Integrated Lens Array for Laser Speckle-Free Light Uniformization

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Solution Overview

Problem

Conventional projection apparatuses using laser light sources face issues with speckle phenomena due to high coherence, requiring numerous optical elements that increase size and manufacturing costs, and dynamic elements that occupy space, hindering miniaturization.

Innovation Solution

A light uniformization system with an integrally-structured lens array element that uniformly diffuses laser beams using a single mold, eliminating speckles and reducing the number of elements, thereby simplifying assembly and lowering costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional light uniformization systems use multiple lens array elements separately mounted, then light uniformization can be achieved, but the number of elements increases, making the projection apparatus larger and more complex

Engineering Contradiction:

Improvelight uniformization effectVSAvoidnumber of optical elements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple lens array elements into a single integrated lens array element that performs the same light uniformization function. This merging reduces the total number of components, simplifies the structure, and lowers assembly complexity while maintaining the light uniformization effect.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated lens array element is designed to perform multiple functions that were previously distributed across separate elements. It simultaneously achieves light diffusion, uniformization, and coherence reduction, eliminating the need for additional separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If dynamic elements such as diffusion wheels and actuators are used in conventional illumination systems, then light uniformization can be achieved, but the illumination system occupies large space and hinders miniaturization

Engineering Contradiction:

Improvelight uniformization effectVSAvoidillumination system size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent replaces dynamic mechanical elements (diffusion wheels and actuators) with a static integrated lens array element. This substitution eliminates moving parts, significantly reducing the volume occupied by the illumination system and enabling miniaturization while maintaining light uniformization performance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Instead of using dynamic elements that move to achieve light uniformization, the patent inverts the approach by using a static integrated lens array that achieves uniformization through its inherent optical design, eliminating the need for mechanical motion.

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If conventional light uniformization systems use multiple separate optical elements, then light uniformization can be achieved, but manufacturing cost increases due to increased assembly complexity

Engineering Contradiction:

Improvelight uniformization effectVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By merging multiple separate optical elements into a single integrated lens array, the patent reduces the number of manufacturing steps and assembly operations. This integration lowers manufacturing cost while maintaining the light uniformization effect through the combined optical functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated lens array element is pre-designed and pre-manufactured as a single unit with all necessary optical functionalities built-in. This preliminary integration eliminates the need for subsequent assembly operations, reducing both manufacturing complexity and cost.

Inventive Principle:

Principle #10Preliminary action

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 integrally-structured lens array element reduces the size of the light engine, lowers manufacturing costs, and enhances reliability by eliminating speckles and minimizing movable diffusing elements.

Implementation Method 1

a beam emitted by a laser light source is a highly coherent laser beam. The energy of the laser beam would be concentrated in a small area, and therefore a speckle phenomenon is produced.

Methodology Applied

Scientific EffectDiffraction: Diffraction

Implementation Method 2

the projection apparatus functions finally to form an image through an image modulator which modulates the beam with a two-dimensional optical structure to form the image

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentUS20260019539A1Projecting apparatus, illumination system and light uniformization system thereof

Publication Date: 2026.01.15 CORETRONIC CORPORATION

AI summary

The present disclosure provides a projection apparatus an illumination system and a light uniformization system thereof. The light uniformization system includes a lens array element including a first array region and a second array region. The first array region has a first light incident surface, a first light exiting surface and a plurality of first micro lenses. The second array region has a second light incident surface, a second light exiting surface and a plurality of second micro lenses. The first light incident surface and the second light exiting surface are on the same surface of the lens array element.