U.S. patent application number 13/929759 was filed with the patent office on 2015-01-01 for waveguide including light turning gaps.
The applicant listed for this patent is John Grant Bennett. Invention is credited to John Grant Bennett.
Application Number | 20150003796 13/929759 |
Document ID | / |
Family ID | 51176492 |
Filed Date | 2015-01-01 |
United States Patent
Application |
20150003796 |
Kind Code |
A1 |
Bennett; John Grant |
January 1, 2015 |
WAVEGUIDE INCLUDING LIGHT TURNING GAPS
Abstract
The technology provides embodiments for a waveguide including
gaps which turn the direction of light. Each of a plurality of
planes located within a waveguide includes a group of gaps so that
each of the gapped planes partially reflects out of the waveguide
light within a first angle range and transmits down the waveguide
light received within a second angle range. In some examples, the
waveguide is formed by joining optically transparent sections, and
each group of gaps is formed in a surface of each optically
transparent section which becomes a joining surface when bonded
with an abutting all flat surface of an adjacent section. The
waveguide may be used in displays, and in particular in near-eye
displays (NED)s.
Inventors: |
Bennett; John Grant;
(Bellevue, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bennett; John Grant |
Bellevue |
WA |
US |
|
|
Family ID: |
51176492 |
Appl. No.: |
13/929759 |
Filed: |
June 27, 2013 |
Current U.S.
Class: |
385/129 ;
156/250; 216/24 |
Current CPC
Class: |
G02B 6/0065 20130101;
G02B 6/0035 20130101; G02B 6/10 20130101; G02B 2027/0178 20130101;
Y10T 156/1052 20150115; G02B 27/0172 20130101 |
Class at
Publication: |
385/129 ;
156/250; 216/24 |
International
Class: |
G02B 6/10 20060101
G02B006/10 |
Claims
1. A waveguide including gaps for turning light comprising: planar
surfaces extending a length of the waveguide including a top planar
surface; a plurality of gapped planes located within the waveguide
surrounded by the planar surfaces, each gapped plane meeting the
top planar surface tilted at a same angle; each gapped plane
includes a group of gaps occupying a fraction of an area of the
respective plane; and each of the gapped planes partially reflects
out of the waveguide light received within a first angle range and
transmits down the waveguide light received within a second angle
range.
2. The waveguide of claim 1 wherein the same angle is thirty (30)
degrees from a normal plane to the top surface.
3. The waveguide of claim 1 wherein the gaps are filled with at
least one of vacuum, air or gas.
4. The waveguide of claim 1 wherein the gaps have parallel sides
tilted at the same angle and are a quarter wavelength in
thickness.
5. The waveguide guide of claim 1 wherein each group of gaps has a
pseudo-randomized pattern.
6. A optically transparent waveguide comprising: planar surfaces
including a top planar surface and a bottom planar surface; joining
surfaces, each joining surface having flat surface areas and a
number of gaps and extending from the top planar surface to the
bottom planar surface; each joining surface is tilted at a same
angle with respect to the top planar surface; each gap of each
joining surface reflecting out of the waveguide light received by
the gap within a first angle range; and each gap of each joining
surface passing for total internal reflection down the waveguide
light received within a second angle range.
7. The waveguide of claim 6 wherein the same angle at which each
joining surface is tilted with respect to the top planar surface is
thirty (30) degrees with respect to a plane normal to the top
planar surface.
8. The optically transparent waveguide of claim 6 further
comprising: each joining surface has a percentage of surface area
occupied by the respective number of gaps, and a fraction of light
received by the respective joining surface within the first angle
range which is reflected out of the waveguide by the respective
joining surface is determined based on the percentage of surface
area occupied by the respective number of gaps.
9. The waveguide of claim 6 wherein each gap in a joining surface
is formed by a respective pit in the joining surface and an
adjacent all flat surface bonded to the flat surface areas of the
joining surface.
10. The waveguide of claim 9 wherein the adjacent all flat surface
bonded to the flat surface areas of the joining surface are vacuum
welded and each of the gaps are filled with vacuum.
11. The waveguide of claim 6 wherein each of the gaps is filled
with air.
12. The waveguide of claim 6 wherein each of the gaps is filled
with a gas.
13. The waveguide of claim 6 wherein the gaps are about a quarter
wavelength in thickness.
14. The waveguide of claim 8 wherein the percentage of the surface
area of the respective partially output reflective joining surface
occupied by the respective number of gaps is based on an inverse of
a number of joining surfaces traversed by light prior to reaching
the respective joining surface.
