Manufacturing for virtual and augmented reality systems and components

• US 10,677,969 B2
• Filed: 03/05/2016
• Issued: 06/09/2020
• Est. Priority Date: 11/27/2013
• Status: Active Grant

• Current Assignee: Magic Leap, Inc.
• Original Assignee: Magic Leap, Inc.
• Inventors: Tekolste, Robert D., Klug, Michael A., Greco, Paul M., Schowengerdt, Brian T.
• Primary Examiner(s): Mellott, James M
• Application Number:
  US15/062,090
• Publication Number:
  US 20160216416A1
• Time in Patent Office: 1,557 Days
• Field of Search: None
• CPC Class Codes: B29D 11/00355 with a refractive index gradient
• CPC Class Codes: B29D 11/00432 Auxiliary operations, e.g. machines for filling the moulds B29D11/00125 takes precedence
• CPC Class Codes: B29D 11/00682 with a refractive index gradient
• CPC Class Codes: B29D 11/0073 Optical laminates
• CPC Class Codes: B29D 11/00865 Applying coatings; tinting; colouring printing, marking or copying processes B41M; identification in general G09F3/00; producing decorative effects in general B44C; positioning or marking of lenses B24B13/0055
• CPC Class Codes: G02B 2027/0112 comprising device for genereting colour display
• CPC Class Codes: G02B 2027/0125 Field-of-view increase by wavefront division
• CPC Class Codes: G02B 2027/0194 with combiner of laminated type, for optical or mechanical aspects
• CPC Class Codes: G02B 27/0172 characterised by optical features
• CPC Class Codes: G02B 27/4205 having a diffractive optical element [DOE] contributing to image formation, e.g. whereby modulation transfer function MTF or optical aberrations are relevant
• CPC Class Codes: G02B 5/1823 in an overlapping or superposed manner
• CPC Class Codes: G02B 5/1842 Gratings for image generation G02B5/1847 takes precedence
• CPC Class Codes: G02B 5/1852 using mechanical means, e.g. ruling with diamond tool, moulding

Abstract

Disclosed is an improved diffraction structure for 3D display systems. The improved diffraction structure includes an intermediate layer that resides between a waveguide substrate and a top grating surface. The top grating surface comprises a first material that corresponds to a first refractive index value, the underlayer comprises a second material that corresponds to a second refractive index value, and the substrate comprises a third material that corresponds to a third refractive index value. According to additional embodiments, improved approaches are provided to implement deposition of imprint materials onto a substrate, which allow for very precise distribution and deposition of different imprint patterns onto any number of substrate surfaces.

Claims

1. A method for manufacturing an eyepiece comprising a first diffractive optical element, comprising:

depositing a first layer onto a first substrate, wherein

the first layer comprises a first portion and a second portion, the first portion is deposited to have a first depth onto a first region on the first substrate, the first portion has a first optical index, the second portion is deposited to have a second depth onto a second region on the first substrate, and the second portion has a second optical index different from the first optical index;

identifying a template having an imprint pattern formed thereon, the template comprising a first set of depth structures and a second set of depth structures, the first set of depth structures corresponding to the first depth of the first portion, and the second set of depth structures corresponding to the second depth of the second portion; and

imprinting the imprint pattern into the first and the second portions on the first substrate with the template, wherein

the imprint pattern comprises a diffraction pattern for the first diffractive optical element,

the first portion is deposited to have the first depth according to at least a first optical function,

the second portion is deposited to have the second depth according to at least a second optical function, before imprinting, and

the first depth is different from the second depth.

2. The method of claim 1, further comprising:

imprinting, using at least the template, the first and second portions that are respectively deposited onto the first and second regions simultaneously to form a first pattern and a second pattern onto the first substrate, wherein

the imprint pattern comprises the first pattern and the second pattern,

the template imprints the first pattern with the first set of depth structures onto the first portion of the materials, and

the template imprints the second pattern with the second set of depth structures onto the second portion of the materials.

3. The method of claim 2, wherein the first pattern corresponds to a first diffraction grating pattern and the second pattern corresponds to a second diffraction grating pattern.

4. The method of claim 2, wherein the first function or the second function includes a first function of in-coupling gratings, a second function of orthogonal pupil expander gratings, or a third function of exit pupil expander gratings.

