Optical Sensor Integrating Concentrator for Beam Shaping
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Solution Overview
Problem
Conventional optical sensors face reduced detection sensitivity due to light loss and the need for multiple lenses and diaphragms to achieve desired beam cross-sections, which complicates alignment and reduces available light for object detection.
Innovation Solution
The optical sensor employs a concentrator with total reflection on its lateral surface, directly connected to the transmitter, to guide and shape transmitted light beams, eliminating the need for additional lenses and diaphragms, thereby enhancing detection sensitivity and allowing flexible beam profiling without reducing light availability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional transmission optics with lenses and diaphragms are used to shape beam cross-sections, then desired beam profiles can be achieved, but light loss increases and detection sensitivity decreases
Solution Approach 1:
The patent merges the beam shaping function and light guidance function into a single integrally formed transmission optic made of transparent plastic. This eliminates the need for separate lenses and diaphragms that cause light loss, while still achieving precise beam cross-section shaping through the molded geometry of the single component.
Solution Approach 2:
The transmission optic performs multiple functions simultaneously: it acts as a lens for beam shaping, a light guide for directing transmitted light, and a structural component for mounting. This multi-functionality reduces the number of separate optical elements needed, thereby minimizing light loss while maintaining beam profile control.
2Quantity of substance
If multiple lenses are used in transmission optics to capture more transmitted light, then light capture improves, but alignment complexity and assembly effort increase
Solution Approach 1:
The patent combines multiple optical functions that would traditionally require separate lenses into a single integrally molded transmission optic. This eliminates the need for complex alignment procedures between multiple lenses while capturing the full cone of transmitted light through the transmitter.
Solution Approach 2:
The transmission optic is designed with functionally segmented zones within a single component: a light-capturing surface facing the transmitter, lateral surfaces for beam shaping, and mounting features. This segmentation of functions within unity simplifies assembly while maintaining high light capture efficiency.
3Shape
If diaphragms are added to transmission optics to create square or rectangular beam cross-sections, then beam profile control improves, but light loss increases further
Solution Approach 1:
The beam shaping function traditionally performed by separate diaphragms is merged into the transmission optic itself through integral molding. The lateral surfaces of the molded optic directly define the beam cross-section geometry, eliminating the need for aperture-limiting diaphragms that block light.
Solution Approach 2:
The transmission optic uses geometric parameter changes in its molded structure (lateral surface angles, thickness variations) to control beam cross-section shape. This allows square or rectangular beam profiles to be achieved through the optic's geometry rather than through light-blocking diaphragms, maintaining light efficiency.
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 design significantly increases detection sensitivity by ensuring almost all transmitted light is utilized for object detection, reducing optical losses and assembly complexity, while enabling precise beam shaping without additional components.
Implementation Method 1
a concentrator (15) which forms a light-guiding element for the transmitted light beams (4). For this purpose, a total reflection of the transmitted light beams (4) takes place on the lateral surface (17) of the concentrator (15)
Data Source
AI summary
The sensor has a transmission optics (6) including a concentrator (15) whose front side is attached to a transmitter (5), where the front side is formed as a coupling surface (16) for transmission light beams (4a-4d). An emission surface (18) is provided at the concentrator's front side that faces the transmitter, and forms a beam shaping unit for the transmission light beams. The coupling surface limits a funnel-shaped hollow space (23) at which the concentrator's front side extends. The transmission optics is directly connected to the transmitter.