Structured-light projector with random DOE for compact 3D mapping
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Solution Overview
Problem
Conventional structured-light projectors suffer from poor performance and high cost or bulkiness due to low decode rate and inefficient optical systems.
Innovation Solution
A structured-light projector design incorporating a light source, beam limiting device, and diffractive optical element (DOE) with randomly disposed optical components on a substrate, which generates collimated and patterned light tiles, enhancing decode rate and reducing volume and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional optical systems are used in projectors, then the system is easier to manufacture with reduced cost, but the projector volume increases and performance deteriorates due to low decode rate
Solution Approach 1:
The optical system is segmented into distinct functional modules: light source, beam limiting device, diffractive optical element (DOE), and pattern generator. Each module performs a specific function, allowing for optimized design of each component while maintaining overall system compactness. The DOE is further segmented into multiple layers with different optical functions.
Solution Approach 2:
Multiple optical components are nested within a compact configuration. The beam limiting device is positioned between the light source and DOE, while the pattern generator is integrated downstream. The multi-layer DOE structure nests multiple optical functions within a single compact element, reducing overall projector volume while maintaining manufacturing feasibility.
2Ease of manufacture
If conventional projectors are designed with traditional optical systems, then cost is reduced, but performance deteriorates due to low decode rate
Solution Approach 1:
Traditional mechanical optical systems are replaced with diffractive optical elements that use light diffraction and interference patterns to achieve beam shaping and pattern generation. This substitution eliminates complex mechanical moving parts while improving decode rate through faster optical modulation, maintaining cost-effectiveness through simplified manufacturing processes for the DOE layers.
Solution Approach 2:
The optical system parameters are optimized by changing the diffraction order, wavelength, and layer spacing in the multi-layer DOE structure. These parameter changes enable higher decode rates through improved light modulation efficiency while maintaining manufacturing feasibility through standard optical fabrication techniques.
3Ease of manufacture
If conventional projectors are designed with traditional optical systems, then cost is reduced, but volume increases
Solution Approach 1:
The optical system transitions from a planar two-dimensional arrangement to a three-dimensional multi-layer diffractive structure. The DOE utilizes multiple layers stacked in the z-dimension, each layer contributing different optical functions. This dimensional transition enables compact integration of multiple optical components within a small volume while maintaining cost-effective manufacturing through layer-by-layer fabrication.
4Illumination intensity
If beam diameter is increased to improve light output, then illumination intensity improves, but distortion increases due to oblique incidence on DOE
Solution Approach 1:
The beam limiting device creates a uniform collimated beam with optimized diameter that maintains appropriate incidence angles across the entire DOE surface. This local optimization of beam parameters ensures consistent diffraction quality and minimizes distortion while maintaining sufficient light output intensity for effective projection.
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
The solution significantly improves decode rate and performance while reducing the projector's volume and cost, maintaining high point density and minimizing distortion for effective 3D mapping.
Implementation Method 1
The DOE receives the collimated light and generates a plurality of light tiles
Implementation Method 2
The beam limiting device receives the emitted light and generates a collimated light
Data Source
AI summary
A structured-light projector includes a diffractive optical element (DOE) that receives a collimated light and generates a plurality of light tiles. The DOE includes a plurality of optical components disposed on a substrate, wherein the optical components of the DOE are randomly arranged on the substrate.