Augmented reality display device and manufacturing method thereof

Abstract

The present application provides an augmented reality display device and a manufacturing method thereof, which comprises a first reflective window and a second reflective window arranged relatively to each other; the second reflective window faces the first reflective window; and a corresponding reflective layer is provided, an exit window is arranged at the first end of the mirror body and surrounds the first reflective window; an incident window is parallel to the exit window, and a micro display is located at the incident window. Light emitted by the micro display is incident from the incident window to the first reflective window, reflected from the first reflective window to the second reflective window, and then emitted through the exit window to form a projected image. The folding of the light path is achieved by the first and second reflective windows, which effectively reduces the overall volume, making it more convenient to adapt to other head-mounted devices, realizing a lightweight design, and greatly improving compatibility and portability.

Description

Technical Field

[0001] The present application belongs to the field of augmented reality display technology, and more specifically, to a method for manufacturing an augmented reality display device and an augmented reality display device. Background Art

[0002] AR is the abbreviation of Augmented Reality, which is a technology that combines virtual information with the real world. The optical module is one of the core components of AR products, and is mainly responsible for the imaging of AR products. AR is different from VR. Although their optical display systems are usually composed of micro-displays and optical components, and both use a series of optical imaging components to form a distant virtual image of the pixels on the display and project it into the human eye, the difference is that AR products require see-through - both seeing the real external world and seeing virtual information.

[0003] AR devices generally include a micro display and an optical module. The micro display is used to provide display content. For the optical module, the mainstream AR display technology currently uses waveguide technology. The waveguide couples the light projected by the micro display into its own glass substrate, and transmits the light coupling like a transmission channel to the front of the eye through the principle of "total reflection", and then releases the light into the human eye through the decoupling part. Of course, there is also PRISM technology, which uses a prism to directly reflect the light from the micro display into the human eye. At the same time, external light can also enter the human eye from the outside through the prism.

[0004] The inventors of this application have discovered that existing AR devices with micro-displays and optical combiners are large in size, which is not conducive to lightweight wearing requirements, or their optical efficiency is low, which brings a poor visual experience to users. In addition, the corresponding processing technology is relatively complicated and the cost is high. Summary of the invention

[0005] The purpose of the embodiments of the present application is to provide an augmented reality display device and a manufacturing method, which can solve the problems of large size and low optical efficiency of augmented reality devices in the prior art.

[0006] To achieve the above objectives, in a first aspect, the technical solution adopted by the present application is to provide an augmented reality display device, which is applied to a head-mounted device that can be worn by a wearer, comprising:

[0007] A first reflective window is provided with a first reflective layer and is configured to allow reflection of light;

[0008] A second reflecting window, located at an opposite end of the first reflecting window, the second reflecting window is provided with a second reflecting layer, and is configured to receive light reflected from the first reflecting window;

[0009] An incident window, surrounded by the second reflecting window and coaxially arranged with the first reflecting window;

[0010] An exit window is arranged around the first reflection window, and the size of the exit window is the same as the size of the second reflection window;

[0011] an annular side wall, one end of which is connected to the second reflection window, and the other end of which is connected to the exit window; and

[0012] The micro display is located at the incident window. The light emitted by the micro display is incident from the incident window to the first reflection window, reflected from the first reflection window to the second reflection window, and then emitted through the exit window to form a projected image.

[0013] To achieve the above objectives, in a second aspect, the present application provides a method for manufacturing an augmented reality display device, comprising:

[0014] Providing a mirror body to be processed, comprising a first surface and a second surface;

[0015] Performing a cutting process on the first surface of the mirror body to form a first structural surface;

[0016] Wherein, the first structural surface includes an exit window and a first reflection window, and the exit window surrounds the first reflection window;

[0017] The second surface of the mirror body is subjected to cutting processing to form a second structural surface; wherein the second structural surface includes an incident window and a second reflecting window, and the second reflecting window surrounds the incident window;

[0018] providing a reflective layer on the first reflective window and the second reflective window;

[0019] The microdisplay is mounted on the incident window. The light emitted by the microdisplay is incident on the first reflection window from the incident window, reflected by the first reflection window to the second reflection window, and then emitted through the exit window to form a projected image.

[0020] The mirror body is cut along the edge of the exit window and / or the second reflection window to form an annular side wall;

[0021] The cut annular side wall is encapsulated to expose the exit window.

[0022] The beneficial effects provided by the present application are that a first reflective window and a second reflective window are respectively arranged on the optical mirror body at the first end and the second end which are relatively arranged; the second reflective window faces the first reflective window; and a corresponding reflective layer is provided, the exit window is arranged at the first end of the mirror body and surrounds the first reflective window; the incident window is parallel to the exit window, the micro display is located at the incident window, the light emitted by the micro display is incident from the incident window to the first reflective window, is reflected from the first reflective window to the second reflective window, and then is emitted through the exit window to form a projected image, the light path folding achieved by the first and second reflective windows effectively reduces the overall volume, and realizes a lightweight and miniaturized design, which is more convenient to adapt to other head-mounted devices, and the compatibility and portability are greatly improved.

[0023] Other aspects and advantages of the embodiments of the present disclosure will be set forth in part in the following description, or may be learned from the description, or may be learned through practice of the embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0025] Figure 1 A schematic diagram of the structure of an embodiment of an augmented reality display device provided in an embodiment of the present application;

[0026] Figure 2 A schematic diagram of the structure of an embodiment of an augmented reality display device provided in an embodiment of the present application;

[0027] Figure 3 The augmented reality display device provided in the embodiment of the present application corresponds to Figure 2 Schematic diagram of the local enlarged structure in;

[0028] Figure 4 A schematic diagram of the structure of another embodiment of the augmented reality display device provided in the embodiment of the present application;

[0029] Figure 5-12 A schematic flow chart of a method for manufacturing an augmented reality display device provided in an embodiment of the present application;

[0030] Fig.13 A schematic structural diagram of another embodiment of the augmented reality display device provided in an embodiment of the present application. DETAILED DESCRIPTION

[0031] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present application more clearly understood, the present application is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and are not used to limit the present application.

