Micro-Lens Array Projection With Optical Expansion for Wide FOI
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Solution Overview
Problem
Existing projection devices struggle with achieving sharp images on inclined or curved surfaces due to the need for extensive tilting, which increases installation space and requires larger micro-lens arrays, leading to higher production costs and complexity, while multi-channel optics have a limited field of illumination (FOI).
Innovation Solution
An optical device utilizing a micro-lens array (MLA) with an optical expander that expands the field of illumination by fanning out light beams, allowing for a wider projection on tilted or curved surfaces, while maintaining a compact design and compensating for distortions through individually distorted images.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multi-channel optics with micro-lens arrays are used to project on inclined or curved surfaces, then image sharpness and depth of focus are improved, but the field of illumination is limited
Solution Approach 1:
The imaging system is divided into multiple channels, each with its own micro-lens and imaging plane region. Each channel independently projects onto a specific area of the projection surface, allowing the system to cover a wider total field of illumination while maintaining sharp images through the depth of focus provided by each micro-lens channel
Solution Approach 2:
The patent distributes images across multiple imaging plane regions arranged in different spatial positions and orientations. By projecting from multiple angles and positions simultaneously, the system expands the effective field of illumination beyond what a single-channel system could achieve, while each channel maintains its own depth of focus for sharp projection
2Illumination intensity
If larger micro-lens arrays are used to increase the field of illumination, then the projection area is increased, but production costs and device complexity increase
Solution Approach 1:
Instead of using one large micro-lens array, the system uses multiple smaller micro-lens arrays or individual micro-lenses arranged in specific patterns. Each micro-lens has a manageable size and focal length, simplifying manufacturing while the collective arrangement achieves the desired wide field of illumination through coordinated projection from multiple channels
3Manufacturing precision
If extensive tilting of object and projection optics is performed to achieve sharp images on inclined surfaces, then image sharpness is improved, but installation space requirements increase
Solution Approach 1:
The projection system is segmented into multiple channels with micro-lenses positioned at different orientations and angles. Each micro-lens channel is optimized to project sharply onto specific regions of the inclined or curved surface, eliminating the need for extensive tilting of a single large optical system while maintaining image sharpness across the entire projection area
Solution Approach 2:
Each micro-lens channel is configured with specific local optical properties and orientations tailored to its designated projection region. This allows each channel to optimize image sharpness for its local area on the projection surface, while the overall system maintains a compact installation footprint through the distributed arrangement of small micro-lenses rather than requiring large tilted optics
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 a wider field of illumination, reducing installation space and production costs, while maintaining image sharpness and adaptability to non-flat surfaces, and is suitable for applications requiring a large projection area.
Implementation Method 1
micro-lenses of a micro-lens-array, MLA, to respective individual images of the plurality of images and forming respective channels of light beams by projecting the respective individual images towards a projecting plane
Implementation Method 2
The optical expander is arranged between the MLA and the projecting plane... The optical expander is provided to fan out and direct the channels of light beams onto the projecting plane
Data Source
AI summary
An optical device includes an imaging system provided to generate a plurality of images being distributed over an imaging plane. It further includes a micro-lens-array, MLA, wherein micro-lenses are assigned to individual images and are provided to form channels of light beams by projecting the individual images towards a projecting plane. An optical expander is arranged between the MLA and the projecting plane and includes an input surface and least two output surfaces. The optical expander is provided to fan out and direct the channels of light beams onto the projecting plane, such that individual projections of the individual images are formed on the projection plane. An overall projection is formed on the projection plane by superimposing the individual projections.