Nanopattern encapsulation function, method, and process in combined optical components

Abstract

Disclosed herein are systems and methods for displays, such as head-wearable devices. An exemplary display can include an infrared illumination layer, which can include a substrate, one or more LEDs disposed on a first surface of the substrate, and a first encapsulation layer disposed on the first surface of the substrate, where the encapsulation layer can include a nanopatterned surface. In some examples, the nanopatterned surface can be configured to improve the visible light transmittance of the illumination layer. In one or more examples, embodiments disclosed herein can provide a robust illumination layer that can reduce haze associated with the illumination layer.

Description

Technical Field

[0001] Cross - reference to Related Applications This application claims the priority of U.S. Provisional Patent Application No. 63 / 176,077, filed on April 16, 2021, the content of which is incorporated herein by reference in its entirety.

[0002] Field The present disclosure generally relates to systems for displaying visual information, and more particularly to eyepieces for displaying visual information and / or performing eye tracking in an augmented reality or mixed reality environment.

Background Art

[0003] Background Virtual environments are ubiquitous in computing environments and are used in video games (where the virtual environment can represent a game world); maps (where the virtual environment can represent the terrain to be navigated); simulations (where the virtual environment can simulate a real - world environment); digital storytelling (where virtual characters can interact with each other in the virtual environment); and many other applications. Modern computer users generally perceive and interact with virtual environments comfortably. However, the user experience with virtual environments can be limited by the technology used to present the virtual environment. For example, conventional displays (e.g., 2D display screens) and audio systems (e.g., fixed speakers) may not be able to realize a virtual environment in a way that creates an attractive, realistic, and immersive experience.

[0004] Virtual reality ("VR"), augmented reality ("AR"), mixed reality ("MR"), and related technologies (collectively "XR") share the ability to present users of XR systems with sensory information corresponding to a virtual environment represented by data within a computer system. This disclosure assumes distinctions between VR systems, AR systems, and MR systems (however, some systems may be classified as VR in one aspect (e.g., a visual aspect) and simultaneously as AR or MR in another aspect (e.g., an auditory aspect)). As used herein, a VR system presents a virtual environment that replaces the user's real environment in at least one aspect. For example, a VR system may present a user with a view of the virtual environment while simultaneously obscuring the view of the real environment, such as by using a light-shielding head-mounted display. Similarly, a VR system may present a user with sounds corresponding to the virtual environment while simultaneously blocking (attenuating) sounds from the real environment.

[0005] VR systems can experience various drawbacks stemming from replacing the user's real-world environment with a virtual one. One drawback is the sensation of motion sickness that can occur when the user's field of view in the virtual environment no longer corresponds to the state of their inner ear that detects their balance and orientation in the real (non-virtual) environment. Similarly, users may experience disorientation in a VR environment where they cannot directly see their own body and limbs (the view on which the user feels "grounded" in the real world). Another drawback is the computational load (e.g., storage, processing power) imposed on VR systems, especially in real-time applications that aim to immerse the user in the virtual environment, as they must present a complete 3D virtual environment. Likewise, users tend to be sensitive to even slight imperfections in the virtual environment, any of which can detract from the sense of immersion; therefore, such environments may need to reach a very high standard of presence to be considered immersive. Furthermore, another drawback of VR systems is that such applications of the system cannot utilize the wide range of sensory data from the real world, such as the various sights and sounds experienced in the real world. A related drawback is that VR systems can sometimes struggle to create shared environments where multiple users can interact, because users sharing a physical space in the real world may not be able to see or interact with each other directly in the virtual environment.

[0006] As used herein, an AR system presents a virtual environment that overlaps with or overlays the real environment in at least one aspect. For example, an AR system can present a user with a view of the virtual environment overlaid on the user's view of the real environment, such as a transparent head-mounted display that presents a display image while allowing light to pass through the display and enter the user's eyes. Similarly, an AR system can present a user with audio corresponding to the virtual environment while simultaneously mixing audio from the real environment. Likewise, as used herein, an MR system, like an AR system, can present a virtual environment that overlaps with or overlays the real environment in at least one aspect, and further, the virtual environment within the MR system may enable interaction with the real environment in at least one aspect. For example, a virtual character in the virtual environment may toggle a light switch in the real environment, turning a corresponding light bulb in the real environment on or off. As another example, a virtual character may react (e.g., with facial expressions) to audio signals in the real environment. By maintaining the presentation of the real environment, AR and MR systems can avoid some of the aforementioned shortcomings of VR systems. For example, visual cues from the real environment (including the user's own body) can remain visible, and such systems do not need to present the user with a fully realized 3D environment for immersion, thus reducing user motion sickness. Furthermore, AR and MR systems can utilize sensory input from the real world (e.g., scenery, objects, and the views and sounds of other users) to create new applications that enhance that input.

