Diffractive Optical Element for VCSEL Collimation and Fan-Out

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Solution Overview

Problem

Existing dot projectors face challenges in efficiently collimating and distributing light beams for 3D sensing and imaging applications, particularly in consumer electronics, due to the strong divergence of light emitted by VCSELs and the need for separate collimating and fan-out diffractive optical elements.

Innovation Solution

A single optical element is designed with split phase functions on its surfaces to provide both collimation and fan-out functions, where the first surface primarily collimates and the second surface provides collimation correction and fan-out, using high and low spatial frequency structures respectively, allowing for efficient light beam distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If separate collimating and fan-out diffractive optical elements are used, then collimation and fan-out functions are achieved, but device complexity increases and space requirement increases

Engineering Contradiction:

Improvenumber of optical elementsVSAvoidmanufacturing complexity

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The patent combines separate collimating and fan-out diffractive optical elements into a single integrated optical element. The collimating structure and fan-out structure are integrated into one component, reducing the total number of elements while maintaining both functions. This merging approach directly addresses the technical contradiction by reducing device complexity without compromising manufacturing feasibility.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single optical element performs multiple functions simultaneously: it provides collimation through its first surface structure and fan-out through its second surface structure. This multi-functional design eliminates the need for separate dedicated elements for each function, thereby reducing device complexity while maintaining ease of manufacture through a unified component approach.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Illumination intensity

If VCSELs are used as light sources, then light emission is achieved, but light divergence is strong requiring complex optical correction

Engineering Contradiction:

Improvelight emissionVSAvoidoptical correction complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The optical correction function is segmented into two distinct surface structures within the single optical element: a first surface with a first diffractive structure for collimation and a second surface with a second diffractive structure for fan-out. This segmentation allows each surface to be optimized for its specific function while working together to correct the strong divergence of VCSEL light, reducing overall optical correction complexity.

Inventive Principle:

Principle #1Segmentation

3Volume of moving object

If a single optical element provides both collimation and fan-out, then device compactness is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveoptical element compactnessVSAvoidsurface structure precision

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

Different regions of the single optical element have different local qualities: the first surface has a first diffractive structure optimized for collimation with specific spatial frequency characteristics, while the second surface has a second diffractive structure optimized for fan-out. This local differentiation allows each region to be manufactured with appropriate precision requirements for its specific function while maintaining overall compactness.

Inventive Principle:

Principle #3Local quality

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 enables compact, efficient, and effective collimation and fan-out of light beams, reducing interference and enhancing performance in 3D sensing and imaging applications.

Implementation Method 1

The first surface is structured to collimate a light beam incident on the first surface... a structure of the first surface that is operable to collimate the light beam has more high-frequency components

Methodology Applied

Scientific EffectDiffraction: Diffraction

Implementation Method 2

the second surface is structured to provide correction to collimation imparted by the first surface and to provide at least one of optical fan-out or diffusion for the light beam... a structure of the second surface that is operable to provide the correction to the collimation imparted by the first surface has fewer high-frequency components

Methodology Applied

Scientific EffectDiffraction: Diffraction

Data Source

PatentUS20250355266A1Optical elements providing collimation and fan-out or diffusion

Publication Date: 2025.11.20 NIL TECH APS (DK)

AI summary

The present disclosure describes optical elements, as well as methods for designing and fabricating such optical elements. An example apparatus includes an optical element having a first surface and a second surface, wherein the first and second surfaces are on opposite sides of the optical element from one another. The first surface is structured to collimate a light beam incident on the first surface, and the second surface is structured to provide correction to collimation imparted by the first surface and to provide at least one of optical fan-out or diffusion for the light beam.