15. The waveguide of claim 6 further comprising the gaps of each
joining surface are positioned in a pseudo-randomized pattern, and
each joining surface has a different pseudo-randomized pattern of
gaps.
16. The waveguide of claim 6 further comprising each of the gaps
has a circular edge boundary in the surface of the joining
surface.
17. A method of making a waveguide using gaps for turning light
comprising: forming a pseudo-randomized pattern of pits in one
surface of each of a number N of optically transparent flat
sections; tilting the pitted N optically transparent flat sections
at a same angle with each of the pitted N surfaces facing in the
same direction; stacking the tilted pitted N optically transparent
flat sections into a stack with each of the pitted N surfaces
facing the in the same direction so each pitted surface abuts an
all flat surface of a respective adjacent optically transparent
flat section; bonding the stack of N sections by bonding flat
non-pitted portions of each of the pitted N surfaces to the all
flat surface of the respective adjacent optical transparent flat
section for forming a gap in each of the pits; slicing across the
stack to form a waveguide including the N bonded sections tilted at
the same angle, and polishing external planar surfaces of the
sliced waveguide for satisfying total internal reflection (TIR)
flatness criteria.
18. The method of claim 17 wherein bonding flat non-pitted portions
of each of the pitted N surfaces to the all flat surface of the
respective adjacent optical transparent flat section further
comprises vacuum welding the flat non-pitted portions of each of
the pitted N surfaces to the all flat surface of the respective
adjacent optical transparent flat section.
19. The method of claim 17 wherein forming a pseudo-randomized
pattern of pits in one surface of each of a predetermined number N
of optically transparent flat sections further comprises impressing
the randomized pattern of pits in the one surface of each of the
predetermined number N of optically transparent flat sections using
at least one of contact embossing, milling or etching.
20. The method of claim 17 wherein the waveguide is made of an
optically transparent material including at least one of plastic,
glass or quartz.
Description
BACKGROUND
[0001] Waveguides can be used in displays, in a variety of sizes,
for example for televisions to near-eye displays (NED)s. A typical
example of a near-eye display is a head mounted display (HMD). In
particular, a kind of waveguide uses internal mirrors to turn a
fraction of the light at multiple positions in the waveguide.
Multi-layer dichroic mirrors have been used. The mirrors are tuned
to be partial reflectors. However, manufacturing a waveguide which
such dichroic mirrors is difficult to manufacture due to the use of
precise multiple optical coatings to create the mirror. Dichroic
mirrors are fragile, limited in the range of angles they can
handle, and limited from use in larger sizes by mechanical
strength. Durable, quality waveguides which can be made for
consumer driven prices are desired.
SUMMARY
[0002] The technology provides embodiments for a waveguide made up
of an optically transparent material having gaps in the material at
points along the length of the waveguide which gaps turn the
direction of light. For examples, the gaps act as reflectors. The
waveguide may include a number of planes at locations along the
waveguide. Each plane includes gaps which occupy a fraction of the
area of the plane. Each gapped plane can simultaneously be a
partial reflector causing light in a first range of angles to exit
the waveguide while also being a transmitter of light in a second
range of angles down the waveguide. The light in the first range of
angles The waveguide may be used in displays. Some examples of
displays are near-eye displays (NED)s, large displays intended for
telepresence or window or heads-up displays.
[0003] The technology provides one or more embodiments of a
waveguide using gaps for turning light. An embodiment of the
waveguide using gaps for turning light comprises planar surfaces
extending a length of the waveguide including a top planar surface.
A plurality of gapped planes are located within the waveguide
surrounded by the planar surfaces, and each gapped plane meeting
the top planar surface tilted at a same angle. Each gapped plane
includes a group of gaps occupying a fraction of the area of the
plane. Each of the gapped planes partially reflects out of the
waveguide light received within a first angle range and transmits
down the waveguide light received within a second angle range.
[0004] The technology provides one or more embodiments of a method
for making a waveguide using gaps for turning light. An embodiment
of a method for making a waveguide using gaps for turning light
comprises forming a pseudo-randomized pattern of pits in one
surface of each of a number N of optically transparent flat
sections. The pattern may appear random but in practice is likely
to be carefully calculated in avoid repetitious features which
would create visible artifacts like ripples or spots of varying
brightness. The embodiment of the method further comprises tilting
the pitted N optically transparent flat sections at a same angle
with each of the pitted N surfaces facing in the same direction,
and stacking the tilted pitted N optically transparent flat
sections into a stack with each of the pitted N surfaces facing in
the same direction so each pitted surface abuts an all flat surface
of a respective adjacent optically transparent flat section. The
embodiment of the method further comprises bonding the stack of N
sections by bonding flat non-pitted portions of each of the pitted
N surfaces to the all flat surface of the respective adjacent
optical transparent flat section for forming a gap in each of the
pits, slicing across the stack to form a waveguide including the N
bonded sections tilted at the same angle; and polishing external
planar surfaces of the slice waveguide for satisfying total
internal reflection (TIR) flatness criteria.
