Micromolded prism geometry waveguide

Abstract

A method of manufacturing a micromolded prismatic geometric waveguide includes forming a first transflective mirror element and a separate second transflective mirror element, forming a first functional coating on an active surface of the first transflective mirror element, forming a second functional coating on an active surface of the second transflective mirror element, and aligning the first transflective mirror element with the second transflective mirror element to form a microprism array.

Description

Cross-references to related applications

[0001] This application claims priority to U.S. Provisional Application No. 63 / 517,221, filed August 2, 2023, pursuant to 35 USC §119(e). Technical Field

[0002] This disclosure relates to a geometric waveguide, and more particularly to a micro-molded prism geometric waveguide. Background Technology

[0003] Virtual reality devices, virtual reality headsets, augmented reality devices, and augmented reality headsets typically include optical systems with microdisplays and imaging optics. Microdisplays are configured to provide an image to be viewed, either directly or indirectly, using, for example, a micro-OLED display or by illuminating a liquid crystal-based display. Display light can be projected to the user's eyes using a waveguide, where light is coupled into the waveguide, transmitted through the waveguide via total internal reflection (TIR), and coupled out at the position of the viewer's eyes.

[0004] In some systems, imaging optics may include geometric waveguides. Using geometric waveguides, light from an optical engine is typically coupled through a mirror or prism and then transmitted via a TIR to a transflective surface array configured to reflect a portion of the light toward the user's eye and transmit the remainder for further propagation. The transmitted light may then encounter another transflective surface, where the reflection and transmission paradigm is repeated.

[0005] Various challenges are associated with the fabrication of geometric waveguides, including the coating and alignment of reflective mirrors. For example, since the intensity of light incident on multiple successive mirrors can decrease after each reflection and transmission event, the reflection / transmission ratio may need to be designed differently for each mirror within a microprism array to ensure uniform light output. Furthermore, the use of polarized light, such as with liquid crystal on silicon (LCoS) microdisplays, may require complex coating structures involving multiple layers requiring multiple masking and deposition steps.

[0006] This disclosure is intended to address at least in part any or all of the aforementioned disadvantages and deficiencies. Summary of the Invention

[0007] According to a first aspect of this disclosure, a method is provided, the method comprising: forming a first transflector element and a separate second transflector element; forming a first functional coating on an active surface of the first transflector element; forming a second functional coating on an active surface of the second transflector element; and aligning the first transflector element and the second transflector element to form a microprism array.

[0008] In some embodiments, forming the first and second mirror elements may include molding optical polymers.

[0009] In some embodiments, the refractive index of the first mirror element may be substantially equal to the refractive index of the second mirror element.

[0010] In some embodiments, forming the first mirror element may include molding a first optical polymer, and forming the second mirror element may include molding a second optical polymer.

[0011] In some embodiments, forming the first functional coating and the second functional coating may include evaporation deposition.

[0012] In some embodiments, forming the first functional coating may include evaporation deposition in a first deposition process, and forming the second functional coating may include evaporation deposition in a second deposition process.

[0013] In some embodiments, the thickness of the first functional coating may be different from the thickness of the second functional coating.

[0014] In some embodiments, the tilt angle of the active surface of the first reflective mirror element may be different from the tilt angle of the active surface of the second reflective mirror element.

[0015] In some embodiments, the first and second mirror elements can be aligned using a matching coupling feature.

[0016] In some embodiments, the first mirror element may include a female coupling feature, the second mirror element may include a male coupling feature, and the first mirror element and the second mirror element may be aligned by engaging the female coupling feature with the male coupling feature.

[0017] In some embodiments, the first functional coating may include a reflective polarizer having a first polarization response, and the second functional coating may include a reflective polarizer having a second polarization response different from the first polarization response.

[0018] In some embodiments, according to a second aspect of the present disclosure, a geometric waveguide is provided, the geometric waveguide comprising: an extension region including an array of independently configured first transflector elements; and a coupling region including an array of independently configured second transflector elements.

[0019] In some embodiments, each first transflector element may include an active surface, and each active surface of the first transflector element may include an optical coating.

[0020] In some embodiments, the thickness of these optical coatings can be different among these first mirror elements.

[0021] In some embodiments, the tilt angle of the active surface of these first mirror elements can be different.

[0022] In some embodiments, each of the second transflector elements may include an active surface, and each of the active surfaces of the second transflector elements may include an optical coating.

[0023] In some embodiments, the thickness of these optical coatings can be different among these second mirror elements.

[0024] In some embodiments, the tilt angle of the active surface of these second mirror elements can be different.

[0025] According to a third aspect of this disclosure, a geometric waveguide is provided, comprising: a first array of independently configured transflector elements; and a second array of independently configured transflector elements.

