SYSTEMS, ARTICLES, AND METHODS FOR INTEGRATING HOLOGRAPHIC OPTICAL ELEMENTS WITH EYEGLASS LENSES

• US 20170068095A1
• Filed: 09/02/2016
• Published: 03/09/2017
• Est. Priority Date: 09/04/2015
• Status: Active Grant

• Current Assignee: Google LLC (Alphabet Inc.)
• Original Assignee: Thalmic Labs Inc.
• Inventors: Holland, Lloyd Frederick, Bailey, Matthew
• Granted Patent: US 10,488,662 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29D 11/00317 Production of lenses with markings or patterns
• CPC Class Codes: B29D 11/00413 made by moulding between two mould parts which are not in direct contact with one another, e.g. comprising a seal between or on the edges B29D11/00019 - B29D11/00355, B29D11/00423, B29D11/00432 take precedence
• CPC Class Codes: B29D 11/00432 Auxiliary operations, e.g. machines for filling the moulds B29D11/00125 takes precedence
• CPC Class Codes: B29D 11/00442 Curing the lens material
• CPC Class Codes: B29D 11/00461 Adjusting the refractive index, e.g. after implanting
• CPC Class Codes: B29D 11/0048 Moulds for lenses moulds for plastic articles in general B29C33/00
• CPC Class Codes: B29D 11/00548 with surfaces formed by films
• 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: B29K 2995/0018 having particular optical properties, e.g. fluorescent or phosphorescent
• CPC Class Codes: G02B 2027/0107 with optical power
• CPC Class Codes: G02B 2027/0109 comprising details concerning the making of holograms
• CPC Class Codes: G02B 2027/0178 Eyeglass type eyeglass details G02C
• CPC Class Codes: G02B 27/0101 characterised by optical features G02B27/0172 takes precedence
• CPC Class Codes: G02B 27/0103 comprising holographic elements
• CPC Class Codes: G02B 27/0172 characterised by optical features
• CPC Class Codes: G02C 11/10 Electronic devices other than hearing aids
• CPC Class Codes: G02C 7/086 Auxiliary lenses located directly on a main spectacle lens or in the immediate vicinity of main spectacles
• CPC Class Codes: G03H 1/0248 Volume holograms
• CPC Class Codes: G03H 1/0256 having specific functional layer
• CPC Class Codes: G03H 1/0402 Recording geometries or arrangements G03H1/0443, G03H1/0476, G03H1/16 take precedence
• CPC Class Codes: G03H 2001/043 : Non planar recording surface, e.g. curved surface
• CPC Class Codes: G03H 2001/0434 : In situ recording when the hologram is recorded within the device used for reconstruction
• CPC Class Codes: G03H 2001/0439 : for recording Holographic Optical Element [HOE] HOE per se G02B5/32
• CPC Class Codes: G03H 2250/37 : Enclosing the photosensitive material
• CPC Class Codes: G03H 2260/12 : Photopolymer
• CPC Class Codes: G03H 2270/55 : being an optical element, e.g. spectacles

Abstract

Systems, articles, and methods that integrate photopolymer film with eyeglass lenses are described. One or more hologram(s) may be recorded into/onto the photopolymer film to enable the lens to be used as a transparent holographic combiner in a wearable heads-up display employing an image source, such as a microdisplay or a scanning laser projector. The methods of integrating photopolymer film with eyeglass lenses include: positioning photopolymer film in a lens mold and casting the lens around the photopolymer film; sandwiching photopolymer film in between two portions of a lens; applying photopolymer film to a concave surface of a lens; and/or affixing a planar carrier (with photopolymer film thereon) to two points across a length of a concave surface of a lens. Respective lenses manufactured/adapted by each of these processes are also described.

Claims

1. A method of manufacturing a lens for use in a wearable heads-up display, the method comprising:

providing a lens mold having a cavity;

positioning a photopolymer film within the cavity of the lens mold;

casting a lens-forming fluid into the cavity; and

curing the lens-forming fluid within the cavity to form a lens having the photopolymer film embedded therein, the lens having dimensions and a geometry at least approximately equal to the cavity.

2. The method of claim 1, further comprising:

applying a curvature to the photopolymer film before casting the lens-forming fluid into the cavity.

3. The method of claim 1, further comprising:

applying an optical adhesive to at least one surface of the photopolymer film before positioning the photopolymer film within the cavity of the lens mold.

