Display system using light extraction configuration for micro light emitting diodes

Abstract

A display system is disclosed that includes an emitter system assembly for providing a light output. The emitter system assembly includes a first emitter providing a first emission spectrum, a cavity at least partially surrounding the first emitter, a first aperture configured to transmit at least a portion of the first emission spectrum from the first emitter, and a shaping element in optical communication with the first aperture. The cavity includes a reflector that reflects the first emission spectrum within the cavity toward the aperture.

Description

[Technical field]

[0001] Related Applications This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 254,967, filed October 12, 2021, U.S. Provisional Patent Application No. 63 / 213,566, filed June 22, 2021, and U.S. Provisional Patent Application No. 63 / 213,574, filed June 22, 2021. The entire contents of each of the above-mentioned applications are incorporated herein by reference. [Background technology]

[0002] background Aspects of the present disclosure relate generally to light emitting diodes (LEDs), and more particularly to assemblies that improve light extraction from micro light emitting diodes (micro LEDs).

[0003] Recent advances in light emitting diode (LED) technology have enabled the formation of high density display devices incorporating arrays of micro LEDs, with each micro LED having an emitter pitch on the order of a few microns to a fraction of a micron. For example, Appendix A discloses various configurations of micro LED-based light field displays.

[0004] To show the contrast between conventional displays and microLED-based displays, FIG. 1 shows a conventional display 110 having an array 120 of light-emitting elements 125, as better seen in inset 130. As mentioned above, the light-emitting elements 125, which may be conventional LEDs, may all emit light at the same wavelength or may be arranged in a pattern of LEDs emitting at two or more wavelengths. For example, the array 120 may include LEDs emitting at red, green, and blue wavelengths in the visible spectrum and arranged in a regular pattern.

[0005] 1, the light emitting elements 125 may be arranged in a Q×P array across an area of ​​the display 110, where Q is the number of rows of light emitting elements 125 in the array and P is the number of columns of light emitting elements 125 in the array. Although not shown, in addition to the light emitting elements 125, a conventional display 110 may include a backplane that includes various electrical traces and contacts configured to selectively route power to one or more of the light emitting elements 125.

[0006] FIG. 2 shows a light field display 210 having an array 220 of super-axels 225, as shown in a first inset 230. Each super-axel 225 further includes a sub-axel 245, as shown in a second inset 240. Each of the sub-axels 245 may be a micro-LED, as described above. That is, each super-axel 225 may correspond in size to the light-emitting element 125 of FIG. 1, while including a plurality of sub-axels 245 formed of micro-LEDs having an emitter pitch of a few microns, or even a fraction of a micron. In the example shown in FIG. 2, each super-axel 225 is shown to have a generally square shape with each side having a super-axel pitch 227. Each super-axel 225 may be configured to emit light in a single wavelength range (e.g., red, green, or blue wavelength range) or across multiple color ranges (e.g., across at least a portion of the visible electromagnetic wavelength range).

[0007] In the example shown in FIG. 2, the superlaceels 225 are arranged in an N×M array, where N is the number of rows of superlaceels 225 in the array and M is the number of columns of superlaceels 225 in the array. As shown in FIG. 2, each of the superlaceels 225 includes a number of sublaceels 245. Each of the sublaceels 245 may include, for example, micro LEDs emitting in red, green, or blue wavelengths in the visible spectrum and arranged in a regular pattern. In one example, the sublaceels 245 of various colors may be monolithically integrated on a common substrate, and each of the micro LEDs in the sublaceels 245 may range in size from a fraction of a micron to approximately 100 microns.

[0008] 3 illustrates the light steering aspects of the superaxels 225. As shown in inset 330, each of the superaxels 225 may include light steering optical elements 340 for directing light emitted from that superaxel 225 to a desired location. In the example shown in FIG. 3, each light steering optical element 340 is shown to have a lens pitch 345 that is about the size of one of the superaxels 225.

[0009] While microLED-based displays enable new applications, various improvements are still possible to maximize the performance of each microLED and the display as a whole. In particular, compact microLED arrays for augmented reality / virtual reality (AR / VR) and other near-eye display applications require high brightness light output with efficient light extraction. Summary of the Invention

[0010] Disclosure Summary The following presents a simplified summary of one or more embodiments in order to provide a basic understanding of such embodiments. This summary is not an extensive overview of all contemplated embodiments, and is not intended to identify key or critical elements of all embodiments or to delineate the scope of any or all embodiments. Its purpose is to present some concepts of one or more embodiments in a simplified form as a prelude to the more detailed description that is presented later.

[0011] In one aspect of the disclosure, a display system is disclosed that includes an emitter system assembly for providing a light output. The emitter system assembly includes a first emitter providing a first emission spectrum, a cavity at least partially surrounding the first emitter, and a first aperture configured to transmit at least a portion of the first emission spectrum from the first emitter. The emitter system assembly further includes a shaping element in optical communication with the first aperture, and the cavity includes a reflector that reflects the first emission spectrum within the cavity toward the aperture.

[0012] In another aspect of the present disclosure, an emitter array system is disclosed that includes a central emitter configured to provide a central emission spectrum, peripheral emitters configured to provide a peripheral emission spectrum, a central cavity at least partially surrounding the central emitter, and a peripheral cavity at least partially surrounding the peripheral emitter. The emitter array system further includes a central aperture configured to transmit at least a portion of the central emission spectrum from the central emitter, a peripheral aperture configured to transmit at least a portion of the peripheral emission spectrum from the peripheral emitter, a central shaping element in optical communication with the central aperture, the central shaping element directing the central emission spectrum at a first angle, and a peripheral shaping element in optical communication with the peripheral aperture, the peripheral shaping element directing the peripheral emission spectrum at a second angle.

[0013] The accompanying drawings depict only some implementations and therefore should not be considered limiting of the scope. [Brief description of the drawings]