[0032] It should be noted that when an element is referred to as being "fixed to" or "disposed on" another element, it can be directly on the other element or indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or indirectly connected to the other element.

[0033] It should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0034] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of this application, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0035] The augmented reality display device provided in the embodiment of the present application is now described.

[0036] See also Figure 1-4 The present application provides an augmented reality display device 100, which is applied to a head-mounted device that can be worn by a wearer, and includes a first reflective window 1212, a second reflective window 1312, an incident window 1311, an exit window 1211, an annular side wall 1313 and a micro display 20.

[0037] The first reflection window 1212 is provided with a first reflection layer and is configured to allow light to be reflected; the second reflection window 1312 is located at the opposite end of the first reflection window 1212, the second reflection window 1312 is provided with a second reflection layer, and is configured to receive light reflected from the first reflection window 1212; the first reflection layer and the second reflection layer can be made of reflective materials such as metal or metal alloy, such as aluminum, silver or a mixture of aluminum and silver, etc.; the incident window 1311 is surrounded by the second reflection window 1312 and is coaxially arranged with the first reflection window 1212 ; an exit window 1211, arranged around the first reflection window 1212, the size of the exit window 1211 is the same as the size of the second reflection window 1312; an annular side wall 1313, one end of which is connected to the second reflection window 1312, and the other end of which is connected to the exit window 1211; and a micro display 20, located at the incident window 1311, the light emitted by the micro display 20 is incident on the first reflection window 1212 from the incident window 1311, reflected from the first reflection window 1212 to the second reflection window 1312, and then emitted through the exit window 1211 to form a projected image. The projected image can enter the pupil of the wearer's glasses and be projected on the retina, and the projected image can directly enter the retina in a desired direction.

[0038] It can be understood that the first reflection window 1212 can be any one of an inclined surface, a spherical surface, an aspherical surface or a free-form surface; wherein the first reflection window 1212 and the exit window 1211 can be arranged non-coplanarly, and in the plane where the exit window 1211 is located, the first reflection window 1212 can be arranged lower than the exit window 1211, and the second reflection window 1312 can be any one of an inclined surface, a spherical surface, an aspherical surface or a free-form surface, and the second reflection window 1312 and the incident window 1311 are arranged non-coplanarly; in the plane where the incident window 1311 is located, the second reflection window 1312 can be arranged lower or partially lower than the incident window 1311, wherein the first reflection window 1212 and the second reflection window 1312 can be formed by injection molding, turning or photolithography. Figure 2-4 It is only a cross-sectional reference schematic diagram, so the first reflective window 1212 in the figure is arc-shaped, and the second reflective window 1312 can be an aspherical inclined plane, or of course, an arc-shaped. Optionally, the size of the micro display 20 can be less than or equal to the size of the first reflective window 1212 to ensure that all the light of the micro display 20 can reach the first reflective window 1212 for reflection.

[0039] Among them, the micro display 20 can be a light-emitting pixel array, and in some embodiments, the pixel-to-pixel pitch of the micro display does not exceed 4 microns. The micro display 20 can be, for example, Micro-LED (Micro Light-Emitting Diode), uLED (Micro Light Emitting Diode), Micro-oled (Micro Organic Light-Emitting Diode), LCoS (Liquid Crystal On Silicon), LCD (Liquid Crystal Display), DMD (Digital Micromirror Device) / DLP (Digital Light Processing) or LBS (Laser Beam Scanning), etc., or any combination of these technologies. The micro display 6 can provide an image source, such as text, video, information prompts, etc.

[0040] After entering from the incident window, the light L is first reflected by the first reflection window to the second reflection window and then emitted from the exit window. In this folded light path, the light transmission can be unaffected. The folding of the light path by the primary and secondary reflection mirrors effectively reduces the overall volume. At the same time, this tiny volume can be assembled on other devices without causing too much impact on other devices (such as the appearance or structure of the device before the major change, etc.).

[0041] In some embodiments, the microdisplay 20 has a resolution of no less than 2 arc minutes per pixel of the wearer's field of view; the field of view angle here can be a horizontal field of view angle. When the wearer's eyes look toward the augmented reality display device 100, the degree of its field of view angle ensures that the wearer can clearly see the content of the projected image. Of course, the above-mentioned augmented reality display device 100 used in the head-mounted device can also be appropriately moved as a whole or the light output direction can be adjusted within the human eye's field of view to adapt to the wearing needs of different users. Optionally, the display device 100 can be set on the lens or frame of a head-mounted device (such as glasses), and of course it can also include some eye tracking sensors to track and determine the direction of the eyes.

[0042] In some embodiments, the magnification of the projected image is not less than 2.5, for example, the image source is magnified to 3, 4 or 10 times before reaching the retina, ensuring that the content of the projected image is clearly seen, which can be measured from the projected image of the microdisplay 20 to the retina of the wearer. The projected image of the microdisplay 20 covers at least 8° of the wearer's field of view, such as 8°, 15°, 20°, etc.; it does not occupy the field of view of about 60° of the entire human eye, ensuring that the wearer can see both the projected image and the image of the real situation.

[0043] In some embodiments, the area enclosed by the first reflective window 1212, the second reflective window 1312, the incident window 1311, the exit window 1211 and the annular side wall 1313 is a solid light-transmitting medium, such as transparent PMMA (polymethyl methacrylate), PC (polycarbonate) plastic, resin glass and other media. The first reflective layer is located on the side of the first reflective window 1212 away from the solid light-transmitting medium, and the second reflective layer is located on the side of the second reflective window 1312 away from the solid light-transmitting medium. The solid light-transmitting medium includes any one of polymethyl methacrylate, polycarbonate, plastic and resin. It can be understood that the first reflective window 1212 can be formed by being recessed relative to a solid transparent substrate. For example, the shapes of the first reflective window 1212 and the second reflective window 1312 can be formed by cutting, injection molding and other processes, and then the reflective material can be directly set on the surface by coating or plating processes, for example Figure 1 In the figure, the first reflective window 1212 is a solid concave setting, and the reflective material is arranged toward the plane of the exit window 1211, wherein the solid uniform light-transmitting or transparent medium can ensure that the light L propagates (reflects) in the uniform same medium without refraction or dispersion, etc., and can also ensure that the entire optical component 10 is more solid.