[0026] In some embodiments, the first array of independently configured transflective mirror elements may include a plurality of facets, each facet having an active surface and an optical coating disposed thereon, and the second array of independently configured transflective mirror elements may include a plurality of facets, each facet having an active surface and an optical coating disposed thereon.

[0027] It should be understood that any features described herein that are suitable for incorporation into one or more aspects or embodiments of this disclosure are intended to be generalizable in any and all aspects and embodiments of this disclosure. Other aspects of this disclosure will be understood by those skilled in the art based on the specification, claims, and drawings of this disclosure. The foregoing general description and the following detailed description are merely exemplary and explanatory, and not intended to limit the scope of the claims. Attached Figure Description

[0028] The accompanying drawings illustrate several exemplary embodiments and are part of the specification. These drawings, together with the following description, illustrate and explain various principles of this disclosure.

[0029] Figure 1 An isometric view of the active portion of a geometric waveguide according to one or more embodiments of the present disclosure.

[0030] Figure 2 An optical coating is formed on the active surface of a plurality of micro-molded prisms according to one or more embodiments of the present disclosure.

[0031] Figure 3 An exploded view is shown illustrating the arrangement of individual prisms according to one or more embodiments of the present disclosure.

[0032] Figure 4 A mirror assembly comprising a plurality of micro-molded prisms is depicted according to one or more embodiments of the present disclosure.

[0033] Figure 5 This is a cross-sectional view of a micro-molded prism assembly and its co-integration with a reflective polarizer according to one or more embodiments of the present disclosure.

[0034] Figure 6 This is an illustration of exemplary augmented reality glasses that can be used in conjunction with one or more embodiments of this disclosure.

[0035] Figure 7 This is an illustration of an exemplary virtual reality head-mounted viewer that can be used in conjunction with one or more embodiments of this disclosure.

[0036] Throughout the accompanying drawings, the same reference numerals and descriptions denote similar but not necessarily identical elements. While the exemplary embodiments described herein allow for various modifications and alternatives, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, the exemplary embodiments described herein are not intended to limit one to the specific forms disclosed. Rather, this disclosure covers all modifications, equivalents, and alternatives falling within the scope of the appended claims. Detailed Implementation

[0037] Virtual reality devices, virtual reality headsets, augmented reality devices, and augmented reality headsets typically include optical systems with microdisplays and imaging optics. Microdisplays are configured to provide an image to be viewed, either directly or indirectly, using, for example, a micro-OLED display or by illuminating a liquid crystal-based display. Display light can be projected to the user's eye using a waveguide, where light is coupled into the waveguide, transmitted through the waveguide via total internal reflection (TIR), and coupled out at the location of the viewer's eye.

[0038] In some systems, imaging optics may include geometric waveguides. Using geometric waveguides, light from an optical engine is typically coupled through a mirror or prism and then transmitted via a transflector (TIR) ​​to a transflector array configured to reflect a portion of the light toward the user's eye and transmit the remainder for further propagation. The transmitted light may then encounter another transflector, where the reflection and transmission paradigm is repeated.

[0039] Various challenges are associated with the fabrication of geometric waveguides, including the coating and alignment of reflective mirrors. For example, since the intensity of light incident on multiple successive mirrors can decrease after each reflection and transmission event, the designed reflectance / transmission ratio may differ for each mirror within a microprism array to ensure uniform light output. Furthermore, the use of polarized light, such as with liquid crystal on silicon (LCoS) microdisplays, may require complex coating structures involving multiple layers requiring multiple masking and deposition steps.

[0040] Despite recent advancements, providing an economical method for fabricating geometric waveguides that minimize defects in the final virtual image, including inhomogeneities, black lines, and ghosting, remains a significant advantage. According to various embodiments, the geometric waveguide includes independently fabricated and processed active components such as extension elements and decoupling elements. By fabricating the different waveguide components independently, design specifications for each component can be addressed and met individually.

[0041] According to specific embodiments, by individually fabricating different transflector mirrors of the geometric waveguide, molding and coating operations can be customized for each mirror, and downstream assembly processes can include optimized alignment and placement, enabling mass production, lower costs, and improved performance. For example, different transflector mirrors can be molded, coated, aligned, and optically bonded to a carrier plate. Refractive index-matched optical bonding can be used to ensure acceptable transmittance for augmented reality applications.

[0042] A geometric waveguide may include two or more prism elements, each comprising an array of microprisms. According to some embodiments, the individual mirrors constituting each array can be independently molded and coated, and then assembled to form the array structure. This approach allows for localized functionality in each individual mirror and eliminates the need for complex masking and coating processes to form a microprism array with a gradient structure. According to some embodiments, precise optomechanical positioning features can be incorporated into each mirror element to ensure accurate alignment.

