Hybrid Resin-Glass Microlens Array for Uniform Light Distribution
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Solution Overview
Problem
Microlens arrays face challenges in forming ideal lens shapes, leading to optical loss due to ineffective portions, especially when made of glass, and are susceptible to thermal degradation when made of resin.
Innovation Solution
A microlens array design where entrance surfaces are made of resin for accurate formation and exit surfaces are made of glass for heat resistance, reducing optical loss and thermal degradation, with the first microlens array focusing light into the effective portions of the corresponding glass microlenses to achieve uniform light intensity distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass is used for microlens arrays, then thermal degradation resistance is improved, but manufacturing precision deteriorates due to difficulty in forming ideal lens shapes
Solution Approach 1:
The microlens array is divided into two separate arrays: a first microlens array made of resin and a second microlens array made of glass. This segmentation allows each array to be optimized for its specific function - resin for precise molding and glass for thermal resistance - thereby resolving the contradiction between manufacturing precision and thermal degradation resistance.
Solution Approach 2:
The invention uses a composite structure combining two different materials (resin and glass) in separate microlens arrays. The resin array provides accurate lens formation while the glass array provides thermal stability, creating a composite optical system that overcomes the limitations of using a single material.
2Manufacturing precision
If resin is used for microlens arrays, then manufacturing precision is improved, but thermal degradation resistance deteriorates
Solution Approach 1:
The microlens array is divided into two separate arrays: a first microlens array made of resin and a second microlens array made of glass. This segmentation allows each array to be optimized for its specific function - resin for precise molding and glass for thermal resistance - thereby resolving the contradiction between manufacturing precision and thermal degradation resistance.
Solution Approach 2:
The invention uses a composite structure combining two different materials (resin and glass) in separate microlens arrays. The resin array provides accurate lens formation while the glass array provides thermal stability, creating a composite optical system that overcomes the limitations of using a single material.
3Area of stationary object
If entire surfaces of microlenses are formed, then optical coverage is improved, but optical loss increases due to ineffective portions at boundaries
Solution Approach 1:
The invention applies different quality characteristics to different parts of the optical system. The first microlens array (resin) is designed with specific local quality features to guide light, while the second microlens array (glass) has different local quality features to focus light. This local differentiation optimizes light utilization and reduces optical loss at boundaries.
Solution Approach 2:
The invention creates a correspondence between the first and second microlens arrays, where each microlens in the first array has a corresponding microlens in the second array. This copying relationship ensures that light passing through the first array is effectively utilized by the second array, reducing optical loss from ineffective portions.
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 design minimizes optical loss and thermal degradation, enhancing light use efficiency and durability by using resin for accurate shaping and glass for heat resistance, while maintaining effective lens performance despite manufacturing errors.
Implementation Method 1
entrance surfaces of the microlenses on which light is incident are made of resin
Implementation Method 2
exit surfaces of the microlenses from which light exits are made of glass
Data Source
AI summary
The present invention provides a microlens array including multiple microlenses arranged axially parallel to one another, wherein entrance surfaces of the microlenses on which light is incident are made of resin, and exit surfaces of the microlenses from which light exits are made of glass.