[0044] In some embodiments, the first reflective window 1212, the exit window 1211, the second reflective window 1312 and the annular sidewall 1313 are solid, the area enclosed by the first reflective window 1212, the second reflective window 1312, the incident window 1311, the exit window 1211 and the annular sidewall 1313 is a hollow area, the first reflective layer is located on the side of the first reflective window 1212 facing the hollow area, the second reflective layer is located on the side of the second reflective window 1312 facing or away from the hollow area, the first reflective window 1212, the second reflective window 1312, the incident window 1311, the exit window 1211 and the annular sidewall 1313 are solid, and include any one of polymethyl methacrylate, polycarbonate, plastic, and resin. It can be understood that the whole body consisting of the solid first reflective window 1212 and the exit window 1211 can be formed by injection molding or turning, and then the reflective material can be set on the surface of the first reflective window 1212 by coating or plating, and then a similar process is used to form the whole body consisting of the solid second reflective window 1312 side wall 1313, and then the reflective material can be set on the front or rear side of the second reflective window 1312 by coating or plating, and finally the two whole bodies of the reflective material are fixed, such as adhesively connected, to form a hollow optical component. The first reflective window 1212 can be located in the hollow area, and the reflective material is also facing the hollow area (i.e. facing the incident window); wherein, the hollow setting can reduce the weight of the whole, further facilitate its assembly to other wearable devices, and of course, can also reduce production materials and costs.

[0045] In some embodiments, in conjunction with Figure 2-4 The augmented reality display device further includes an intermediate layer 22, which is located between the micro display 20 and the incident window 1311. The intermediate layer 22 can be air or optical glue, etc. The thickness of the intermediate layer 22 is less than the distance from the incident window 1311 to the first reflective window 1212. When the intermediate layer 22 is air, the micro display 20 and the incident window 1311 can be fixed by a packaging member. When the intermediate layer 22 is optical glue, the micro display 20 can be directly fixed to the incident window 1311 by optical glue. Of course, if the micro display 20 and the incident window 1311 are pressed tightly enough, the intermediate layer 22 may not exist.

[0046] In some embodiments, in conjunction with Figure 2-4 The microdisplay 20 further includes a back plate 21, which is located on the side of the microdisplay 20 away from the incident window 1311 and is electrically connected to the microdisplay 20. The back plate 21 is used to connect a driving power source. The back plate 21 can be a driving board such as a circuit board, which can be rigid or flexible. The back plate 21 is used to connect a driving power source to provide electrical drive for the microdisplay 20. The back plate 21 can be greater than or equal to the microdisplay 20 (such as a light-emitting device). Optionally, the back plate 21 can also be a part of the microdisplay 20.

[0047] In some embodiments, in conjunction with Figure 2-4 The augmented reality display device further includes an encapsulation layer 30, which includes an opaque material. The encapsulation layer 30 may be a black or other opaque material, such as a coating or material such as black epoxy resin, black silicone rubber, carbon black, nickel black, black chrome or Vanta black. The encapsulation layer 30 wraps the annular side wall 1313. In some embodiments, the encapsulation layer 30 also fills the gap between the second reflective window 1312 and the back plate 21, such as when it is black epoxy resin or black silicone rubber, the gap can be filled, allowing at least part of the exit window 1211 and the back plate 21 to leak out relative to the encapsulation layer 30, such as ensuring that the wires of the back plate 21 leak out. The encapsulation layer 30 is configured to fix the second reflective window 1312, the micro display 20 and the back plate 21. The encapsulation layer 30 can realize the overall pre-positioning and encapsulation of the optical component 10, the micro display 20 and the back plate 21, and reduce the probability of positional displacement of each component.

[0048] In some embodiments, along the direction perpendicular to the sidewall 1313, the thickness of the encapsulation layer 30 on the annular sidewall 1313 is less than the thickness of the encapsulation layer 30 on the microdisplay 20. Since the second reflective window 1312 and the microdisplay 20 are not in the same plane, it is necessary to fill more material between the microdisplay 20 and the second reflective window 1312 to ensure that the final package forms a complete column, such as a cylinder, a prism, etc.

[0049] In some embodiments, the augmented reality display device further includes an encapsulation layer 30, which includes an opaque sleeve, which may be black rubber or plastic, etc. The annular side wall 1313, the second reflective window 1312, the micro display 20 and the back plate 21 are located in the sleeve, and the leads of the back plate 21, the first reflective window 1212, and the exit window 1211 are exposed relative to the sleeve. It can be understood that a through hole may be provided at the bottom of the sleeve, so that the leads of the back plate 21 are conveniently passed through the through hole to be electrically connected to the micro display 20.

[0050] In some embodiments, Figure 4 The augmented reality display device further includes a light-transmitting protective layer 40, which is covered on the first reflective window 1212, the exit window 1211 and / or the encapsulation layer 30, and the size of the light-transmitting protective layer 40 is equal to the size of the exit window 1211. The light-transmitting protective layer 40 can be fixed by means such as gluing, and the light-transmitting protective layer 40 can be made of a light-transmitting material, which can not change the propagation path of the original light, and can protect the exit window 1211 and the first reflector 1212, reduce the wear on them, and also reduce the entry of dust and other debris to affect their optical efficiency.

[0051] In some embodiments, the lateral dimension of the exit window 1211 is equal to the lateral dimension of the second reflective window 1312, that is, to ensure that the entire augmented reality display device can be cylindrical or prismatic, etc., and the overall size of the first reflective window 1212, the second reflective window 1312, the incident window 1311, the exit window 1211, the annular side wall 1313, the microdisplay 20 and the light-transmitting protective layer 40 can be between 0.5 cubic millimeters and 5 cubic centimeters, for example, 0.5 cubic millimeters, 1 cubic millimeter, 8 cubic millimeters, 1 cubic centimeter, 2 cubic centimeters, 5 cubic centimeters, etc., which is relatively small to the naked eye, and is relatively easy to integrate into various other devices without affecting the appearance or large-area structure of the original device, such as glasses or other head-mounted devices, etc., and has a good adaptation space.