[0043] The mirrors can be molded from a suitable plastic material (e.g., polycarbonate), but other optical materials are also considered. In some embodiments, multiple mirrors can be formed from the same material and can have equal or substantially equal refractive indices, while the geometry of the multiple mirrors and / or the functional coatings applied to these mirrors can be configured differently for each mirror within the microprism array.

[0044] A method for manufacturing a multi-part geometric waveguide may include forming a primary transflector and separate secondary transflectors, forming a functional coating on an active surface of the primary transflector, forming a functional coating on an active surface of the secondary transflectors, and aligning and combining the primary transflector and the secondary transflectors to form a microprism array.

[0045] The following will refer to Figures 1 to 7 This provides a detailed description of the methods used to fabricate micro-molded prism geometric waveguides. Figures 1 to 5 The related discussion includes descriptions of example waveguide components and assemblies, including their respective structures and manufacturing methods. Figure 6 and Figure 7 The related discussion relates to exemplary virtual reality devices and augmented reality devices, which may include one or more micro-molded prism geometric waveguides as disclosed herein.

[0046] Figures 1 to 4 A perspective view of a micro-molded prism geometry waveguide is shown, which can include the independent design, fabrication, and integration of multiple microprisms. (Reference) Figure 1 The shape (including flatness) and function of each facet within a pair of microprism arrays can be configured independently.

[0047] The micromolded prism geometry waveguide 100 may include an input prism 110. The input prism 110 may be sized and dimensioned to guide image light into the waveguide. For example, the input prism 110 may be formed of glass or a polymer. The micromolded prism geometry waveguide 100 also includes an extension region 120 and a coupling region 130. The extension region 120 includes an array of prism elements 121, and the coupling region 130 includes an array of prism elements 131.

[0048] The extension region 120 is configured to extend the image beam entering the waveguide through the input prism 110 along a first dimension. The illustrated prism element 121 can be formed by molding, and each prism element may include an active surface 122 and a draft (i.e., inactive) surface 124. In some embodiments, the active surface 122 may be coated with a functional optical coating.

[0049] The coupling region 130 is configured to extend the image light in a second dimension orthogonal to the first dimension and guide the extended light to the user's eye. The illustrated prism element 131 can be formed by molding, and each prism element may include an active surface 132 and a draft surface (not visible). In some embodiments, the active surface 132 may be coated with a functional optical coating. It is understood that the design and manufacture of prism element 121 can be independent of the design and manufacture of prism element 131. Furthermore, each prism element 121 within the extension region 120 and each prism element 131 within the coupling region 130 can be designed and manufactured independently.

[0050] By manufacturing these prism elements separately, component-specific features can be processed piece by piece, thereby improving yield and performance. For example, different functional coatings can be formed on the active surfaces of the respective prism elements using more economical processing methods (e.g., batch processing).

[0051] For example, Figure 2 This demonstrates the formation and coating of individual mirrors using precision molding to form primary and secondary prism elements. Each active facet can be covered with an optical layer, and each optical layer can be configured independently. For example, as... Figure 2 As shown, the thickness of optical layer 122A can be greater than the thickness of optical layer 122B formed on the active surface of adjacent facets, and the thickness of optical layer 122B can be greater than the thickness of optical layer 122C. A passive filler layer 240 can be formed on the coated facets. The filler layer 240 can comprise any suitable optical polymer and can be UV-cured or thermosetting. The optical polymer constituting the filler layer 240 can be refractively matched to the underlying prism elements 121 and 131.

[0052] Figure 3 An exploded view showing the individual facets of the microprism array is shown, and Figure 4 The corresponding assembled microprism array is shown. (See reference...) Figure 1 And refer to Figure 3 Each prism element 121, 131 includes active surfaces 122, 132 and inactive (draft) surfaces 124, 134. The active surfaces 122, 132 may include an overmolded optical coating, while the inactive surfaces 124, 134 may remain uncoated.

[0053] In some embodiments, prism elements 121, 131 may include coupling features 352, 354. The coupling features may be configured to align and connect two or more prism elements 121, 131 to form an array. In the illustrated example, the female coupling feature 352 of the first prism element may engage the male coupling feature 354 of the second prism element to interconnect the first and second prism elements, such as... Figure 4As shown.

[0054] Figure 5 A cross-sectional view illustrating the co-integration of the optical coating with the active surface of each of the multiple prism elements is shown. Prism elements 121, 131 can be laid up by a support fixture 510 or otherwise supported. After laminating the optical coating 520, the prism elements can be removed from the support fixture 510 and assembled to form a microprism array. The optical coating 520 may include a uniform or non-uniform dielectric layer, an anti-reflective coating, a reflective polarizing layer, etc. That is, the micromirrors of prism elements 121, 131 can be coated equally or differently.

