Micro-LED Lens Array Calibration for Adaptive Beam Steering
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Solution Overview
Problem
The alignment and assembly of micro-LED arrays with optical elements is challenging due to mechanical tolerances and conventional methods are time-consuming and costly, leading to inaccurate placement.
Innovation Solution
A micro-LED array system with randomly positioned LEDs and a micro-lens array, where each LED can be individually controlled, allowing for adaptive illumination by selectively activating LEDs to tune the radiation pattern, and a calibration process to record and adjust light profiles using a processor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional alignment methods are used to align micro-LEDs with optical elements, then manufacturing precision can be achieved, but the assembly process becomes time-consuming and costly
Solution Approach 1:
The patent applies preliminary action by pre-aligning micro-LEDs with optical elements during the manufacturing process rather than during final assembly. Micro-LEDs are positioned and aligned in advance on the substrate, allowing the optical elements to be subsequently attached without requiring complex real-time alignment procedures, thus improving assembly speed while maintaining precision
Solution Approach 2:
The patent replaces complex mechanical alignment systems with optical alignment methods. Instead of using mechanical positioning and adjustment mechanisms, the system uses optical techniques such as optical alignment marks and optical inspection to achieve precise alignment, thereby reducing assembly time and cost while maintaining high alignment precision
2Manufacturing precision
If mechanical alignment systems are used to position micro-LEDs, then alignment accuracy is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical alignment systems with optical alignment methods. Optical alignment marks and optical inspection techniques are used to achieve precise positioning without requiring complex mechanical adjustment mechanisms, thereby reducing device complexity while maintaining high alignment accuracy
Solution Approach 2:
The patent uses optical alignment marks as copies or representations of the actual micro-LED positions. These alignment marks are easier to position and detect than the micro-LEDs themselves, allowing for simplified alignment procedures while maintaining the same level of accuracy for the actual light-emitting components
3Adaptability or versatility
If individual micro-LED control is implemented for beam steering, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the illumination system into individually controllable micro-LED elements. Each micro-LED or group of micro-LEDs can be independently controlled to steer the beam in different directions, enabling flexible and adaptive illumination patterns while using modular control units that simplify the overall system architecture
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
Enables high-speed, high-data-rate image projection and adaptive illumination with precise control over light intensity and direction, overcoming alignment issues and improving efficiency.
Implementation Method 1
Micro-LED arrays often include thousands to millions of microscopic light-emitting diode (LED) pixels that can emit light and that can be individually controlled
Implementation Method 2
additional optics around the light source may be used to direct the emitted light toward a desired region
Data Source
AI summary
A structure and method of operating micro-LEDs are described. The micro-LEDs are arranged in a micro-LED array and have random orientations, distributions, and positions within the array. A lens array includes micro-lenses configured to capture light from the micro-LEDs. The micro-LED array structure is calibrated by capturing light from each of the micro-LEDs at different times and determining characteristics of the light from each of the micro-LEDs. Once image data of an image to be generated by the micro-LED array is received, a combination of the micro-LEDs to activate to produce the image, as well as the characteristics for driving the individual micro-LEDs is determined. The micro-LEDs are then activated to produce the image.