[0052] Corresponding to the augmented reality display device, an embodiment of the present application further provides a method for manufacturing the augmented reality display device, comprising:

[0053] Providing a mirror body 10 to be processed, comprising a first surface 12 and a second surface 13;

[0054] like Figure 5 The mirror body 10 can be a transparent or light-transmitting hard machinable material, such as PMMA (polymethyl methacrylate), PC (polycarbonate) plastic, resin, etc. The mirror body 10 can be a regular shape such as a cylinder, a prism or a truncated cone, and of course, it can also be an irregular shape, as long as it is convenient for positioning and processing. The mirror body 10 can include any one of polymethyl methacrylate, polycarbonate, plastic, and resin, and the first surface 12 and the second surface 13 can be two opposite surfaces.

[0055] The first surface 12 of the mirror body 10 is cut to form a first structured surface 121; wherein the first structured surface 121 includes an exit window 1211 and a first reflection window 1212, and the exit window 1211 surrounds the first reflection window 1212;

[0056] Understandable, see Figure 6The mirror body 10 to be processed can be installed on the positioning piece 11. The positioning piece can be a tooling fixture, a jig or other fixing parts to achieve positioning or fixing of the mirror body 10. Of course, a groove + plate positioning or fixing method can also be used. The first surface 12 of the mirror body 10 to be processed is cut to form a first structural surface 121. The first structural surface 121 can be a recessed area formed by cutting off excess material from the center of the mirror body 10; the positioning piece 11 can be positioned or clamped or fixed on other surfaces other than the first surface 12, such as the surface opposite to the first surface 12 and / or its side surface. Specifically, the formed first structural surface 121 may include an exit window 1211 and a first reflection window 1212, the first reflection window 1212 is located at the center of the exit window 1211, the exit window 1211 surrounds the first reflection window 1212, the exit window 1211 may be horizontal, the first reflection window 1212 may be spherical or aspherical, and the curved surface of the first reflection window 1212 is curved in a direction away from the first surface 12. Taking the flat first surface 12 of the cylindrical mirror body 10 as an example, the distance from the exit window 1211 to the plane where the first surface 12 is located is less than the distance from the first reflection window 1212 to the plane where the first surface 12 is located, so that Figure 5 In the example, it is protruding in the direction of the first positioned positioning member 11 (i.e.). During cutting, a groove with uniform height can be cut out first (this process can always use fixed position cutting) to form a flat exit window 1211, and then a spherical or aspherical groove can be further cut out at the center of the exit window 1211 (this process can adjust the relative distance between the cutting tools or use a customized cutter head, etc.) to form the first reflection window 1212.

[0057] In some implementations, during cutting, it is also possible to Figure 4 The mirror body 10 to be processed is cut to form a concave spherical or aspherical first reflection window 1212. At this time, the outer periphery of the first reflection window 1212 is the exit window 1211, that is, the exit window 1211 does not need to be cut concave relative to the first surface 12, and the first surface 12 can be directly used as the exit window 1211.

[0058] The second surface 13 of the mirror body 10 is cut to form a second structured surface 131; wherein the second structured surface 131 includes an incident window 1311 and a second reflective window 1312, and the second reflective window 1312 surrounds the incident window 1311;

[0059] like Figure 7As shown, the mirror body 10 to be processed is installed on the positioning member 11, and the second surface 13 of the mirror body 10 to be processed is cut to form a second structural surface 131. The second structural surface 131 can be a central convex surface formed by cutting off the excess part of the periphery of the mirror body 10, wherein the first surface 12 and the second surface can be two surfaces arranged opposite to each other. It can be understood that the position where the first surface 12 is cut and removed is the center, and the position where the second surface 13 is cut and removed is the corresponding periphery. In addition, the projection area of ​​the cut second structural surface 131 on the first structural surface 121 can be less than or equal to the area of ​​the first structural surface 121. In this step, the mirror body 10 can be installed in the positioning member 11 at a different position from that of the positioning member 11 when cutting the first structural surface. It can be understood that the positioning, clamping or fixing of the mirror body 10 to be processed can be other surfaces other than the second surface 13, such as the first surface 12. That is, after the first surface 12 is cut and the first structural surface 121 is formed, the mirror body 10 can be turned over to process the other surface. Of course, it is also acceptable if it can be ensured that it is always clamped on the side of the mirror body without affecting the cutting of the two opposite surfaces. Figure 6 For illustration, the dotted line may be the cut portion while the solid line portion within the dotted frame is retained.

[0060] Provide a reflective layer on the first reflective window 1212 and the second reflective window 1312;

[0061] The metal or metal alloy reflective layer can be provided by mask coating, sputtering coating or ion coating.

[0062] The micro display 20 is mounted on the incident window 1311. The light emitted by the micro display 20 is incident on the first reflection window 1212 from the incident window 1311, reflected by the first reflection window 1212 to the second reflection window 1312, and then emitted through the exit window 1211 to form a projected image.

[0063] The mirror body 10 is cut along the edge of the exit window 1211 and / or the second reflection window 1312 to form an annular side wall 1313, and the size of the cut exit window 1211 is the same as the size of the second reflection window 1312;

[0064] The cut annular side wall 1313 is packaged to expose the exit window 1211 .

[0065] It can be understood that, in the above steps, each step is not strictly performed in the above order, the assembly of the micro display 20 can be performed after packaging, or after cutting, and the cutting process of the second surface 13 of the mirror body 10 can be performed before the cutting process of the first surface 12 of the mirror body 10.

[0066] In some embodiments, the first surface 12 of the mirror body 10 is subjected to a cutting process to form the first structural surface 121, further comprising:

[0067] Providing a positioning member 11 to fix the second surface 13;

[0068] The center of the first surface 12 is cut to form an exit window 1211 lower than the first surface 12 , and the center of the exit window 1211 is cut to form a first reflection window 1212 lower than the exit window 1211 . The first reflection window 1212 includes a spherical surface, an aspherical surface or a free-form surface.

