Systems, articles, and methods for integrating holographic optical elements with eyeglass lenses

• US 10,488,662 B2
• Filed: 09/02/2016
• Issued: 11/26/2019
• Est. Priority Date: 09/04/2015
• Status: Active Grant

• Current Assignee: Thalmic Labs Inc.
• Original Assignee: North Inc.
• Inventors: Holland, Lloyd Frederick, Bailey, Matthew
• Primary Examiner(s): Chwasz, Jade R
• Application Number:
  US15/256,148
• Publication Number:
  US 20170068095A1
• Time in Patent Office: 1,180 Days
• Field of Search: 359 14, 359 15, 359 19
• 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 curved lens for use in a wearable heads-up display, the method comprising:

providing a lens mold having a cavity wherein at least one inner face of the lens mold is curved;

recording a hologram that compensates for an optical effect of a curvature of the lens into a photopolymer film, the curvature of the lens generated by at least one of;

the dimensions and geometry of the lens when the lens is cured, and grinding away lens material, wherein the optical effect of a curvature of the lens comprises refraction caused by the curvature of the lens;

positioning the 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 2 wherein recording a hologram that compensates for an optical effect of a curvature of the lens into a photopolymer film includes recording a hologram that compensates for the curvature applied to the photopolymer film.

4. 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.

5. 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, wherein recording a hologram that compensates for an optical effect of a curvature of the lens into a photopolymer film includes recording a hologram that compensates for refraction of light due to the eyeglass prescription of the lens.

6. The method of claim 1 wherein recording a hologram that compensates for an optical effect of a curvature of the lens into a photopolymer film includes recording a hologram that compensates for an alteration of an incoming property of laser light impingent on the hologram caused by the curvature of the lens.

7. The method of claim 1 wherein recording a hologram that compensates for an optical effect of a curvature of the lens into a photopolymer film includes recording a hologram that compensates for an alteration of an outgoing property of laser light redirected by the hologram caused by the curvature of the lens.

8. The method of claim 1 wherein recording a hologram that compensates for an optical effect of a curvature of the lens into a photopolymer film includes recording a hologram that compensates for a shift in the trajectory of a projected di splay light.

9. The method of claim 8 wherein recording a hologram that compensates for a shift in the trajectory of projected display light includes recording a hologram that compensates for a shift in the trajectory of a projected display light caused by refraction of the projected display light.

10. The method of claim 1 wherein recording a hologram that compensates for an optical effect of a curvature of the lens into a photopolymer film includes recording a hologram that compensates for an optical power of the lens.

11. The method of claim 10 wherein the lens comprises a prescription lens and wherein recording a hologram that compensates for an optical effect of a curvature of the lens into a photopolymer film includes recording a hologram that compensates for a prescription optical power of the lens.

12. 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 wherein at least one inner face of the lens mold is curved;

recording a hologram that compensates for an optical effect of a curvature of the lens into a photopolymer film, the curvature of the lens generated by at least one of;

the dimensions and geometry of the lens when the lens is cured, and grinding away lens material, wherein the optical effect of a curvature of the lens comprises refraction caused by the curvature of the lens;

positioning the 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.