Optical Beam Former with Misaligned Microlens Arrays
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing beam shaping technologies for far-field distributions face challenges in generating sharp edges and maintaining high system efficiency, with diffusers limiting intensity profile shaping and arrayed projectors suffering from significant transmission loss and stray light issues.
Innovation Solution
A double-sided microlens array with a shared exit microlens and a larger number of condenser lenses compared to projection lenses, allowing for easy manufacturing and high-quality far-field distributions with reduced stray light and artifacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a diffuser is used for far-field beam shaping, then arbitrary intensity profiles can be achieved, but sharp edges of the beam cannot be generated and the centroid cannot be controlled independently
Solution Approach 1:
The optical system is segmented into multiple discrete channels, each with its own microlens and absorbing mask. This segmentation allows independent control of each beam channel, enabling sharp edges through precise mask positioning while maintaining arbitrary intensity profiling through channel-wise absorption control.
Solution Approach 2:
Absorbing masks are introduced as intermediary elements between the microlenses and the far-field region. These masks serve as mediators that selectively block light in specific channels, enabling precise intensity control and sharp edge formation without requiring complex diffuser surface geometries.
2Adaptability or versatility
If absorbing masks are used in each channel of a double-sided microlens array, then arbitrary continuous beam shaping is achieved, but significant transmission loss and reduced optical efficiency occur
Solution Approach 1:
Absorption is applied locally only where needed in specific channels rather than throughout the entire optical path. The absorbing masks are positioned and sized to provide precise local intensity control, minimizing unnecessary absorption and maintaining high transmission in channels where full intensity is required.
Solution Approach 2:
Absorption is applied partially only in the extent necessary to achieve the desired intensity profile. The absorbing masks are designed with optimal size and positioning to provide just enough absorption for the required beam shaping, avoiding excessive absorption that would reduce overall system transmission.
3Adaptability or versatility
If an irregular Fly's Eye Condenser with maskless double-sided microlens array is used, then arbitrary continuous intensity profiles are achievable, but stray light is caused by profile height jumps between neighboring microlenses
Solution Approach 1:
Instead of creating physical irregularities in the microlens array, the invention uses absorbing masks to copy the desired intensity profile through selective channel blocking. This virtual copying approach achieves arbitrary intensity distributions without the physical height jumps that cause stray light in irregular microlens arrays.
4Ease of manufacture
If a regular Fly's Eye Condenser with equal number of condenser and projection lenses is used, then manufacturing is simplified, but design freedom is limited
Solution Approach 1:
The lens array is segmented into channels with different numbers of condenser and projection lenses. This segmentation allows independent optimization of each channel's optical path, providing design freedom for complex beam shaping while maintaining regular, manufacturable lens structures within each segment.
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
This approach enables the projection of sharp edges in the far field while maintaining high system efficiency, achieving complex arbitrary intensity profiles without absorbing elements or irregular structures.
Implementation Method 1
a condenser lens array (C) comprising a first plurality of condenser lenses (C0-C6), the first plurality of condenser lenses configured for receiving the incident light beam (12)
Implementation Method 2
a projection lens array (P) comprising a second plurality of projection lenses (P0-P7) configured for receiving light from the condenser lens array (C) and for radiating the emerging light beam (14)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An optical beam former for generating an emerging light beam from an incident light beam comprises a condenser lens array comprising a first plurality of condenser lenses, the first plurality of condenser lenses configured for receiving the incident light beam. The optical beam former comprises a projection lens array comprising a second plurality of projection lenses configured for receiving light from the condenser lens array and for radiating the emerging light beam. A number of the first plurality of condenser lenses is larger than a number of the second plurality of projection lenses and an edge of a projection lens is misaligned with regard to an opposing condenser lens.