[0069] It can be understood that, when the first surface 12 of the mirror body 10 to be processed is cut to form the first structural surface 121 including the exit window 1211 and the first reflection window 1212, the exit window 1211 and the first reflection window 1212 can be recessed relative to the first surface 12. At this time, when the second surface 13 is cut, the positioning or fixing member (such as a clamp) is clamped when the first surface 12 is clamped (such as Figure 6 On the other hand, if the recessed exit window 1211 is cut first and then the first reflection window 1212 is further recessed and cut, the center positioning of the first reflection window 1212 can be more convenient, the accuracy of the cutting alignment of the first reflection window 1212 can be improved, and the deviations such as inaccurate positioning caused by cutting can be reduced.

[0070] In some embodiments, the second surface 13 of the mirror body 10 is subjected to a cutting process to form the second structural surface 131, which includes:

[0071] The positioning member 11 is provided to fix the first surface 12, and there is a gap between the surface of the positioning member 11 and the first reflection window 1212; that is, the positioning member 11 does not directly contact the first reflection window 1212 and the first reflection window 1212. Ensure that the positioning member 11 does not contaminate or damage the exit window and the first reflection mirror when contacting the surface.

[0072] The periphery of the second surface 13 is cut to form an incident window 1312, a second reflective window 1312 and at least a portion of a side wall 1313, wherein at least a portion of the side wall 1313 is perpendicular to the second surface 13, the incident window 1312 is parallel to the exit window 1211, the second reflective window 1312 is lower than the incident window 1311, and the second reflective window 1312 includes one of an inclined surface, a spherical surface, an aspherical surface or a free-form surface.

[0073] It can be understood that the position when the second surface 13 is cut is just complementary to the position when the first surface 12 is cut. When the outer periphery of the second surface 13 is cut to retain the central area, the second structural surface 13 formed by cutting is finally relatively convex (for example, a convex cylindrical or prism-shaped, etc.), specifically including a side wall 1313, an incident window 1311 and a second reflecting window 1312, wherein the incident window 1311 formed is parallel to the exit window 1212, and the second reflecting window 1312 is arranged around the incident window 1311; the maximum lateral dimension of the incident window 1311 is smaller than the maximum dimension surrounded by the side wall 1313, the incident window 1311 and the side wall 1313 are arranged at intervals, and the second reflecting window 1312 is formed between the side wall 1313 and the incident window 1311; Figure 6 For example, the second reflection window 1312 can be set with respect to the inclined surface of the incident window 1311. In this case, the outer contours of the incident window 1311 and the second reflection window 1312 can be an inverted trapezoid. Of course, the second reflection window 1312 can also be designed as an arc or curved surface, and its curved surface is oriented in the same direction as the first reflection window 1212. Of course, the curvatures of the two can be different, as long as it can satisfy the requirement of further reflecting the light reflected from the first reflection window 1212 (the reflection window with a metal reflection layer) to the exit window 1211; the side wall 1313 can be perpendicular to the exit window 1211. In addition, when cutting, the maximum lateral dimension D1 of the cut exit window 1211 needs to be greater than or equal to the maximum lateral dimension D2 of the side wall 1313, so as to ensure that the mathematical parameters between the incident window 1311, the second reflection window 1312 and the exit window 1211 can be matched in the subsequent cutting steps, thereby reducing the related production processes. During the cutting process, for example, a cylinder or a polyhedral prism can be cut first, and then the excess part can be cut off to form a protruding column according to the size of the incident window 1311 and the inclination or curvature of the second reflection window 1312. After cutting, the second surface 13 may be completely removed or only the outer part may be retained (such as the position part that is convenient for clamping by the clamp).

[0074] In some embodiments, the projected image of the microdisplay 20 covers at least an 8° field of view of the wearer; the magnification of the projected image is not less than 2.5, the microdisplay has a resolution of not less than 2 arc minutes per pixel of the wearer's field of view; the pixel-to-pixel spacing of the microdisplay does not exceed 4 microns. The description of these parameters can be found in the embodiments of the corresponding device, and will not be repeated here.

[0075] In some embodiments, providing a reflective layer on the first reflective window 1212 and the second reflective window 1312 further includes:

[0076] A first baffle 15 is provided, wherein the first baffle 15 comprises a first shielding area and a first hollowing area, wherein the first shielding area does not allow metal particles to pass through, and the first hollowing area allows metal particles to pass through;

[0077] The first shielding area shields the incident window 1311, the first hollow area corresponds to the second reflective window 1312, and a metal reflective layer is evaporated on the second reflective window 1312 corresponding to the first hollow area;

[0078] A second baffle 16 is provided. The structure of the first baffle 15 is different from that of the second baffle 16. The first baffle 16 includes a second blocking area and a second hollow area. The second blocking area does not allow metal particles to pass through, while the second hollow area allows metal particles to pass through. Since the incident window 1311 and the first reflection window 1212 are aligned, and the exit window 1211 and the second reflection window 1312 are aligned, different first baffles 15 and second baffles 16 can be used.

[0079] The second shielding area shields the exit window 1211 , the second hollow area corresponds to the first reflective window 1212 , and a metal reflective layer is evaporated on the first reflective window 1212 corresponding to the second hollow area.

[0080] In some embodiments, installing the microdisplay 20 on the incident window 1311 further includes coating an adhesive on the surface of the microdisplay 20 and / or the incident window 1311 , and bonding the microdisplay 20 and the incident window 1311 using a positioning member.

[0081] In some embodiments, cutting the mirror body 10 along the edge of the exit window 1211 and / or the second reflective window 1312 also includes: using laser cutting to produce a cylindrical mirror body 10 with a complete side wall 1313 in the vertical direction along the edge of the exit window 1211 and / or the second reflective window 1312.

[0082] In some embodiments, encapsulating the cut mirror body 10 to expose the exit window 1211 further includes encapsulating the circumference of the side wall 1313 and the circumference of the micro display 20 with a light-proof encapsulation layer 30 to expose the exit window 1211, and fixing the second reflective window 1312, the micro display 20 and the back plate 21 with the encapsulation layer 30. Optionally, the light-proof encapsulation layer 30 includes black epoxy resin, black silicone rubber, or the light-proof encapsulation layer 30 includes a cylindrical light-proof sealing sleeve.

[0083] In some embodiments, the manufacturing method further includes: providing a light-transmitting protective layer 40 ; covering the light-transmitting protective layer 40 on the exit window 1211 , the first reflective window 1212 and / or the encapsulation layer 30 , and the size of the light-transmitting protective layer 40 is equal to the size of the exit window 1211 .