5. The method of claim 1, further comprising:

depositing, for the first diffractive optical element of the eyepiece, a second layer above the first layer, wherein

the second layer comprises a first material having a first refractive index value in a first region of the second layer,

the second layer further comprises a second material having a second refractive index value in a second region of the second layer,

the first substrate comprises a third material having a third refractive index value, and

the first, second, and third refractive index values are selected based at least in part upon a first requirement for a diffraction efficiency or a second requirement for a field of view provided by the first diffractive optical element of the eye piece.

6. The method of claim 1, further comprising:

stacking, for the eyepiece, a second diffractive optical element above a first negative lens that is further stacked above the first diffractive optical element, wherein

the first diffractive optical element is closer to a viewer'"'"'s eye than the second diffractive optical element and defines a first focal plane with a first focal distance of optical infinity,

the second diffractive element comprises a second substrate and defines a second focal plane with a second focal distance that is smaller than the first focal distance of the optical infinity, and

the second diffractive element is separated from the first diffractive element by the first lens.

7. The method of claim 6, further comprising:

stacking, for the eyepiece, a third diffractive optical element above the second diffractive optical element, wherein

the third diffractive optical element comprises a third substrate and is disposed farther away from the viewer'"'"'s eye than the second diffractive optical element,

the third diffractive optical element defines a third focal plane with a third focal distance that is smaller than the second focal distance, and

the third diffractive optical element is separated from the second diffractive element by a second lens.

8. The method of claim 7, further comprising:

disposing, for the eyepiece, a compensation lens layer above the third diffractive optical element, wherein the compensation lens layer is selected based at least in part upon an aggregate power of the first and the second lens.

9. The method of claim 7, wherein the first lens and the second lens create wavefront divergence to define a different focal plane with a different focal distance that is smaller than the third focal distance.

10. The method of claim 7, further comprising stacking, for the eyepiece, one or more additional diffractive optical elements above the third diffractive optical element and away from the viewer'"'"'s eye, wherein the third diffractive element is separated from the one or more additional diffractive optical elements by a separate lens, and the one or more diffractive optical elements respectively define respective focal planes with one or more corresponding focal distances that are smaller than the third focal distance.

11. The method of claim 10, further comprising:

disposing a compensation lens layer above the one or more additional diffractive optical elements, wherein the compensation lens layer is selected based at least in part upon an aggregate power of lenses separating diffractive optical layers in the eyepiece.

12. The method of claim 7, wherein at least two of the first diffractive optical element, the second diffractive optical element, and the third diffractive optical element are multiplexed to create at least one additional focal plane in addition to the first focal plane, the second focal plane, and the third focal plane.

13. The method of claim 6, wherein at least some of the first portion of the materials is deposited above at least some of the second portion of the materials before imprinting the imprint pattern into the first and the second portions.

14. The method of claim 6, wherein the first diffractive optical element corresponds to a first set of one or more projectors, and the second diffractive optical element corresponds to a second set of one or more projectors.

15. The method of claim 1, further comprising:

imprinting a first pattern of the imprint pattern into the first portion; and

imprinting a second pattern into the second portion that is different from the first pattern, wherein the imprint pattern comprises the first pattern and the second pattern.

16. The method of claim 1, wherein the first substrate having a first imprinted pattern is overlaid onto a second substrate having a second imprinted pattern.

17. The method of claim 1, further comprising:

depositing, for the first diffractive optical element of the eyepiece, a second layer onto the first substrate, wherein

the second layer is deposited on an opposite surface opposing a surface onto which the first layer is deposited,

the second layer comprises a first material having a refractive index value in a first region of the second layer,

the first substrate comprises a different material having a different refractive index value, and

the first and the third refractive index values are selected based at least in part upon a first requirement for a diffraction efficiency or a second requirement for a field of view provided by the first diffractive optical element of the eye piece.

18. The method of claim 1, wherein the first refractive index value is smaller than the second refractive index value and a substrate refractive index value of the first substrate, and the substrate refractive index value is smaller than the second refractive index value.

19. The method of claim 1, further comprising determining a thickness value for the first layer based at least in part upon a light incident angle for the first layer, the first refractive index value, and the second refractive value.