MicroLED Cluster Offset for Dot Projection in 3D Sensing

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Solution Overview

Problem

There is a need for cost-effective and space-efficient dot projectors for applications such as mobile phones and handheld devices, which require simplified design and manufacturing, and can implement facial recognition and 3D sensing without the complexity and expense of VCSEL technology.

Innovation Solution

A miniature pattern projector module using microLED clusters with offset centers relative to their micro-lenses, allowing for individual dot projection and 3D feature determination, integrated with a sensing module for 3D sensing applications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If VCSEL technology is used for dot projection, then projection capability is achieved, but cost and device complexity increase significantly

Engineering Contradiction:

Improvemanufacturing costVSAvoidprojection performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent uses microLEDs as a cost-effective alternative copy to VCSEL technology for dot projection. Instead of using expensive vertical-cavity surface-emitting lasers, the invention employs micro-scale light-emitting diodes that replicate the dot projection function at a fraction of the cost, making the technology accessible for mobile phones and handheld devices

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent employs inexpensive microLED components that can be mass-produced using standard semiconductor fabrication processes. These microLEDs are designed to be cost-effective and replaceable, allowing manufacturers to implement dot projection functionality without the high cost of VCSEL technology

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Device complexity

If VCSEL technology is used for dot projection, then projection capability is achieved, but device size and complexity increase

Engineering Contradiction:

Improvesystem complexityVSAvoidprojection performance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent divides the projection system into discrete microLED clusters arranged in arrays, with each cluster containing multiple microLEDs that can be independently controlled. This segmentation allows for simplified system architecture compared to VCSEL technology, enabling easier integration into mobile devices while maintaining projection performance

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines multiple microLEDs into clusters that function together as single projection units. By merging multiple light-emitting elements into coordinated clusters, the system achieves VCSEL-like projection capability with reduced complexity and better scalability for mobile applications

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If microLED clusters are used with offset centers, then individual dot projection is achieved, but alignment precision requirements increase

Engineering Contradiction:

Improveindividual dot controlVSAvoidLED cluster to lens alignment

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent intentionally introduces asymmetry by offsetting the center of microLED clusters from the optical center of corresponding micro-lenses. This asymmetric arrangement enables individual dot projection capability where each microLED cluster projects through its associated lens to create distinct dots on the projection surface, facilitating precise control of projected patterns

Inventive Principle:

Principle #4Asymmetry

4Volume of moving object

If miniaturized microLED chips are used, then device size is reduced, but manufacturing complexity increases

Engineering Contradiction:

Improveprojector sizeVSAvoidmanufacturing process

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The patent transitions from planar LED arrangements to three-dimensional microLED clusters with vertical stacking and offset positioning. By utilizing the third dimension (vertical offset from lens centers), the system achieves compact form factor while enabling individual dot projection control, effectively resolving the conflict between miniaturization and functional complexity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 solution provides a compact, low-cost, and efficient light projection system capable of projecting individual dots or areas of smooth light, facilitating 3D feature detection and enabling applications like facial recognition in space-constrained devices.

Implementation Method 1

a micro-lens disposed over the plurality of LEDs; and each of the LED clusters being arranged to emit light through each of the micro-lenses in a pattern of dots

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentUS11674795B2Miniature pattern projector using microLEDs and micro-optics

Publication Date: 2023.06.13 LUMILEDS SINGAPORE PTE LTD

AI summary

An apparatus projecting light onto a projection surface comprises: a substrate having disposed thereon two or more LED clusters and two or more micro-lenses, each LED cluster comprising a plurality of LEDs and each of the micro-lenses being disposed the plurality of LEDs. Each of the LED clusters is arranged to emit light through each of the micro-lenses in a pattern of dots. A center of at least one LED cluster is off-set from an optical center of the micro-lens of its LED cluster. A projected image includes arrangements of individual dots and/or areas of smooth light resulting from the pattern of dots.