[0084] like Figure 8 As shown, the second reflection window 1312 is subjected to coating treatment to form a second reflection layer 13121. Specifically, the mirror body 10 having the first reflection window 1212 and the second reflection window 1312 after cutting can be placed in a coating positioning member or a fixing member, etc. Figure 7In the example, the second reflective window 1312 of the second structural surface 131 is first coated. Since the mirror body 10 with the side wall 1313, the incident window 1311 and the second reflective window 1312 has been cut out in the previous step, directly coating at this time can reduce the replacement of the fixture and reduce the manufacturing steps. Of course, the first reflective window 1212 of the first structural surface 121 can also be coated first, and the order of the two can be adjusted according to the actual production line. In the specific coating step, after the mirror body 10 is positioned and fixed, the baffle 15 is placed at the position corresponding to the second structural surface 131. Specifically, a positioning member (such as a clamp, etc.) can be used to fix the baffle 15, wherein the baffle 15 can be a mask, such as a metal mask, etc., and of course other baffles 15 with shielding effects or materials are also feasible. It can be understood that the baffle 15 has a shielding area and a hollow area (not shown in the figure), the shielding area covers the other areas of the second structural surface 131 except the second reflection window 1312, that is, the incident window 1311 and the side wall 1313 are shielded, and the hollow area corresponds to the second reflection window 1312 to allow metal particles to pass through; a layer of metal can be evaporated on the second reflection window by a method such as evaporation to form the second reflection layer 13121, and the metal can be aluminum, silver, or a mixture of aluminum and silver, etc. Of course, other methods such as sputtering or ion plating are also feasible, and both of them should avoid the incident window 1311 and the side wall 1313 from being plated.

[0085] like Fig. 9 As shown, the first reflective window 1212 is coated to form a first reflective layer 12121. The specific coating method can be the same as the above steps, but it is still necessary to ensure that only the first reflective window 1212 is coated, and the exit window 1211 is not coated (for example, the metal mask is also used for corresponding shielding); that is, the shielding area of ​​the baffle 15 blocks the exit window 1211, and the hollow area of ​​the baffle 15 corresponds to the first reflective window 1212, allowing metal particles and the like to pass through to form a metal reflective layer.

[0086] In some embodiments, the baffle 15 may be positioned as close to the non-coated surface as possible, when coating the second reflective window 1312. Figure 8As shown, since the side wall 1313, the incident window 1311 and the second reflective window 1312 are not in the same plane, the shielding area 151 of the baffle 15 that blocks the incident window 1311 and the shielding area 152 of the baffle 15 that blocks the side wall 1313 are also not in the same plane, that is, the shielding area of ​​the baffle 15 in each area needs to be close to the corresponding shielding area, so that the metal layer can be reduced from obliquely entering the non-coated surface (side wall 1313 and incident window 1311) during coating; of course, if the coating process is more accurately controlled, a baffle (metal mask, etc.) 15 with the same plane can also be used for shielding. When coating the first reflective window 1212, vertical and horizontal baffles 15 can be included, and the vertical and horizontal baffles 15 are shielding areas. Two parallel vertical shielding areas 15 are formed as hollow areas, and their size can be just the same as the maximum horizontal size of the second reflective window 1212, so that only the first reflective window 1212 is allowed to be coated.

[0087] like Fig.10 As shown, the microdisplay 20 is mounted on the incident window 1311 of the second structural surface 131 so that the microdisplay 20 is fixed on the mirror body 10. It can be understood that an adhesive can be applied to the microdisplay 20 in advance, and then the positioning member 11 is used to clamp the microdisplay 20 and bond it to the incident window 1311. Of course, the adhesive can also be applied to the incident window 1311 first, and then the microdisplay 20 is clamped and bonded to the incident window 1311. Optionally, other methods can be used for fixed connection, such as mechanical connection, welding, etc. The size of the microdisplay 20 can be the same as that of the incident window 1311; of course, the incident window 1311 can also be appropriately larger than the microdisplay 20, as long as it is ensured that all the light of the microdisplay 20 can enter through the incident window 1311.

[0088] like Fig.11 As shown, the mirror body 10 to be processed is mounted on the fixture 11, and the mirror body 10 to be processed is cut along the edge of the exit window 1211 of the first structural surface 121. According to the maximum transverse dimension D2 of the side wall 1313 of the second structural surface 131 (combined with Figure 7 ) determine the cutting position corresponding to the exit window 1211, for example, to ensure that the side wall 1313 will not be cut too much or damaged, etc. The cutting method can be mechanical or laser cutting, etc. After cutting, a mirror body with a reflective layer and a micro display that has not yet been packaged can be obtained.

[0089] like Fig.12As shown, the optical mirror body is packaged to expose the first structural surface 121. It can be understood that the side wall of the mirror body 10 and the second reflective window 13121 are both packaged. A black or opaque sealing sleeve 18 can be used for packaging and the first structural surface 121 is kept exposed. Of course, injection molding and other processes can also be used to place the above-mentioned mirror body 10 in a mold and inject black or opaque glue to achieve packaging and keep the first structural surface 121 exposed.

[0090] Alternatively, if Fig.12 As shown, in order to further protect the exit window 1211, an optical protection layer 40 can be added on the first structural surface 121. Finally, the packaged finished product is obtained as shown in FIG. Fig.13 As shown, the finished product is the aforementioned augmented reality display device 100 .

[0091] Among them, the cutting processing in the above steps can adopt one or more processing such as turning, drilling, boring, milling, planing, broaching, grinding, honing, super finishing and polishing.

[0092] Among them, the micro display 20 includes but is not limited to Micro-LED (Micro Light-Emitting Diode), uLED (micro light-emitting diode), Micro-oled (Micro Organic Light-Emitting Diode), LCoS (Liquid Crystal On Silicon), LCD (Liquid Crystal Display), DMD (Digital Micromirror Device) / DLP (Digital Light Processing) or LBS (Laser Beam Scanning), etc., or any combination of these technologies.

