Slim Headlamp Optics Using Beam Reshaping for MLA Efficiency
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Solution Overview
Problem
Conventional slim optic designs for automotive front lighting using micro-lens arrays (MLAs) require large optics due to collimated input needs, reversing the trend towards smaller and more compact solutions, and pre-collimator optics are not scalable or reusable.
Innovation Solution
An optical system utilizing a collimator to generate a collimated beam, an etendue re-shaper to split and arrange beam parts adjacent to each other, and micro-lens arrays (MLAs) to produce beams with optimum optical efficiency and far field intensity distribution, reducing optical cross-talk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If MLAs are used in slim optic design, then optical efficiency is improved, but large optics are required which reverses the trend towards smaller designs
Solution Approach 1:
The patent divides the collimated beam into multiple separate beam parts using an etendue re-shaper, then directs each beam part to a separate MLA. This segmentation allows each MLA to receive a smaller, more manageable beam that can be collimated within the required acceptance angle, thereby enabling compact optics while maintaining high optical efficiency through the use of multiple MLAs working in parallel
Solution Approach 2:
The patent transitions from a single large beam to multiple smaller beams arranged in a specific spatial configuration. By changing the dimensional arrangement of the beam parts and using an optical relay system to map them to the MLA array, the system achieves compact optics size while preserving the optical efficiency that would otherwise require large single-beam optics
2Manufacturing precision
If pre-collimator optics are tailored to a specific design case, then optical performance is optimized, but re-use and scaling are prevented
Solution Approach 1:
The patent creates a modular optical system where the etendue re-shaper and optical relay system can be configured to work with different numbers and types of MLAs. The beam splitting and relay optics are designed to be adaptable, allowing the same basic architecture to serve multiple design cases by simply changing the number of beam parts or the specific configuration of MLAs, thereby achieving both optimized performance and scalability
Solution Approach 2:
The system allows for parameter changes in the optical design by adjusting the number of beam parts, the configuration of the optical relay system, and the specific characteristics of the MLAs. This flexibility enables the same optical architecture to be adapted to different application requirements, achieving both optimized performance for each case and the ability to scale across different design scenarios
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
Achieves nearly parallel light emissions within MLA acceptance angles, maintaining compact design while minimizing optical cross-talk and optimizing optical efficiency.
Implementation Method 1
a collimator that receives the light emissions and that generates a collimated beam
Implementation Method 2
an etendue re-shaper that splits the collimated beam into at least two beam parts and that arranges the at least two beam parts adjacent to each other
Implementation Method 3
one or more micro-lens arrays that receive the adjacent beam part arrangement and that generate two or more beams
Data Source
AI summary
An optical system is provided. The optical system includes a light emitting diode that generates light emissions. The optical system includes a collimator that receives the light emissions and that generates a collimated beam. The optical system includes an etendue re-shaper that splits the collimated beam into beam parts and that arranges the beam parts adjacent to each other to generate an adjacent beam part arrangement. The optical system includes micro-lens arrays that receive the adjacent beam part arrangement and that generate beams. Each of the beams includes an optimum optical efficiency or a far field intensity distribution.