[0014] [Figure 1] FIG. 2 illustrates an example of a display having a plurality of pixels, according to an aspect of the present disclosure. [Diagram 2] FIG. 2 illustrates an example of a light field display having multiple picture elements, in accordance with an aspect of the present disclosure. [Diagram 3] FIG. 2 illustrates an example of a light field display having multiple picture elements, in accordance with an aspect of the present disclosure. [Figure 4] FIG. 1 illustrates an overall configuration for light extraction from an LED, according to an embodiment of the present disclosure. [Diagram 5] 1A-1C illustrate example light extraction configurations according to aspects of the present disclosure. [Figure 6] 1A-1C illustrate example light extraction configurations according to aspects of the present disclosure. [Figure 7] 1A-1C illustrate example light extraction configurations according to aspects of the present disclosure. [Figure 8] FIG. 1 illustrates an example configuration for light extraction from an array of micro LEDs, according to an embodiment of the present disclosure. [Figure 9] FIG. 1 illustrates an example configuration for light extraction from an array of micro LEDs, according to an embodiment of the present disclosure. [Figure 10] FIG. 1 illustrates an example configuration for light extraction from an array of micro LEDs, according to an embodiment of the present disclosure. [Figure 11] 1 is a flowchart illustrating a process for forming a light extraction feature for a micro-LED, according to an embodiment of the present disclosure. [Figure 12] FIG. 1 is a top schematic diagram of a near-eye display system according to an aspect of the present disclosure. [Figure 13] FIG. 2 is a top schematic diagram of an emitter array system with lenslets in accordance with an aspect of the present disclosure. [Figure 14]FIG. 1 is a top schematic diagram of an emitter array system having a grating, according to an aspect of the present disclosure. [Figure 15] FIG. 2 is a top schematic diagram of an emitter array system having prisms, according to an aspect of the present disclosure. [Figure 16A] FIG. 1 illustrates a front view of an emitter array system in accordance with an aspect of the present disclosure. [Figure 16B] FIG. 1 illustrates a front view of an emitter array system in accordance with an aspect of the present disclosure. [Figure 16C] FIG. 1 is a perspective view of an emitter array system according to an aspect of the present disclosure. [Figure 17] FIG. 1 is a top schematic diagram of a near-eye display system according to an aspect of the present disclosure. [Figure 18A] FIG. 1 illustrates a front view of an emitter array system in accordance with an aspect of the present disclosure. [Figure 18B] FIG. 1 is a perspective view of an emitter array system according to an aspect of the present disclosure. [Figure 19] FIG. 2 is a top schematic diagram of an emitter array system according to an aspect of the present disclosure. [Figure 20] FIG. 1 is a top schematic diagram of a near-eye display system according to an aspect of the present disclosure. [Figure 21A] FIG. 2 is a top schematic diagram of an emitter array system having light absorbing elements, according to an aspect of the present disclosure. [Figure 21B] FIG. 2 is a top schematic diagram of an emitter array system having light absorbing elements, according to an aspect of the present disclosure. [Figure 22A] FIG. 2 is a top schematic diagram of an emitter array system with a parallax barrier, according to an aspect of the present disclosure. [Figure 22B] FIG. 2 is a top schematic diagram of an emitter array system having a shutter, according to an aspect of the present disclosure. [Figure 22C] FIG. 1 is a top schematic diagram of a near-eye display system having a movable shutter, according to an aspect of the present disclosure. [Figure 22D] FIG. 1 is a top schematic diagram of a near-eye display system having a movable shutter, according to an aspect of the present disclosure. [Diagram 23]1A-1D show a top schematic view and two detailed views of a uniform telecentric near-eye display according to an embodiment of the present disclosure. [Figure 24] FIG. 2 is a top-view schematic diagram of an optical system having a uniform chief ray tilt configuration, in accordance with an aspect of the present disclosure. [Diagram 25] FIG. 1 is a top-view schematic diagram of an optical system having a hyper-telecentric chief ray tilt configuration, in accordance with aspects of the present disclosure. [Figure 26] FIG. 1 illustrates a front view of an emitter array system having a hyper-telecentric chief ray tilt configuration in accordance with aspects of the present disclosure. [Figure 27] FIG. 1 is a top-view schematic diagram of a near-eye display system having a hyper-telecentric chief ray tilt configuration, according to an aspect of the present disclosure. [Figure 28] FIG. 1 is a top-view schematic diagram of an optical system having a converging chief ray tilt configuration, in accordance with aspects of the present disclosure. [Figure 29] FIG. 1 illustrates a front view of an emitter array system having a converging chief ray tilt configuration, in accordance with aspects of the present disclosure. [Diagram 30] FIG. 1 is a top-view schematic diagram of a near-eye display system having a converging chief ray tilt configuration, according to an aspect of the present disclosure. [Figure 31A] 1 is a partial top view schematic diagram of an emitter array system having a non-uniform diffractive structure according to an aspect of the present disclosure. [Figure 31B] 1 is a partial top view schematic diagram of an emitter array system having a non-uniform diffractive structure according to an aspect of the present disclosure. [Figure 32A] 1 is a perspective schematic diagram of a display system and an optical system having a waveguide according to an aspect of the present disclosure. [Figure 32B] 1 is a perspective schematic diagram of a display system and an optical system having a waveguide according to an aspect of the present disclosure. [Figure 33A] FIG. 2 is a front view of an emitter array panel according to an aspect of the present disclosure. [Figure 33B] FIG. 2 is a top view of an emitter array panel in accordance with an aspect of the present disclosure. [Figure 33C]FIG. 2 is a front view of an emitter array panel according to an aspect of the present disclosure. [Figure 33D] FIG. 2 is a top view of an emitter array panel in accordance with an aspect of the present disclosure. [Figure 34A] FIG. 2 is a central detail view of an emitter array panel in accordance with an aspect of the present disclosure. [Figure 34B] FIG. 2 is a detailed peripheral view of an emitter array panel in accordance with an aspect of the present disclosure. [Figure 34C] FIG. 2 illustrates an embodiment of an emitter array panel in accordance with aspects of the present disclosure. [Fig. 34D] FIG. 2 illustrates an embodiment of an emitter array panel in accordance with aspects of the present disclosure. [Diagram 35] FIG. 2 illustrates an example of an elongated projection lens, according to aspects of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] Detailed Description The detailed description set forth below with reference to the accompanying drawings is intended as a description of various configurations and is not intended to show the only configurations in which the concepts described herein may be implemented. The detailed description includes specific details intended to provide a thorough understanding of the various concepts. However, it will be apparent to those skilled in the art that these concepts may be implemented without these specific details. In some instances, well-known components are shown in block diagram form to avoid obscuring such concepts.

[0016] To take advantage of the small size and high efficiency of micro-LEDs, as much of the light generated by each micro-LED must be extracted as possible, therefore new configurations for improved extraction of the light generated by micro-LEDs are desired.

[0017] FIG. 4 illustrates an exemplary configuration for improved light extraction from a light emitter, such as a micro-LED. As illustrated in FIG. 4, an emitter system 400 includes an emitter 410 for generating light emission. For example, the emitter 410 can be a conventional LED or a micro-LED based on quantum well (QW) technology, or another type of small light emitter. The emitter 410 is surrounded by an LED cavity 420. An etendue gate 430 provides a spatial aperture for the light from the emitter 410 to be emitted toward a mode matching optics 440. The mode matching optics 440 is configured to shape the light from the LED cavity 420 into an output 450 that meets the requirements of a particular application, such as for use in a projector device.

[0018] More specifically, the LED cavity 420 may include, for example, highly reflective surfaces to confine the light generated by the emitter 410. The geometry of the LED cavity 420 may be tailored to provide an optimal geometry for light coupling through the etendue gate 430 for a particular application. It should be noted that although referred to as a "cavity," the LED cavity 420 may be filled with a material other than air, such as a solid semiconductor (such as gallium nitride) or another material (such as an insulator) that is substantially transparent to the light emitted by the emitter 410.

[0019] The etendugate 430 may be a fixed or adjustable spatial aperture for efficiently coupling light exiting the LED cavity 420 to the mode matching optics 440. The etendugate 430 may further include filters for selectively transmitting light having certain characteristics, such as light incident at the etendugate 430 within a certain range of angles of incidence, polarization states, wavelengths, resonant cavity modes, and other optical properties. For example, the etendugate 430 may include one or more non-reflective, low-reflective, or anti-reflective layers for improving display contrast in the presence of external light. As an example, an array of emitter systems 400 may be formed in a display, with each emitter system generating light that contributes to an image generated by the display. In such a display, in the presence of external light that has entered the display, each etendugate 430 may reflect the external light, thereby detracting from the image generated by the display. Such undesirable effects can be reduced by incorporating one or more non-reflective, low-reflective, or anti-reflective layers in the etendugate 430 so that any external light that reaches the etendugate 430 can be trapped within the LED cavity 420.

[0020] The mode adaptation optics 440 may include one or more refractive, reflective, or diffractive optical elements arranged in an imaging or non-imaging configuration. The mode adaptation optics 440 may be tailored to provide an output 450 that matches the acceptance light field of a particular application. For example, if the emitter system 400 is intended to provide light emission for use in a projector, such as for an augmented reality (AR) or virtual reality (VR) headset, then the mode adaptation optics 440 may be configured to convert the light transmitted through the etendue gate 430 into an output 450 that best matches the acceptance criteria for the projector. Again, non-reflective, low-reflective, or anti-reflective layers may be incorporated into the mode adaptation optics 440 to reduce the effects of external light leaking into the emitter system 400.

[0021] 5, the etendue gate 430 and mode matching optics 440 for the emitter system 500 may be replaced by a textured surface 530 to diffuse the light emitted from the emitter 410. In this case, the LED cavity 420 may be configured to efficiently direct the light emitted from the emitter 410 towards the textured surface to provide a light output suitable for use in applications that do not require a collimated light output.

[0022] In certain cases, with the proper design for the mode matching optics 440, the LED cavity 420 can be reduced or eliminated. For example, as shown in FIG. 6, an emitter system 600 can include an emitter 410 positioned at the apex of a truncated compound parabolic curve (CPC) collimator 620 that serves as the mode matching optics 440. In the case of the emitter system 600, the truncated CPC collimator 620 can provide sufficient mode matching and shaped light output for certain applications. Alternatively, as shown in FIG. 7, an aspheric lens 740 can be used as the mode matching optics 440 formed adjacent to the emitter 410. The aspheric lens 740 can include shaped sidewalls 760, such that with the proper design of the shaped sidewalls 760, the aspheric lens 740 alone can provide a properly shaped light output for certain applications without a cavity.

[0023] FIG. 8 illustrates a cross-sectional view of an emitter array system 800 including a light extraction feature according to one embodiment. The emitter array system 800 includes an LED substrate 805 supporting a plurality of emitters 810A, 810B, and 810C arranged, for example, in a two-dimensional array. As an example, the emitter 810A can be a quantum well-based micro LED configured to emit light in a red wavelength range, the emitter 810B can be a micro LED configured to emit light in a green wavelength range, and the emitter 810C can be a micro LED configured to emit light in a blue wavelength range. In another configuration, the emitters 810A, 810B, and / or 810C can be configured to emit light in the same wavelength range. In one example, each of the emitters 810A, 810B, and 810C is surrounded by a reflective surface 815, which causes the light emitted by that emitter to be directed downward in FIG. 8. The reflective surface 815 may be formed of a metal (eg, aluminum, gold, silver), a dielectric, a multi-layer stack of dielectric materials, or any combination thereof.

