Illumination Device Asymmetric Lens Width for Mounting Error Tolerance
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Solution Overview
Problem
Illumination devices using light-emitting elements face reduced light-use efficiency due to mounting errors in the alignment of optical systems, leading to inefficient light emission onto a predetermined region.
Innovation Solution
The illumination device incorporates a collimating optical system, a first multi-lens array, a second multi-lens array, and a superimposing lens, where the second lenses are arranged with a larger width in one direction than the first lenses, allowing for efficient light emission even with deviations, and are preferably hexagonal for close packing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the width of second lenses is made equal to the width of first lenses to maintain compact structure, then device complexity is reduced, but light-use efficiency deteriorates due to light protrusion from the optical system caused by mounting errors
Solution Approach 1:
The patent applies local quality by making the width of second lenses larger than first lenses specifically in the direction where mounting errors occur (Y-direction), while maintaining the original width in the orthogonal direction (X-direction). This localized dimensional adjustment compensates for alignment deviations without unnecessarily increasing overall device complexity, thereby improving light-use efficiency while controlling structural complexity.
2Loss of energy
If the width of second lenses is increased to compensate for mounting errors, then light-use efficiency is improved, but manufacturing precision requirements are worsened due to asymmetric lens dimensions
Solution Approach 1:
The patent changes the width parameter of second lenses asymmetrically relative to first lenses, specifically increasing the width in the Y-direction where mounting errors occur. This parameter modification creates a tolerance buffer that accommodates alignment deviations, thereby improving light-use efficiency while actually relaxing the effective manufacturing precision requirements by built-in compensating geometry.
3Reliability
If the width of second lenses is increased to accommodate mounting errors, then reliability is improved by reducing light loss, but device complexity increases due to non-uniform lens arrangement
Solution Approach 1:
The patent implements local quality by selectively increasing the width of second lenses only in the Y-direction (the direction where mounting errors occur) while maintaining the original width in the X-direction. This localized modification improves reliability by accommodating alignment deviations and reducing light loss, while minimizing the increase in overall device complexity through targeted rather than universal dimensional changes.
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 configuration ensures high light-use efficiency by minimizing light protrusion from the second lenses, even with deviations, and facilitates cost reduction through relaxed manufacturing accuracy.
Implementation Method 1
a collimating optical system on which light emitted from the plurality of light-emitting elements is incident
Implementation Method 2
a first multi-lens array on which light emitted from the collimating optical system is incident and which includes a plurality of first lenses; a second multi-lens array on which light emitted from the first multi-lens array is incident and which includes a plurality of second lenses
Data Source
AI summary
An illumination device includes: a plurality of light-emitting elements; a collimating optical system; a first multi-lens array including a plurality of first lenses; a second multi-lens array including a plurality of second lenses; and a superimposing lens. The plurality of second lenses are arranged respectively corresponding to the plurality of first lenses. The plurality of first lenses form a plurality of first lens columns. A width, in a first direction, of one second lens of the plurality of second lenses has a distribution in a second direction, where the first direction is a direction in which the plurality of first lens columns are arranged and the second direction is a direction orthogonal to the first direction.