[0007] Presenting a virtual environment in a realistic way and creating a robust and cost-effective user immersion experience can be challenging. For example, a head-mounted display may include an optical system with one or more multilayer eyepieces. The eyepiece can be an expensive and fragile component containing multiple layers that perform different functions. For instance, one or more layers may be used to display virtual content to the user, and one or more layers may be used as infrared (IR) illumination layers for eye tracking. Multiple layers can result in a large eyepiece that adds weight to the MR system. Furthermore, light transmission loss due to reflections and fogging on the layer surfaces can affect the quality of the virtual content. In addition, layers containing electronic components such as LEDs and metal interconnects, such as the IR illumination layer, can be susceptible to corrosion and / or oxidation. Therefore, it is desirable to improve the transmittance of the eyepiece, prevent corrosion of electronic components and leads, and achieve a lightweight and compact form factor. [Overview of the Initiative] [Means for solving the problem]

[0008] overview This specification discloses systems and methods for displays, such as those for head-wearable devices. An exemplary display may include an infrared illumination layer, which may include a substrate, one or more LEDs disposed on a first surface of the substrate, and a first encapsulation layer disposed on the first surface of the substrate, the encapsulation layer may include a nanopatterned surface. In some examples, the nanopatterned surface may be configured to improve the visible light transmittance of the illumination layer. Embodiments disclosed herein may provide a robust illumination layer that can reduce fogging associated with the illumination layer. Furthermore, embodiments disclosed herein may prevent corrosion of electronic components and / or lead wires. Furthermore, embodiments disclosed herein may provide a smaller display with a reduced number of optical components and optical interfaces that can improve the optical image quality presented to the user. The present invention provides, for example, the following items: (Item 1) A display including an infrared illumination layer, wherein the infrared illumination layer is Substrate and One or more LEDs are arranged on the first surface of the substrate, A first encapsulation layer disposed on the first surface of the substrate, wherein the first encapsulation layer includes a nanopatterned surface configured to improve the visible light transmittance of the illumination layer. A display equipped with a screen. (Item 2) The display according to item 1, wherein one or more LEDs are covered by the first encapsulation layer. (Item 3) The first encapsulation layer has a finite radius of curvature, as described in item 1 of the display. (Item 4) The display according to item 3, wherein the radius of curvature of the first encapsulation layer is configured to increase the refractive power of the illumination layer. (Item 5) The display according to item 1, wherein the first encapsulation layer is substantially planar. (Item 6) The display according to item 1, further comprising a second encapsulation layer disposed on a second surface of the substrate, wherein the second encapsulation layer has a second geometric shape different from the first geometric shape of the first encapsulation layer. (Item 7) The display according to item 1, wherein the substrate comprises a carrier plate, and further comprises a polymer layer disposed on a first surface of the carrier plate. (Item 8) The display according to item 1, wherein the nanopatterned surface includes at least one nanopattern selected from line-and-space patterns, pillar patterns, and pore patterns. (Item 9) The display according to item 8, wherein the nanopattern has a pitch in the range of 100 to 150 nm. (Item 10) It is a display, It is an illumination layer, Substrate and One or more LEDs are arranged on the first surface of the substrate, A first encapsulation layer disposed on the first surface of the substrate, wherein the first encapsulation layer includes a patterned surface such that the patterned surface is configured to improve the visible light transmittance of the illumination layer. A lighting layer A display equipped with a screen. (Item 11) The display according to item 10, wherein the illumination layer further comprises a second encapsulation layer on the second surface of the substrate, the second encapsulation layer having a second geometric shape different from the first geometric shape of the first encapsulation layer. (Item 12) The display according to item 10, further comprising an eyepiece, the eyepiece being configured to display digital content. (Item 13) The first encapsulation layer is the display according to item 12, having a finite radius of curvature. (Item 14) The display according to item 13, wherein the radius of curvature is configured to increase the refractive power of the eyepiece. (Item 15) The display according to item 10, wherein one or more LEDs are covered by the first encapsulation layer. (Item 16) The display according to item 10, further comprising a light sensor configured to detect light reflected from the user's eye, the light being emitted by one or more LEDs. (Item 17) It is a method, The method involves depositing a resin onto a first surface of a substrate, wherein the substrate includes an outer periphery having one or more edges. Bringing the first surface of the mold into contact with the resin, Using a first volume of resin, an encapsulation layer having a patterned surface is formed on the first surface of the substrate, A second volume of resin is introduced to the outer periphery of the substrate, wherein the first surface of the type is configured to include a plurality of nano-features, A first portion configured to overlap with the aforementioned substrate, A second portion configured to extend beyond the outer circumference of the substrate, wherein at least one of the plurality of nanofeatures is located on the second portion and This includes, Filling the at least one nano-feature located on the second portion of the first surface of the aforementioned type with the second volume of resin, The resin is cured to adhere the encapsulation layer to the substrate, The process involves removing the mold from the substrate, wherein the second volume of resin is removed together with the mold. Methods that include... (Item 18) The method according to item 17, wherein the mold comprises a soft mold, the first surface of the mold has a finite radius of curvature, and the encapsulation layer is formed having the radius of curvature such that the encapsulation layer has refractive power. (Item 19) The method according to item 17, wherein the substrate comprises one or more LEDs arranged on the first surface, and the encapsulation layer covers the one or more LEDs. (Item 20) Depositing a second resin on the second surface of the substrate, The first surface of the aforementioned type is brought into contact with the second resin, Using a third volume of resin, a second encapsulation layer having a second patterned surface is formed on the second surface of the substrate, A fourth volume of resin is guided to the outer periphery of the substrate, Filling the at least one nano-feature, which is arranged on the second portion of the first surface of the aforementioned type, with the fourth volume of resin, The second resin is cured to bond the second encapsulation layer to the substrate, The process involves removing the mold from the substrate, wherein the fourth volume of resin is removed together with the mold. The method described in item 17, further including the method described in item 17. [Brief explanation of the drawing]