[0024] 8, the emitter array system 800 further includes LED cavities 820A, 820B, and 820C adjacent to the emitters 810A, 810B, and 810C, respectively. The LED cavities 820A, 820B, and 820C may be formed, for example, of a semiconductor (such as GaN) or other material (such as an insulator or transparent conductive oxide) compatible with light transmission within the desired wavelengths. The LED cavities 820A, 820B, and 820C include reflective surfaces 825 therein for confining and / or shaping the light emitted from the emitters 810A, 810B, and 810C, respectively. The reflective surfaces 825 may also be formed of a metal (e.g., aluminum, gold, silver), a dielectric, a multi-layer film stack of dielectric materials, or any combination thereof. For example, LED cavity 820A may be defined by a cavity shape optimized for coupling light emitted by emitter 810A to aperture 830A, LED cavity 820B may be optimized for coupling light emitted by emitter 810B to aperture 830B, and LED cavity 820C may be formed to best fit the light emitted by emitter 810C to be coupled to aperture 830C. In another example, two or more of LED cavities 820A, 820B, and 820C may be identical to one another. Similarly, aperture 830A may be different from apertures 830B and / or 830C, or apertures 830A, 830B, and 830C may be identical in dimensions. Apertures 830A, 830B, and 830C may be formed conjugate with the plane of an input coupling grating (ICG), such as one that serves as a waveguide input port for near-eye display glasses, in one example. Other types of throughput-limiting aperture configurations may also be implemented according to the requirements of the mode-coupling optical elements, or other optical elements downstream from the apertures. Additionally, optionally, apertures 830A, 830B, and / or 830C may include additional optical properties, such as angle, wavelength, and / or polarization filtering capabilities.

[0025] Light emitted from LED cavities 820A, 820B, and 820C through apertures 830A, 830B, and 830C, respectively, is directed through lenslets 840 in the example shown in Figure 8. Each one of the lenslets 840 corresponds to mode matching optical element 440 of Figure 4. In the example shown in Figure 8, each lenslet 840 is configured to direct light from multiple emitters 810A, 810B, and 810C. Each one of the lenslets 840 may be formed directly on a backplane, for example, or a lenslet array may be formed separately and then attached to a backplane after formation of the apertures and absorber coating.

[0026] Each one of the lenslets 840 may be separated from each other one of the lenslets 840 by a light baffle absorber 845. For example, the light baffle absorber 845 may be configured to reduce crosstalk between adjacent lenslets 840. In addition, the areas between the apertures 830A, 830B, and 830C may be covered by an absorber material 847 to further reduce stray light traveling through the lenslets 840. In an exemplary embodiment, the line 870 represents a demarcation line above which the arrangement of the emitters 810A, 810B, and 810C, the reflector 815, portions of the LED cavities 820A, 820B, and 820C, and the reflector 825 may be formed as part of the fabrication of the micro-LEDs (as indicated by the arrow 872). Below the line 870 (as indicated by arrow 874), various components may be formed during processing performed after the fabrication of the micro-LEDs is completed and the emitter and LED cavity portions are bonded to the backplane wafer.

[0027] 9 illustrates an emitter array system 900 according to one embodiment. The emitter array system 900 includes the same micro LED fabrication components as the emitter array system 800 of FIG. 8. However, each one of the apertures 830A, 830B, and 830C is coupled with its own lenslet 940A, 940B, and 940C, respectively. Adjacent lenslets 940A, 940B, and 940C are separated by a light baffle absorber 945, and the areas between apertures 830A and 830B and between 830B and 830C may be covered by an absorber material 947. In this configuration, each one of the lenslets 940A, 940B, and 940C may be configured to couple with a particular wavelength and other optical characteristics of the light emitted by the corresponding one of the emitters 810A, 810B, and 810C.

[0028] FIG. 10 illustrates an emitter array system 1000 according to one embodiment. The emitter array system 1000 includes an LED substrate 1005 that supports the same emitters 810A, 810B, and 810C as shown in FIG. 8 along with a reflector 815. In contrast to the emitter array system 800 of FIG. 8, the emitter array system 1000 includes one LED cavity 1020 for the group of emitters 810A, 810B, and 810C. The geometry of the LED cavity 1020 and the properties of the reflector 1025 can be tailored for optimal coupling of the light emitted from the emitters 810A, 810B, and 810C into the aperture 1030 and into the lenslet 1040. In one example, the lenslet 1040 can be identical to the lenslet 840 of FIG. 8. Adjacent lenslets 1040 may be separated by a light baffle absorber 1045 , and the areas between the apertures 1030 may be coated with an absorber material 1047 .

[0029] 11 illustrates an exemplary process for forming the emitter array system disclosed above, according to one embodiment. Process 1100 begins with step 1110 of forming an emitter array on an emitter substrate. Step 1110 may include, with reference to FIG. 8 , forming emitters 810A, 810B, and 810C supported on or in a substrate 805, forming a reflector 815 surrounding emitters 810A, 810B, and 810C, and forming the micro LED side of LED cavities 820A, 820B, and 820C, as well as a portion of reflector 825.

[0030] The process 1100 proceeds to step 1120, where the emitter array is attached to a backplane, and then to step 1130, where the remaining portions of the LED cavities and apertures are formed. For example, the emitter array may be attached to a backplane, after which the emitter substrate supporting the emitter array may be removed. Finally, the process 1100 proceeds to step 1140, where the lenslets are attached, forming, for example, the structure shown in Figures 8-10.

[0031] As described above, the emitter array system can be included in a variety of optical and display systems. For example, FIG. 12 shows a top view of a near-eye display system 1200 having an emitter array system 1201, as shown in the detailed view in the left square inset. The emitter array system 1201 includes a plurality of emitters 1210 (e.g., micro LEDs) disposed on or within an LED substrate 1205. The system 1201 further includes a plurality of cavities 1220, similar to the cavity 820 described above with respect to FIG. 8, configured to receive light from the emitters 1210. A plurality of lenslets 1240, or other optical elements, can be disposed over the cavities 1220 such that light emitted by the emitters 1220 exits the emitter array system 1201 as a light beam 1250a. The beam 1250a is shaped as a cone 1252 defined by the angle Ω between the outermost rays of the beam. The emitter array system 1201 may be coupled with one or more back-end components, such as a backplane display floor 1272 and / or a backplane driver and buffer 1274.

[0032] The light beam 1250a emitted from the emitter array system 1201 may travel through an interface region 1254 between the emitter array system 1201 and the projection lens 1256. The interface region 1254 may be an air gap or a layer of material with a refractive index selected as a design choice. When the light reaches the projection lens 1256, a number of optical elements 1258 disposed therein may shape the light and output the beam 1250b towards an incoupling element 1262 disposed on or within one or more waveguides 1260. The incoupling element 1262 may redirect a portion of the light from the beam 1250b, such that a portion of the light 1250c travels within the waveguide 1260 until it reaches the outcoupling element 1264 (e.g., via total internal reflection). The outcoupling element 1264 redirects a portion of the light 1250c, causing it to exit the waveguide 1260 as light 1250d towards the user's eye 1268. Thus, the light emitted by the light emitting array 1201 is relayed through the near-eye display system and is visible to the user. In addition, if the waveguide 1260 is transparent, the user may also see the world light 1266 passing through it. Thus, the world light and at least a portion of the light from the emitter array system (e.g., an augmented reality view) may be presented to the user. The system 1200 may benefit from the improved light extraction provided by the cavity adjacent to the emitter, as described above.

[0033] FIG. 12 shows that lenslets 1240 can be used to shape the light emitted by emitter 1210, although other configurations are possible. FIGS. 13-15 show alternative options for shaping the light generated by emitter 1310 and passed through cavity 1320 and aperture 1330. FIG. 13 shows lenslets 1340 surrounded on the sides by light baffle absorbers 1345. Additional light absorbing material with openings to allow light to pass through aperture 1330 can be placed between the base of lenslets 1340 and cavity 1320. The absorber material helps prevent crosstalk between adjacent lenslets. FIGS. 14 and 15 show that lenslets 1340 can be replaced with diffractive elements 1440 (e.g., diffractive or metamaterial lenses) or prisms 1540. Lenslets 1340, diffractive elements 1440, and / or prisms 1540 may be used to focus and / or redirect light from emitters 1310. Although each of the configurations shown in Figures 12-15 show a one-to-one relationship between emitters and cavities, and emitters and light shaping elements (e.g., lenslets, diffractive elements, prisms, metalenses), light from multiple emitters may be shaped by a single light shaping element, as described below.

