Micro-Lens Array Illumination System for Projection Devices
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Solution Overview
Problem
Current illumination systems for projection devices using solid-state light sources often result in light energy waste and uneven light distribution due to light beams exceeding the projection lens aperture or requiring larger apertures, increasing manufacturing difficulty and cost.
Innovation Solution
An illumination system comprising a light source with multiple light-emitting units, a micro-lens-array element as a light-homogenizing device, and a light-homogenizing element, which homogenizes and refracts overlapping or non-overlapping light beams to produce a uniform illumination beam suitable for smaller aperture projection lenses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple light sources are arranged in an array to increase brightness, then illumination intensity is improved, but light beam width increases causing it to exceed the projection lens aperture, resulting in light energy waste
Solution Approach 1:
The illumination system segments the light beam into multiple sub-beams using a micro-lens array, where each micro-lens converts one light source's beam into multiple sub-beams. These sub-beams are then combined and homogenized to form a unified illumination beam that fits within the projection lens aperture, thereby maintaining high brightness while preventing light energy waste.
Solution Approach 2:
The patent employs a nested structure where multiple light sources are integrated on a single substrate, each light source's beam is processed through the micro-lens array, and all beams are combined within the illumination system to form a single consolidated beam that fits the projection lens aperture, maximizing light utilization.
2Adaptability or versatility
If multiple light sources of different colors are arranged in an array to form a color light source module, then color illumination capability is improved, but uniformity of color and illuminance distribution deteriorates
Solution Approach 1:
The patent applies local quality by positioning different types of light sources (emitting different colors) at specific locations on the substrate, with each light source's beam processed individually through the micro-lens array. The illumination beams from different light sources are then combined and homogenized in a controlled manner, ensuring uniform color and illuminance distribution across the final illumination beam while maintaining the capability to emit multiple colors.
3Loss of energy
If the projection lens aperture is increased to accommodate wider light beams, then light energy utilization is improved, but manufacturing difficulty and cost increase
Solution Approach 1:
The patent changes the spatial dimension of light beam control by introducing a micro-lens array that operates in the transverse dimension to segment and redirect light beams. This allows the system to maintain a compact projection lens aperture while effectively utilizing light energy through precise beam shaping and homogenization in the lateral dimension, avoiding the need for larger apertures and associated manufacturing complexities.
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 system achieves improved light uniformity and reduced beam width, allowing for the use of smaller aperture projection lenses, thereby decreasing manufacturing complexity and cost while enhancing light use efficiency by at least 10%.
Implementation Method 1
a light-homogenizing device, and a light-homogenizing element. The light source includes multiple light-emitting units. The light-emitting units respectively emit multiple light beams. The light-homogenizing device includes a micro-lens-array element. The micro-lens-array element includes multiple micro lenses. The light beams irradiate the micro-lens-array element, and each of the light beams irradiates at least two of the micro lenses.
Data Source
AI summary
An illumination system configured to provide an illumination light is provided. The illumination system includes a light source, a light-homogenizing device, and a light-homogenizing element. The light source includes multiple light-emitting units, and the light-emitting units emit multiple light beams respectively. The light-homogenizing device includes a micro-lens-array element. The micro-lens-array element includes multiple micro lenses, and each of the light beams irradiates at least two of the micro lenses. The light beams are totally overlapped, non-overlapped, or partially overlapped with each other before being incident on the light-homogenizing device, and overlapped with each other on an incident surface of the light-homogenizing element. A projection device is also provided.