Monolithic Structured Light Projector Using Diffractive Optical Element
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Solution Overview
Problem
Existing structured light projectors require precise alignment and additional components, such as collimators, which increase manufacturing costs, size, and complexity, especially in applications needing extensive or complicated light patterns.
Innovation Solution
A monolithic structured light projector integrates a specialized diffractive optical element with the light source, using non-uniform grating features to compensate for the non-collimated beam, eliminating the need for a separate collimator and enabling compact, reliable, and efficient beam shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a separate collimator component is used to shape the divergent beam, then beam collimation is achieved, but device complexity and alignment requirements increase
Solution Approach 1:
The patent combines the collimator and diffractive optical element into a single integrated component called a specialized DOE. This merged structure eliminates the need for separate collimator and DOE components, reducing alignment requirements while maintaining beam collimation and diffraction functions. The specialized DOE incorporates internal collimation capabilities through its unique grating feature geometry.
Solution Approach 2:
The specialized DOE performs multiple functions simultaneously: it collimates the divergent beam from the laser diode, diffracts the collimated beam to create the desired pattern, and compensates for wavefront aberrations. This multi-functional element replaces what would traditionally require separate optical components, simplifying the overall projector structure.
2Stability of the object's composition
If a separate collimator and DOE are used, then beam shaping is achieved, but manufacturing precision requirements increase
Solution Approach 1:
By merging the collimator and DOE into a single specialized DOE component, the patent eliminates the need for precise alignment between separate components. The integrated structure ensures that the collimation and diffraction functions are inherently aligned, removing tight alignment tolerance requirements while maintaining proper beam shaping.
3Reliability
If individual discrete components are used, then optical functions are achieved, but projector size increases
Solution Approach 1:
The patent integrates multiple optical functions into a single specialized DOE component, significantly reducing the overall projector size. The merged structure eliminates the space required for separate collimator and DOE components and their associated mounting and alignment mechanisms, enabling compact projector designs while maintaining all necessary optical functions.
4Stability of the object's composition
If a specialized DOE with non-uniform features is used, then beam compensation is achieved, but device complexity increases
Solution Approach 1:
The specialized DOE incorporates non-uniform grating feature spacing and/or thickness distributed throughout its structure. This local variation in geometric properties allows different regions of the DOE to compensate for specific wavefront aberrations at corresponding locations in the beam, achieving comprehensive wavefront correction through spatially varying local characteristics.
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 solution simplifies the manufacturing process, reduces size, and enhances reliability by integrating collimation and diffraction functions into a single component, allowing for precise and compact structured light projection without the need for additional alignment steps.
Implementation Method 1
a specialized diffractive optical element disposed to intercept the non-collimated light beam... diffract the compensated beam to create as an output an interference pattern of light dots
Implementation Method 2
create as an output an interference pattern of light dots
Data Source
AI summary
A structured light projector for generating a far-field image of light dots in a defined pattern is proposed, where the structured light projector includes a light source providing as an output a non-collimated light beam and a specialized diffractive optical element disposed to intercept the non-collimated light beam. The specialized diffractive optical element is formed to exhibit a non-uniform pattern of grating features configured to compensate for the non-planar wavefront and phase retardation of the non-collimated output beam, providing as an output of the projector an interference pattern of light dots exhibiting the desired configuration.