[0034] 16A, there are shown light emitting elements 1610a-c arranged in a hexagonal packed configuration with intermittent gaps 1611 to correspond to the hexagonal packed configuration of lenslets 1640, as described below. The light emitting elements 1610 may each emit light having the same or different wavelengths. For example, all light emitting elements 1610a-c may emit the same color light, or alternatively, 1610a may emit a first color of light (e.g., red light), 1610b may emit a second color of light (e.g., green light), and 1610c may emit a third color of light (e.g., blue light). Although the elements 1610 are shown as hexagons, they may be any shape, including circles, squares, or other shapes as a matter of design choice.

[0035] Multiple light emitting elements 1610a-c may be covered by a single lenslet 1640 as shown. The lenslet 1640 may be chamfered (e.g., from a circular shape) around the perimeter to form a hexagonal footprint. As shown in the front and perspective views of FIGS. 16B and 16C, respectively, the hexagonal lenslet advantageously allows adjacent lenslets to nest in a hexagonal packing configuration similar to the light emitting elements 1610a-c. Although other lenslet shapes may be selected as a matter of design choice, the hexagon may allow for the largest lenslets and / or the most densely packed lenslet array. Additionally, although three light emitting elements are shown under each lenslet, more or fewer elements per lenslet may be used.

[0036] Referring to FIG. 17, a top view of a near-eye display system 1700 is shown. A detailed view of the emitter array system 1701 is shown in the left circle. The emitter array system 1701 includes a number of light emitting elements 1710a-c configured to direct light through respective apertures 1730a-c to a single lenslet 1740. A light absorber or baffle 1745 may be disposed between adjacent lenslets 1740. The lenslets 1740 may be spherical, aspheric, cylindrical, or other contoured lenslets. Light from each emitter is directed differently depending on the position of the light emitting element relative to the lenslets 1740. For example, light from emitter 1710a (e.g., the cone of light shown by the dotted line) is directed by the lenslet 1740 at a downward angle and exits the system 1701 as a first beam 1712a at a first angle. Light from emitter 1710b (e.g., the cone of light shown by the dashed line) may be centered with respect to lenslet 1740 and exits system 1701 as second beam 1712b at a second angle (e.g., perpendicular to the flat back face of lenslet 1740). Light from emitter 1710c (e.g., the cone of light shown by the solid line) is directed at an upward angle by lenslet 1740 and exits system 1701 as third beam 1712c at a third angle. Although light paths from three emitters 1710a-c are described, array 1701 extends in the x and y directions, and many beams of light may exit the array in substantially the same manner as described above for beams 1712a-c. In some embodiments, the light emitting elements can be arranged so that all light having a first wavelength exits the array system at a first angle, all light having a second wavelength exits the array system at a second angle, and all light having a third wavelength exits the array system at a third angle, as shown in the system diagram on the right of FIG.

[0037] Light from each of the activated emitters 1710 in the emitter array system 1701 travels through its respective aperture and lenslet, where the beam is angled before exiting the emitter array system toward the projection lens 1756, as shown. The light beams 1712a (e.g., beams represented by dotted lines) that enter the projection lens 1756 at a first angle may all carry the same first color of light (e.g., red light). The beams 1712a pass through the projection lens 1756 and form a first light pupil at a first location 1714a centered at a first coordinate location (x1, y1, z1). Similarly, the beams 1712b and 1712c (e.g., beams represented by dashed and solid lines, respectively) pass through the projection lens 1756 and are focused at second and third locations 1714b, 1714c, respectively. The second and third locations have second and third coordinate locations (x2, y2, z2) and (x3, y3, z3), respectively. Therefore, the light exiting the projection lens 1756 may be spatially separated by color.

[0038] The multiple waveguides 1760a-c may be configured to receive spatially separated light beams. For example, a first waveguide 1760a may be positioned such that an incoupling element 1762a thereon is positioned at or near a first coordinate location (x1, y1, z1). Light having a first wavelength may be incoupled into the first waveguide by the first incoupling element and enter the first waveguide, where it may travel through the waveguide by total internal reflection ("total internal reflection") toward the first outcoupling element 1764a. Similarly, the second and third waveguides 1760b, 1760c may be positioned such that the second and third incoupling elements 1762b, 1762c on the second and third waveguides 1760b, 1760c are located at or near the second and third coordinate locations (x2, y2, z2) and (x3, y3, z3), respectively. Light having second and third wavelengths is incoupled into the second and third waveguides, respectively, where it travels by TIR towards the second and third outcoupling elements 1764b, 1764c. The first, second, and third outcoupling elements 1764a-c may be substantially aligned with the visual axis 1765 such that all wavelengths of light are outcoupled into substantially the same location. The first, second, and third outcoupled beams, represented as cones of light 1750a-c, may substantially overlap such that the user's eye 1768 receives light of all the different wavelengths and therefore the user may perceive a full color image.

[0039] Spatially separating the input light by color before incoupling the light into different waveguides may allow incoupling and outcoupling elements to be designed for each specific wavelength of light, for each waveguide. The overall optical system may therefore produce higher quality images (e.g., brighter, sharper, more uniform, fewer artifacts) and be more power efficient compared to systems that incouple a wide range of wavelengths into a single waveguide. Although the system has been described for three wavelengths, more or fewer wavelengths of light may be spatially separated by adjusting the arrangement of the emitter array relative to the lenslet array.

[0040] 18A-B show front and perspective views of an emitter array system 1801. The light emitting elements 1810 in the emitter array system 1801 may be arranged in a hexagonal packing configuration similar to that described with respect to FIG. 16, however, the emitter array system 1801 may not have gaps between the emitters 1810. Between the light emitting elements 1810 and the lenslets 1840 is a cavity structure 1870. The cavity structure 1870 may be formed from an opaque material configured to cover and surround a plurality (e.g., a triad) of emitters (e.g., red, green, and blue emitters). The cavity structure 1870 includes an aperture 1871 that may be located near a center of the plurality of emitters such that a substantially equal portion of the light emitted by each of the emitters 1810 passes through the aperture 1871. Light from multiple emitters is combined in aperture 1871 and, in some embodiments, white light or light of various colors depending on the activation of the emitters may be produced at the output of the aperture. Although aperture 1871 is shown as a hexagon, other shapes, such as a circle, may be used as a matter of design choice. The opaque material forming the cavity structure may be a bilayer of a reflective material on the inside and an absorbing material on the outside (e.g., to reduce scattering and crosstalk). A variety of materials may be used, including metallic, carbon-based, and dielectric materials.

[0041] A plurality of lenslets 1840 are disposed on the cavity and configured to receive light emitted through apertures 1871. As shown in FIG. 18A, each lenslet 1840 may receive light through two adjacent apertures 1871. The lenslets 1840 are spherical (e.g., chamfered from a circle) lenslets arranged in an array such that each of the two apertures is aligned on a first axis 1843 that bisects the lenslet 1840, and each of the two apertures is equidistant from a second axis 1847 that bisects the lenslet 1840 in a direction perpendicular to the first axis. The intersection of the first and second axes may be the apex of the spherical lenslet.

[0042] FIG. 19 shows a top cross-sectional view of an emitter array system 1901 having a similar structure to the emitter array system 1801. The system 1901 includes an emitter 1910, a cavity structure 1970, an aperture 1930, and a lenslet 1940. A light baffle absorber 1945 may be disposed between the aperture 1930 and the lenslet 1940 to reduce crosstalk between a first light beam 1950a and a second light beam 1950b of light exiting the two apertures. The aperture 1930 may be equidistant from the axis 1947 of the lenslet 1940 and offset relative to the apex of the lenslet. Such a position allows the first light beam 1950a from the first aperture to be directed at a first angle and the second light beam 1950b from the second aperture to be directed at a second angle after interacting with the lenslet 1940. Therefore, the system 1901 can spatially separate light from adjacent light emitting element groups. Such a system can have advantages, as shown in FIG. 20. As shown in FIG. 19, a near-eye display system 2000 having an emitter array system 1901 is shown. First and second beams 1950a, 1950b from a single lenslet are shown, while light from other lenslets in the array are omitted from the figure for clarity. The beams 1950a, 1950b proceed towards a projection lens 2056 which forms first and second pupils at first and second locations 2014a, 2014b, respectively. The first and second locations are laterally offset in the x-direction. First and second waveguides 2060a, 2060b having first and second incoupling elements 2062a, 2062b may be positioned such that the first and second incoupling elements are configured to receive the first and second beams, respectively. Light from the first beam 1950a is incoupled into the first waveguide and travels (e.g., by TIR) towards the outcoupling element where it is extracted from the waveguide and directed towards the user's right eye 2068a.Similarly, light from the second beam 1950b is incoupled into the second waveguide and travels (e.g., by TIR) toward the outcoupling element, where it is extracted from the waveguide and directed toward the user's left eye 2068b. Thus, by activating one group of light-emitting elements per lenslet to display right image light, and by activating the other group of light-emitting elements associated with the same lenslet to display left image light, the system 1901 can simultaneously generate separate left and right images. The left and right images can be the same or different images. A light absorber 2045 can be disposed between the first and second waveguides to prevent light from the first beam from reaching the second waveguide and vice versa.

