Hi Electricman,
The key to your IR distance problem is "IR LED Array". You have only a single IR LED pumping only 30mA. With your 1:4 duty-cycle you could use 120mA. Have you seen IR headphones systems that use 6 or more LEDs? They would use current pulses of 720mA. 24 times more!
Another problem is that your receiver uses a slow phototransistor, please post its part number or datasheet so we can see how low its gain is at 37KHz. A PIN photodiode would be much faster.
Another problem with the gain of your receiver is that the opamp preamp has a gain of only about 10. A digital inverter would have much more gain and limit the FM much better. Or you could use a second opamp as a high gain limiter.
The web is full of high quality IR FM headphones systems. Here is a receiver that uses a fast Pin photodiode with an LC bandpass filter, a digital inverter preamp and a more-modern PLL. Your opamp could replace its FET and your LM565PLL will be OK. This system operates at 100KHz.
The key to your IR distance problem is "IR LED Array". You have only a single IR LED pumping only 30mA. With your 1:4 duty-cycle you could use 120mA. Have you seen IR headphones systems that use 6 or more LEDs? They would use current pulses of 720mA. 24 times more!
Another problem is that your receiver uses a slow phototransistor, please post its part number or datasheet so we can see how low its gain is at 37KHz. A PIN photodiode would be much faster.
Another problem with the gain of your receiver is that the opamp preamp has a gain of only about 10. A digital inverter would have much more gain and limit the FM much better. Or you could use a second opamp as a high gain limiter.
The web is full of high quality IR FM headphones systems. Here is a receiver that uses a fast Pin photodiode with an LC bandpass filter, a digital inverter preamp and a more-modern PLL. Your opamp could replace its FET and your LM565PLL will be OK. This system operates at 100KHz.