Microlens Array Tiling for Uniform Illumination
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Solution Overview
Problem
Existing optics using microlens arrays often produce far-field illumination patterns with intensity variations and boundary shapes that are undesirable in certain applications, as the shapes of the microlenses influence the intensity distribution and overall shape of the illumination pattern.
Innovation Solution
A plurality of lenses with different polygonal boundary shapes are arranged in various configurations and densities to create a desired far-field illumination pattern, allowing for a collective boundary shape and intensity distribution that minimizes the signature of individual lens shapes, such as using a tiling pattern of octagonal and square lenses to achieve a circular boundary shape with a super Gaussian intensity distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If microlens arrays with uniform shapes are used, then manufacturing is simplified, but the far-field illumination pattern exhibits intensity variations and carries the shape signature of individual lenses
Solution Approach 1:
The patent applies local quality by varying the shape of individual lenses within the array. Instead of using uniform lenses throughout, different regions use different polygonal shapes (e.g., hexagons, octagons, squares, triangles), which locally compensates for the shape signature effect and creates a more uniform far-field illumination pattern.
Solution Approach 2:
The patent employs asymmetry by intentionally using non-uniform lens shapes in the array. The deliberate introduction of asymmetric polygonal shapes (different numbers of sides, different geometries) breaks the symmetry that would otherwise cause the far-field pattern to replicate the individual lens shapes, thereby eliminating the unwanted shape signature.
2Device complexity
If microlens arrays with uniform shapes are used, then device complexity is reduced, but the boundary shape of the far-field illumination pattern carries the shapes of the microlenses
Solution Approach 1:
The patent applies local quality by varying the shape of individual lenses within the array. Instead of using uniform lenses throughout, different regions use different polygonal shapes (e.g., hexagons, octagons, squares, triangles), which locally compensates for the shape signature effect and creates a more uniform far-field illumination pattern.
Solution Approach 2:
The patent employs asymmetry by intentionally using non-uniform lens shapes in the array. The deliberate introduction of asymmetric polygonal shapes (different numbers of sides, different geometries) breaks the symmetry that would otherwise cause the far-field pattern to replicate the individual lens shapes, thereby eliminating the unwanted shape signature.
3Illumination intensity
If different polygonal shapes are used in a tiling pattern, then the far-field illumination pattern achieves a desired boundary shape and homogeneous intensity distribution, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by systematically varying the geometric parameters of the lenses, specifically the number of sides and shapes of the polygonal boundaries. By changing these geometric parameters across different regions of the array, the patent achieves the desired far-field illumination characteristics while maintaining manufacturability through standardized polygonal geometries.
4Shape
If the number and variety of polygonal lens shapes are increased, then the far-field illumination pattern more closely matches the desired homogeneous circular shape, but device complexity increases
Solution Approach 1:
The patent applies parameter changes by systematically varying the geometric parameters of the lenses, specifically the number of sides and shapes of the polygonal boundaries. By changing these geometric parameters across different regions of the array, the patent achieves the desired far-field illumination characteristics while maintaining manufacturability through standardized polygonal geometries.
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 effectively generates a far-field illumination pattern with a boundary shape and intensity distribution that is distinct from what individual lenses would produce, reducing unwanted variations and achieving a more homogeneous beam appearance.
Implementation Method 1
a plurality of lenses positioned relative to one another according to a predefined pattern and adapted to receive light from a light source
Data Source
AI summary
Optics and optical devices and systems are disclosed that employ a plurality of refractive and/or reflective optical elements, such as lenses and mirrors, with different shapes to achieve a desired illumination pattern. In various aspects, a plurality of lenses in which at least two of the lenses have different boundary shapes are arranged, e.g., according to a predefined pattern, to receive light from one or more light sources and to redirect the received light to form collectively a desired far-field illumination pattern. For example, the lenses can be configured such that the far-field illumination pattern has a boundary shape that is different from the boundary shape of a far-field illumination pattern that can be provided individually by the lenses.