[0043] Producing two different images (e.g., one for the left eye and one for the right eye) can be important for creating an augmented reality ("AR") near-eye display system. In some systems, the different images are produced by using two separate emitter arrays and projection lens assemblies. This approach increases the size, weight, and cost of the overall system. Alternatively, if only a single emitter array and projection lens assembly is used (e.g., with a system such as that described below with reference to Figures 22C, 22D), the emitter array can alternate between projecting light for the left image and light for the right image. This approach can result in a perceived reduction in the system frame rate, since only half of the light generated is directed to each eye. The emitter array system 1901 provides the benefit of space savings. Although twice as many emitter groups are used to generate the two separate images, the arrangement of the light-emitting elements in a hexagonal packing configuration allows for more densely packed emitters (e.g., compared to an orthogonal grid), resulting in an overall area size that is less than twice as large despite encompassing twice as many emitter groups. Furthermore, the frame rate of the system is not reduced because each emitter group is dedicated to generating light for only one of the two separate images. A single backplane and set of driver electronics may reduce the power consumption of the system. Minimal additional processing may be required to assemble the left and right interleaved images.

[0044] 21A and 21B show top-down cross-sectional views of emitter array systems 2101a, 2101b, respectively. Systems 2101a, 2101b are similar to system 1901 shown in FIG. 19, but implement different crosstalk mitigation configurations. In FIG. 21A, peripheral absorbers 2145a, 2145b extend from the top of cavity structure 2170 and cover the sides of lenslet 2140. Central absorber 2145c extends from the top of cavity structure 2170 through lenslet 2140 to its apex. Central absorber 2145c prevents light from a first beam from traveling through the lens and out-coupling with a second beam, and vice versa. In FIG. 21B, peripheral absorbers 2145d, 2145e and central absorber 2145f extend from the top of cavity structure 2170 to the bottom of lenslet 2140. Additional absorbers 2147 may be substantially perpendicular to the perimeter absorbers 2145d-f and may act as an aperture to narrow the first and second beams so that they are further separated as they pass through the lenslet 2140. This second aperture may help suppress crosstalk between the two light beams. The variations shown in Figures 21A and 21B may be combined, and other buffers and light absorbers may be placed around or within the cavity structure and lenslets to maintain separation between the first and second beams. In addition, although spherical lenslets are described in this configuration, cylindrical lenses may be used in this configuration, as well as other configurations described in this disclosure. The use of cylindrical lenses may advantageously reduce or eliminate diffraction that occurs in spherical lenslets, but cylindrical lenses may also result in a loss of light concentration in one microdisplay axis.

[0045] 22A and 22B show optical systems 2200a and 2200b, respectively, that do not rely on lenslets to spatially separate light beams. Instead, in both systems, an aperture 2231 is used to sample the emission cone generated by the emitter 2210 such that light from adjacent emitter groups (or a single emitter in some configurations) is centered on opposite input angles to the downstream projection lens (not shown). By omitting lenslets, systems 2200a, 2200b can benefit from reduced artifacts caused by TIR reflections in the lenslets, reduced edge scattering, and reduced diffraction.

[0046] The system 2200a in Figure 22A includes a parallax barrier 2233 between two adjacent cavity apertures 2230. The parallax barrier 2233 may act to block portions of each of the light beams 2212a, 2212b, such that the portion of light passing through the aperture 2231 is angled. In some embodiments, approximately half of each of the light beams 2212a, 2212b is blocked by the parallax barrier 2233. This spatial separation of light may be used to simultaneously create two different images (e.g., a first image for the left eye and a second image for the right eye).

[0047] System 2200b in FIG. 22B includes a liquid crystal, or otherwise movable physical barrier, MEMS shutter 2235, for selectively blocking portions of beams 2212a, 2212b. In the top panel, a first portion of light beams 2212a, 2212b is blocked by shutter 2235 at a first time, and in the bottom panel, a second portion of light beams 2212a, 2212b is blocked by shutter 2235 at a second time. The portions of light that are blocked may alternate, such that light is alternately directed at opposite angles. This temporal and spatial separation may be used to create two different images (e.g., a first image for the left eye and a second image for the right eye).

[0048] 22C and 22D show a system 2200c including a movable or otherwise dynamic shutter 2237 in front of the incoupling elements 2262a, 2262b on the waveguides 2260a, 2260b. The shutter 2237 may include a liquid crystal or a movable MEMS shutter. At a first time, as shown in FIG. 22C, the shutter 2237 may be in a first position, which blocks a first portion of the light projected by the projection lens 2256, while a second portion of the light is transmitted through it and impinges on the second incoupling element 2262b. The second portion of the light incouples into the second waveguide 2260b and propagates through the waveguide by TIR until it is outcoupled towards the user's left eye 2268b. At a second time, as shown in FIG. 22D, the shutter 2237 is moved to a second position, which blocks a second portion of the light projected by the projection lens, while the first portion of the light transmits through the open shutter and strikes the first incoupling element 2262a. The first portion of the light incouples into the first waveguide 2260a and propagates through the waveguide by TIR until it is outcoupled towards the user's right eye 2268a. Thus, the light from the projection lens 2256 may be spatially and temporally modulated to create two different images. The movable shutter configuration shown in FIG. 22C-D may be used in combination with the emitter array system shown in FIG. 21A-B and FIG. 22A-B.

[0049] In addition to spatially modulating the output beam by uniformly positioning the light emitting elements relative to the lenslets, diffractive elements, prisms, metalenses, parallax barriers, or shutters, the location of the light pupil exiting the projection lens may be gradually altered by having the angle of light exiting the emitter array system as a function of distance from the center of the array. Adjusting the angle at which light is emitted by the emitter array system may result in a change in the location of the pupil formed by the projection lens. In some embodiments, the change in pupil location may result in a change in the working distance of the projection lens (i.e., the distance between the projection lens output bezel and the focal point of the light). In other embodiments, changing the emission angle of the light from the emitter array may result in a lateral shift of the pupil formed by the projection lens.

[0050] 23, there is shown a near-eye display system 2300. The system 2300 includes an emitter array system 2301, a projection lens 2356, and a waveguide 2360 having an in-coupling element 2362 and an out-coupling element 2364. A working distance d1 is shown between the bezel of the projection lens and the focal point of the emitted light.

[0051] A first detailed view of the central portion 2303 of the emitter array system 2301 is shown in the lower circle in FIG. 23. The central emitter 2310a and the associated aperture 2330a of the cavity 2320a are aligned with the symmetry axis 2309a of the central lenslet 2340a. Therefore, light emitted from the emitter 2310a through the aperture 2330a and through the lenslet 2340a has a chief ray directed along the axis 2309a of the lenslet 2340a. A second detailed view of the peripheral portion 2305 of the emitter array system 2301 is shown in the upper circle. The peripheral emitter 2310b and the associated aperture 2330b of the cavity 2320b are also aligned with the symmetry axis 2309b of the peripheral lenslet 2340b in a similar manner as the central emitter is aligned. All emitters and lenslets in the array system 2301 from center to periphery are aligned in the same manner, such that all emission cones from the system 2301 are uniform and have chief rays that are substantially parallel to one another. All chief rays are also substantially perpendicular to the emitter array system panel. This configuration is considered a telecentric emission configuration, and results in a working distance d1, and a pupil centered at the coordinate location (x0, y0, z0) as shown.

[0052] FIG. 24 illustrates an optical system 2400 with uniform chief ray tilt across the emitter array system 2401. The light cone shown in dotted lines is a uniform telecentric emission as described with respect to FIG. 23 and serves as a reference for the solid line chief ray tilt configuration. By uniformly changing the angle of each emission cone across the entire emitter array system 2401 (e.g., by an angle θ in the yz plane), the pupil location of the light exiting the projection lens 2456 can be adjusted in the +y direction as shown. Such a uniform angular shift can be achieved by moving the entire lenslet array laterally relative to the emitter aperture array. Thus, when the light cone enters the projection lens 2456 at an angle θ, the coordinate location of the exit pupil from the projection lens is (x0, y0 + y, z0). Although the angle θ is shown in the yz plane, the input angle of light into the projection lens can be adjusted in the xz plane to affect the x location of the pupil, or can be adjusted in both the xz and yz planes simultaneously to affect both the x and y locations of the exit pupil.