[0093] The black filler or sealing sleeve layer used for encapsulation is black epoxy resin or black silicone rubber. It is understood that the thickness of the black filler or sealing sleeve layer can be as small as possible and does not allow light to escape; in some embodiments, the black filler or sealing sleeve layer can also be completed by a similar method of plating an opaque film; in other embodiments, if other devices assembled with the display device have opaque or sealing sleeve layers, etc., they can be directly combined with other devices without encapsulation.

[0094] Among them, in the step of "installing the mirror body 10 to be processed on the tooling fixture 11, cutting the mirror body 10 to be processed along the edge of the first structural surface 121, cutting out the side wall 1313, and forming an optical mirror body composed of the first structural surface 121, the second structural surface 131 and the side wall 1313", the cutting process can be carried out by laser cutting or mechanical cutting, etc.

[0095] The method for manufacturing an augmented reality display device of the present application can package and manufacture an optical module and a microdisplay, with a streamlined process flow and low cost. It can also reduce the risk of damage to optical components during the manufacturing process, and ultimately produce an augmented reality display device with a small size and high optical utilization, which has good application prospects.

[0096] The above description is only a preferred embodiment of the present application and is not intended to limit the present application. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present application should be included in the protection scope of the present application.

Claims

1. An augmented reality display device, applied to a head-mounted device that can be worn by a wearer, characterized in that: include: A first reflective window (1212) is provided with a first reflective layer and is configured to allow reflection of light; A second reflecting window (1312), located at an opposite end of the first reflecting window (1212), the second reflecting window (1312) being provided with a second reflecting layer and configured to receive light reflected from the first reflecting window (1212) and further reflect the light; An incident window (1311) is surrounded by the second reflecting window (1312) and is coaxially arranged with the first reflecting window (1212); an exit window (1211), arranged around the first reflection window (1212), the size of the exit window (1211) being the same as the size of the second reflection window (1312); an annular side wall (1313), one end of which is connected to the second reflection window (1312) and the other end of which is connected to the exit window (1211); as well as A microdisplay (20) is located at the incident window (1311), and light emitted by the microdisplay (20) is incident from the incident window (1311) to the first reflective window (1212), is reflected from the first reflective window (1212) to the second reflective window (1312), and then is emitted through the exit window (1211) to form a projected image.

2. The augmented reality display device according to claim 1, wherein: The projected image of the microdisplay (20) covers a wearer's viewing angle of at least 8°.

3. The augmented reality display device according to claim 1, wherein: The magnification of the projected image is not less than 2.

5.

4. The augmented reality display device according to claim 1, wherein: The microdisplay (20) has a resolution per pixel no less than 2 arc minutes of the wearer's field of view.

5. The augmented reality display device according to claim 1, wherein: The pixel-to-pixel pitch of the microdisplay does not exceed 5 microns.

6. The augmented reality display device according to claim 1, wherein: The first reflective window (1212) and the second reflective window (1312) include any one of an inclined surface, a spherical surface, an aspherical surface or a free-form surface; the first reflective layer and the second reflective layer include metal or metal alloy reflective materials.

7. The augmented reality display device according to claim 1, wherein: The area enclosed by the first reflecting window (1212), the second reflecting window (1312), the incident window (1311), the exit window (1211) and the annular side wall (1313) is a solid light-transmitting medium, the first reflecting layer is located on a side of the first reflecting window (1212) away from the solid light-transmitting medium, the second reflecting layer is located on a side of the second reflecting window (1312) away from the solid light-transmitting medium, and the solid light-transmitting medium comprises any one of polymethyl methacrylate, polycarbonate, plastic and resin.

8. The augmented reality display device according to claim 1, wherein: The first reflection window (1212), the exit window (1211), the second reflection window (1312) and the annular side wall (1313) are solid; the area enclosed by the first reflection window (1212), the second reflection window (1312), the incident window (1311), the exit window (1211) and the annular side wall (1313) is a hollow area; the first reflection layer is located on the side of the first reflection window (1212) facing the hollow area; the second reflection layer is located on the side of the second reflection window (1312) facing or away from the hollow area; the first reflection window (1212), the second reflection window (1312), the incident window (1311), the exit window (1211) and the annular side wall (1313) are solid and include any one of polymethyl methacrylate, polycarbonate, plastic and resin.

9. The augmented reality display device according to claim 1, wherein: The augmented reality display device further comprises an intermediate layer (22), wherein the intermediate layer (22) is arranged between the incident window (1311) and the microdisplay (20), and the thickness of the intermediate layer (22) is less than the distance from the incident window (1311) to the first reflective window (1212).

10. The augmented reality display device according to claim 9, characterized in that The microdisplay (20) further comprises a back plate (21), wherein the back plate (21) is located on a side of the microdisplay (20) away from the incident window (5) and is electrically connected to the microdisplay (20), and the back plate (21) is used to connect a driving power source.

11. The augmented reality display device according to claim 10, wherein: The augmented reality display device further comprises an encapsulation layer (30), wherein the encapsulation layer (30) comprises an opaque material, the encapsulation layer (30) wraps the annular side wall (1313), the encapsulation layer (30) also fills the gap between the second reflective window (1312), the microdisplay (20) and / or the back plate (21), and allows at least part of the exit window (1211) and the back plate (21) to leak out relative to the encapsulation layer (30), and the encapsulation layer (30) is configured to fix the second reflective window (1312), the microdisplay (20) and the back plate (21).

12. The augmented reality display device according to claim 11, characterized in that: In the direction from the microdisplay (20) to the exit window (1211), the outer contour dimensions of the encapsulation layer (30) are the same, and in the direction perpendicular to the side wall (1313), the thickness of the encapsulation layer (30) on the annular side wall (1313) is smaller than the thickness of the encapsulation layer (30) on the microdisplay (20).

13. The augmented reality display device according to claim 10, characterized in that: The augmented reality display device further comprises a packaging layer (30), the packaging layer (30) comprising a light-proof sleeve, the annular side wall (1313), the second reflective window (1312), the microdisplay (20) and the back plate (21) being located within the sleeve, and the leads of the back plate (21) and the exit window (1211) being exposed relative to the sleeve.

