Microlens Diffusor Profile for Wide-Angle Light Distribution
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Solution Overview
Problem
Existing diffusers and optical systems fail to efficiently produce a diffused light beam with a Full Width Half Maximum (FWHM) angle of diffusion greater than 140 degrees due to limitations in microlens design and placement, leading to reduced luminous intensity and efficiency.
Innovation Solution
A diffusor with a microlens array where the bases of the microlenses are arranged on a plane, featuring a continuous and smooth curved surface, optimized by specific derivative conditions (D/D0 and d values) to enhance luminous intensity at wide angles, and positioned on the light source side to prevent light blocking, combined with a convex surface opposite the light source for improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a microlens array with quadric function contour is used, then the diffused light beam achieves a wide angle of diffusion (FWHM of 140 degrees), but the luminous intensity at wide angles is insufficient
Solution Approach 1:
The patent changes the mathematical function from quadric to a specific higher-order polynomial function (z = c1*x^4 + c2*x^2 + c3*y^4 + c4*y^2 + c5*x^2*y^2) with optimized coefficients. This parameter change in the contour function enables the microlens to simultaneously achieve wide angle diffusion (FWHM ≥ 140 degrees) and sufficient luminous intensity at wide angles by controlling the light distribution pattern.
2Adaptability or versatility
If the microlens array is placed on the side of the illuminated surface, then the angle of diffusion is increased, but the efficiency is reduced due to light blocking by adjacent microlenses
Solution Approach 1:
The patent applies local quality by giving each microlens a specifically optimized contour shape (higher-order polynomial function) that differs from conventional designs. This local optimization of each microlens's light manipulation capability allows the array to achieve wide angle diffusion while minimizing inter-lens light blocking, thereby maintaining high efficiency.
3Ease of manufacture
If conventional microlens designs are used, then the manufacturing process is simple, but the luminous intensity at wide angles is not sufficiently great
Solution Approach 1:
The patent modifies the contour function parameters from simple quadric to optimized higher-order polynomial with specific coefficients. This parameter change achieves sufficient luminous intensity at wide angles while maintaining manufacturability through standard injection molding processes, as the surface can still be formed using conventional manufacturing techniques.
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 enables the production of a diffused light beam with FWHM angles exceeding 140 degrees, achieving high efficiency and uniform luminous intensity, with efficiencies up to 78.8% in the optical system.
Implementation Method 1
A diffusor according to a first aspect of the present invention is provided with a microlens array including microlenses arranged in such a way that bases of the microlenses are placed on a plane. A curved surface of each microlens is continuous and smooth except at the boundary and in each microlens
Data Source
AI summary
The diffusor has a microlens array including microlenses with the bases placed on a plane. Concerning a curved surface of each microlens, the following expressions are satisfied, where in a cross section perpendicular to the plane and containing a straight line passing through the projection point onto the plane of the vertex and maximizing a distance between two points of the straight line on the periphery of the base, coordinate along the straight line, coordinate of the curved surface of the microlens in the direction perpendicular to the plane, the maximum value of the first derivative of z′ with respect to x′, the absolute value of the second derivative of z′ with respect to x′ at x′ coordinate of the projection point and the absolute value at x′ coordinate of an end of the straight line are represented respectively by x′, z′, d, D0 and D.D/D0<1andd≥2