[0009] [Figure 1A] Figures 1A to 1C illustrate exemplary mixed reality environments relating to one or more embodiments of the present disclosure. [Figure 1B] Figures 1A to 1C illustrate exemplary mixed reality environments relating to one or more embodiments of the present disclosure. [Figure 1C]Figures 1A to 1C illustrate exemplary mixed reality environments relating to one or more embodiments of the present disclosure.

[0010] [Figure 2A] Figures 2A to 2D illustrate components of an exemplary mixed reality system that can be used to generate and interact with a mixed reality environment, according to one or more embodiments of the present disclosure. [Figure 2B] Figures 2A to 2D illustrate components of an exemplary mixed reality system that can be used to generate and interact with a mixed reality environment, according to one or more embodiments of the present disclosure. [Figure 2C] Figures 2A to 2D illustrate components of an exemplary mixed reality system that can be used to generate and interact with a mixed reality environment, according to one or more embodiments of the present disclosure. [Figure 2D] Figures 2A to 2D illustrate components of an exemplary mixed reality system that can be used to generate and interact with a mixed reality environment, according to one or more embodiments of the present disclosure.

[0011] [Figure 3A] Figure 3A shows an exemplary mixed reality handheld controller that can be used to provide input to a mixed reality environment, according to one or more embodiments of the present disclosure.

[0012] [Figure 3B] Figure 3B shows an exemplary auxiliary unit that can be used with an exemplary mixed reality system according to one or more embodiments of the present disclosure.

[0013] [Figure 4] Figure 4 shows an exemplary functional block diagram of an exemplary mixed reality system according to one or more embodiments of the present disclosure.

[0014] [Figure 5]Figure 5 shows an exemplary optical system for an exemplary mixed reality system according to one or more embodiments of the present disclosure.

[0015] [Figure 6A] Figures 6A and 6B show examples of illumination layers for exemplary mixed reality systems according to one or more embodiments of the present disclosure. [Figure 6B] Figures 6A and 6B show examples of illumination layers for exemplary mixed reality systems according to one or more embodiments of the present disclosure.

[0016] [Figure 7A] Figures 7A to 7D show examples of illumination layers for exemplary mixed reality systems according to one or more embodiments of the present disclosure. [Figure 7B] Figures 7A to 7D show examples of illumination layers for exemplary mixed reality systems according to one or more embodiments of the present disclosure. [Figure 7C] Figures 7A to 7D show examples of illumination layers for exemplary mixed reality systems according to one or more embodiments of the present disclosure. [Figure 7D] Figures 7A to 7D show examples of illumination layers for exemplary mixed reality systems according to one or more embodiments of the present disclosure.

