Self-Assembled LiDAR Receiver With Non-Planar Field of View
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Solution Overview
Problem
Existing LiDAR systems face challenges in achieving a large field of view without excessive cost and complexity, often requiring complex assembly processes and mechanical scanning.
Innovation Solution
A self-assembled extended field of view receiver device is fabricated using sub-units on a planar substrate with hinges and actuators to form a non-planar structure, allowing for a composite field of view through relative movement and optical/electrical connections between sub-units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If focal plane arrays are used in an imaging configuration to achieve a large field of view, then the field of view coverage is improved, but the device complexity and manufacturing cost increase due to complex assembly processes
Solution Approach 1:
The receiver device is divided into multiple sub-units, each with its own optical sensing structure, that can be independently fabricated on a planar substrate and then assembled. This segmentation allows for simpler individual components while achieving large field of view coverage when combined, resolving the contradiction between FOV area and assembly complexity
Solution Approach 2:
The patent transitions from traditional two-dimensional focal plane arrays to a three-dimensional non-planar formation of sub-units. By folding the connected network of sub-units into a non-planar structure, the system achieves extended field of view coverage in multiple dimensions while maintaining simpler individual sub-unit designs, thus resolving the contradiction between FOV coverage and assembly complexity
2Area of stationary object
If mechanical scanning is used to achieve extended field of view, then the field of view coverage is improved, but the device complexity and bulkiness increase
Solution Approach 1:
Instead of using mechanical scanning to achieve extended field of view, the patent creates a static non-planar formation of sub-units with hinges that provides inherent multi-directional sensing capability. This dynamic structural configuration eliminates the need for moving mechanical scanning components, resolving the contradiction between FOV coverage and mechanical structure complexity
Solution Approach 2:
The patent replaces mechanical scanning systems with a hinge-based folding structure that achieves extended field of view through geometric configuration rather than mechanical motion. This substitution eliminates bulky mechanical scanners while maintaining or improving field of view coverage, resolving the contradiction between FOV area and device complexity
3Manufacturing precision
If hand assembly processes are used for manufacturing, then manufacturing precision can be achieved, but the productivity decreases and cost increases
Solution Approach 1:
The sub-units are pre-fabricated on a planar substrate with integrated hinge structures and connection interfaces before final assembly. This preliminary fabrication of precise components enables faster subsequent assembly while maintaining manufacturing precision, resolving the contradiction between assembly precision and productivity
Solution Approach 2:
The hinge structures and connection interfaces are designed to enable self-alignment and self-assembly of sub-units, reducing or eliminating the need for manual positioning and adjustment. This self-service mechanism maintains manufacturing precision while significantly improving assembly productivity and reducing costs
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 simplifies assembly, enables a larger number of sensors with granular subdivision of the field of view, reducing the need for mechanical scanning and achieving a larger coverage with lower cost and bulkiness.
Implementation Method 1
One or more of the actuators is configured to apply a magnetic force
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
The method comprises: fabricating a plurality of sub-units (402) on a planar substrate, where each sub-unit (402) comprises: an optical sensing structure configured to receive at least a portion of an optical wavefront that impinges on one or more of the sub-units (402), and material forming at least a portion of a hinge (408) in a vicinity of a border with at least one adjacent sub-unit (402); removing at least a portion of the substrate on respective borders between each of at least three different pairs of sub-units (402) to enable relative movement between the sub-units (402) in each pair constrained by one of the hinges (408) formed from the material; and providing one or more actuators configured to apply a force to fold a connected network of multiple sub-units (402) into a non-planar formation.