[0055] As described herein, a high-optical-efficiency geometric waveguide (GWG) has a modular construction in which the constituent elements of the GWG are fabricated individually and then assembled. An exemplary GWG may include coupling elements, extension elements, and decoupling elements. The extension and decoupling elements may each comprise an array of microprisms formed from prism elements, which are fabricated independently according to their respective design specifications, coated with one or more functional layers, and then aligned and bonded. That is, each component in the GWG can be individually molded and coated, allowing for mass production and reduced costs. The molding process may include microinjection molding. The coating process may include, for example, evaporation and may be used to form an anti-reflective coating or polarizing layer on the facets of mirrors within the extension or decoupling element. By fabricating waveguide components individually, the manufacturing process, including molding and coating, can be optimized for each component, and the assembly can be optimized for alignment and sizing settings to enable a scalable, high-yield manufacturing approach.

[0056] Embodiments of this disclosure may include various types of artificial reality systems or combinations thereof. Artificial reality is a form of reality that has been modulated in some way before being presented to a user. Artificial reality may include, for example, virtual reality, augmented reality, mixed reality, or some combination and / or derivative thereof. Artificial reality content may include entirely computer-generated content or computer-generated content combined with acquired (e.g., real-world) content. Artificial reality content may include video, audio, haptic feedback, or some combination thereof, any one of which may be presented in a single channel or multiple channels (e.g., stereoscopic video that produces a three-dimensional (3D) effect for the viewer). Furthermore, in some embodiments, artificial reality may also be associated with applications, products, accessories, services, or some combination thereof, which are used, for example, to create content in artificial reality and / or otherwise used in artificial reality (e.g., to perform activities in artificial reality).

[0057] Artificial reality systems can be implemented in a variety of different shapes and configurations. Some artificial reality systems can be designed to operate without a near-eye display (NED). Other artificial reality systems may include NEDs that also provide visibility into the real world (e.g., Figure 6 Augmented reality systems (600) or NEDs that visually immerse users in artificial reality (e.g., augmented reality systems 600) or NEDs that allow users to be visually immersed in artificial reality. Figure 7 (700 of the Virtual Reality System). While some artificial reality devices may be standalone systems, others may communicate with and / or cooperate with external devices to provide an artificial reality experience to a user. Examples of such external devices include handheld controllers, mobile devices, desktop computers, wearable devices, one or more other wearable devices, and / or any other suitable external systems.

[0058] Transfer to Figure 6 The augmented reality system 600 may include a glasses device 602 with a frame 610 configured to hold a left display device 615(A) and a right display device 615(B) in front of a user's eyes. The display devices 615(A) and 615(B) may operate together or independently to present a single image or a series of images to the user. Although the augmented reality system 600 includes two displays, embodiments of this disclosure can be implemented in augmented reality systems having a single NED or two or more NEDs.

[0059] In some embodiments, the augmented reality system 600 may include one or more sensors, such as sensor 640. Sensor 640 may generate measurement signals in response to motion of the augmented reality system 600 and may be located on virtually any part of the frame 610. Sensor 640 may represent a position sensor, an inertial measurement unit (IMU), a depth camera assembly, a structured light emitter and / or a detector, or any combination thereof. In some embodiments, the augmented reality system 600 may or may not include sensor 640, or may include more than one sensor. In embodiments where sensor 640 includes an IMU, the IMU may generate calibration data based on measurement signals from sensor 640. Examples of sensor 640 may include, but are not limited to, accelerometers, gyroscopes, magnetometers, other suitable types of sensors for detecting motion, sensors for IMU error correction, or some combination thereof.

[0060] The augmented reality system 600 may also include a microphone array having multiple acoustic transducers 620(A) to 620(J) (collectively referred to as acoustic transducers 620). The acoustic transducers 620 may be transducers that detect changes in air pressure caused by sound waves. Each acoustic transducer 620 may be configured to detect sound and convert the detected sound into an electronic format (e.g., analog or digital format). For example, Figure 6 The microphone array may include ten acoustic transducers: acoustic transducers 620(A) and 620(B), which may be designed to be placed in the corresponding ear of the user; acoustic transducers 620(C), 620(D), 620(E), 620(F), 620(G) and 620(H), which may be positioned at different locations on the frame 610; and / or acoustic transducers 620(I) and 620(J), which may be positioned on the corresponding neckband 605.

