Integrated Structured Light Projector for Compact 3D Illumination
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Solution Overview
Problem
Existing 3D sensing systems face challenges in achieving compactness, miniaturization, multi-functionality, and reduced power consumption while maintaining performance.
Innovation Solution
A projector and illumination module with an array of individual emitters and optical transfer devices, featuring two groups of transfer devices with different properties for generating illumination patterns and diverging light beams, allowing for scene illumination and pattern projection with adjustable emission power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If separate illumination module and projector module are used, then illumination function and pattern projection function are independent and reliable, but device complexity and module count increase
Solution Approach 1:
The patent combines the illumination module and projector module into a single integrated device. The housing contains both the illumination source (LED or VCSEL array) and the projector components (laser source, collimating optics, DOE) in one unified structure, reducing the number of separate modules while maintaining both illumination and pattern projection functions
Solution Approach 2:
The integrated module serves multiple functions simultaneously: it provides both diffuse illumination for general scene lighting and structured light projection for 3D sensing. The device can operate in different modes (illumination-only mode and projection mode) depending on the application requirements, making it a universal component for various 3D sensing scenarios
2Ease of manufacture
If multiple separate modules are used, then each module can be optimized for its specific function, but manufacturing complexity and assembly costs increase
Solution Approach 1:
By integrating multiple functions into a single module, the patent reduces the number of assembly steps and components. The housing is designed as a single unit that accommodates all necessary components (illumination source, projector source, optics, diffuser), simplifying the manufacturing process and reducing assembly complexity compared to assembling separate modules
3Measurement precision
If VCSEL array with collimation optics is used for projection, then structured light pattern quality is improved, but device complexity and power consumption increase
Solution Approach 1:
The patent employs a DOE (diffractive optical element) that uses diffraction physics to shape the laser beam into structured light patterns. This optical approach replaces or complements the VCSEL array with collimation optics, achieving pattern projection with potentially lower power consumption while maintaining pattern quality through precise optical design
4Volume of moving object
If micro-LED arrays are used instead of VCSEL arrays, then device compactness is improved, but illumination intensity and projection brightness may be reduced
Solution Approach 1:
The patent uses a diffuser element positioned in the light path to redistribute the light from the compact micro-LED array. This local optical modification ensures uniform illumination distribution across the field of view, compensating for any intensity variations and maintaining adequate brightness levels despite the smaller, more compact light source
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
Enables reduced module count, adaptive illumination, and improved reliability, enabling uniform illumination and structured light projection with a single miniature module, reducing complexity, material usage, and assembly costs while enhancing performance.
Implementation Method 1
the projector module may comprise a vertical cavity surface emitting laser (VCSEL) array
Implementation Method 2
collimation optics such as comprising a micro lens array
Implementation Method 3
The optical system may comprise a diffuser element arranged between the array of individual emitters and the array of transfer devices
Data Source
Figure 1
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AI summary
A projector and illumination module (110) configured for scene illumination and pattern projection is proposed. The projector and illumination module (110) comprises at least one array (116) of a plurality of individual emitters (117) and at least one optical system (114). Each of the individual emitters (117) is configured for generating at least one illumination light beam. The optical system (114) comprises at least one array of a plurality of transfer devices (118). The array of transfer devices (118) comprises at least one transfer device (118) for each of the individual emitters (117). The array of transfer devices (118) comprises at least two groups of transfer devices (118). The transfer devices (118) of the two groups differ in at least one property. The transfer devices (118) of one of the groups are configured for generating at least one illumination pattern in response to illumination light beams impinging on said transfer devices (118). The transfer devices (118) of the other group are configured for generating diverging light beams in response to illumination light beams impinging on said transfer devices (118).