Optical modules

• US 8,384,999 B1
• Filed: 01/09/2012
• Issued: 02/26/2013
• Est. Priority Date: 01/09/2012
• Status: Active Grant

• Current Assignee: META Platforms Technologies LLC (Meta Platforms, Inc. (f/k/a Facebook, Inc.))
• Original Assignee: CERR Limited
• Inventors: Crosby, David Nicholas, Hayes, David, Greenhalgh, Philip Andrew
• Primary Examiner(s): PINKNEY, DAWAYNE
• Application Number:
  US13/345,769
• Time in Patent Office: 414 Days
• Field of Search: 359630-639, 359/404, 359/407, 359409-410, 359618-619, 359/625, 359 13- 14, 359/727, 359/732, 345 7- 9, 631/633, 631/640, 351 41-176, 351205-206, 351/210, 351/221, 340/438, 340/980, 340/995.1, 340/815.47, 340/815.74, 349/11, 348/115, 353 11- 12, 353/28, 353/119
• US Class Current: 359/631
• CPC Class Codes: G02B 27/0172 characterised by optical features

Abstract

An optical module for head mounted displays and other applications comprises: an optical substrate and optical superstrate having inter-engaging ridged surfaces. A reflective layer is formed on at least one of the surfaces. An index matching material may be located between the surfaces. A region that receives a projected image, from a projector, directs rays launched from the projector onto the ridged surfaces, so that in use a viewer perceives an augmented image. The augmented image comprising reflected rays from the projector and transmitted rays from an object located on an opposite side of the module to that of the viewer.

Claims

1. An optical apparatus comprising

a curved embedded ridged reflector module, wherein said module comprises an optical substrate and optical superstrate having inter-engaging ridged surfaces with a freeform profile, wherein the interengaging ridged surfaces comprise alternating first surfaces and second surfaces and wherein at least said first surfaces are freeform curved;

a reflective layer formed on at least one of said surfaces;

said reflective layer being partially reflective and partially transmissive; and

a complementary lens configured to receive a projected image, from a projector, and directs output rays from the projector onto the ridged surfaces on a first side of said module,

wherein said module and said complimentary lens are arranged in an off axis optical configuration and wherein said complimentary lens is freeformed to pre-compensate for optical aberrations and distortions resulting from the embedded ridge reflector module such that in use, an augmented image, comprising reflected rays from the projector and transmitted rays from an object located on a second side of the module, is correctly presented to a viewer located on a first side of the module without further conditioning of the reflected rays.

2. An apparatus according to claim 1, wherein

said inter-engaged ridged surfaces are formed on flat planar inner faces of said optical substrate and optical superstrate.

3. An apparatus according to claim 1, wherein said substrate and superstrate in the module are freeform curved.

4. An apparatus according to claim 3 wherein said substrate has a freeformed curved outer face on said first side of said module, and wherein said superstrate has a freeformed curved outer face on said opposite side of said module.

5. An apparatus according to claim 1, wherein said reflector layer formed on said at least one surface comprises reflective material deposited on said at least one surface.

6. An apparatus according to claim 5 wherein said embedded ridge reflector further comprises indexing matching material located between the inter-engaged ridged surfaces.

7. An apparatus according to claim 1, wherein said reflective layer formed on said at least one surface comprises an air gap between said inter-engaged ridged surfaces.

8. An apparatus according to claim 1 wherein the ratio of reflectivity to transmission of said reflective layer is adjustable.

9. An apparatus according to claim 1 comprising a pair of said embedded ridged reflector modules;

and a head mounted display;

wherein said pair of embedded ridged reflector modules are supported on said head mounted display.

10. An apparatus according to claim 9 wherein motion sensors are arranged to detect motion about three independent axes.

11. An apparatus according to claim 1 wherein a nose bridge connects the pair of optical modules and permits signals to pass to and from each module.

