Packed Pillow Optic Array for Uniform Beam Shaping
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Solution Overview
Problem
Optical designers face challenges in creating a diffuse beam with a precisely diverging round shape from near collimated light rays using conventional methods, which often result in low efficiency or high costs, especially when trying to maintain a round beam pattern.
Innovation Solution
A packed pillow optic array is implemented, where first-order pillow optic elements are arranged in a two-dimensional grid with interstice spaces containing second and third-order optic elements of decreasing diameter, effectively redistributing light to achieve a uniform, diffuse beam with a 'top hat' distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional methods (concave/convex impressions, sandblasting, chemical etching, laser etching) are used to create diffuse beam patterns, then a round beam shape can be achieved, but light scattering efficiency decreases and manufacturing cost increases
Solution Approach 1:
The optic surface is segmented into multiple discrete pillow optic elements arranged in a grid pattern, where each element independently refracts light. This segmentation allows precise control over light distribution while maintaining a round overall beam shape, resolving the contradiction between shape control and light efficiency by distributing refraction across many small elements rather than relying on diffuse scattering
Solution Approach 2:
Each pillow optic element has locally optimized curvature and dimensions to refract light in specific directions. The varying sizes and positions of elements throughout the grid create different local refraction characteristics that collectively produce a uniform round beam pattern with high light efficiency, avoiding the energy loss associated with conventional diffuse scattering methods
2Shape
If conventional methods are used to create diffuse beam patterns, then beam shaping can be achieved, but manufacturing precision and uniformity of light distribution deteriorate
Solution Approach 1:
The optic is divided into a grid of discrete pillow elements with precisely controlled dimensions and spacing. This segmentation enables independent optimization of each element's light-refracting properties, achieving uniform beam distribution and precise beam patterns through systematic arrangement rather than relying on imprecise conventional surface treatments
Solution Approach 2:
The pillow optic elements feature precisely controlled parameters including curvature radius, element size, and spacing distances. By systematically varying these parameters across the grid (e.g., different element sizes in different regions), the invention achieves precise control over beam uniformity and distribution patterns that cannot be obtained through conventional manufacturing methods
3Shape
If a round beam pattern is maintained using conventional methods, then beam shape is preserved, but light efficiency decreases due to over-scattering
Solution Approach 1:
The round beam pattern is achieved through the collective action of many discrete pillow elements that refract light directionally rather than scatter it diffusely. This segmentation approach maintains the desired round shape while dramatically improving light efficiency by replacing inefficient scattering with precise refraction at each element interface
Solution Approach 2:
The invention replaces the mechanical scattering process (sandblasting, chemical etching) with an optical refraction process through precisely shaped pillow elements. This substitution eliminates the energy loss inherent in scattering-based methods while maintaining the round beam pattern through controlled refraction at each element boundary
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 packed pillow optic array achieves a more uniform light distribution over a wider angular range, reducing peak intensity and creating a pronounced shoulder at far-out angles, while maintaining a narrow central beam and steep drop-off, thus addressing the inefficiencies of conventional methods.
Implementation Method 1
An optical designer is often times faced with the challenge of designing an optic that receives near collimated light rays from a Fresnel lens or parabolic reflector and creating a diffuse beam
Data Source
AI summary
A pillow optic array comprising a plurality of first order pillow optic elements arranged as a two-dimensional grid with a plurality of interstice spaces between adjacent first order pillow optic elements. Each of a plurality of second order pillow optic elements, located within respective interstice spaces. Pillow optic elements of the second order have a predetermined dimension that is less than a predetermined dimension for pillow optic elements of the first order. A ratio of a cross-sectional width of pillow optic elements to a cross-sectional height of pillow optic element is the same proportion for each order of pillow optic elements in the pillow optic array, the cross-sectional width being located in a plane along the pillow optic array and the cross-sectional height located in a plane vertical to the pillow optic array. The higher order pillow optic elements touching, about tangentially, a lower order pillow optic element.