[0005] The technology provides one or more embodiments of an
optically transparent waveguide. An embodiment of the optically
transparent waveguide comprises planar surfaces including a top
planar surface and a bottom planar surface and joining surfaces.
Each joining surface has flat surface areas and a number of gaps,
and each joining surface extends from the top planar surface to the
bottom planar surface and is tilted at a same angle with respect to
the top planar surface.
[0006] Each gap of each joining surface reflects out of the
waveguide light received by the gap within a first angle range, and
each gap of each joining surface passes for total internal
reflection down the waveguide light received within a second angle
range.
[0007] This Summary is provided to introduce a selection of
concepts in a simplified form that are further described below in
the Detailed Description. This Summary is not intended to identify
key features or essential features of the claimed subject matter,
nor is it intended to be used as an aid in determining the scope of
the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a block diagram of an embodiment of a waveguide
using gaps for turning light.
[0009] FIGS. 2A and 2B are block diagrams illustrating examples of
pit or gap patterns which vary in pattern and percentage of surface
coverage.
[0010] FIG. 3A is a flow chart of an embodiment of a method for
making a waveguide using gaps for turning light.
[0011] FIG. 3B is a flow chart of a more detailed example of a
method for making a waveguide using gaps for turning light.
[0012] FIG. 3C is a block diagram illustrating a slicing step in an
embodiment of a method for making a waveguide using gaps for
turning light.
[0013] FIG. 3D is a block diagram of a side view of a waveguide
resulting from the slicing step of FIG. 3B.
[0014] FIG. 4A is a top view of an embodiment of a near-eye display
(NED) including an embodiment of a waveguide using gaps which is
optically coupled with an image generation unit in a NED
system.
[0015] FIG. 4B is a block diagram of example hardware components
including a computer system within control circuitry of a NED
device.
DETAILED DESCRIPTION
[0016] As noted above, the technology provides embodiments for a
waveguide made up of an optically transparent material having gaps
in the material at points along the length of the waveguide which
gaps turn the direction of light. The gaps may be vacuum filled in
some examples, air filled in other examples, and gas filled in yet
other examples. Thus, the gaps act as mirrors. A group of gaps may
be surrounded by flat material in a plane, and these gapped planes
are located along the waveguide for providing different fractional
turning of light out of the waveguide at the locations. The
percentage of planar area occupied by the gaps determines the
fraction of light reflected out. Whether light is partially
reflected out of the waveguide by a gapped plane at a location or
transmitted depends on the angle at which light approaches the
gapped plane. Each of the gapped planes can simultaneously
partially reflect out of the waveguide light from a planar surface
received within a first angle range and transmit down the waveguide
light from a planar surface received within a second angle
range.
[0017] As discussed below, in some embodiments, the waveguide may
be made up of sections, e.g. optical flats, of optically
transparent material, for example an optically transparent plastic
or other typical waveguide material. Before being joined together,
one flat joining surface of each section is pitted, and the pitted
joining surface is the same joining surface for each section. The
pattern of pits and percentage of pits to flat surface area on the
joining surfaces may be varied for each optical section to allow
for different fractional turning of light along the resulting
waveguide. The sections with their pitted joining surfaces are
tilted at an angle allowing for total internal reflection for light
received in one angle range by a pitted joining surface and passing
with minimal loss light received in another angle range. The
sections are then stacked and bonded so that an all flat surface of
one section abuts a pitted joining surface. The flat surface areas
of the pitted joining surface are bond or fused with the all flat
abutting surface. The bonded abutted flat surface and each pit form
a gap. A waveguide made up of the tilted sections bonded at the
joining surfaces is sliced from the stack and polished.
[0018] This technology allows for not using optical coatings,
allowing simpler manufacture, the use of durable materials, and a
wider range of angles. The thin gaps covering a fraction of the
joining surface can act as total internal reflection (TIR) mirrors.
