Prismatic multiple waveguide for near-eye display

• US 8,649,099 B2
• Filed: 09/13/2011
• Issued: 02/11/2014
• Est. Priority Date: 09/13/2010
• Status: Active Grant

• Current Assignee: Vuzix Corporation
• Original Assignee: Vuzix Corporation
• Inventors: Schultz, Robert J., Burdick, Nathan E.
• Primary Examiner(s): Mack, Ricky
• Assistant Examiner(s): Manikeu, Daniele
• Application Number:
  US13/231,628
• Publication Number:
  US 20120062998A1
• Time in Patent Office: 882 Days
• Field of Search: 359/20, 359629-633
• US Class Current: 359/630
• CPC Class Codes: B29D 11/00663 Production of light guides
• CPC Class Codes: G02B 2027/0125 Field-of-view increase by wavefront division
• CPC Class Codes: G02B 27/0101 characterised by optical features G02B27/0172 takes precedence
• CPC Class Codes: G02B 6/00 Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor

Abstract

A near-eye display includes a compound waveguide for presenting viewers with virtual images visible within an eyebox at a limited relief distance from the compound waveguide. The compound waveguide is assembled from a plurality of waveguides that are at least partially optically isolated for conveying different portions of the virtual image. An input couple injects the different portions of the virtual image into predetermined combinations of the waveguides, and an output coupling ejects the different portions of the virtual image from the waveguides toward the eyebox in a form that at least partially constructs a pupil within the eyebox.

Claims

1. A near-eye display for displaying virtual images comprising

an image generator for generating angular transforms of the virtual images intended for display as angularly related beamlets representing different spatially related points in the images,

a plurality of different waveguides that convey the angularly related beamlets toward an eyebox,

an input coupling for injecting the angularly related beamlets into the waveguides for propagation along the waveguides,

an output coupling for ejecting the angularly related beamlets from the waveguides toward the eyebox,

each of the plurality of different waveguides having a front surface and a back surface, a thickness between the front and back surfaces, and a length that extends between the input coupling and the output coupling,

the input coupling being optically spaced from the image generator for injecting different angular ranges of the angularly related beamlets into the different waveguides so that each of the different waveguides conveys a different region of the intended virtual images,

each of the different waveguides being spatially offset from one another in a direction normal to the front and back surfaces of the different waveguides for separately propagating a different one of the different angular ranges of the angularly related beamlets along the length of each of the different waveguides between the input and output couplings, and

the output coupling being oriented for ejecting the different angular ranges of the beamlets from the different waveguides on converging paths toward the eyebox into positions of increasing spatial overlap.

2. The display of claim 1 in which the output coupling converges the different angular ranges of the beamlets toward the eyebox without contributing optical power affecting an angular magnification of the virtual images.

3. The display of claim 1 in which the image generator includes an aperture within which the angular transforms of the virtual images overlap and the optical spacing between the input coupling and the image generator positions the aperture of the image generator at an optical distance from the input coupling so that the angularly related beamlets are partially spatially separated at the input coupling.

4. The display of claim 3 in which the different angular ranges of the beamlets are distributed among the waveguides so that the convergence of the different angular ranges of the beamlets from the output coupling reduces the spatial separation between the angularly related beamlets within the eyebox.

5. The display of claim 1 in which the waveguides are optically isolated from one another for propagating the angularly related beamlets through a first range of grazing angles and are optically coupled to one another through a second higher range of grazing angles.

6. The display of claim 5 in which the waveguides include an anterior waveguide remote from the eyebox, a posterior waveguide proximate to the eyebox, and at least one intermediate waveguide located between the anterior waveguide and the posterior waveguide.

7. The display of claim 6 in which the input coupling injects the angularly related beamlets that propagate at the lowest grazing angle into the anterior waveguide without injecting the angularly related beamlets that propagate at the lowest grazing angle into the posterior waveguide, and the input coupling injects the angularly related beamlets that propagate at the highest grazing angle into the posterior waveguide without injecting the angularly related beamlets that propagate at the highest grazing angle into the anterior waveguide.

8. The display of claim 7 in which the input coupling injects the angularly related beamlets that propagate at both the lowest grazing angle and the highest grazing angle within the at least one intermediate waveguide.

9. The display of claim 1 in which (a) the thickness of each of the waveguides extends between plane-parallel front and back surfaces for supporting internal reflection of the angularly related beamlets and the length of each of the waveguides extends between an entrance end and an exit end, (b) the input coupling includes an at least partially reflective surface proximate to the entrance end of each of the substantially parallel waveguides, and (c) the output coupling includes an at least partially reflective surface proximate to the exit end of each of the substantially parallel waveguides.

10. The display of claim 9 in which the waveguides vary in thickness for filling the eyebox with a more uniform distribution of light from the angularly related beam lets.

11. The display of claim 9 in which at least one of the angularly related beamlets has a beam width subject to truncation by the input coupling, and the length of one of the waveguides is set in relation to its thickness so that the truncated portion of the beam width is not required for filling the eyebox.

