Projector Illuminator Free-Form Lens Array Uniformity
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Solution Overview
Problem
Existing illuminators for projectors face challenges in achieving uniform illuminance distribution across an illuminated area while minimizing the size and number of components, as increasing the diffusion angle to enhance uniformity often results in decreased fluorescence use efficiency and increased size, and additional components like multi-lens arrays complicate the system.
Innovation Solution
A projector illuminator featuring a light source with a collimation system and a light forming system comprising a lens array with non-rotationally symmetric free-form lenses, which divides the light beam into sub-beams to adjust the irradiated area and homogenize illuminance distribution, allowing independent curvature design in the x and y directions and flexible lens design to optimize the light irradiated area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the diffusion angle is increased to lower the power density, then the uniformity of the illuminance distribution is improved, but the size of the excitation light spot on the phosphor is increased and the fluorescence use efficiency decreases
Solution Approach 1:
The patent divides the single light beam into multiple sub-light beam fluxes using a lens array with multiple lenses. Each lens creates a separate sub-beam that is directed to a specific region of the illuminated area, achieving uniform illuminance distribution without requiring excessive diffusion that would reduce fluorescence efficiency.
Solution Approach 2:
The patent employs non-rotationally symmetric free-form surfaces on the lenses, where the curvature in the x-direction differs from the curvature in the y-direction. This asymmetric design allows independent optimization of light distribution in different directions, enabling uniform illuminance while maintaining compact light spot size and high fluorescence efficiency.
2Illumination intensity
If the diffusion angle is increased to enhance uniformity, then the illuminance distribution is improved, but the size of the entire illuminator increases
Solution Approach 1:
The patent utilizes free-form surfaces with different curvatures in x and y directions, introducing dimensional independence to the lens design. This allows the light distribution to be optimized in multiple dimensions simultaneously, achieving uniform illuminance without increasing the overall illuminator size through excessive diffusion angles.
3Illumination intensity
If additional components like multi-lens arrays are added to homogenize the blue light illuminance distribution, then the uniformity is improved, but the number of parts and the size of the light source apparatus increase
Solution Approach 1:
Each lens in the array serves multiple functions simultaneously: it divides the light beam into sub-beams, directs light to specific regions, and the non-rotationally symmetric free-form surface also performs homogenization of the illuminance distribution. This multi-functionality reduces the need for separate homogenization components.
Solution Approach 2:
The patent combines the light division function and the illuminance homogenization function into a single integrated lens array structure. The non-rotationally symmetric free-form surfaces are incorporated directly into the lens geometry, merging multiple optical functions into one component rather than requiring separate elements.
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 enhances the uniformity of illuminance distribution across the illuminated area, reduces power density, and maintains a compact design by adjusting the shape and size of the light irradiated area, thereby improving fluorescence conversion efficiency and projector performance.
Implementation Method 1
a collimation system on which a light beam flux emitted from the light source is incident
Implementation Method 2
a light forming system including a lens array including a plurality of lenses. The plurality of lenses each have a lens surface having a non-rotationally symmetric free-form surface. The light forming system is configured to cause the plurality of lenses to divide the light beam flux having passed through the collimation system into a plurality of sub-light beam fluxes
Implementation Method 3
a phosphor, a diffuser plate disposed between the excitation light source and the phosphor
Data Source
AI summary
An illuminator includes a light source, a collimation system on which a light beam flux emitted from the light source is incident, and a light forming system including a lens array including a plurality of lenses. The plurality of lenses each have a lens surface having a non-rotationally symmetric free-form surface. The light forming system is configured to cause the plurality of lenses to divide the light beam flux having passed through the collimation system into a plurality of sub-light beam fluxes and the plurality of sub-light beam fluxes to be incident on an illuminated area.