[0017] [Figure 8A] Figures 8A to 8D show examples of illumination layers for exemplary mixed reality systems according to one or more embodiments of the present disclosure. [Figure 8B] Figures 8A to 8D show examples of illumination layers for exemplary mixed reality systems according to one or more embodiments of the present disclosure. [Figure 8C] Figures 8A to 8D show examples of illumination layers for exemplary mixed reality systems according to one or more embodiments of the present disclosure. [Figure 8D] Figures 8A to 8D show examples of illumination layers for exemplary mixed reality systems according to one or more embodiments of the present disclosure.

[0018] [Figure 9] Figure 9 shows an exemplary transmittance graph for an illumination layer for an exemplary mixed reality system according to one or more embodiments of the present disclosure.

[0019] [Figure 10] Figure 10 shows an example of a lighting layer for an exemplary mixed reality system according to one or more embodiments of the present disclosure.

[0020] [Figure 11] Figure 11 shows an example of a lighting layer for an exemplary mixed reality system according to one or more embodiments of the present disclosure.

[0021] [Figure 12] Figure 12 shows an example of a lighting layer for an exemplary mixed reality system according to one or more embodiments of the present disclosure.

[0022] [Figure 13] Figure 13 shows an example of a lighting layer for an exemplary mixed reality system according to one or more embodiments of the present disclosure.

[0023] [Figure 14] Figure 14 shows an example of a lighting layer for an exemplary mixed reality system according to one or more embodiments of the present disclosure.

[0024] [Figure 15] Figure 15 shows an example of a lighting layer for an exemplary mixed reality system according to one or more embodiments of the present disclosure.

[0025] [Figure 16] Figure 16 shows an example of a lighting layer for an exemplary mixed reality system according to one or more embodiments of the present disclosure.

[0026] [Figure 17A]Figures 17A to 17E show examples of nanopatterns for an illumination layer in an exemplary mixed reality system according to one or more embodiments of the present disclosure. [Figure 17B] Figures 17A to 17E show examples of nanopatterns for an illumination layer in an exemplary mixed reality system according to one or more embodiments of the present disclosure. [Figure 17C] Figures 17A to 17E show examples of nanopatterns for an illumination layer in an exemplary mixed reality system according to one or more embodiments of the present disclosure. [Figure 17D] Figures 17A to 17E show examples of nanopatterns for an illumination layer in an exemplary mixed reality system according to one or more embodiments of the present disclosure. [Figure 17E] Figures 17A to 17E show examples of nanopatterns for an illumination layer in an exemplary mixed reality system according to one or more embodiments of the present disclosure.

[0027] [Figure 17F] Figure 17F is a graph showing exemplary transmittance for an illumination layer for an exemplary mixed reality system according to one or more embodiments of the present disclosure.

[0028] [Figure 18] Figure 18 shows a process for manufacturing an illumination layer for an exemplary mixed reality system according to one or more embodiments of the present disclosure.

[0029] [Figure 19] Figure 19 shows a block diagram of a process for manufacturing an illumination layer for an exemplary mixed reality system according to one or more embodiments of the present disclosure.

[0030] [Figure 20A] Figures 20A and 20B show examples of illumination layers for exemplary mixed reality systems according to one or more embodiments of the present disclosure. [Figure 20B]Figures 20A and 20B show examples of illumination layers for exemplary mixed reality systems according to one or more embodiments of the present disclosure. [Modes for carrying out the invention]

[0031] Detailed explanation The following examples refer to the accompanying drawings illustrating specific examples that form part of this specification and can be implemented. It should be understood that other examples may be used and structural modifications may be made without departing from the scope of the disclosed examples.

[0032] Mixed reality environment Like all people, users of a mixed reality system are present in the real environment, that is, in all three-dimensional parts and contents of the "real world" that are perceptible to the user. For example, the user perceives the real environment using their normal human senses (sight, sound, touch, taste, smell) and interacts with the real environment by moving their body within it. A position in the real environment can be described as coordinates in coordinate space. For example, coordinates can include latitude, longitude, and altitude relative to sea level; distance in three orthogonal dimensions from a reference point; or other appropriate values. Similarly, vectors can describe quantities that have direction and magnitude in coordinate space.

