Reflective diffractive gratings with variable reflectivity and display systems having the same

• US 10,371,876 B2
• Filed: 07/23/2018
• Issued: 08/06/2019
• Est. Priority Date: 04/18/2017
• Status: Active Grant

• Current Assignee: Magic Leap, Inc.
• Original Assignee: Magic Leap, Inc.
• Inventors: Menezes, Marlon Edward, Schmulen, Jeffrey Dean, Ricks, Neal Paul, Liu, Victor Kai, Wang, Zongxing, Jurbergs, David Carl
• Primary Examiner(s): Lepisto, Ryan A
• Application Number:
  US16/042,996
• Publication Number:
  US 20180329132A1
• Time in Patent Office: 379 Days
• CPC Class Codes: G02B 2027/0125 Field-of-view increase by wavefront division
• CPC Class Codes: G02B 2027/0185 Displaying image at variable distance
• CPC Class Codes: G02B 27/0075 with means for altering, e.g. increasing, the depth of field or depth of focus
• CPC Class Codes: G02B 27/0172 characterised by optical features
• CPC Class Codes: G02B 5/0808 having a single reflecting layer G02B5/0883, G02B5/0891 take precedence
• CPC Class Codes: G02B 5/1861 Reflection gratings characterised by their structure, e.g. step profile, contours of substrate or grooves, pitch variations, materials G02B5/1809, G02B5/1828, G02B5/1833, G02B5/1838 and G02B5/1847 take precedence
• CPC Class Codes: G02B 6/0016 Grooves, prisms, gratings, scattering particles or rough surfaces
• CPC Class Codes: G02B 6/0065 Manufacturing aspects; Material aspects
• CPC Class Codes: G02B 6/0076 Stacked arrangements of multiple light guides of the same or different cross-sectional area
• CPC Class Codes: G02B 6/34 utilising prism or grating G02B6/293 takes precedence

Abstract

In some embodiments, compositions and methods comprising reflective flowable materials, e.g., reflective liquids including reflective inks and/or liquid metals, are described. In some embodiments, a surface is contacted with a reflective flowable material, thereby forming a reflective layer on the surface. In some embodiments, the surface is a surface of a waveguide, for example a waveguide for a display device, and the flowable material coats surfaces of protrusions on the surface to form reflective diffractive optical elements. Some embodiments include a display device comprising a reflective layer of reflective flowable material.

Claims

1. An optical device comprising:

an optical waveguide structure comprising;

an incoupling optical element configured to redirect incident light at angles such that the incident light propagates through the optical waveguide structure by total internal reflection, wherein the incoupling optical element comprises;

a diffractive optical grating structure comprising;

a plurality of protrusions; and

a reflective layer on surfaces of the protrusions, and

wherein at least one parameter of the reflective layer varies across an area occupied by the plurality of protrusions, and

wherein a reflectivity of the diffractive optical grating structure varies with the at least one parameter of the reflective layer across the area occupied by the plurality of protrusions.

2. The optical device of claim 1, wherein the at least one parameter is a thickness of the reflective layer across the area occupied by the plurality of protrusions.

3. The optical device of claim 2, wherein the thickness of the reflective layer varies by 25% or more across the area occupied by the plurality of protrusions.

4. The optical device of claim 1, wherein the at least one parameter is a composition of the reflective layer across the area occupied by the plurality of protrusions.

5. The optical device of claim 1, wherein the at least one parameter is the coverage over the reflective layer, and wherein the reflective layer covers less than an entirety of the area occupied by the plurality of protrusions.

6. The optical device of claim 1, wherein the reflective layer comprises metal.

7. The optical device of claim 6, wherein the metal is a liquid metal.

8. The optical device of claim 7, wherein the liquid metal is selected from the group consisting of:

gallium;

indium;

mercury;

gallium-indium eutectic;

gallium-indium alloy;

gallium indium tin alloy;

Ga, In, Sn and Zn alloy;

Ga, In, and Sn alloy;

sodium-potassium alloy;

gallium, indium and stannum;

gallium-indium-zinc-copper metallic; and

silver indium gallium.

9. The optical device of claim 6, wherein the metal forms a reflective ink.

10. The optical device of claim 9, wherein the metal is aluminum, silver, or a combination thereof.

11. The optical device of claim 9, wherein the reflective ink is a particle-free ink.

12. The optical device of claim 1, wherein the optical waveguide structure comprises a first waveguide configured to propagate light therein by total internal reflection.

13. The optical device of claim 12, wherein the optical waveguide structure comprises at least one additional waveguide, wherein the first waveguide and the at least one additional waveguide form a waveguide stack.

14. The optical device of claim 13, wherein the area occupied by the diffractive optical grating is delineated by walls or barriers on the surface of the optical waveguide structure, wherein the walls or barriers extend vertically to a height above the plurality of protrusions, and wherein the walls or barriers are configured to function as spacers to provide a gap between the first waveguide and the at least one additional waveguide in the stack of waveguides.

15. The optical device of claim 13, wherein the diffractive optical grating structure is configured to incouple the incident light into the first waveguide, and wherein the at least one additional waveguide has associated additional incoupling optical elements.

16. The optical device of claim 15, wherein the incoupling optical element and the additional incoupling optical elements are configured to incouple light of different ranges of wavelengths.

17. The optical device of claim 13, wherein the waveguide stack is optically coupled to a spatial light modulator, wherein the spatial light modulator is configured to inject light into the waveguide stack.

18. The optical device of claim 13, wherein the first waveguide and the at least one additional waveguide each comprise associated outcoupling optical elements, wherein the respective associated outcoupling optical elements are configured to redirect light out of the first waveguide and the at least one additional waveguide with different amounts of wavefront divergence.

19. The optical device of claim 13, wherein the incoupling optical element and the additional incoupling optical elements are laterally offset from one another in a top-down view.

20. The optical device of claim 13, wherein the optical device is an augmented reality display, wherein the first waveguide and the at least one additional waveguide are configured to transmit light from an ambient environment.

21. The optical device of claim 1, further comprising an image injection device configured to direct light with image information to the incoupling optical element.