The TIR effect precisely covers a wider range of angles than coated
dichroic mirrors, inherently almost all the angles that the
waveguide itself can use, while controlling the surface pattern
allows fine control of the relative proportions of transmission and
reflection. Using gaps to make a mirror surface is compatible with
direct material fusion which eliminates surface discontinuity or
weakness.
[0019] FIG. 1 is a block diagram of an embodiment of a waveguide
123 using gaps for turning light. A representative portion of the
waveguide is illustrated. As indicated by the dashed lines
extending from planar surfaces 210 and 212, the waveguide continues
in both directions. Light illustrated by representative center ray
204 such as image light from an image generation unit of a display
system is coupled into waveguide 123, for example by an input
window (not shown). Light fills the waveguide, bouncing off bottom
and top sides, so there are many ray paths which could be
illustrated. Any given ray will approach some joining surfaces
sloping down, as illustrated for the ray passing thru joining
surface 202a, and some joining surfaces passing up, as illustrated
for the ray passing thru joining surface 202b. At any given time,
every joining surface has rays originating from the image which may
be arriving from the upper surface or the lower surface of the
waveguide at a variety of angles. So, every joining surface is
typically handling half of its light on paths from the top, while
at the same time half of the light is on paths reflecting from
below. For illustrative purposes, processing of one exemplary light
ray 204 is shown.
[0020] Representative waveguide sections of optically transparent
material 208a and 208b are bonded at pitted joining surface 202a,
and optically transparent material sections 208b and 208c are
bonded at pitted joining surface 202b. (Illustrations of pitted
surfaces are discussed below.) Some examples of optically
transparent material are glass, plastic and quartz. Each of the
joining surfaces 202a and 202b are in a respective plane which
meets the top planar surface and is tilted at a same angle.
Illustrated are two planar surfaces 210 and 212 which extend the
length of the waveguide and are formed by polishing the exterior
surfaces of the waveguide formed from the sections. The waveguide
would have at least two more planar surfaces which reflect light,
for example in a rectangular shaped waveguide. The number of planar
surfaces may vary in other waveguide configurations. In this
embodiment, pitted joining surface 202a reflects for exit from the
waveguide light of representative ray 204 received in a first range
of angles, while pitted joining surface 202b passes along the
waveguide light from a planar surface received in a second angle
range. These angle ranges are the result of alternate total
internal reflections from the planar surfaces of the waveguide.
[0021] In this example, the first angle range 205 is centered about
an angle .theta., which is the tilt angle formed by each pitted
joining surface with a normal plane which intersects planar
surfaces 212 and 210. A normal plane is a perpendicular plane.
Thirty (30) degrees from the normal is a preferred tilt angle as
light at that angle will be perpendicular both when emerging and
when passing through the gaps when the gaps have a quarter
wavelength thickness. The first angle range 205 for partial
reflection includes angles with an angle deviation about angle
.theta.. The angle deviation is determined in part based on the
optically transparent material used. Materials with a greater
refractive index allow a slightly wider angle deviation. For
example, glass or plastic with a refractive index of 1.7 may allow
an angle deviation of plus or minus 24 degrees about angle .theta..
(For angle .theta. of 30 degrees, the first angle range would be
about from 6 to 54 degrees.) For a glass or plastic material with a
refractive index of 1.5, the angle deviation may be plus or minus
20 degrees about angle .theta.. The second angle range 203 in which
light received from a planar surface will be passed through for
total internal reflection down the waveguide is 90 degrees relative
to the joining surface plus or minus the same angle deviation. So
the center angles in the range differ, but the size of each of the
first and second angle ranges is the same due to the same angle
deviation being used.
[0022] In this embodiment, image light within an angle range of
about 54 degrees to 60 degrees centered about angle .theta. formed
between pitted joining surface 202a and planar surface 212 is in
the first angle range 205 and will be reflected by pitted joining
surface 202a as indicated by central exit ray 206b, which is coming
out of the page. Pitted joining surface 202b passes through light
received from planar surface 210 in the second angle range centered
about 90 degrees
[0023] Before discussing patterns of gaps, on each surface, a few
properties of the gaps themselves are discussed. The sides of each
gap sharing the tilt angle with the joining surface are parallel.
For example, if the side formed by the abutting flat surface is
called a front side of the gap, the back side formed by the pitting
process is parallel with the front side. Preferably, the back side
and the front side separation is a quarter wavelength. As discussed
below, the edges or boundaries of the gap may take different
shapes.
