Microlens Array Reflective Diffuser Plate Uniform Luminance
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Solution Overview
Problem
Conventional microlens array diffuser plates face challenges in achieving uniform diffusion angle distribution properties, particularly with variations in microlens pitch, height, and surface roughness, leading to non-uniform luminance distribution and reduced energy homogeneity in collimated light and telecentric light applications.
Innovation Solution
A microlens array reflective diffuser plate with varying aperture diameters and radii of curvature, featuring irregularly located single lenses with a reflective layer, ensures a uniform luminance distribution and controlled diffusion angle range, characterized by a top hat luminance profile within a predetermined diffusion angle, where the ratio of reflection luminance values is maintained between 0.3 and 1, and the perturbation amount is optimized to achieve homogeneous diffusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If microlens array diffuser plate uses variations in microlens pitch and height to achieve light diffusion, then light scattering capability is improved, but diffusion angle distribution uniformity deteriorates
Solution Approach 1:
The patent applies local quality by making each microlens have different optical parameters (aperture diameter, radius of curvature, pitch, height) tailored to its specific location within the array. This localized variation in lens characteristics creates a distributed diffusion effect that achieves uniform overall diffusion angle distribution while maintaining high light scattering capability through optimized local properties.
Solution Approach 2:
The patent systematically varies multiple microlens parameters including aperture diameter, radius of curvature, pitch, and height across the array. By controlling the statistical distribution of these parameters rather than using uniform values, the invention achieves both high light scattering and uniform diffusion angle distribution, resolving the technical contradiction.
2Manufacturing precision
If microlens array diffuser plate uses random locating pattern to enhance diffusion uniformity, then light distribution homogeneity is improved, but stress concentration control deteriorates
Solution Approach 1:
The patent employs asymmetric and irregular microlens shapes with non-uniform boundary curves between adjacent lenses. This asymmetry in the locating pattern and lens geometry achieves superior diffusion uniformity by eliminating periodic patterns, while the irregular shapes are designed to distribute mechanical stresses more evenly across the substrate, preventing stress concentration.
3Illumination intensity
If microlens array diffuser plate uses conventional Gaussian light diffusion, then light scattering is achieved, but diffusion angle distribution uniformity deteriorates
Solution Approach 1:
The patent fundamentally changes the diffusion mechanism from conventional Gaussian distribution to a controlled uniform distribution by systematically varying microlens parameters (aperture diameter, radius of curvature, pitch, height) according to specific statistical distributions. This parameter control transforms the light diffusion pattern to achieve uniform angular distribution while maintaining high scattering capability.
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 achieves more uniform diffusion angle distribution properties, ensuring high homogeneity of diffusely reflected light and controlled reflection distribution, effectively addressing the limitations of conventional Gaussian light diffusion and enhancing optical aperture control.
Implementation Method 1
A diffuser plate that utilizes light refraction resulting from the surface shape is what is called a microlens array diffuser plate including a plurality of microlenses having sizes of approximately several tens of micrometers and located on the surface of the bulk body
Implementation Method 2
a reflective layer is further provided on a surface of the single lens group
Data Source
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AI summary
To achieve more uniform diffusion angle distribution properties. A reflective diffuser plate according to the present invention is a microlens array reflective diffuser plate including a single lens group positioned on a surface of a transparent base material. There are variations in aperture diameter and radius of curvature that respective single lenses constituting the single lens group have in the single lens group as a whole, and vertex positions of the respective single lenses are located irregularly. A luminance distribution of reflected light of light vertically incident on the single lens group is substantially uniform in a predetermined diffusion angle range. For at least either light incident on the single lens group from a direction that forms an angle of 20 degrees with a surface normal direction of the transparent base material or light incident on the single lens group from a direction that forms an angle of 40 degrees with the surface normal direction of the transparent base material, a relation of 0.3 ≤ A/B ≤ 1 holds where A represents a reflection luminance value in the surface normal direction, and B represents a peak reflection luminance value of a diffuse reflection component.