[0033] A computing device can maintain a representation of a virtual environment in, for example, the memory associated with the device. As used herein, a virtual environment is a computational representation of a three-dimensional space. A virtual environment can include representations of any object, action, signal, parameter, coordinate, vector, or other properties associated with that space. In some examples, the circuitry of a computing device (e.g., a processor) can maintain and update the state of a virtual environment. That is, the processor can determine the state of the virtual environment at a second time t1 based on data associated with the virtual environment and / or inputs provided by the user at a first time t0. For example, if an object in the virtual environment is located at a first coordinate at time t0 and has certain programmed physical parameters (e.g., mass, coefficient of friction), the input received from the user instructs that a force should be applied to the object in a direction vector. The processor can apply the laws of kinematics to determine the object's position at time t1 using basic mechanics. The processor can determine the state of the virtual environment at time t1 using any appropriate information known about the virtual environment and / or any appropriate inputs. When maintaining and updating the state of a virtual environment, the processor may run any appropriate software, including: software related to the creation and deletion of virtual objects in the virtual environment; software for defining the behavior of virtual objects or characters in the virtual environment (e.g., scripts); software for defining the behavior of signals in the virtual environment (e.g., audio signals); software for creating and updating parameters associated with the virtual environment; software for generating audio signals in the virtual environment; software for handling input and output; software for implementing network operations; software for applying asset data (e.g., animation data for moving virtual objects over time); or many other possibilities.

[0034] Output devices such as displays or speakers can present any or all aspects of a virtual environment to the user. For example, a virtual environment may include virtual objects that can be presented to the user (this may include representations of inanimate objects; people; animals; lights, etc.). A processor can determine the view of the virtual environment (e.g., corresponding to a “camera” with origin coordinates, view axes, and a frustum) and render a viewable scene of the virtual environment corresponding to that view on the display. Any suitable rendering technique may be used for this purpose. In some examples, the viewable scene may include only some virtual objects in the virtual environment and exclude certain other virtual objects. Similarly, a virtual environment may include audio aspects that can be presented to the user as one or more audio signals. For example, virtual objects in a virtual environment may generate sounds resulting from the object’s position coordinates (e.g., a virtual character may speak or produce sound effects). Alternatively, a virtual environment may be associated with musical cues or ambient sounds that may or may not be associated with a specific location. The processor can handle audio signals corresponding to "listener" coordinates, such as the synthesis of sounds within a virtual environment, determine a mixed and processed audio signal to simulate the audio signal heard by the listener at listener coordinates, and present the audio signal to the user through one or more speakers.

[0035] Because virtual environments exist only as computational structures, users cannot directly perceive them using their normal senses. Instead, users can only perceive virtual environments indirectly, such as through displays, speakers, or haptic output devices. Similarly, while users cannot directly touch, manipulate, or interact with virtual environments, they can provide input data via input devices or sensors to a processor that can use the device or sensor data to update the virtual environment. For example, a camera sensor can provide optical data indicating that the user is attempting to move an object within the virtual environment, and the processor can use that data to cause the object to respond accordingly within the virtual environment.

[0036] A mixed reality system can present a user with a mixed reality environment ("MRE") that combines aspects of the real and virtual environments, for example, using a transparent display and / or one or more speakers (which may be incorporated, for example, into a wearable head device). In some embodiments, one or more speakers may be located outside the head-mounted wearable unit. As used herein, an MRE is a simultaneous representation of the real environment and its corresponding virtual environment. In some examples, the corresponding real and virtual environments share a single coordinate space. In some examples, the real coordinate space and the corresponding virtual coordinate space are related to each other by a transformation matrix (or other suitable representation). Thus, a single coordinate (in some examples, together with the transformation matrix) can define a first location in the real environment and a second corresponding location in the virtual environment, and vice versa.