[0024] The thickness or separation between the front side and the
back side of the gap may be a quarter wavelength in many examples
due to its anti-reflective property. A gap from glass or plastic to
air or vacuum or a gas or other gap filler turns the direction of
light, e.g. creates reflection or diffraction. Reflection is used
in this example. There is partial reflection of the light coming
into the gap and partial reflection of the light coming out of the
gap. With glass, each of those partial (Fresnel) reflections are on
the order of 5%. That would eventually add up, and cause again
stray light, unwanted light, going backwards in the wrong
direction. However, at a quarter wavelength thickness of the gap,
the entry and exit reflections cancel each other out which
suppresses the reverse reflection. Thus, a quarter wavelength
separation or thickness provides a good antireflective property.
Other wavelengths at multiples of half a wavelength from the
quarter wavelength like 3/4wavelength, and 1 and a quarter also
have this property. Because of this property, unwanted Fresnel
reflection is reduced, although some Fresnel reflection can be
tolerated.
[0025] The thin quarter wavelength gap does mean that the TIR ratio
will be less than 100% since some energy passes through the gap via
an evanescent wave. Losses from 17% to 30% may result, dependent
upon color and angle of incidence. However, the reduction is not
problematic as the gaps are being used for partial reflection.
[0026] The use of gaps at a quarter wavelength in a small fraction
of area of the joining surface is also very beneficial for
transmissive surface crossings, e.g. as illustrated at 202b. For
example, for a pitted joining surface of 90% or so being flat and
clear, and 10% of the surface 202b being pitted to include the
gaps, the pitted part of the surface transmits >95% of light due
to the antireflective quarter wave, which means less than 3% of 5%
light is reflected, <0.5%. That loss ratio is low enough to
allow many transmissive crossings.
[0027] The quarter wavelength may be set based on a bandwidth for a
color of the coupled image light. For example, the quarter
wavelength may be set for the color green, to which the eye is most
sensitive. It's also not that bad as a quarter wave cancellation
for blue and for red. Three quarter wavelength or 1 and 1/4, will
result in a more aggressive change across the spectrum; some places
it will reflect more, some places it will reflect less. The quarter
wavelength actually used may be chosen for getting a compromise
across the whole spectrum, of getting cancellation of the
reflection. For green, reflection cancellation will be near
complete because the quarter wavelength is set for it.
[0028] Thicker gaps like 3/4 and 1 and 1/4 could be used,
eliminating evanescence but increasing reverse reflections at the
transmissive pitted joining surfaces. This tradeoff might be
preferred in some devices.
[0029] If the variation in transmission by color is a problem,
fortunately, it is a gradual variation by color and by angle and so
the net result is a predictable variation over the resulting image.
This can be compensated for by use of gradation in the source
illumination and compensating multipliers of pixel intensity by an
image source providing the image light.
[0030] Each of the gapped planes like the joining surfaces along
the length of the waveguide implements partial reflection.
Otherwise, the light will not travel down the waveguide past the
first few mirrors, even when considering transmission due to the
evanescent wave. In order to travel through many gapped planes or
joining surfaces, e.g. 40 surfaces in a waveguide in a near-eye
display (NED), only a fraction of the plane of joining surface has
gaps. As discussed for embodiments below, a joining surface is
pitted to make gaps. The percentage of a joining surface like 202a
that is pitted in some examples may be roughly the inverse of the
number of joining surfaces which will partially reflect light
received within a first angle range out of the waveguide prior to
reaching a gapped plane or pitted joining surface. The entry angle
at which light for display is coupled into a waveguide is
predetermined, and the path for light of that entry angle through
the gapped planes or joining surfaces can be predetermined, so the
number of partial reflections which have occurred at each location
along the waveguide can be reliably identified from design
parameters.
[0031] Increasing the fraction of gaps to flat surface keeps the
reflection intensity near constant as light for display progresses
and reflects further along the waveguide. In some examples, the
fraction of pitted areas will change slowly until the last few
mirrors. For example, if 20 pitted joining surfaces were to be used
with ten partially reflecting at every other joining surface for
light coupled at the entry angle, then the percentage coverage by
the gaps on a first partially reflecting pitted joining surface may
be about 1/10, or 10%. The coverage ratio increases as there are
fewer remaining surfaces, so the next partially reflecting pitted
surface has 1/9 coverage, then the next such surface has 1/8 or
12.5% coverage, and so on until the last surface acting as a
partial reflector which may actually be a 100% mirror. The last
reflective surface may be pitted for 100% reflection or it may be
made of other material. For example, it may be an aluminized
mirror. In many embodiments, the overall planar area of each gapped
plane or surface area of each joining surface is about the
same.
