Segmented Collimator Lens with Pivot Diffuser for Compact Illumination
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Solution Overview
Problem
Current illumination optics face challenges in compactness, light efficiency, and manufacturing complexity, particularly in accommodating sensors and achieving uniform light distribution, while also being cost-effective and adaptable for varying light projections.
Innovation Solution
A collimator lens with a solid monolithic structure and TIR inner peripheral surfaces, combined with a diffusion lens that can pivot to adjust the light projection's size, shape, and orientation, allowing for efficient light collection and distribution without the need for axial displacement of optical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a circular collimator lens is used, then the structure is simple and easy to manufacture, but it is difficult to accommodate sensors, cameras or other features in the immediate vicinity of the front side
Solution Approach 1:
The circular lens is segmented into multiple lobed segments (e.g., four segments) separated by radial slots. This segmentation allows sensors or cameras to be positioned in the slots or at the periphery of the lens without interfering with the optical path, thus accommodating additional features while maintaining manufacturing simplicity.
2Adaptability or versatility
If the light source is moved along the central optical axis to change projection size, then the focal distance can be adjusted, but the available space is very limited and additional complexities are created
Solution Approach 1:
The illumination device incorporates a movable collimator lens that can shift position relative to the light source along the optical axis. This dynamic adjustment changes the focal distance and thus the size of the light projection without requiring the light source itself to move, reducing mechanical complexity and space requirements.
3Length of moving object
If a reflector is used inside the illumination device, then the light source can be positioned closer to the light output improving compactness, but the overall length along the central optical axis must still be minimized
Solution Approach 1:
The patent introduces a diffuser as an intermediary element between the light source and the collimator lens. This diffuser redistributes light more uniformly across the lens aperture, improving light collection efficiency and reducing losses while allowing the compact reflector-based layout to be maintained.
4Productivity
If injection molding is used to manufacture collimator lenses, then mass production is enabled, but the process causes deformations of the optical active surfaces due to differential cooling
Solution Approach 1:
The lens is designed with radial slots that divide it into separate lobed segments. These slots act as cooling channels during injection molding, allowing more uniform heat dissipation and reducing differential cooling deformations. This segmented structure maintains surface accuracy while enabling mass production through injection molding.
5Strength
If thicker portions are present in the lens, then the structural integrity is improved, but the surface accuracy and performances are detrimental
Solution Approach 1:
The lens employs variable thickness distribution with thicker regions strategically positioned at the periphery and thinner regions toward the center. This local quality variation provides structural reinforcement where needed while maintaining optimal surface accuracy in the optical active regions, balancing strength and manufacturing precision.
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
Enhances light output efficiency and uniformity, reduces manufacturing costs, and enables flexible light projection adjustments, overcoming the limitations of traditional circular lenses in compact and space-constrained applications.
Implementation Method 1
each lobed segment having a TIR inner peripheral surface extending from the rear side towards the front side of the collimator lens, from which the light rays are reflected inside the collimator lens towards a corresponding one of the light exit surfaces
Implementation Method 2
each side wall surface being configured and disposed to collimate a portion of the light rays onto a corresponding one of the TIR inner peripheral surfaces
Implementation Method 3
the TIR inner peripheral surfaces being separated from one another by a medium having a second refractive index that is lower than the first refractive index
Data Source
AI summary
The illumination optic is a collimator lens having a solid monolithic structure that includes spaced-apart and longitudinally-extending side lobed segments laterally disposed around a central core section. Each lobed segment has a TIR inner peripheral surface extending from a rear side towards a front side of the collimator lens and has a light exit surface generally facing the front side. Also disclosed is an illumination device including the collimator lens and a diffusion lens that is coaxially positioned next to its front side to redirect light coming out of the light exit surfaces. The diffusion lens has spaced-apart outlying optical regions disposed around a central optical axis, at least one for each light exit surface, to be selectively positioned in or out of alignment with a corresponding one of the light exit surfaces depending on a relative angular position between the collimator lens and the diffusion lens.