12. The display of claim 9 in which the at least partially reflective surfaces proximate to the exit end of each of the substantially parallel waveguides are oriented at a common exit angle and located within a common plane.

13. The display of claim 10 in which the at least partially reflective surfaces proximate to the entrance end of each of the substantially parallel waveguides are oriented at a common entrance angle and located within a common plane.

14. The display of claim 13 in which the image generator generates the angular transforms of the virtual images in a plurality of colors, and the common entrance angle substantially equals the common exit angle for limiting chromatic aberrations of the virtual images.

15. A compound waveguide system for a near-eye virtual image display comprising

a plurality of at least three parallel waveguides arranged in a stack, each having a front surface and a back surface, a thickness between the front and back surfaces, an entrance end and an exit end joining the front and back surfaces, and a length extending between the entrance and exit ends,

an optical medium between adjacent pairings of the parallel waveguides within the stack for at least partially optically isolating the waveguides from one another for separately propagating different angular ranges of angularly related beamlets along the lengths of the parallel waveguides,

a prismatic input coupling arranged for injecting the different angular ranges of the angularly related beamlets into different ones of the parallel waveguides and including at least partially reflective surfaces at the entrance ends of the parallel waveguides that are oriented through a common entrance angle and located in a common plane that is inclined to the front and back surfaces of the waveguides, and

a prismatic output coupling arranged for ejecting the different angular ranges of the angularly related beamlets from the different plane parallel waveguides, including at least partially reflective surfaces at the exit ends of the parallel waveguides that are oriented through a common exit angle and located in a common plane that is inclined to the front and back surfaces waveguides.

16. The waveguide system of claim 15 in which the at least partially reflective surfaces at the exit ends of the parallel waveguides are partially transmissive, and further comprising a mating prismatic waveguide extender that compensates for refractive effects associated with transmissions through the partially reflective surfaces at the exit ends of the parallel waveguides.

17. The waveguide system of claim 16 in which the prismatic waveguide extender includes front and back plane-parallel surfaces that extend substantially parallel to the front and back plane-parallel surfaces of the plurality of waveguides and a prismatic surface that mates with the prismatic surfaces at the exit ends of the waveguides.

18. The waveguide system of claim 15 in which the waveguides include front and back surfaces that extend plane-parallel to each other at a first accuracy and extend plane-parallel between adjacent waveguides at a second accuracy that is less than the first accuracy by a factor of 10 or more.

19. The waveguide system of claim 15 in which the plurality of parallel waveguides have a first index of refraction and the optical medium separating the plurality of parallel waveguides from one another has a second index of refraction that is lower than the first index of refraction for supporting internal reflections between parallel surfaces of the waveguides through a first range of grazing angles and transmissions between the waveguides through the second range of grazing angles.

20. The waveguide system of claim 19 in which the optical medium separating the plurality of parallel waveguides is an optical adhesive that binds the parallel waveguides together.

21. A method of making a compound waveguide system for a near-eye virtual image display comprising steps of

assembling a plurality of waveguides into a stack in a form that at least partially optically isolates the waveguides from one another by locating an optical medium between adjacent pairing of the waveguides, each of the waveguides having an entrance end, an exit end, and plane parallel front and back surfaces that extend between the entrance end and the exit end for propagating angularly related beamlets by reflections from the plane parallel front and back surfaces from the entrance end to the exit end of each of the waveguides,

fashioning prismatic surfaces at the entrance ends of the waveguides so that each of the entrance ends is oriented in a common direction that is inclined to the plane parallel front and back surfaces of the waveguides, and

fashioning prismatic surfaces at the exit ends of the waveguides so that each of the exit ends is oriented in a common direction that is inclined to the plane parallel front and back surfaces of the waveguides.

22. The method of claim 21 including steps of appending a mating prismatic waveguide extender to the exit ends of the waveguides and forming a partially reflective surface at an interface between the mating prismatic waveguide extender and the prismatic surfaces at the exit ends of the waveguides.

23. The method of claim 22 in which the prismatic waveguide extender includes front and back plane-parallel surfaces and a prismatic surface, and including the step of orienting the prismatic waveguide extender so that the prismatic surface of the prismatic waveguide extender mates with the prismatic surfaces at the exit ends of the waveguides and the front and back plane-parallel surfaces of the prismatic waveguide extend substantially parallel to the front and back plane-parallel surfaces of the plurality of waveguides.

24. The method of claim 22 including steps of appending a second mating prismatic waveguide extender to the entrance ends of the waveguides and forming a partially reflective surface at an interface between the second mating prismatic waveguide extender and the prismatic surfaces at the entrance ends of the waveguides.

25. The method of claim 21 in which the step of assembling the plurality of waveguides includes bonding adjacent waveguides together with an optical adhesive having a refractive index that is lower than refractive indices of the adjacent waveguides.