[0032] These ratios are approximate, and actual products may use
slightly different ratios as determined by detailed numerical
simulations and actual measurements, to adjust for other factors in
the system such as evanescence and waveguide losses. For external
light passing vertically the waveguide will seem almost clear since
such light encounters only one fractional reflection. External
light which is reflected will mostly exit on a parallel path at
neighboring joining surfaces. This combination of small fraction
and parallel continuation should minimize loss or blur of external
light.
[0033] FIGS. 2A and 2B are block diagrams illustrating examples of
pit patterns which vary in pattern and percentage of surface
coverage. FIG. 2A is an example of a pseudo-randomized pit pattern
220 using pits or gaps 250 each with a circular boundary indicating
the edges of each gap. The pits or gaps occupy about 10% of the
surface area of the pitted joining surface, in this example
partially reflective pitted joining surface 202a. Just one gap is
labeled to avoid overcrowding the drawing. In FIG. 2B, the pits 252
in this pseudo-randomized pattern 240 also have circular
boundaries. About 1/5 or 20% of the surface of joining surface 202j
is pitted or gapped. Some examples of other boundary shapes of each
pit include square or annular. The edges or boundaries of the pits
are a source of diffraction, and diffraction creates stray light
which degrades the image. A circle has the lowest ratio of boundary
to area.
[0034] The pits are to be wide enough to be effective as classic
mirrors, and not be strongly diffractive. In some examples, a pit
is at least 30 microns across. For a 5% reflection ratio, this
implies there is on average one pit per 110 microns linear
separation. It may be possible to go even larger. The tradeoff in
size of pits is controlling stray light from diffraction while
avoiding visible structure.
[0035] For a display, it is desirable that the view received by a
pupil of a viewer's eye originate from several of the pits so the
eye receives a fairly uniform amount of light coming from an
apparently infinite image. In the context of a display like a
television which a user views from at least a few feet or so, the
pits or gaps can be relatively large, for example, they might be
like a millimeter or so. However, in a near-eye display where
they're about a centimeter from a viewer's eye, the pits are to be
small enough in size so that the viewer's pupil encompasses several
of these pits. As the viewer's eye moves around, the eye will pass
out of the region of a beam coming from one pit, and start picking
up the light beam from another pit. The number of pits are
determined based on making that experience fairly uniform, so that
no matter which direction the viewer is looking at, the viewer sees
an average selection of pits. Taking the pupil of the human eye to
be about 2000 microns, a pit size about 30 microns to 200 microns
across the joining surface with about 110 micron separation from
the next gap or pit on the surface will work for a near-eye
display.
[0036] Pit patterns 220 and 240 are deliberately pseudo-randomized
and deliberately made to have different pseudo-random patterns from
each other. The pattern of pits is a source of diffraction. For
example, a regular pattern creates regular diffraction which may
create things like rainbows and images at unwanted angles. Patterns
may also be designed to ensure that adjacent pitted surfaces have
minimal and pattern-free interactions with each other due to the
systematic occlusion of transmitted or reflected light from nearby
surfaces.
[0037] Some blurring of the wavefront may occur due to phase shift
in the fraction of light passing by evanescent wave, which may
impress a ripple on the wavefront which keeps the pattern of the
pit boundary shape. However, this blurring may have a worst case
effect of 0.5% of the light per reflective incident, varying by
angle and color. The image will, however, be preserved since all
pits will produce similar phase shift. Thus, a subtle change in
colors and brightness from one side of the waveguide to the other
is predicted to be created. However, humans will not notice the
changes in color and brightness unless they are at the center of
view, e.g. along the optical axis of a display. Therefore, the
change may be measured to identify its effect when looking at the
part of the waveguide in the direction of the part of the image
being computed. A correction may be applied to a source pixel which
should balance the changes for that zone. The shift occurs
gradually so the correction does not need to be exact. The
corrections can be measured in a lab and then copied into all
display systems.
[0038] FIG. 3A is a flow chart of an embodiment of a method for
making a waveguide using gaps for turning light. In step 302, a
pseudo-randomized pattern of pits is formed in one surface of each
of a number N of optically transparent flat sections. For example,
contact impression, or milling techniques may be used. Contact
impression involves pressure molding against a template. In some
embodiments, milling may be plasmaionic or electrochemical milling
where a patter is transferred by etching with an electrical ion. In
step 304, the pitted N optically transparent flat sections are
tilted at a same angle with each of the pitted N surfaces facing in
the same direction, and in step 306, the tilted pitted N optically
transparent flat sections are stacked with each of the pitted N
surfaces facing in the same direction so each pitted surface abuts
an all flat surface of a respective adjacent optically transparent
flat section. In step 308, the N sections are bonded by bonding
flat non-pitted portions of each of the pitted N surfaces to the
all flat surface of the respective adjacent optical transparent
flat section for forming a gap in each of the pits. In step 310,
the external planar surfaces of the bonded N sections are polished
for satisfying total internal reflection (TIR) flatness
criteria.