[0061] In some embodiments, one or more of the acoustic converters 620(A) to 620(F) can be used as output converters (e.g., speakers). For example, acoustic converter 620(A) and / or acoustic converter 620(B) can be earbuds or any other suitable type of headphones or speakers.

[0062] The configuration of the acoustic transducer 620 in the microphone array can be varied. While the augmented reality system 600... Figure 6The diagram shows ten acoustic transducers 620, but the number of acoustic transducers 620 may be more or less than ten. In some embodiments, using a larger number of acoustic transducers 620 can increase the amount of audio information collected and / or improve the sensitivity and accuracy of the audio information. In contrast, using a smaller number of acoustic transducers 620 can reduce the computational power required by the associated controller 650 to process the collected audio information. Additionally, the position of each acoustic transducer 620 in the microphone array can be varied. For example, the position of the acoustic transducer 620 may include a defined position on the user, defined coordinates on the frame 610, an orientation associated with each acoustic transducer 620, or some combination thereof.

[0063] Acoustic transducers 620(A) and 620(B) can be positioned on different parts of the user's ear, such as behind the pinna, behind the tragus, and / or within the auricle or ear canal. Alternatively, additional acoustic transducers 620 may be present on or around the ear in addition to the acoustic transducer 620 within the ear canal. Positioning the acoustic transducers 620 close to the user's ear canal allows the microphone array to collect information about how sound reaches the ear canal. By positioning at least two of the multiple acoustic transducers 620 on either side of the user's head (e.g., as binaural microphones), the augmented reality system 600 can simulate binaural hearing and acquire a 3D stereo sound field around the user's head. In some embodiments, acoustic transducers 620(A) and 620(B) can be connected to the augmented reality system 600 via a wired connection 630, and in other embodiments, acoustic transducers 620(A) and 620(B) can be connected to the augmented reality system 600 via a wireless connection (e.g., Bluetooth connection). In some other embodiments, acoustic transducers 620(A) and 620(B) may not be used in conjunction with the augmented reality system 600 at all.

[0064] The acoustic transducers 620 on frame 610 can be positioned along the length of the temple, across the beam, above or below display devices 615(A) and 615(B), or some combination thereof. The acoustic transducers 620 can also be oriented such that the microphone array can detect sound in a wide range of directions around the user wearing the augmented reality system 600. In some embodiments, optimization processes can be performed during the manufacture of the augmented reality system 600 to determine the relative positioning of each acoustic transducer 620 within the microphone array.

[0065] In some examples, the augmented reality system 600 may include an external device (e.g., a pairing device) or be able to connect to such an external device, such as a neckband 605. Neckband 605 generally represents any type or form of pairing device. Therefore, the following discussion of neckband 605 can also be applied to a variety of other pairing devices, such as charging cases, smartwatches, smartphones, wristbands, other wearable devices, handheld controllers, tablets, laptops, other external computing devices, etc.

[0066] As shown in the figure, the neck strap 605 can be coupled to the eyewear device 602 via one or more connectors. These connectors can be wired or wireless and can include electronic and / or non-electronic components (e.g., structural components). In some cases, the eyewear device 602 and the neck strap 605 can operate independently without any wired or wireless connection between them. Although Figure 6 The illustration shows example locations of components of the eyeglasses device 602 and the neckband 605 on the eyeglasses device 602 and neckband 605, but these components may be located at other locations on the eyeglasses device 602 and / or neckband 605 and / or distributed in different ways on the eyeglasses device 602 and / or neckband 605. In some embodiments, the components of the eyeglasses device 602 and the neckband 605 may be located on one or more additional peripheral devices paired with the eyeglasses device 602, on the neckband 605, or some combination thereof.

[0067] Pairing an external device (e.g., neckband 605) with an augmented reality glasses device allows the glasses device to achieve the shape features of a pair of glasses while still providing sufficient battery power and computing power for expanded functionality. Some or all of the battery power, computing resources, and / or additional features of the augmented reality system 600 can be provided by the paired device or shared between the paired device and the glasses device, thus reducing the overall weight, heat distribution, and shape features of the glasses device while still retaining the desired functionality. For example, the neckband 605 can allow components that would otherwise be included in the glasses device to be included in the neckband 605, since the weight load on the user's shoulders can be greater than the weight load on the user's head. The neckband 605 can also have a large surface area through which heat is diffused and dissipated into the surrounding environment. Therefore, the neckband 605 can allow for greater battery power and stronger computing power compared to the battery power and computing power feasible in a standalone glasses device. Since the weight carried in the neck strap 605 is less invasive to the user than the weight carried in the glasses device 602, the user can tolerate wearing the lighter glasses device and carrying or wearing the paired device for a longer period of time than the user can tolerate wearing the heavier standalone glasses device for a longer period of time, thus enabling the user to more fully integrate the artificial reality environment into their daily activities.