14. The augmented reality display device according to claim 1, wherein: It also comprises a light-transmitting protective layer (40), the light-transmitting protective layer (40) being covered on the first reflecting window (1212), the exit window (1211) and / or the encapsulation layer (30), and the size of the light-transmitting protective layer (40) being equal to the size of the exit window (1211).

15. The augmented reality display device according to claim 14, characterized in that: The overall size of the first reflective window (1212), the second reflective window (1312), the incident window (1311), the exit window (1211), the annular side wall (1313), the microdisplay (20) and the light-transmitting protective layer (40) is between 0.5 cubic millimeters and 5 cubic centimeters.

16. A method for manufacturing an augmented reality display device, characterized in that: include: Providing a mirror body (10) to be processed, comprising a first surface (12) and a second surface (13); The first surface (12) of the mirror body (10) is subjected to a cutting process to form a first structured surface (121), wherein the first structured surface (121) comprises an exit window (1211) and a first reflection window (1212), and the exit window (1211) surrounds the first reflection window (1212); The second surface (13) of the mirror body (10) is subjected to a cutting process to form a second structured surface (131); wherein the second structured surface (131) comprises an incident window (1311) and a second reflection window (1312), the second reflection window (1312) surrounds the incident window (1311), and the incident window (1311) and the first reflection window (1212) are coaxially arranged; Providing a reflective layer on the first reflective window (1212) and the second reflective window (1312); The microdisplay (20) is mounted on the incident window (1311), and the microdisplay (20) is used to emit light, which is incident from the incident window (1311) to the first reflective window (1212), reflected from the first reflective window (1212) to the second reflective window (1312), and then emitted through the exit window (1211) to form a projected image; The mirror body (10) is cut along the edge of the exit window (1211) and / or the second reflection window (1312) to form an annular side wall (1313), wherein the size of the cut exit window (1211) is the same as the size of the second reflection window (1312); The cut annular side wall (1313) is packaged to expose the exit window (1211).

17. The method for manufacturing an augmented reality display device according to claim 16, wherein: The step of cutting the first surface (12) of the mirror body (10) to form a first structural surface (121) further comprises: Providing a positioning member (11) to fix the second surface (13); The center of the first surface (12) is cut to form the exit window (1211) lower than the first surface (12), and the center of the exit window (1211) is cut to form a first reflection window (1212) lower than the exit window (1211), wherein the first reflection window (1212) includes any one of a spherical surface, an aspherical surface or a free-form surface.

18. The method for manufacturing an augmented reality display device according to claim 16, wherein: The cutting process of the second surface (13) of the mirror body (10) to form a second structural surface (131) comprises: A positioning member (11) is provided to fix the first surface (12), and a gap exists between the surface of the positioning member (11) and the first reflective window (1212); The periphery of the second surface (13) is cut to form an incident window (1312), a second reflective window (1312) and at least a portion of a side wall (1313), wherein at least a portion of the side wall (1313) is perpendicular to the second surface (13), the incident window (1312) is parallel to the exit window (1211), the second reflective window (1312) is lower than the incident window (1311), and the second reflective window (1312) includes one of an inclined surface, a spherical surface, an aspherical surface or a free-form surface.

19. The method for manufacturing an augmented reality display device according to claim 16, wherein: The projected image of the microdisplay (20) covers at least an 8° field of view of the wearer; the magnification of the projected image is not less than 2.5, and the microdisplay has a resolution of not less than 2 arc minutes per pixel of the wearer's field of view; the pixel-to-pixel spacing of the microdisplay does not exceed 4 microns.

20. The method for manufacturing an augmented reality display device according to claim 16, wherein: The step of providing a reflective layer on the first reflective window (1212) and the second reflective window (1312) further comprises: Providing a first baffle (15), the first baffle (15) comprising a first shielding area and a first hollowing area, the first shielding area does not allow metal particles to pass through, and the first hollowing area allows metal particles to pass through; The first shielding area shields the incident window (1311), the first hollow area corresponds to the second reflective window (1312), and a metal reflective layer is evaporated on the second reflective window (1312) corresponding to the first hollow area; providing a second baffle (16), wherein the structure of the first baffle (15) is different from that of the second baffle (16), the first baffle (16) comprising a second shielding area and a second hollow area, the second shielding area does not allow metal particles to pass through, and the second hollow area allows metal particles to pass through; The second shielding area shields the exit window (1211), the second hollow area corresponds to the first reflection window (1212), and a metal reflection layer is evaporated on the first reflection window (1212) corresponding to the second hollow area.

21. The method for manufacturing an augmented reality display device according to claim 16, wherein: The step of installing the microdisplay (20) on the incident window (1311) further includes coating an adhesive on the surface of the microdisplay (20) and / or the incident window (1311), and bonding the microdisplay (20) and the incident window (1311) using a positioning member.

22. The method for manufacturing an augmented reality display device according to claim 16, wherein: The step of cutting the mirror body (10) along the edge of the exit window (1211) and / or the second reflection window (1312) further comprises: Laser cutting is used to produce a cylindrical mirror body (10) having a complete side wall (1313) in the vertical direction along the edge of the exit window (1211) and / or the second reflection window (1312).

23. The method for manufacturing an augmented reality display device according to claim 16, wherein: The step of packaging the cut mirror body (10) to expose the exit window (1211) further includes packaging the circumference of the side wall (1313) and the circumference of the microdisplay (20) with an opaque packaging layer (30) to expose the exit window (1211), and fixing the second reflective window (1312), the microdisplay (20) and the back panel (21) with the packaging layer (30).

24. The method for manufacturing an augmented reality display device according to claim 16, wherein: Also includes: Providing a light-transmitting protective layer (40); The light-transmitting protective layer (40) is covered on the exit window (1211), the first reflective window (1212) and / or the encapsulation layer (30), and the size of the light-transmitting protective layer (40) is equal to the size of the exit window (1211).

25. The method for manufacturing an augmented reality display device according to claim 23, wherein: The mirror body (10) includes any one of polymethyl methacrylate, polycarbonate, plastic, and resin, and the light-proof packaging layer (30) includes black epoxy resin, black silicone rubber, or the light-proof packaging layer (30) includes a cylindrical light-proof sealing sleeve.

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