[0039] FIG. 3B is a flow chart of a more detailed example of a
method for making a waveguide using gaps for turning light. The
method embodiment may be performed in a vacuum environment for
vacuum filled gaps or in a clean, unreactive gas such as nitrogen.
Steps 322, 324 and 326 provide an example way of impressing pits
onto one side of optically transparent sections, which in this
example are optical-quality flats. FIG. 3C illustrates examples of
optical quality flats 356. Only one flat is labeled to avoid
overcrowding the drawing. For vacuum welding later, in step 320,
the optical flats are heated to achieve a temperature warm enough
to mold the pits and allow a vacuum weld of the surfaces after
stacking.
[0040] Etching, milling or contact embossing, a process well
developed for use in the manufacture of optical disks such as DVDs,
are some examples of processes which may be used to perform the
impressing. In step 322, a loop counter is initialized and a limit
of iterations set for N which is a predetermined number of optical
quality flats being impressed. In step 324, a pit pattern (i) for
the current optical quality flat (i) is set by the manufacturing
machinery to impress on the current optical flat (i). In step 326,
the set pit pattern (i) is impressed on one side of optical quality
flat (i), for example, using contact embossing. In step 328, the
loop counter iterates as per i=i+1. In step 330 designated end
loop, it is determined whether this is the last flat, optical flat
N. The loop continues until all N optical flats have been impressed
with their individually randomized patterns.
[0041] The optical flats 356 may have been produced with clean
surfaces which can be bonded. Or optionally, in step 332, the pit
imprinted surfaces of the optical quality flats may be treated with
a surfactant to activate the pitted surfaces. Throughout the
process before the cooling step, the optical flats may be
maintained at a temperature allowing for vacuum welding. In other
examples, the flats may be heated again to such temperature when
ready for the stacking step.
[0042] In step 334, the N optical flats are tilted at an angle,
preferably 30 degrees from a normal. In step 336, while the pitted
optical flats are at a temperature allowing for vacuum welding, the
tilted optical flats 356 are stacked. FIG. 3C illustrates an
example of the stacked optical flats. In step 337, the non-pitted
flat portions of each pitted joining surface is vacuum welded to an
all flat surface of an abutting optical flat in the stack. The
surfaces being vacuum welded are typically very clean. In step 338,
the stack of vacuum welded optical flats is cooled uniformly and
slowly for keeping alignment of the welded flats. Vacuum welding is
clean, transparent, strong, and durable.
[0043] In step 340, after the stack has satisfied cooling criteria
to allow for slicing, for example with saws, a predetermined number
of the stacked vacuum welded flats are horizontally sliced to be a
waveguide such as that illustrated in FIG. 3D. In step 342, the
external planar surfaces of the sliced waveguide are polished for
satisfying total internal reflection (TIR) flatness criteria for
the external surfaces. An example of such criteria is mirror
surface flatness.
[0044] FIG. 3C is a block diagram illustrating a slicing step in an
embodiment of a method for making a waveguide using gaps for
turning light. Lines 352 and 354 illustrate slice lines across the
N pitted, tilted, stacked and bonded, via vacuum welding, optical
flats 356. FIG. 3D is a block diagram of a display side view of a
waveguide from which image light is directed toward a viewer
resulting from the slicing step of FIG. 3C. In this example, each
joining surface has a same uniform overall surface area which
includes its pitted and non-pitted sections. Just one pitted
joining surface 360 is labeled to avoid overcrowding the
drawing.
[0045] A resulting waveguide may have a thickness of several
millimeters (mm) for a small display. For a near-eye display, the
waveguide may have a thickness of just a couple of millimeters in a
depth direction from the viewer's eye. However, the waveguide may
be made at different sizes. At a large size for television sized
panels that show what seems to be a distant image, a waveguide of a
centimeter to a few centimeters thickness may be used.
[0046] As illustrated in FIG. 3C, the joins would be stacked fairly
close, maybe half (1/2) the separation as compared to the waveguide
thickness. This ensures that the observer sees a smooth
contribution from multiple pitted joining surfaces. In one example,
a waveguide had 40 pitted joining surfaces.