[0068] The neckband 605 can be communicatively coupled to the glasses device 602 and / or communicatively coupled to other devices. These other devices can provide certain functions to the augmented reality system 600 (e.g., tracking, localization, depth map construction, processing, storage, etc.). Figure 6 In some embodiments, the neckband 605 may include two acoustic transducers (e.g., 620(I) and 620(J)) that are part of a microphone array (or potentially form their own microphone subarrays). The neckband 605 may also include a controller 625 and a power supply 635.

[0069] The acoustic transducers 620(I) and 620(J) of the neckband 605 can be configured to detect sound and convert the detected sound into an electronic format (analog or digital). Figure 6 In some embodiments, acoustic transducers 620(I) and 620(J) can be positioned on the neckband 605, thereby increasing the distance between the neckband acoustic transducers 620(I) and 620(J) and other acoustic transducers 620 positioned on the eyewear device 602. In some cases, increasing the distance between the individual acoustic transducers 620 of the microphone array can improve the accuracy of beamforming performed via the microphone array. For example, if acoustic transducers 620(C) and 620(D) detect sound, and the distance between acoustic transducers 620(C) and 620(D) is greater than, for example, the distance between acoustic transducers 620(D) and 620(E), the determined source location of the detected sound may be more accurate compared to the case where the sound is detected by acoustic transducers 620(D) and 620(E).

[0070] The controller 625 of the neckband 605 can process information generated by multiple sensors on the neckband 605 and / or on the augmented reality system 600. For example, the controller 625 can process information from a microphone array describing sound detected by the microphone array. For each detected sound, the controller 625 can perform direction-of-arrival (DOA) estimation to estimate the direction in which the detected sound arrives at the microphone array. When the microphone array detects sound, the controller 625 can populate the audio dataset with information. In embodiments where the augmented reality system 600 includes an inertial measurement unit (IMU), the controller 625 can perform all inertial and spatial calculations based on the IMU located on the glasses device 602. Connectors can transmit information between the augmented reality system 600 and the neckband 605, and between the augmented reality system 600 and the controller 625. This information can be in optical data form, electronic data form, wireless data form, or any other transmissible data form. Moving the processing of information generated by the augmented reality system 600 to the neckband 605 reduces the weight and heat of the glasses device 602, making the glasses device more comfortable for the user.

[0071] The power source 635 in the neckband 605 can provide power to the eyeglass device 602 and / or to the neckband 605. The power source 635 may include, but is not limited to, a lithium-ion battery, a lithium-polymer battery, a disposable lithium battery, an alkaline battery, or any other form of power storage device. In some cases, the power source 635 may be a wired power source. Including the power source 635 on the neckband 605 rather than on the eyeglass device 602 can help to better distribute the weight and heat generated by the power source 635.

[0072] As noted, some artificial reality systems can largely replace a user's sensory perception of the real world with virtual experiences, rather than blending artificial reality with actual reality. An example of this type of system is a head-mounted display system, such as... Figure 7 A virtual reality system 700 that covers most or all of the user's field of vision. The virtual reality system 700 may include a front rigid body 702 and a strap 704 shaped to fit around the user's head. The virtual reality system 700 may also include an output audio converter 706(A) and an output audio converter 706(B). Furthermore, although in Figure 7 Not shown, but the front rigid body 702 may include one or more electronic components, including one or more electronic displays, one or more inertial measurement units (IMUs), one or more tracking transmitters or detectors, and / or any other suitable devices or systems for creating artificial reality experiences.

[0073] Artificial reality systems can include various types of visual feedback mechanisms. For example, the display devices in augmented reality system 600 and / or virtual reality system 700 can include one or more liquid crystal displays (LCDs), one or more light-emitting diode (LED) displays, one or more organic light-emitting diode (OLED) displays, one or more digital light projector (DLP) microdisplays, one or more liquid crystal on silicon (LCoS) microdisplays, and / or any other suitable type of display screen. These artificial reality systems can include a single display screen for each eye, or a display screen for each eye, which can allow for additional flexibility in zoom adjustment or correction of the user's refractive errors. Some of these artificial reality systems can also include multiple optical subsystems with one or more lenses (e.g., conventional concave or convex lenses, Fresnel lenses, adjustable liquid lenses, etc.) through which the user views the display screen. These optical subsystems can be used for a variety of purposes, including collimating light (e.g., making an object appear to be at a greater distance than its physical distance), magnifying light (e.g., making an object appear larger than its actual size), and / or relaying light (e.g., to the viewer's eye). These optical subsystems can be used in non-pupil-forming architectures (e.g., single-lens constructions that directly collimate light but cause so-called pincushion distortion) and / or pullil-forming architectures (e.g., multi-lens constructions that produce so-called barrel distortion to eliminate pincushion distortion).

