Projection Device Free-Form Optical Channels
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Solution Overview
Problem
Current projection technologies face challenges in miniaturization, leading to reduced luminous flux and power efficiency, and are limited in generating high-resolution light distributions due to intolerance to non-collimated input light sources and smearing effects, especially when trying to project fine structures.
Innovation Solution
A projection device using an array of optical channels with two refractive optical free-form surfaces that apply Köhler illumination to create a light object structure, allowing for the generation of high-resolution light distributions without blurring effects, even with divergent or non-collimated light, by redistributing light angularly and enhancing irradiance through transmission-modulated structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If miniaturization of projection optics is performed, then the optical height is reduced, but the luminous flux transmission is reduced
Solution Approach 1:
The projection system is divided into multiple optical channels arranged in an array, each channel containing free-form surfaces that redirect light from different regions of the light source. This segmentation allows the system to maintain compact dimensions while preserving overall luminous flux transmission through parallel light paths
Solution Approach 2:
The patent transitions from single-channel to multi-channel array architecture, adding spatial dimensionality to the optical system. Multiple optical channels are arranged in a two-dimensional array, enabling the system to achieve both miniaturization and high luminous flux transmission by utilizing multiple parallel light paths
2Loss of energy
If free-form light redistribution is used, then power efficiency is improved, but the system is intolerant to real input light distributions causing smearing effects
Solution Approach 1:
The light source is divided into multiple regions, with each region feeding into a separate optical channel with dedicated free-form surfaces. This segmentation allows each channel to handle a specific portion of the light distribution, reducing the sensitivity to input variations and eliminating smearing effects while maintaining high power efficiency
Solution Approach 2:
Each optical channel is designed with locally optimized free-form surfaces tailored to its specific input light characteristics. This local optimization allows each channel to efficiently process its designated light portion while being tolerant to variations in the overall input distribution, preventing smearing across the entire system
3Manufacturing precision
If absorptive structures are used for projection, then light distribution control is improved, but power transmission is reduced
Solution Approach 1:
The patent replaces absorptive mechanical structures with refractive free-form optical surfaces that redirect light through refraction. This substitution eliminates light absorption losses while maintaining precise light distribution control through the geometric design of the free-form surfaces
Solution Approach 2:
The system changes the fundamental parameter of light interaction from absorption to refraction. By using refractive free-form surfaces, the system achieves precise light distribution control through parameter optimization of surface geometry rather than through absorptive material properties, thereby maintaining high power transmission
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 approach significantly reduces blurring effects, improving image sharpness by at least 20%, 40%, or 60%, and enables the creation of high-resolution, high-contrast light patterns with increased luminous flux and power efficiency, overcoming the limitations of conventional systems.
Implementation Method 1
with refractive optical free-form surfaces... The first and the second refractive optical freeform surface bring about Köhler illumination of a projection optics
Implementation Method 2
the projection optics bring about Köhler illumination... which result in the image to be projected in an image surface of the projection optics
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
The invention relates to a projection device (2) comprising at least one light source (4) and an array of optical channels (6, 6a, 6b). Each channel comprises a first refractive optical free-form surface (8a, 8b) and a second refractive optical free-form surface (10a, 10b) and a projection optical system (12). The first and the second refractive optical free-form surfaces (8, 10) are arranged between the light source (4) and the projection optical system (12) and bring about a Köhler illumination of the projection optical system (12) from a light object structure (13a, 13b, 13a', 13b', 13a", 13b"), which produce the image (14a, 14b) to be projected on an image surface of the projection optical system (12), wherein the images of the array of optical channels (6) overlap.