4. The method of claim 1, further comprising:

recording a hologram into the photopolymer film before positioning the photopolymer film within the cavity of the lens mold, wherein the hologram compensates for an optical effect of the lens.

5. The method of claim 1, further comprising:

recording a hologram into the photopolymer film embedded in the lens after curing the lens-forming fluid within the cavity to form the lens, wherein;

positioning the photopolymer film within the cavity of the lens mold;

casting the lens-forming fluid into the cavity; and

curing the lens-forming fluid within the cavity to form the lens having the photopolymer film embedded therein,

are all performed in a dark environment.

6. The method of claim 1, further comprising:

applying an eyeglass prescription to the lens after curing the lens-forming fluid within the cavity to form the lens.

7. The method of claim 1, further comprising:

annealing the lens at temperature between 50°

C. and 100°

C. for at least thirty minutes.

8. A lens for use in a wearable heads-up display, the lens prepared by a process comprising the acts of:

providing a lens mold having a cavity;

positioning a photopolymer film within the cavity of the lens mold;

casting a lens-forming fluid into cavity; and

curing the lens-forming fluid within the cavity to form a lens having the photopolymer film embedded therein, the lens having dimensions and a geometry at least approximately equal to the cavity.

9. A method of manufacturing a lens for use in a wearable heads-up display, the method comprising:

providing a front half portion of a lens;

providing a rear half portion of the lens;

providing a photopolymer film;

applying an optical adhesive to at least one surface selected from a group consisting of;

a surface of the front half portion of the lens, a surface of the rear half portion of the lens, and a surface of the photopolymer film;

positioning the photopolymer film in between the front half portion of the lens and the rear half portion of the lens; and

pressing the front half portion of the lens and the rear half portion of the lens together with the photopolymer film sandwiched therebetween.

10. The method of claim 9, further comprising:

applying a curvature to the photopolymer film before positioning the photopolymer film in between the front half portion of the lens and the rear half portion of the lens.

11. The method of claim 9, further comprising:

recording a hologram into the photopolymer film before positioning the photopolymer film in between the front half portion of the lens and the rear half portion of the lens, wherein the hologram compensates for at least one optical effect introduced by at least one of the front half portion of the lens, a curvature of the photopolymer film, and/or the rear half portion of the lens.

12. The method of claim 9, further comprising:

recording a hologram into the photopolymer film after pressing the front half portion of the lens and the rear half portion of the lens together with the photopolymer film sandwiched therebetween, wherein;

applying the optical adhesive to at least one surface selected from the group consisting of;

the surface of the front half portion of the lens, the surface of the rear half portion of the lens, and the surface of the photopolymer film;

positioning the photopolymer film in between the front half portion of the lens and the rear half portion of the lens; and

pressing the front half portion of the lens and the rear half portion of the lens together with the photopolymer film sandwiched therebetween, are all performed in a dark environment.

13. The method of claim 9, further comprising:

applying an eyeglass prescription to at least one of the front half portion of the lens and/or the rear half portion of the lens after pressing the front half portion of the lens and the rear half portion of the lens together with the photopolymer film sandwiched therebetween.

14. A lens for use in a wearable heads-up display, the lens prepared by a process comprising the acts of:

providing a front half portion of a lens;

providing a rear half portion of the lens;

providing a photopolymer film;

applying an optical adhesive to at least one surface selected from a group consisting of;

a surface of the front half portion of the lens, a surface of a rear half portion of the lens, and a surface of the photopolymer film;

positioning the photopolymer film in between the front half portion of the lens and the rear half portion of the lens; and

pressing the front half portion of the lens and the rear half portion of the lens together with the photopolymer film sandwiched therebetween.

15. A method of adapting a lens for use in a wearable heads-up display, the method comprising:

providing a lens having a concave surface; and

applying a photopolymer film to the concave surface of the lens, wherein the photopolymer film adopts a concave curvature at least approximately equal to a curvature of the concave surface of the lens.

16. The method of claim 15 wherein applying a photopolymer film to the concave surface of the lens includes:

providing the photopolymer film;

applying an optical adhesive to at least one surface selected from a group consisting of;

the concave surface of the lens and a surface of the photopolymer film;

pressing the concave surface of the lens and the surface of the photopolymer film together; and

curing the optical adhesive.