12. An apparatus according to claim 1 wherein the outer faces of the substrate and superstrate in the optical module are freeform curved to enable fixed correction of complex vision defects such as astigmatism and presbyopia.

13. An apparatus according to claim 1 wherein the substrate and superstrate have a refractive index between 1.6-1.95.

14. An apparatus according to claim 1 wherein a characteristic dimension, such as a length/width or major/minor axis or diameter, of the substrate and superstrate, is between 20 mm and 100 mm.

15. An apparatus according to claim 1 wherein said reflective layer is selectively deposited on said interengageble ridged surfaces such that the reflective layer is omitted from flyback surfaces of said ridged surfaces.

16. An apparatus according to claim 1 further comprising an electronic circuitry for changing the shape of the image forming device of said projector to reduce residual aberrations after optical conditioning.

17. An apparatus according to claim 1 further comprising an electronic controllable variable focusing device arranged in the projected unreflected ray path for positioning the image plane of the computer generated image between infinity and about 30 cm from the front surface of the module.

18. An apparatus according to claim 1 comprising an electronic controllable variable focusing device provided on one or more surfaces of the embedded ridged reflector module for enabling adjustment of the image for in focus viewing by a long sighted or short sighted user or a user having astigmatic vision defects.

19. A system for controlling and operating projectors, which are located in a frame portion of a head mounted display, according to claim 9, includes a data transmitter, for transmitting data to a projector in the head mounted display.

20. A system according to claim 19 including a multiplexer for combining signals intended for left and right projectors separate optical fibres are provided for driving the left and right projectors in respective optical modules into a single optical fiber.

21. A system according to claim 19 including a multiplexer for combining signals intended for left and right projectors in respective optical modules.

22. An optical apparatus as claimed in claim 9, further comprising an eye tracking device included in said head mounted display for monitoring eye movement and providing a feedback signal.

23. A method of fabricating an optical embedded ridged reflector apparatus comprises the steps of:

forming a curved embedded ridged reflector module, wherein forming said curved embedded ridged reflector module comprises;

forming an optical substrate and optical superstrate;

wherein forming said optical substrate and optical superstrate includes forming interengageable ridged surfaces with a freeform profile;

wherein forming said interengagable ridged surfaces with a freeform profile comprises forming alternating first surfaces and second surfaces;

said at least first surfaces being freeform curved;

forming a reflective layer on at least one of said surfaces;

wherein forming the reflective layer comprises forming a partially reflecting and partially transmissive reflective layer; and

placing respective first and second inter-engagable ridged surfaces adjacent one another so as to achieve optical coupling;

configuring a complimentary lens to receive a projected image, from a projector, and direct output rays from the projector onto the ridged surfaces on a first side of said curved embedded ridged reflector module, wherein configuring said complimentary lens includes freeforming said complimentary lens to pre-compensate for optical aberrations and distortions resulting from the embedded ridge reflector module; and

arranging said module and said complimentary lens in an off axis optical configuration, whereby, in use, an augmented image, comprising reflected rays from the projector and transmitted rays from an object located on a second side of the module, is correctly presented to a viewer located on a first side of the module without further conditioning of the reflected rays.

24. A method according to claim 23, further comprising interposing an index matching material between said surfaces.

25. A method of claim 23 wherein forming said optical substrate and optical superstrate includes forming said inter-engaged ridged surfaces on flat planar inner faces of said optical substrate and optical superstrate.

26. The method of claim 23 wherein forming said optical substrate and optical superstrate having inter-engageable ridged surfaces comprises forming a freeform curved optical substrate and a freeform curved optical superstrate having said inter-engaged ridged surfaces on freeform curved inner faces of said optical substrate and optical superstrate.

27. A method of fabricating an optical module according to claim 26 wherein the substrate and superstrate are pressed and/or heated so that the substrate and superstrate take up the curvature of the master moulds.

28. A method of fabricating an optical module according to claim 23 further including the step of encapsulating a substrate in refractive index matched optical resin using an over-molding process.