Three-dimensional simultaneous multiple-surface method and free-form illumination-optics designed therefrom
First Claim
1. A method of defining and manufacturing a free-form optical system, comprising:
- simultaneously generating a first set and a second set of span points, where each point has an associated normal vector, such that the first and second sets of span points form interdependent first and second chains of corresponding points, respectively;
curve-fitting through the first set of span points defining an initial first spine;
curve-fitting through the second set of span points defining an initial second spine;
generating first and second sets of ribs extending from said first and second spines, respectively, such that tangent vectors of said ribs are perpendicular to said normal vectors of said spines;
defining patches of a first surface that is bounded by said first set of ribs of said first spine, and defining patches of a second surfaces that is bounded by said second set of ribs of said second spine, where said first and second spines are bounded by respective ones of the patches such that a portion of the spine is not coincident with boundaries of the respective patches; and
manufacturing a free-form optical system having at least two active free-form optical surfaces comprising a body further comprising surfaces corresponding to the first and second surfaces where the optical system receives an input light and emits an output light according to a light prescription.
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Accused Products
Abstract
The embodiments provide methods for use in designing and/or manufacturing optical systems. Some embodiments further provide for the optical systems generated utilizing the methods for use in designing and/or manufacturing. In some embodiments, a method simultaneously generates first and second sets of span points defining first and second surfaces, respectively, where sets of span points are interdependent. The method curve fits through the first and second sets of span points defining initial first and second spines, smoothes the curve fittings such that tangent vectors are perpendicular to normal vectors, and defines patches of the first and second surfaces relative to the first and second spines. Some embodiments simultaneously generate the first and second sets of span points by alternatively determining the points of the sets based on propagation of input wavefronts and associated output wavefronts relative to previously determined points.
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Citations
34 Claims
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1. A method of defining and manufacturing a free-form optical system, comprising:
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simultaneously generating a first set and a second set of span points, where each point has an associated normal vector, such that the first and second sets of span points form interdependent first and second chains of corresponding points, respectively; curve-fitting through the first set of span points defining an initial first spine; curve-fitting through the second set of span points defining an initial second spine; generating first and second sets of ribs extending from said first and second spines, respectively, such that tangent vectors of said ribs are perpendicular to said normal vectors of said spines; defining patches of a first surface that is bounded by said first set of ribs of said first spine, and defining patches of a second surfaces that is bounded by said second set of ribs of said second spine, where said first and second spines are bounded by respective ones of the patches such that a portion of the spine is not coincident with boundaries of the respective patches; and manufacturing a free-form optical system having at least two active free-form optical surfaces comprising a body further comprising surfaces corresponding to the first and second surfaces where the optical system receives an input light and emits an output light according to a light prescription. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A method designing a free-form optical system to be used in manufacturing the free-form optical system, comprising:
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defining first input and output wavefronts and a first optical path length between said first input and output wavefronts; defining second input and output wavefronts and a second optical path length between said second input and output wavefronts; defining a deflection type of a first free-form surface and a deflection type of a second free-form surface; defining a first spine of the first surface and defining a second spine of the second surface; calculating a first and second seed rib of each of the first and second surfaces, respectively, comprising simultaneously calculating dependent first and second sets of span points, respectively, defining, in part, the first and second surfaces; defining a first patch of the first surface that is defined by said first seed rib, where said first spine is bounded by said first patch of the first surface such that a portion of the first spine is not coincident with boundaries of the first patch; defining a second patch of the second surface that is defined by said second seed rib, where said second spine is bounded by said second patch of the second surface such that a portion of the second spine is not coincident with boundaries of the second patch; and defining the first surface comprising the first patch in accordance with the first seed rib; defining the second surface comprising the second patch in accordance with the second seed rib; and storing the defined first and second surfaces and the deflection type of the first and second surfaces to be accessed by a computer, where the defined first and second surfaces and the deflection type of the first and second surfaces are used to manufacture a free-form optical system comprising free-form surfaces as defined by the defined first and second surfaces. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29)
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30. A free-form optical system, comprising:
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a body comprising; a transparent medium; a first free-form surface receiving at least a first optical input wavefront and a second optical input wavefront; and a second free-form surface separated from the first surface and emitting at least a first optical output wavefront and a second optical output wavefront; the first and second surfaces are respectively defined at least in part according to interdependent first and second sets of span points, and the first and second surfaces are further defined according to patches dictated by the first and second sets of span points, respectively; the first and second surfaces are further defined by first and second set of spines that are dependent on the first and second sets of span points, respectively, and ribs extending from the first and second sets of span points associated with said first and second sets of spines, respectively, where the ribs are simultaneously generated and at least in part bound the patches and said first and second spines are bounded by first and second patches, respectively, such that a portion of the first spine is not coincident with boundaries of the first patch and a portion of the second spine is not coincident with boundaries of the second patch. - View Dependent Claims (31, 32, 33, 34)
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Specification