[0037] In MRE, virtual objects (e.g., in a virtual environment associated with the MRE) can correspond to real-world objects (e.g., in a real-world environment associated with the MRE). For example, if the real-world environment of the MRE includes a real-world ramp post (real-world object) at its position coordinates, the virtual environment of the MRE may include a virtual ramp post (virtual object) at its corresponding position coordinates. As used herein, a real-world object, combined with its corresponding virtual object, constitutes a "mixed-reality object." A virtual object does not need to perfectly match or align with its corresponding real-world object. In some examples, a virtual object can be a simplified version of its corresponding real-world object. For example, if the real-world environment includes a real-world ramp post, the corresponding virtual object may include a cylinder with approximately the same height and radius as the real-world ramp post (reflecting that the ramp post can have a nearly cylindrical shape). Simplifying virtual objects in this way can improve computational efficiency and simplify the calculations performed on such virtual objects. Furthermore, in some examples of MRE, not all real-world objects in the real-world environment are necessarily associated with corresponding virtual objects. Similarly, in some MRE examples, not all virtual objects within the virtual environment are necessarily associated with corresponding real-world objects. That is, some virtual objects may exist only within the MRE's virtual environment without any real-world counterparts.

[0038] In some examples, virtual objects may have properties that sometimes differ significantly from those of their corresponding real-world objects. For instance, a real-world environment within an MRE might contain a green, two-armed cactus (a thorny, inanimate object), while a corresponding virtual object within the MRE might possess the characteristics of a green, two-armed virtual character with human facial features and an expressionless face. In this example, the virtual object resembles its corresponding real-world object in certain properties (color, number of arms), but differs in other properties (facial features, personality). In this way, virtual objects can represent real-world objects in creative, abstract, exaggerated, or imaginative ways, or otherwise give behavior (e.g., human personality) to inanimate real-world objects. In some examples, virtual objects may be purely imaginative creations with no real-world counterparts (e.g., a virtual monster in a virtual environment that, in some cases, occupies a position corresponding to an empty space in the real-world environment).

[0039] Compared to VR systems, which present a virtual environment to the user while obscuring the real environment, mixed reality systems presenting MRE offer the advantage that the real environment remains perceptible while the virtual environment is being presented. Therefore, users of mixed reality systems can experience and interact with the corresponding virtual environment using visual and auditory cues associated with the real environment. For example, as mentioned above, users of VR systems may struggle to perceive or interact with virtual objects displayed in the virtual environment because they cannot directly perceive or interact with the virtual environment. However, users of MR systems may find it intuitive and natural to interact with virtual objects by seeing, hearing, and touching the corresponding real objects within their own real environment. This level of interactivity can enhance the user's sense of immersion, connection, and engagement with the virtual environment. Similarly, by presenting the real and virtual environments simultaneously, mixed reality systems can reduce the negative psychological (e.g., cognitive dissonance) and negative physical (e.g., motion sickness) associated with VR systems. Mixed reality systems further offer many possibilities for applications that can enhance or modify the experience of the real world.

[0040] Figure 1A shows an exemplary reality environment 100 in which a user 110 uses a mixed reality system 112. The mixed reality system 112 may include a display (e.g., a transmissive display) and one or more speakers, as well as one or more sensors (e.g., a camera), as described below, for example. The illustrated reality environment 100 includes a rectangular room 104A in which the user 110 is standing, and reality objects 122A (a lamp), 124A (a table), 126A (a sofa), and 128A (a painting). Room 104A further includes position coordinates 106, which can be considered the origin of the reality environment 100. As shown in Figure 1A, an environment / world coordinate system 108 (including x-axis 108X, y-axis 108Y, and z-axis 108Z) having its origin 106 (world coordinates) can define the coordinate space of the reality environment 100. In some embodiments, the origin 106 of the environment / world coordinate system 108 may correspond to the location where the mixed reality system 112 is powered on. In some embodiments, the origin 106 of the environment / world coordinate system 108 may be reset during operation. In some examples, the user 110 may be considered a real object in the real environment 100. Similarly, parts of the user 110's body (e.g., hands, feet) may be considered real objects in the real environment 100. In some examples, a user / listener / head coordinate system 114 (including x-axis 114X, y-axis 114Y, and z-axis 114Z) with point 115 (e.g., user / listener / head coordinate) as its origin can define a coordinate space for the user / listener / head on which the mixed reality system 112 is positioned. The origin 115 of the user / listener / head coordinate system 114 may be defined for one or more components of the mixed reality system 112. For example, the origin 115 of the user / listener / head coordinate system 114 may be defined relative to the display of the mixed reality system 112, such as during the initial calibration of the mixed reality system 112. Matrices (which may include translation matrices and quaternion matrices or other rotation matrices), or other suitable representations, can characterize the transformation between the user / listener / head coordinate system 114 space and the environment / world coordinate system 108 space.In some embodiments, the left ear coordinates 116 and the right ear coordinates 117 may be defined relative to the origin 115 of the user / listener / head coordinate system 114. Matrices (which may include translation matrices and quaternion matrices or other rotation matrices), or other suitable representations, can characterize the transformation between the left ear coordinates 116 and the right ear coordinates 117 and the user / listener / head coordinate system 114 space. The user / listener / head coordinate system 114 can simplify the representation of the user's head, or the position of a head-mounted device relative to, for example, the environment / world coordinate system 108. The transformation between the user coordinate system 114 and the environment coordinate system 108 can be determined and updated in real time using simultaneous localization and mapping (SLAM), visual odometry, or other techniques.

