Irregular Lenslet Arrays with Planar Facets for Sharp Beam Profiles
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Solution Overview
Problem
Existing optical devices, such as collimators, often produce beam patterns with artefacts due to non-uniform light sources like LED arrays, and achieving a round beam with sharp edge profiles is challenging, as circular lenslets cannot form tessellated arrays and polygonal lenslets result in poorly defined edge gradients.
Innovation Solution
An integrating lenslet arrangement featuring a first lenslet array with irregularly tessellated, non-circular lenslets and a second lenslet array aligned with planar facets covering the spaces between lenslets, allowing closer packing and reducing artefacts by creating a uniform halo effect around the main beam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If circular lenslets are used to generate a round beam profile, then the beam shape is improved, but the lenslets cannot form a tessellated array and spaces between them cause artefacts
Solution Approach 1:
The invention divides the lenslet array into two opposing arrays (first and second lenslet arrays) with irregular polygonal lenslets. Each lenslet in the first array is optically aligned with a corresponding lenslet in the second array, creating paired lenslet combinations that work together to form the round beam profile while maintaining tessellation capability.
Solution Approach 2:
The invention uses irregular polygonal lenslets instead of regular circular or uniform polygonal shapes. The lenslets have varying shapes and sizes within the tessellated array, which allows them to pack more efficiently without leaving large gaps that would cause artefacts, while still achieving the desired round beam profile through the paired lenslet configuration.
2Ease of manufacture
If polygonal lenslets are used to form a tessellated array, then the array structure is improved, but the beam edge profile becomes poorly defined
Solution Approach 1:
The invention transitions from a single lenslet array to a three-dimensional paired lenslet configuration with two opposing arrays. The light from the first lenslet array is focused onto the second lenslet array, creating a far-field image that combines the advantages of tessellation with improved beam edge definition through the optical pairing mechanism.
Solution Approach 2:
The paired lenslet configuration acts as an intermediary mechanism between the tessellated array structure and the desired round beam profile. The first lenslet array focuses light onto the second lenslet array, which then projects the improved beam profile to the far field, mediating between the polygonal lenslet shapes and the round beam output.
3Shape
If lenslets are arranged on rings with regularized random placement, then average round patterns are achieved, but pattern edge gradients are poorly defined due to protruding polygon corners
Solution Approach 1:
Instead of arranging lenslets directly in a random pattern on rings and accepting the poor edge definition, the invention inverts the approach by using a regular paired lenslet array configuration that optically creates the round beam profile. The pairing mechanism ensures that protruding corners are optically compensated, producing well-defined edge gradients in the far-field image.
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 arrangement effectively minimizes artefacts and achieves a well-defined, artefact-free round beam with a sharp edge profile, improving beam forming capability and color uniformity in lighting applications.
Implementation Method 1
A first lenslet of the array facing the collimator typically focuses its incident light on the paired lenslet of the opposing array
Implementation Method 2
planar facets covering pockets in between the lenslets, allowing closer packing and reducing artefacts by creating a uniform halo effect around the main beam
Data Source
AI summary
A lighting device includes at least on LED light source, ca collimator, a first lenslet array of lenslets tessellated in an irregular pattern, and a second array of lenslets tessellated in the same irregular pattern as the first array of lenslets, such that each of the lenslets in the first array is aligned with a corresponding one of the lenslets in the second array. The first array further includes a plurality of transmissive planar facets covering an intersection between lenslet.