Optical Element Microstructures Super-Cosine Profile
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Solution Overview
Problem
Conventional diffusers for 3D sensing applications, such as Gaussian diffusers and diffractive optical elements, fail to provide uniform illumination and efficient light concentration due to limited beam shaping capabilities and poor wavelength flexibility, making them unsuitable for wide field of view and diverging light sources.
Innovation Solution
An optical element with a body of optical material and microstructures having a sag profile, which generates a super-cosine intensity profile to provide uniform irradiance over a field of view, optimized for diverging light sources and adaptable to specific illumination requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional Gaussian diffusers are used for beam shaping, then fabrication is simple, but uniformity and light concentration are poor
Solution Approach 1:
The optical element is divided into multiple discrete microstructures (microlenses, prisms, or microfacets) arranged in an array pattern. Each microstructure independently shapes light rays, collectively achieving superior beam shaping and homogenization compared to conventional continuous diffusers while maintaining fabrication simplicity through modular manufacturing processes.
Solution Approach 2:
The invention transitions from conventional 2D surface diffusers to 3D microstructured surfaces with controlled sag profiles. The microstructures extend in the depth dimension with specific curvature radii and conic constants, enabling precise control of light propagation paths and achieving superior beam shaping, uniformity, and light concentration simultaneously.
2Manufacturing precision
If diffractive optical elements are used for beam shaping, then wavelength flexibility is poor, but beam shaping capability is improved
Solution Approach 1:
The invention replaces diffractive optical mechanisms with refractive microstructures. Instead of relying on wavelength-dependent diffraction effects, the microlenses and microprisms use wavelength-independent refraction to shape light beams. This substitution enables the optical element to maintain consistent beam shaping performance across multiple wavelengths, including visible and infrared regions, while preserving superior beam shaping capability.
3Device complexity
If conventional diffusers are used for wide field of view illumination, then illumination uniformity is poor, but device complexity is reduced
Solution Approach 1:
Different regions of the microstructured surface are designed with locally optimized microstructure parameters including varying sizes, shapes, and sag profiles. This local customization enables each region to contribute appropriately to the overall illumination pattern, achieving superior uniformity across wide field of view applications while maintaining a single integrated optical element without complex additional components.
4Manufacturing precision
If holographic diffusers are used for beam shaping, then angle control is improved, but intensity uniformity is poor
Solution Approach 1:
The microstructures incorporate asymmetric designs including cylindrical microlenses with different curvature radii in orthogonal directions and microprisms with non-uniform orientations. This asymmetry enables independent control of angular distribution in different directions while the collective arrangement of multiple microstructures ensures uniform intensity distribution across the illuminated field, resolving the trade-off between angle control and intensity uniformity.
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 optical element achieves optimal efficiency and uniformity in illumination, minimizing diffraction artifacts and hot spots, and is compatible with various wavelengths, enhancing the quality of diffused illumination in 3D sensing systems without the need for additional collimation optics.
Implementation Method 1
An optical element with a body of optical material and microstructures having a sag profile, which generates a super-cosine intensity profile to provide uniform irradiance over a field of view
Implementation Method 2
each microstructure of the plurality of microstructures has a sag profile... each microstructure of the plurality of microstructures generates a super-cosine intensity profile
Data Source
AI summary
An optical element including a body of optical material; and a plurality of microstructures along a surface of the body, wherein each microstructure of the plurality of microstructures has a sag profile. An optical system can include a light source; and an optical element having a body of optical material and a plurality of microstructures along a surface of the body, wherein each microstructure of the plurality of microstructures generates a super-cosine intensity profile that provides an irradiance over a field of view. Methods of making and using the optical element and optical system are also disclosed.