[0074] In addition to or instead of using a display screen, some artificial reality systems may include one or more projection systems. For example, the display device in augmented reality system 600 and / or virtual reality system 700 may include a micro-LED projector that projects light (using, for example, a waveguide) into the display device, which may be a transparent composite lens that allows ambient light to pass through. The display device can refract the projected light toward the user's pupil, allowing the user to simultaneously view both the artificial reality content and the real world. This can be achieved using any of a variety of optical components, including waveguide components (e.g., holographic waveguide elements, planar waveguide elements, diffractive waveguide elements, polarizing waveguide elements, and / or reflective waveguide elements), light-manipulating surfaces and elements (e.g., diffractive elements and gratings, reflective elements and gratings, and refractive elements and gratings), coupling elements, etc. Artificial reality systems may also be configured with any other suitable type or form of image projection system, such as a retinal projector for a virtual retinal display.

[0075] Artificial reality systems can also include various types of computer vision components and subsystems. For example, augmented reality system 600 and / or virtual reality system 700 may include one or more optical sensors, such as two-dimensional (2D) cameras or three-dimensional (3D) cameras, structured light emitters and detectors, time-of-flight depth sensors, single-beam rangefinders or scanning laser rangefinders, 3D LiDAR sensors, and / or any other suitable type or form of optical sensor. Artificial reality systems can process data from one or more of these sensors to identify the user's location, map the real world, provide the user with context about the real-world environment, and / or perform various other functions.

[0076] Artificial reality systems may also include one or more input audio converters and / or output audio converters. Figure 7 In the examples shown, output audio converters 706(A) and 706(B) may include voice coil speakers, ribbon speakers, electrostatic speakers, piezoelectric speakers, bone conduction converters, cartilage conduction converters, tragus vibration converters, and / or any other suitable type or form of audio converter. Similarly, input audio converters may include condenser microphones, dynamic microphones, ribbon microphones, and / or any other type or form of input converter. In some embodiments, a single converter may be used for both audio input and audio output.

[0077] Despite Figure 6Not shown, but artificial reality systems can include tactile (i.e., haptic) feedback systems that can be integrated into headwear, gloves, clothing, handheld controllers, environmental devices (e.g., chairs, floor mats, etc.), and / or any other type of device or system. Haptic feedback systems can provide various types of skin feedback, including vibration, force, tension, texture, and / or temperature. Haptic feedback systems can also provide various types of kinematic feedback, such as motion and compliance. Haptic feedback can be implemented using motors, piezoelectric actuators, fluid systems, and / or various other types of feedback mechanisms. Haptic feedback systems can be implemented independently of other artificial reality devices, within other artificial reality devices, and / or in conjunction with other artificial reality devices.

[0078] By providing tactile perception, auditory content, and / or visual content, artificial reality (AI) systems can create complete virtual experiences or enhance a user's real-world experience in a variety of contexts and environments. For example, AI systems can assist or extend a user's perception, memory, or cognition within a specific environment. Some systems can enhance a user's interaction with others in the real world or enable more immersive interaction with others in the virtual world. AI systems can also be used for educational purposes (e.g., for teaching or training in schools, hospitals, government organizations, military organizations, commercial enterprises, etc.), entertainment purposes (e.g., for playing video games, listening to music, watching video content, etc.), and / or for accessibility purposes (e.g., as hearing aids, visual aids, etc.). The embodiments disclosed herein can realize or enhance a user's AI experience in one or more of these contexts and environments and / or in other contexts and environments.

[0079] The order of process parameters and steps described and / or illustrated herein is given by way of example only and may be changed as desired. For example, while the steps shown and / or described herein may be shown or discussed in a particular order, these steps do not necessarily need to be performed in the order shown or discussed. The various exemplary methods described and / or illustrated herein may also omit one or more of the steps described or illustrated herein, or include additional steps in addition to those disclosed.

[0080] The foregoing description has been provided to enable others skilled in the art to best utilize various aspects of the exemplary embodiments disclosed herein. This exemplary description is not intended to be exhaustive or limited to any precise form disclosed. Many modifications and variations are possible without departing from the scope of this disclosure. The embodiments disclosed herein should be considered illustrative rather than restrictive in all respects. Reference should be made to the appended claims and their equivalents in determining the scope of this disclosure.