[0047] FIG. 4A is a top view of an embodiment of a near-eye display
(NED) 14r including an embodiment of a waveguide 123 using gaps
which is optically coupled with an image generation unit 120 in a
NED device 2. A representative tilted pitted joining surface 270 is
labeled within the waveguide 123. The near-eye display is in an
eyeglasses form factor. In order to show the components of the
display optical system 14, in this case 14r for the right eye, a
portion of a top frame section covering the display 14r and the
image generation unit 120 is not depicted. Arrow 142 represents an
optical axis of the display optical system 141. Eye space 140
approximates a location of a user's eye when the device 2 is
worn.
[0048] In this embodiment, the displays 14r is an optical
see-through displays, but in other embodiments, it can be a
video-see display. The display 14r includes a waveguide 123
including gapped planes like the pitted joining surfaces 270. Just
one joining surface is labeled to avoid overcrowding the drawing.
Input window 207 receives collimated image light from the image
generation unit 120 via optically coupling collimating lens 122.
The waveguide 123 directs the received image light towards the user
eye space 140 while also allowing light from the real world to pass
through towards the user's eye space, thereby allowing the user to
have an actual direct view of the space in front of NED device 2 in
addition to seeing an image of a virtual feature from the image
generation unit 120.
[0049] In the illustrated embodiment, the image generation unit 120
is in a right side housing 130r which also supports an outward
facing camera 113r which collects image data of the scene in front
of the user. The housing 130r is also supported by a temple arm
102r of the eyeglasses. The image generation unit 120 includes one
or more LEDs, and a microdisplay which produces the image light.
Nose bridge 104 in this embodiment supports a microphone 110 and
control circuitry 136. Electrical connections (not shown) are
provided within the frame of the eyeglasses.
[0050] FIG. 5B is a block diagram of example hardware components
including a computer system within control circuitry of a NED
device. Control circuitry 136 provides various electronics that
support the other components of head mounted, near-eye display
device 2. In this example, the control circuitry 136 for the
display device 2 comprises a processing unit 210, a memory 244
accessible to the processing unit 210 for storing processor
readable instructions and data, a communication module 137
communicatively coupled to the processing unit 210 which can act as
a network interface for connecting the NED device to another
computer system. A power supply 239 provides power for the
components of the control circuitry 136 and the other components of
the display device 2 like the capture devices 113, the microphone
110, other sensor units, and for power drawing components for
displaying image data on the display 14 such as light sources and
electronic circuitry associated with an image generation unit like
a microdisplay and an illumination unit 222 in the image generation
unit 120.
[0051] The processing unit 210 may comprise one or more processors
including a central processing unit (CPU) and a graphics processing
unit (GPU). Memory 244 is representative of the various types of
memory which may be used by the system such as random access memory
(RAM) for application use during execution, buffers for sensor data
including captured image data and display data, read only memory
(ROM) or Flash for instructions and system data, and other types of
nonvolatile memory for storing other items, some examples of which
are applications for which image light representing image data is
generated. In this example, an electrical connection of a data bus
270 connects the sensor units 257, the display driver 246,
processing unit 210, memory 244, and the communication module 137.
The data bus 270 also derives power from the power supply 239
through a power bus 272 to which all the illustrated elements of
the control circuitry are connected for drawing power.
[0052] The control circuitry further comprises a display driver 246
for selecting digital control data, e.g. control bits, to represent
image data which digital control data may be decoded by
microdisplay circuitry 259 and different active component drivers
of the image generation unit 120 like an illumination unit 122. An
example of an active component driver is a display illumination
driver 247 which converts digital control data to analog signals
for driving an illumination unit 222 which includes one or more
light sources like one or more light emitting diodes (LEDs).
Corrections to be applied to source pixels such as corrections for
adjusting the color and brightness changes measured for image data
in different zones of the waveguide 123 may compensating
multipliers of pixel intensity for gradation of illumination can be
stored in memory 244 and applied by the display illumination driver
247 under control of the control circuitry 136 having access to
memory 244.
[0053] The control circuitry 136 may include other control units
not illustrated here but related to other functions of a NED device
such as providing audio output, identifying head orientation and
location information.
[0054] Although the subject matter has been described in language
specific to structural features and/or methodological acts, it is
to be understood that the subject matter defined in the appended
claims is not necessarily limited to the specific features or acts
described above. Rather, the specific features and acts described
above are disclosed as example forms of implementing the
claims.
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