[0053] Adjusting the location of the exit pupil in the + / -z direction has the effect of changing the working distance of the optical system. It is advantageous to be able to customize the working distance to fit a particular form factor or other geometric constraints within the optical system. FIG. 25 shows a hyper-telecentric optical system 2500 having an emitter array system 2501 and a projection lens 2556. The reason the system is considered hyper-telecentric is because the chief ray of the emitted cone of light, shown by the solid line (where the dotted line represents a uniform telecentric cone for reference), is substantially perpendicular to the emitter array panel at the center of the emitter array panel and progressively increases in angle away from the center line 2511 of the projector 2556 as the distance from the center of the emitter array panel increases. This concept is shown diagrammatically in FIG. 26, which shows a front view of the emitter array system 2501. The lenslet array in the emitter array system emits light with chief rays directed substantially out of the paper at the center of the array, and with chief rays most inclined away from the center of the emitter array system 2501 at the periphery of the array. Therefore, the angle of the chief rays in the emitted cone of light is a function of the (x,y) location of the emitters in the emitter array system 2501. The maximum chief ray angle (i.e., the chief ray angle at the periphery of the emitter array system) can determine the magnitude of the change in pupil location in the +z direction. In some embodiments, there can be a chief ray angle large enough that the projection lens size must be increased to capture all the light from the emitter array system to minimize vignetting at the edges of the image.

[0054] Referring again to FIG. 25, the pupil formed at the exit of the projection lens 2556 is shifted in the +z direction compared to the uniform telecentric case and has a coordinate location of (x0, y0, z0+z). FIG. 27 shows a near-eye display system 2700 including the optical system 2500 described above. The system 2700 further includes a waveguide 2760 having an in-coupling element 2762 and an out-coupling element 2764. The pupil formed at the exit of the projection lens 2556 is at the coordinate location (x0, y0, z0+z). Here, since z is a positive number, the working distance d2 between the projection lens exit and the pupil is larger than the working distance d1 for the uniform telecentric configuration (FIG. 23). Therefore, the incoupling element 2762 configured to receive the pupil and incoupling light into the waveguide 2760 can be positioned further from the exit of the projection lens 2556 when compared to a near-eye display system 2300 having a uniform telecentric emitter array system 2301.

[0055] A modified angle of the chief ray across the emitter array 2501 may be achieved by changing the relative positions between the emitters and the lenslets. For example, the central aperture 2730a and the central emitter 2710a may be aligned with the central axis 2709a of the central lenslet 2740a, as shown in the detail in the lower left circle. The positions between the emitters and the lenslets at the periphery of the emitter array 2501 may be different. For example, as shown in the detail in the top circle of FIG. 27, the peripheral aperture 2730b and the peripheral emitter 2710b may be offset a distance relative to the central axis 2709b of the peripheral lenslet 2740b, such that the center of the lenslet 2740b is closer to the periphery of the array system than the center of the emitter 2710b. When light from the peripheral emitter 2710b passes through the offset peripheral lenslet 2740b, it is redirected such that the chief ray of the light cone has an angle directed away from the center of the emitter array system 2501. The offset between the emitter and the lenslet can be gradually increased with increasing distance from the center of the emitter array system 2501 to achieve a change in the +z direction of the pupil location. Although a single emitter per lenslet is shown, configurations having groups of emitters per lenslet are also possible, as described with respect to Figures 16-22. The focal length and surface profile of the lenslet can determine the concentration of light within the emission solid angle omega. Additionally, while lenslets 2740 are shown, gratings, metalenses, prisms, or other micro-optical elements may be incorporated to modify the chief ray angle. 31A and 31B show an example of an off-axis diffractive structure 3140 in which the pitch of the diffractive structure 3140 is non-uniform and diffracts the cone of light such that the chief ray is angled with respect to the normal vector 3143.

[0056] FIG. 28 shows an example of a convergent chief ray tilt optical system 2800 having an emitter array system 2801 and a projection lens 2856. The reason the system is considered convergent chief ray tilt is because the chief ray of the emitted cone of light, shown by the solid line (where the dotted line represents a uniform telecentric cone for reference), is substantially perpendicular to the emitter array panel at the center of the emitter array panel, and progressively increases in angle toward the centerline 2811 of the projector 2856 as the distance from the center of the emitter array panel increases. This concept is shown diagrammatically in FIG. 29, which shows a front view of the emitter array system 2801. The lenslet array in the emitter array system emits light with a chief ray directed in the z-direction (i.e., substantially out of the plane of the paper) at the center of the array, and emits light at the periphery of the array with a chief ray most tilted toward the center of the array. Therefore, the angle of the chief ray in each emitted cone of light is a function of the (x,y) location of the emitter in the emitter array system 2801. The maximum chief ray angle (i.e., the chief ray angle at the periphery of the emitter array system) may determine the magnitude of the change in pupil location in the -z direction. Because light at the periphery of the emitter array is angled inward toward the center, it may be possible to reduce the size of the projection lens 2856 without blocking light or causing vignetting of the image. Alternatively, instead of reducing the size of the projection lens, the size of the emitter array system may be increased so that more emitters and lenslets are included in the array. In this configuration, more angles of light may be fed into the projection lens 2856, which may increase the field of view supported by the optical system 2800.

[0057] Referring again to FIG. 28, the pupil formed at the exit of the projection lens 2856 is shifted in the -z direction compared to the uniform telecentric case and has a coordinate location of (x0, y0, z0-z). FIG. 30 shows a near-eye display system 3000 including the optical system 2800 described above. The system 3000 further includes a waveguide 3060 having an in-coupling element 3062 and an out-coupling element 3064. The pupil formed at the exit of the projection lens 2856 is at a coordinate location (x0, y0, z0-z) related to a working distance d3 between the projection lens exit and the pupil. The distance d3 is smaller than the working distance d1 for the uniform telecentric configuration (FIG. 23). Therefore, the in-coupling element 3062 configured to receive the pupil and in-couple light to the waveguide 3060 can be positioned closer to the exit of the projection lens 2856 when compared to the near-eye display system 2300 having the uniform telecentric emitter array system 2301.

[0058] A modified angle of the chief ray across the emitter array 2801 may be achieved by changing the relative positions between the emitters and the lenslets. For example, the central aperture 3030a and the central emitter 3010a may be aligned with the central axis 3009a of the central lenslet 3040a, as shown in the detail in the lower left circle. The positions between the emitters and the lenslets at the periphery of the emitter array 2801 may be different. For example, as shown in the detail in the top circle of FIG. 30, the peripheral aperture 3030b and the peripheral emitter 3010b may be offset a distance relative to the central axis 3009b of the peripheral lenslet 3040b, such that the center of the lenslet 3040b is closer to the center of the array system than the center of the emitter 3010b. When light from the peripheral emitter 3010b passes through the offset peripheral lenslet 3040b, it is redirected such that the chief ray of the light cone has an angle directed toward the center of the emitter array system 2801. The offset between the emitter and the lenslet may be gradually increased between the center and the periphery of the emitter array system 2801 to achieve a change in the -z direction of the pupil location. Although a single emitter per lenslet is shown, configurations with groups of emitters per lenslet are also possible, as described with respect to Figures 16-22. In addition, while lenslets 3040 are shown, gratings, metalenses, prisms, or other micro-optical elements may be incorporated to modify the chief ray angle. An example of an off-axis diffractive structure 3140 is shown in Figures 31A and 31B, where the pitch of the diffractive structure 3040 is non-uniform and diffracts the light cone such that the chief ray is angled with respect to the normal vector 3143.

[0059] Referring to FIG. 32A, an exemplary optical system 3200 is shown. As described in more detail below, because the light directing and shaping is performed in multiple stages, and because different light forms are used for the two optical power axes, the system 3200 can be considered a "split" system for transmitting light from the display 3202 into the eyepiece 3204. The display system 3202 includes an emitter array panel 3206 and a projection lens 3208. The emitter array panel 3206 can include an array of light emitters (e.g., micro LEDs) and an array of lenslets (e.g., cylindrical lenslets, not shown, which can be symmetric or asymmetric) covering the emitters. The positioning between the emitters and the lenslets can be similar in some respects to the configuration described for the emitter array 2801 in the convergent chief ray tilt system 2800 (FIGS. 28-30). However, the emitter array panel 3206 can differ from the emitter array 2801 in some respects. For example, the light beam emitted by the emitter array panel 3202 may be tilted in only one dimension (e.g., along the x-axis) rather than two dimensions. Additionally, in some embodiments, the emitter array panel has an elongated shape (e.g., having a width dimension w greater than a height dimension h). In some embodiments, the ratio of width w to height h may be approximately 4:1. In some embodiments, the width w of the emitter array panel may be approximately 20 mm, and the height h of the emitter array panel may be approximately 5 mm. However, other dimensions and ratios are possible as a matter of design choice without departing from the scope of the present application.