[0081] Unless otherwise stated, the terms “connected to” and “coupled to” (and their derivatives) as used in the specification and claims shall be interpreted as allowing both direct connection and (i.e., indirect connection via other elements or components). Furthermore, the terms “a” or “an” as used in the specification and claims shall be interpreted as meaning “at least one of…”. Finally, for ease of use, the terms “comprising” and “having” (and their derivatives) as used in the specification and claims are interchangeable with the word “including” and have the same meaning.

[0082] It should be understood that when an element (e.g., a layer or region) is referred to as being formed on, deposited on, or disposed “on” or “above” another element, the element may be directly located on at least a portion of the other element, or one or more intermediate elements may be present. Conversely, when an element is referred to as being “directly on” or “directly above” another element, the element may be located on at least a portion of the other element without intermediate elements.

[0083] As used herein, in some embodiments, the term "about" relating to a particular numerical value or range of values ​​may refer to and include the value as well as all values ​​within 10% of the value. Thus, for example, in some embodiments, the numerical value "50" referred to as "about 50" may include values ​​equal to 50 ± 5, i.e., values ​​in the range of 45 to 55.

[0084] As used herein, the term "substantially" with respect to a given parameter, property, or condition may refer to and include, to the extent that a given parameter, property, or condition is satisfied with a small degree of variation (e.g., within acceptable manufacturing tolerances). For example, depending on the particular parameter, property, or condition that is substantially satisfied, it may be satisfied at least about 90%, at least about 95%, or even at least about 99%.

[0085] While the transitional phrase “comprising” may be used to disclose various features, elements, or steps of a particular embodiment, it should be understood that alternative embodiments (including those described using the transitional phrases “consisting of” or “essentially composed of”) are implicit. Thus, for example, implicit alternative embodiments of a prism comprising or including polycarbonate include embodiments where the prism is substantially composed of polycarbonate and embodiments where the prism is composed of polycarbonate.

Claims

1. A method comprising: Forming a first transparent mirror element and a separate second transparent mirror element; A first functional coating is formed on the active surface of the first reflective mirror element; A second functional coating is formed on the active surface of the second transparent mirror element; as well as The first and second mirror elements are aligned to form a microprism array.

2. The method according to claim 1, wherein, Forming the first and second mirror elements involves molding an optical polymer.

3. The method according to claim 1 or 2, wherein, The refractive index of the first mirror element is substantially equal to that of the second mirror element.

4. The method according to any one of the preceding claims, wherein, Forming the first mirror element includes molding a first optical polymer, and forming the second mirror element includes molding a second optical polymer.

5. The method according to any one of the preceding claims, wherein, The formation of the first functional coating and the second functional coating includes evaporation deposition; and preferably, the formation of the first functional coating includes evaporation deposition in a first deposition process, and the formation of the second functional coating includes evaporation deposition in a second deposition process.

6. The method according to any one of the preceding claims, wherein, The thickness of the first functional coating is different from the thickness of the second functional coating; and / or The first functional coating includes a reflective polarizer having a first polarization response, and the second functional coating includes a reflective polarizer having a second polarization response different from the first polarization response.

7. The method according to any one of the preceding claims, wherein, The tilt angle of the active surface of the first reflective mirror element is different from the tilt angle of the active surface of the second reflective mirror element.

8. The method according to any one of the preceding claims, wherein, The first and second mirror elements are aligned using a matching coupling feature; and preferably, the first mirror element includes a female coupling feature, the second mirror element includes a male coupling feature, and the first and second mirror elements are aligned by engaging the female coupling feature with the male coupling feature.

9. A geometric waveguide, comprising: An extension region comprising an array of independently configured first transparent mirror elements; as well as The coupling region includes an array of independently configured second transparent mirror elements.

10. The geometric waveguide according to claim 9, wherein, Each first transflector element includes an active surface, and each active surface of the first transflector element includes an optical coating; preferably, the thickness of the optical coating is different among the first transflector elements.

11. The geometric waveguide according to claim 10, wherein, The tilt angles of the active surfaces of the first reflective mirror element are different.

12. The geometric waveguide according to any one of claims 9 to 11, wherein, Each second transflector element includes an active surface, and each active surface of the second transflector element includes an optical coating; preferably, the thickness of the optical coating is different between the second transflector elements.

13. The geometric waveguide according to claim 12, wherein, The tilt angle of the active surface of the second reflective mirror element is different.

14. A geometric waveguide, comprising: A first array of independently configured transmission and reflection mirror elements; as well as A second array of independently configured transmission and reflection mirror elements.

15. The geometric waveguide according to claim 14, wherein, The first array of independently configured mirror elements includes multiple facets, each facet having an active surface and an optical coating disposed on each active surface; and the second array of independently configured mirror elements includes multiple facets, each facet having an active surface and an optical coating disposed on each active surface.

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