Method for producing a waveguide with a predetermined shape

DE602019070371T2Active Publication Date: 2025-05-21MAGIC LEAP INC
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Patent Information

Application Number
DE602019070371
Authority / Receiving Office
DE · DE
Patent Type
Patents
Current Assignee / Owner
Priority Date
2018-10-16
Filing Date
2019-10-16
Publication Date
2025-05-21
Estimated Expiration
2039-10-16

AI Technical Summary

Technical Problem

The production of polymer films for optical applications, such as eyepieces in imaging systems, is hindered by imperfections like wrinkles, uneven thicknesses, and cracks introduced during the singulation process, which affect the precision and consistency of the films, leading to reduced performance and increased variability.

Method used

A method involving the use of molds and controlled irradiation of photocurable materials to form polymer films with varying rigidity, allowing for precise cutting and annealing to minimize imperfections, and the use of a singulation frame to cut the polymer film without direct cutting of the material, ensuring accurate and consistent production.

Benefits of technology

This approach enables the production of polymer films with improved edge quality, reduced variability, and enhanced optical characteristics, suitable for high-resolution optical imaging systems by minimizing cracks and chips, thus improving the precision and consistency of polymer products.

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Abstract

In an example method of forming a waveguide part having a predetermined shape, a photocurable material is dispensed into a space between a first mold portion and asecond mold portion opposite the first mold portion. A relative separation between a surface of the first mold portion with respect to a surface of the second mold portion opposing the surface of the first mold portion is adjusted to fill the space between the first and second mold portions. The photocurable material in the space is irradiated with radiation suitable for photocuring the photocurable material to form a cured waveguide film so that different portions of the cured waveguide film have different rigidity. The cured waveguide film is separated from the first and second mold portions. The waveguide part is singulated from the cured waveguide film. The waveguide part corresponds to portions of the cured waveguide film having a higher rigidity than other portions of the cured waveguide film.
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