[0060] The elongated shape of the emitter array panel 3206 is further illustrated in FIGS. 33A and 33B, which show front and top views of the emitter array panel, respectively. The emitter array panel 3206 may be elongated along the same axis along which the light rays emitted therefrom are tilted (e.g., the x-axis). Tilting in one dimension may be achieved by offsetting the array of cylindrical lenslets relative to the underlying light emitters, as shown in FIGS. 34A and 34B. The offset between the central axis 3234 of the cylindrical lenslets and the central axis 3236 of the underlying aperture associated with the light emitter, or group of light emitters, may be gradual, such that the tilt is minimal (e.g., approximately 0) along the centerline 3212 of the emitter array panel, as shown in FIG. 34A. This allows the chief light rays 3218 emitted from the center of the emitter array panel to travel substantially perpendicular to the emitter array panel. The tilt angle is determined by the maximum offset d at the left and right edges of the emitter array panel, as shown in FIG. o,max The chief ray 3210 located near the edge of the emitter array panel has an offset d o,max The dotted lines in Figures 34A and 34B represent the cones of light associated with each chief ray. The dashed lines indicate the image foci associated with the cones of light. The cones of light are located at a distance d from the lenslet. f The light may be focused at a focal point 3238 located at a distance d f is determined by the particular design of the cylindrical lenslet. The focal length d f may be greater than the distance between the emitter array panel 3206 and the waveguide 3204. For example, in some embodiments, the focal length may be approximately one meter, although other distances may be selected as a matter of design choice without departing from the scope of this application. In one example, at least a portion of the cylindrical lenslets form images of at least a portion of the emitters in the emitter array at distances between approximately 500 millimeters and infinity.

[0061] 33A and 33B also show a one-dimensional tilt of the chief rays, where the arrows represent the chief rays emitted by the light emitters and directed by the cylindrical lenses in the emitter array panel. The chief ray 3210 furthest from the centerline 3212 of the emitter array panel 3206 is angled toward the centerline 3212 at a first angle θ1 measured from a line perpendicular to the front surface of the emitter array panel (e.g., the front surface of a cylindrical lenslet). The first angle θ1 can be greater than the second and third angles θ2 and θ3 associated with the rays 3214, 3216, respectively. The rays 3214 and 3216 emanate from positions closer to the centerline 3212 in the x-direction than the ray 3210. Chief rays 3218 emitted from a location substantially on the centerline 3212 may have a trajectory that is substantially parallel to a line perpendicular to the front surface of the emitter array panel, and therefore have a slope of approximately 0. In some embodiments, all chief rays emitted from the emitter array panel 3206 are within a distance d from the front surface of the emitter array panel. x , where each chief ray represents a cone of light (FIGS. 34A, 34B) that is focused at a non-infinite distance (e.g., approximately one meter or more from the viewpoint where the user's eyes are located). x Instead of a small focus, the light at may form a wider beam waist 3240 (FIG. 32).

[0062] Referring again to FIG. 32A, the dashed lines extending from the emitter array panel 3206 represent a group of light rays 3222 (e.g., chief rays 3210, 3214, 3216, 3218, and associated cones of light) emitted by the emitter array panel 3206 angled inward by an amount that varies with the position of the emitter along the x-axis, as described with respect to FIGS. 33A-34B. The trajectories of the light rays do not vary along the y-dimension of the emitter array panel. Light rays emanating from emitters that share a common x-coordinate on the emitter array panel but have different y-coordinates may follow substantially parallel trajectories. Therefore, the light emitted from the emitter array panel would not converge to a focal point in the y-dimension without the use of the projection lens 3208.

[0063] The light rays 3222 from the emitter array panel impinge on the projection lens 3208. An example of the components of the projection lens 3208 are shown in detail in FIG. 35. The projection lens may include one or more optical elements, such as lenses 3224. Each lens 3224 may have a shape that is different or the same as the other lenses in the projection lens. In some embodiments, the lenses may be cylindrical or toroidal lenses, such that the cross-sectional shape as viewed in the yz plane remains constant across the x dimension, while the cross-sectional shape as viewed in the xz plane changes along the y dimension. The projection lens may not have any refractive power along the x axis. Therefore, the trajectories of the light rays 3222 entering the projection lens 3208 may be modified as a function of the y coordinate location where each light ray enters the optical element 3208. In some embodiments, the projection lens 3208 collimates the cone of light in the y direction and directs the chief ray to a distance d from the projection lens components. y 32. In some embodiments, the light rays may converge in the y direction at a location different from where the light rays converge in the x direction or form a beam waist. In the exemplary system shown in FIG. 32, the convergence in the y direction occurs at a point along the light path closer to the emitter array panel than the convergence in the x direction.

[0064] The chief rays, represented by dotted lines 3226, emerging from the projection lens 3208 are on trajectories that converge in both the x and y directions when they impinge on an incoupling optical element 3230 disposed on or within the waveguide 3204. The cone of light associated with each chief ray is collimated in the y direction and is projected over some large distance d in the x direction. fThe spacing between the emitter array panel, the shaped optical element, and the incoupling optical element, as well as the light path angles created at the emitter array panel and the projection lens, may be selected such that the light ray 3226 strikes the incoupling optical element 3230 at the y-direction convergence location 3228 and prior to the x-direction convergence location. As the light ray incouples into the waveguide via the incoupling optical element, at least a portion of the light is diffracted and / or reflected (e.g., by total internal reflection "TIR") within the waveguide 3204 to the outcoupling optical element 3232. The optical path of the light within the waveguide 3204 is represented by the dashed line between the incoupling optical element 3230 and the outcoupling optical element 3232. The outcoupling optic redirects the light as it travels in the -y dimension and interacts with the outcoupling optic 3232, causing a portion of the light to exit the waveguide 3204 toward the user's eye (as represented by the dashed arrow pointing away from the outcoupling optic 3232) while the remaining portion continues in the -y dimension. The outcoupling optic 3232 therefore replicates the pupil formed in 3228 and expands the eyebox (e.g., the area in which the viewer's eye may observe the image represented by the light exiting the outcoupling optic) in the y dimension. The length of the light's path from the incoupling optic to the viewer's eye is represented as two dashed lines, l e In some embodiments, the distance l e is the distance l c where the distance l c is the distance between the incoupling optical element of the waveguide 3204 and the beam waist 3240. Therefore, as the light travels through the waveguide 3204, it continues to converge and focus such that the location of the beam waist coincides with the location of the viewer's eyes.

[0065] Another embodiment of an optical system 3201 is shown in FIG. 32B. Similar to system 3200, system 3201 can be considered a "split" system for transmitting light from a display 3202' into an eyepiece 3204'. The display system 3202' includes an emitter array panel 3206' and a projection lens 3208. The emitter array panel 3206' can include an array of light emitters (e.g., micro LEDs) and an array of lenslets (e.g., cylindrical lenslets, not shown, which can be symmetric or asymmetric) disposed over the emitters. The positioning between the array of light emitters and the array of lenslets is such that the light exiting the lenslets towards the projection lens 3208' is not tilted along the x-direction. Therefore, the light does not converge in the x-dimension. This is illustrated in the front and top views of the emitter array panel 3206' shown in FIG. 33C and FIG. 33D, respectively. The chief rays 3210', 3214', 3216', 3218' emerging from the emitter array panel 3206' are substantially parallel to one another in both the x and y dimensions. The relationship between the emitter array, apertures, and lenslet array may be constant throughout the emitter array panel 3206' and may be similar to the relationship shown in FIG.

[0066] Other configurations of the emitter array panel 3206' are possible. For example, referring first to FIG. 34C, multiple micro LED emitters 3402 may be associated with a single aperture 3236' and a single lenslet 3404. The lenslet 3404 may be positioned such that the centerline 3234' of the lenslet aligns with the center of the aperture 3236' in the x dimension. Chief rays (e.g., light ray 3210') may be emitted from the lenslet at an angle that is substantially perpendicular to the emitter array panel 3206'. A cone of light associated with each chief ray may also be emitted by the lenslet 3404 at a distance d from the lenslet, as shown by the dashed lines. f In some embodiments, the focal point may be shaped to create a focal point at a distance d fmay be approximately 1 meter, although other distances are possible depending on the lenslet design. Furthermore, the chief ray may travel in a direction substantially perpendicular to the front surface of the emitter array panel 3206'. The multiple emitters 3402 may be disposed in the emitter array panel with a pitch p, which may be approximately 25 μm. The width dimension of the lenslets 3404 may be approximately equal to the pitch p.

