction patterns, then optical quality is improved, but device complexity increases due to multiple layers
Solution Approach 1:
The RPLs are nested within the multi-layer structure, with each layer containing specific micro-optic elements. The MLA forms the base layer, RPLs form the middle layer embedded within the structure, and LSD features form the top layer, creating a nested configuration where each layer is integrated into the overall design.
4Shape
If a light shaping diffuser (LSD) pattern is added to camouflage the diffuser from human view, then aesthetic appearance is improved, but manufacturing complexity increases
Solution Approach 1:
The MLA and RPL layers are fabricated first to establish the optical performance foundation. The LSD pattern is then added as a final top layer that camouflages the underlying structures. This preliminary fabrication of functional layers followed by aesthetic layer addition simplifies the manufacturing sequence.
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 achieves a flat top distribution with reduced diffraction patterns and improved visual aesthetics, suitable for both coherent and incoherent light sources, while maintaining high optical efficiency.
Implementation Method 1
Each lenslet has a boundary shape. The lenslets are configured in a regularly spaced micro-lens array (MLA)
Implementation Method 2
the lenslets are overwritten with partially filled randomly placed lenses (RPLs), which cover from 1 percent to 99 percent of the MLA
Implementation Method 3
A light shaping diffuser (LSD) pattern is added on top of the micro-optic unit cell, wherein the LSD comprises an overlay micro-structure that at least partially camouflages the LSD from human viewers
Data Source
AI summary
Optical diffusers are disclosed with improved optical properties and improve aesthetic designs. A micro lens array may be overwritten with randomly placed lenses. A light shaping diffuser may be included. The light shaping diffuser may have a microstructure that includes features that aid in camouflaging the micro lenses from consumers, improving the aesthetic appearance while retaining other desirable optical properties.