17. The method of claim 16 wherein pressing the concave surface of the lens and the surface of the photopolymer film together includes warming the photopolymer film to a temperature below about 80 degrees Celsius.

18. The method of claim 15 wherein applying the photopolymer film to the concave surface of the lens includes:

applying the photopolymer film to a surface of a carrier;

curving the carrier to provide a concave curvature that at least approximately matches the concave surface of the lens;

applying an optical adhesive to at least one surface selected from a group consisting of;

the concave surface of the lens, a surface of the photopolymer film, and a surface of the carrier;

pressing the concave surface of the lens and the carrier, with the photopolymer film thereon, together to sandwich the optical adhesive; and

curing the optical adhesive.

19. The method of claim 18 wherein curving the carrier, with the photopolymer film thereon, includes:

warming the photopolymer film to a temperature below about 80 degrees Celsius; and

pressing the carrier, with the photopolymer film thereon, over a curved surface, the curved surface having a curvature that at least approximately matches or mates with the concave surface of the lens.

20. The method of claim 18, further comprising:

removing the carrier.

21. The method of claim 15 wherein applying a photopolymer film to the concave surface of the lens includes depositing the photopolymer film directly on the concave surface of the lens by at least one thin film deposition technique selected from a group consisting of:

spin-coating, dip-coating, and vacuum deposition.

22. The method of claim 15, further comprising:

applying an eyeglass prescription to the lens before applying the photopolymer film to the concave surface of the lens.

23. The method of claim 15, further comprising:

recording a hologram into the photopolymer film before applying the photopolymer film to the concave surface of the lens, wherein the hologram compensates for an optical effect of the lens.

24. The method of claim 15, further comprising:

recording a hologram into the photopolymer film after applying the photopolymer film to the concave surface of the lens, wherein;

applying a photopolymer film to the concave surface of the lens is performed in a dark environment.

25. A lens for use in a wearable heads-up display, the lens adapted by a process comprising the acts of:

providing a lens having a concave surface; and

applying a photopolymer film to the concave surface of the lens, wherein the photopolymer film adopts a concave curvature at least approximately equal to a curvature of the concave surface of the lens.

26. A method of adapting a lens for use in a wearable heads-up display, the method comprising:

providing a lens having a concave surface;

applying a photopolymer film to a planar carrier, wherein the planar carrier is optically transparent; and

affixing at least two points of the planar carrier to at least two respective points on the concave surface of the lens, the at least two points of the planar carrier at opposite ends of at least a portion of a length of the planar carrier.

27. The method of claim 26 wherein affixing at least two points of the planar carrier to at least two respective points on the concave surface of the lens defines a cavity in between the concave surface of the lens and the planar carrier, and wherein affixing at least two points of the planar carrier to at least two respective points on the concave surface of the lens includes adhering at least two points of the planar carrier to at least two respective points on the concave surface of the lens using an optical adhesive.

28. The method of claim 26, further comprising:

applying an eyeglass prescription to the lens before affixing the at least two points of the planar carrier to the at least two respective points on the concave surface of the lens.

29. The method of claim 26, further comprising:

recording a hologram into the photopolymer film before affixing the at least two points of the planar carrier to the at least two respective points on the concave surface of the lens, wherein the hologram compensates for at least one of an optical effect of the lens and/or a curvature of the photopolymer film.

30. The method of claim 26, further comprising:

recording a hologram into the photopolymer film after affixing the at least two points of the planar carrier to the at least two respective points on the concave surface of the lens, wherein;

applying the photopolymer film to the planar carrier; and

affixing at least two points of the planar carrier to at least two respective points on the concave surface of the lens, are both performed in a dark environment.

31. The method of claim 26, further comprising:

forming a recess in the concave surface of the lens; and

positioning the planar carrier, with the photopolymer film applied thereto, within the recess, wherein affixing at least two points of the planar carrier to at least two respective points on the concave surface of the lens includes affixing the planar carrier within the recess in the concave surface of the lens.

32. A lens for use in a wearable heads-up display, the lens adapted by a process comprising:

providing a lens having a concave surface;

applying a photopolymer film to a planar carrier, wherein the planar carrier is optically transparent; and

affixing at least two points of the planar carrier to at least two respective points on the concave surface of the lens, the at least two points of the planar carrier at opposite ends of at least a portion of a length of the planar carrier.