[0067] 34D, another embodiment of an emitter array panel 3206″ is shown. A plurality of micro LED emitters 3402 may be associated with a plurality of apertures 3236″, each of which may be associated with a single lenslet 3406. The lenslets 3406 may be positioned such that the centerline 3234″ of each lenslet 3406 aligns with the center of the aperture 3236″ in the x dimension. Chief rays may be emitted from each lenslet 3406 at different angles. In the illustrated embodiment, where three lenslets are shown, light passing through the central lenslet may have a chief ray oriented substantially perpendicular to the emitter array panel 3206″. Lenslets to the left and right of the central lenslet may have chief rays angled away from the central lenslet. Each lenslet may have a focal point a distance d from the lenslet. f 3. The micro LED emitters emit a cone of light, represented by the dotted line, shaped to form a cone of light at 3.5 mm. Multiple apertures and multiple lenslets are used to shape and direct the light from the micro LED emitters, resulting in multiple focal points. In some embodiments, the pitch p' of the micro LED array may be approximately 25 μm. The width dimension of the multiple lenslets associated with each group of micro LED emitters may be equal to the pitch p'. Thus, compared to the lenslets 3404 in system 3206', the lenslets 3406 may have a smaller width. The lenslets 3406 with a smaller width may provide a higher fidelity pixel image than a single larger lenslet 3404.

[0068] When the light from the emitter array system, represented by dotted lines 3222', 3206', reaches the projection lens 3208, the projection lens 3208 may serve to focus and / or collimate the light in the y dimension, as represented by dotted line 3226'. The light is focused a distance d y The light may reach a y-dimension focal point at -y. The waveguide eyepiece 3204' may be positioned such that the incoupling optic 3228' is at the focal point, and the light is then incoupled into the eyepiece. The light incoupled into the eyepiece diffracts and / or reflects within the eyepiece along the -y dimension where it encounters the outcoupling optic 3232'. As the light interacts with the outcoupling optic 3232' and travels in the -y dimension, multiple pupils of light will exit the waveguide 3204', thereby forming an eyebox where the viewer can observe the image represented by the light.

[0069] Systems 3200 and 3201 provide several advantages. Specifically, the split system allows for a practical form factor for a minimalist brow-mounted display and projector. Such a form factor can be easily integrated into a pair of glasses near the user's brows without the need for bulky frames. In addition, system 3200 includes a large ICG configured to incouple a large amount of light from the display and projector. Incoupling such a large amount of light results in improved brightness and efficiency of the image emerging from the outcoupling optics for viewing by the user. Furthermore, due to the elongated shape of the emitter array panel, projector, and incoupling optics, the eyepiece only needs to replicate the optical pupil in one direction (e.g., the y-direction). Reducing the requirement for outcoupling optics improves the efficiency of the waveguide eyepiece and simplifies the optical design and fabrication requirements.

[0070] Thus, although the present disclosure has been provided according to the illustrated implementation, those skilled in the art will readily recognize that there may be variations in the embodiments, and such variations will fall within the scope of the present disclosure. Thus, many modifications may be made by those skilled in the art without departing from the scope of the appended claims.

Claims

1. A method for manufacturing a light-emitting diode (LED) comprising: the first micro LED emitter is configured to output light from the first micro LED emitter as a first collimated light; the first collimated light has a first chief ray angle; a second micro LED emitter optically coupled to the second optical element; the second micro LED emitter is configured to output light from the second micro LED emitter as a second collimated light having a second chief ray angle different from the first chief ray angle.

2. The first collimated light has a first cone angle, 10. The micro LED display of claim 1, wherein the second collimated light has a second cone angle different than the first cone angle.

3. The first collimated light has a first polarization, 10. The micro LED display of claim 1 , wherein the second collimated light has a second polarization different than the first polarization.

4. The first micro-LED emitter is optically coupled to the first optical element via a first cavity configured to at least partially enable the first collimated light to have the first chief ray angle; 2. The micro LED display of claim 1, wherein the second micro LED emitter is optically coupled to the first optical element via a second cavity configured to at least partially enable providing the second collimated light with the second chief ray angle.

5. The first cavity includes a first emission aperture that is smaller than the first micro LED emitter; 5. The micro LED display of claim 4, wherein the second cavity includes a second exit aperture that is smaller than the second micro LED emitter.

6. The micro LED display of claim 1, wherein a focal length of radiation from the micro LED display is based, at least in part, on the difference between the second chief ray angle and the first chief ray angle.

7. The first micro LED emitter is configured to emit light of a first color; 10. The micro LED display of claim 1, wherein the second micro LED emitter is arranged to emit light of a second color different from the first color.

8. The micro LED display of claim 1, wherein the first optical element and the second optical element are optically coupled to a collimator configured to output an image of the micro LED display, and a position of the image in a direction parallel to the micro LED display is based on the difference between the first chief ray angle and the second chief ray angle.

9. The micro LED display of claim 1, wherein the first optical element and the second optical element are optically coupled to a collimator configured to output an image of the micro LED display, and a position of the image in a direction perpendicular to the micro LED display is based on the difference between the first chief ray angle and the second chief ray angle.

10. An emitter array including a plurality of micro LED emitters; a plurality of optical elements respectively optically coupled to the plurality of micro LED emitters; 13. A micro LED panel, wherein at least one of a shape of each of the plurality of micro LED emitters or an optical property of each of the plurality of optical elements varies spatially across the emitter array such that a chief ray angle of each of the light emitted from the plurality of optical elements varies.

11. The micro LED panel of claim 10, wherein light emitted from a center of the micro LED panel has a chief ray angle perpendicular to the plane of the micro LED panel.

12. The micro LED panel of claim 10, wherein light emitted from an edge of the micro LED panel has a chief ray angle that is non-perpendicular to the plane of the micro LED panel.

13. A micro LED panel as described in claim 10, wherein each offset between the optical axis of each of the plurality of optical elements and the center of each of the plurality of micro LED emitters varies across the emitter array.

14. The micro LED panel of claim 10, wherein the chief ray angles of each of the light emitted from the plurality of optical elements gradually increase from a center of the micro LED panel to an edge of the micro LED panel.

15. A micro LED panel, The micro LED panel comprises: a first plurality of micro LED emitters each configured to emit a first light at a first chief ray angle; a second plurality of micro LED emitters each configured to emit a second light at a second chief ray angle; a lens assembly optically coupled to the first plurality of micro LED emitters and the second plurality of micro LED emitters to receive the first light and the second light; and a combiner. the combiner has a first entrance pupil having a first spatial location on the combiner and a second entrance pupil having a second spatial location different from the first spatial location on the combiner; the combiner is optically coupled to the lens assembly; A display system, wherein the first light passes through the lens assembly to reach the first entrance pupil and the second light passes through the lens assembly to reach the second entrance pupil.

16. The method of claim 1, wherein the first plurality of micro LED emitters emit light of a first color; 16. The display system of claim 15, wherein the second plurality of micro LED emitters emit light of a second color different than the first color.

17. The display system of claim 15, wherein the first entrance pupil and the second entrance pupil are laterally separated on the combiner.

18. The display system of claim 15, wherein the combiner includes a diffractive waveguide.

19. The optical fiber according to claim 1, wherein the first entrance pupil includes a first diffractive coupler; 20. The display system of claim 18, wherein the second entrance pupil includes a second diffractive coupler.

20. The display system of claim 15, wherein the combiner includes a first waveguide including the first entrance pupil and a second waveguide including the second entrance pupil.

21. The display system of claim 15, wherein the combiner includes an exit pupil configured to output the first light and the second light.

22. A display system as described in claim 15, wherein the combiner includes a first exit pupil configured to output the first light and a second exit pupil configured to output the second light.

23. A display system as described in claim 22, wherein the first exit pupil is configured to transmit the first light to a first eye of a viewer, and the second exit pupil is configured to transmit the second light to a second eye of the viewer.

24. Each micro LED emitter of the first plurality of micro LED emitters includes a respective cavity and a respective optical element optically arranged to impart the first light with the first chief ray angle; 23. The display system of claim 22, wherein each micro LED emitter of the second plurality of micro LED emitters includes a respective cavity and a respective optical element optically disposed to impart the second light with the second chief ray angle.

25. A micro LED device configured to emit LED light during operation; a cavity including an exit aperture optically coupled to the micro LED device and configured to output a portion of the LED light as a first light; a micro-optical element optically coupled to the exit aperture and configured to output a portion of the first light as a second light having a chief ray angle; a collimating optical element optically coupled to the micro-optical element and configured to output a portion of the second light as a third light, The collimating optical element has an optical axis, The cavity and the micro-optical element are arranged such that the chief ray angle is not parallel to the optical axis.

26. The emitter of claim 25, wherein the center of the emission aperture is offset from the center of the micro LED device.

27. The emitter of claim 25, wherein the center of the emission aperture is offset from the center of the micro-optical element.

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