Integrated Light Pipe Folded Optical Path Design
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Solution Overview
Problem
The challenge in mass-producing miniaturized optical devices lies in achieving a balance between high precision, reliability, and low manufacturing cost, while maintaining tight assembly tolerances and structural strength within strict size and cost constraints.
Innovation Solution
The development of an integrated optical device with a folded optical design, featuring a pair of transparent plates and planar reflectors fixed in mutually-parallel orientations, forming a cavity that extends the optical path while maintaining a low profile, and incorporating lenses and a patterning element to generate patterned light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the optical path is extended to improve optical quality, then the device length increases, but the miniaturization goal is compromised
Solution Approach 1:
The patent employs a folded optical path design where light reflects off planar reflectors at diagonal orientations (45 degrees) to extend the optical path length in a three-dimensional folded configuration rather than a straight line. This allows the optical path to extend beyond the simple linear dimensions of the device, achieving extended optical length while maintaining a compact overall device footprint.
2Reliability
If tight assembly tolerances are maintained to improve reliability, then manufacturing complexity increases, but mass production becomes difficult
Solution Approach 1:
The patent integrates multiple optical components (lenses, planar reflectors, patterning elements) into a single integrated optical package where components are fixed relative to each other on opposing sides of transparent plates. This integration reduces the number of separate assemblies required, simplifies alignment procedures, and enables the entire optical system to be manufactured as one unit, thereby improving reliability while facilitating mass production.
3Strength
If structural strength is increased to maintain tight tolerances, then device complexity increases, but miniaturization is compromised
Solution Approach 1:
The transparent plates in the device serve multiple functions: they act as structural substrates that provide mechanical strength and maintain structural integrity, serve as mounting surfaces for fixing optical components (lenses, reflectors, patterning elements), and function as optical elements themselves by transmitting light through their transparent regions. This multi-functionality reduces the need for additional separate structural components, thereby maintaining strength while minimizing device complexity.
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 design enhances the reliability and manufacturability of miniaturized optical devices, enabling extended optical length without increasing overall dimensions, suitable for applications like 3D mapping and other optical projection systems.
Implementation Method 1
First and second planar reflectors are spaced apart and fixed between the first and second plates in mutually-parallel orientations diagonal to the first and second plates, thereby defining an optical path through the device from the entrance face, reflecting from the first and second reflectors
Implementation Method 2
At least one lens is formed over at least one of the first and second transparent regions... passing through the at least one refractive surface
Data Source
AI summary
An optical device includes a first plate having a first transparent region defining an exit face of the device, and a second plate having a second transparent region defining an entrance face of the device. At least one lens is formed over at least one of the first and second transparent regions. First and second planar reflectors are spaced apart and fixed between the first and second plates in mutually-parallel orientations diagonal to the first and second plates, thereby defining an optical path through the device from the entrance face, reflecting from the first and second reflectors, through the exit face and passing through the at least one refractive surface.