Micro-Scale Optical Capture System for Fabric Imaging
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Solution Overview
Problem
Current micro-scale optical imaging systems fail to achieve 1:1 magnification with uniform flat-wave illumination from multiple angles, leading to self-occlusions and inadequate capture of geometric and optical properties of materials, particularly for fibrous materials with thick fibers and complex patterns.
Innovation Solution
A micro-scale optical capturing system with low divergence incident light and low acceptance angle, utilizing 60-100 high-power white LEDs for planar wave front illumination and a digital camera with a 50 mm focal objective and extension tube for 1:1 magnification, minimizing occlusions and enabling detailed fiber-level imaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple viewing directions are used to capture SV-BRDF or BTF, then material appearance modeling is improved, but depth of field at grazing angles deteriorates and self-occlusions increase
Solution Approach 1:
The patent transitions from capturing images at multiple viewing directions (2D angular sampling) to capturing images along a single central viewing direction while varying illumination angles (3D parameter space: x, y, θ). This dimensional shift eliminates depth of field issues at grazing angles while still enabling comprehensive material characterization through controlled illumination variation.
Solution Approach 2:
The patent segments the lighting function into multiple independent luminaires positioned at different angles around the sample, each providing controlled illumination from a specific direction. This segmentation allows precise control over illumination angles while maintaining a fixed, optimal camera position, resolving the contradiction between comprehensive lighting coverage and maintaining adequate depth of field.
2Volume of moving object
If macro lenses with short optical working distances are used, then system dimensions are reduced, but self-occlusions increase and fiber-level detail capture deteriorates
Solution Approach 1:
The patent introduces an extension tube as an intermediary element between the macro lens and the camera sensor. This extension tube increases the optical working distance, allowing the lens to be positioned farther from the sample while maintaining 1:1 magnification. The result is reduced self-occlusions and improved fiber-level detail capture while keeping the overall system compact through the use of LED arrays positioned around the extension tube.
3Reliability
If 1:1 magnification is achieved with extended optical working distance, then self-occlusions are minimized, but system complexity increases
Solution Approach 1:
The patent employs a modular luminaire design where each lighting unit can be independently positioned and angled, allowing the same basic module to serve multiple illumination directions. This multi-functional approach simplifies the overall system architecture compared to requiring different optical configurations for each viewing angle, reducing complexity while achieving 1:1 magnification with minimized self-occlusions.
4Adaptability or versatility
If conventional optical imaging systems are used for fibrous materials, then general surface properties are captured, but geometric and optical properties of thick fibers are inadequately resolved
Solution Approach 1:
The patent applies local quality by using multiple luminaires positioned at different angles to illuminate specific regions of the fibrous sample from different directions. This enables the capture of geometric properties (through shadow and highlight patterns) and optical properties (through specular and diffuse reflection variations) of individual fibers and yarns, providing detailed local characterization that conventional uniform illumination cannot achieve.
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 provides high-quality data for realistic rendering of fabrics by avoiding self-occlusions and ensuring uniform illumination, capturing detailed geometric and optical properties with improved resolution and accuracy.
Implementation Method 1
a lens coupled to an extension tube and the extension tube disposed in front of the optical sensor guiding light from the lens to the optical sensor
Implementation Method 2
an extension tube and the extension tube disposed in front of the optical sensor guiding light from the lens to the optical sensor
Implementation Method 3
a lighting module including a plurality of light units spatially arranged around the sample holder and directed towards the sample holder, where each light unit is configured to provide a planar wave front illumination of the incident light on the fabric sample
Data Source
AI summary
According to various embodiments of the present invention, an optical capture system is provided. In one embodiment, a micro-scale optical capturing system is provided with low divergence (approximately 1°) of the incident light and low acceptance angle (<8°) of the captured light. According to embodiments, a micro-scale optical capturing system is provided with a large number of collimated high-power white LEDs as light sources, between 60 and 100 units, for example, and may be positioned at distances of about 650 mm from the sample. In one embodiment, a digital camera using 50 mm focal objective with a 25 mm length extension tube captures images of the sample. This provides a working distance of approximately 100 mm and at the same time maintains ×0.5 magnification for microscale captures, with an image size of 4×4 microns per pixel.