Optical Sensor Integrating Plastic Light Concentrator
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Solution Overview
Problem
Conventional optical sensors face reduced detection sensitivity due to light loss from divergent emission characteristics and the need for multiple lenses and diaphragms to achieve desired beam cross-sections, which increases structural complexity and light loss.
Innovation Solution
An optical sensor design featuring a concentrator with a concave coupling surface and a convex exit surface integrated directly with the transmitter, utilizing total reflection to guide and shape light beams without additional lenses or diaphragms, ensuring maximum light capture and flexible beam shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single lens is used for beam shaping, then the structure is simple, but light loss occurs due to divergent emission characteristics
Solution Approach 1:
The patent combines the light guide function and beam shaping function into a single integrated concentrator component. The concentrator directly couples to the transmitter and uses its outer surface for total reflection to guide light while its exit surface shapes the beam, eliminating the need for separate lenses and reducing light loss.
Solution Approach 2:
The concentrator acts as an intermediary element between the divergent light source and the desired beam shape. It captures divergent light through its coupling surface, guides it via total reflection on the outer surface, and outputs shaped beams through the exit surface, mediating the transition from divergent to controlled beam patterns.
2Loss of energy
If two lenses are used to capture more light, then light capture improves, but the structural complexity and alignment requirements increase
Solution Approach 1:
The patent merges multiple optical functions (light capture, guidance, and beam shaping) into a single concentrator component, eliminating the need for two separate lenses and their complex alignment requirements while maintaining high light capture efficiency.
Solution Approach 2:
The concentrator performs multiple functions simultaneously: it captures divergent light through its coupling surface, guides the light using total reflection on its outer surface, and shapes the output beam through its exit surface design, replacing what would traditionally require multiple specialized components.
3Shape
If diaphragms are added to create square or rectangular beam cross-sections, then beam shape control improves, but light loss increases
Solution Approach 1:
The patent replaces the mechanical diaphragm system with an optical surface shaping approach. The exit surface of the concentrator is designed with specific geometries (such as flat or angled surfaces) that naturally shape the light beams into square or rectangular cross-sections through total reflection, eliminating the need for absorbing diaphragms.
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
Significantly enhances detection sensitivity by minimizing optical losses and eliminating the need for separate lenses and diaphragms, reducing assembly effort and maintaining high light availability for object detection.
Implementation Method 1
For this purpose, there is a total reflection of the transmitted light rays on the outer surface of the concentrator
Implementation Method 2
The end face of the concentrator assigned to the transmitter is designed as a concave coupling surface for the transmitted light rays
Implementation Method 3
an exit surface is provided which forms a beam shaping means for the transmitted light beams and which is a convex surface
Data Source
Figure 1~3
AI summary
The optical sensor has a transmitting optics (6) which is directly connected to a transmitter (5). The transmitting optics has a concentrator (15) which forms a light guide element for the transmission light beams (4). The total reflection of the transmission light beams takes place on the lateral area (17) of the concentrator. The front side of the concentrator assigned to the transmitter is formed as coupling surface (16) for the transmission light beams. The concentrator consists of plastic.