[0041] Figure 1B shows an exemplary virtual environment 130 corresponding to a real environment 100. The illustrated virtual environment 130 includes a virtual rectangular room 104B corresponding to a real rectangular room 104A, and virtual objects 122B corresponding to a real object 122A; virtual object 124B corresponding to a real object 124A; and virtual object 126B corresponding to a real object 126A. The metadata associated with virtual objects 122B, 124B, and 126B may include information derived from the corresponding real objects 122A, 124A, and 126A. The virtual environment 130 further includes a virtual monster 132 that does not correspond to any real object in the real environment 100. Real object 128A in the real environment 100 does not correspond to any virtual object in the virtual environment 130. A persistent coordinate system 133 (including x-axis 133X, y-axis 133Y, and z-axis 133Z) with point 134 as its origin (persistent coordinates) can define the coordinate space of the virtual content. The origin 134 of the persistent coordinate system 133 may be defined with respect to / relative to one or more real objects, such as real object 126A. Matrices (which may include translation matrices and quaternion matrices or other rotation matrices), or other suitable representations, can characterize transformations between the persistent coordinate system 133 space and the environment / world coordinate system 108 space. In some embodiments, each of the virtual objects 122B, 124B, 126B, and 132 may have its own persistent coordinate point with respect to the origin 134 of the persistent coordinate system 133. In some embodiments, there may be multiple persistent coordinate systems, and each of the virtual objects 122B, 124B, 126B, and 132 may have its own persistent coordinate point with respect to one or more persistent coordinate systems.

[0042] Persistent coordinate data can be coordinate data that persists with respect to the physical environment. Persistent coordinate data may be used by an MR system (e.g., MR systems 112, 200) to position persistent virtual content, and the persistent virtual content does not have to be tied to the movement of the display on which the virtual object is displayed. For example, a two-dimensional screen may only display a virtual object relative to its position on the screen. As the two-dimensional screen moves, the virtual content may move with the screen. In some embodiments, persistent virtual content may be displayed in the corner of a room. The MR user may look at the corner, see the virtual content, look out from the corner (the virtual content may no longer be visible because, due to the user's head movement, it may have moved from within the user's field of view to outside of it), or look behind them and see the virtual content in the corner (similar to how a real object may behave).

[0043] In some embodiments, persistent coordinate data (e.g., a persistent coordinate system and / or persistent coordinate frame) may include an origin and three axes. For example, a persistent coordinate system may be assigned by the MR system to the center of a room. In some embodiments, the user may move around in the room, leave the room, and re-enter the room, and the persistent coordinate system may remain at the center of the room (e.g., persisting relative to the physical environment). In some embodiments, virtual objects may be displayed using a transformation to persistent coordinate data that enables the display of persistent virtual content. In some embodiments, the MR system may use simultaneous localization and mapping to generate persistent coordinate data (e.g., the MR system may assign persistent coordinate systems to points in space). In some embodiments, the MR system may map the environment by generating persistent coordinate data at regular intervals (e.g., the MR system may assign persistent coordinate systems within a grid, where each persistent coordinate system may be at least 5 feet from another persistent coordinate system).

[0044] In some embodiments, persistent coordinate data may be generated by the MR system and transmitted to a remote server. In some embodiments, the remote server may be configured to receive persistent coordinate data. In some embodiments, the remote server may be configured to synchronize persistent coordinate data from multiple observation instances. For example, multiple MR systems may map the same room with persistent coordinate data and transmit that data to the remote server. In some embodiments, the remote server may use this observation data to generate standard persistent coordinate data that can be obtained based on one or more observations. In some embodiments, the standard persistent coordinate data may be more accurate and / or reliable than a single observation of persistent coordinate data. In some embodiments, the standard persistent coordinate data may be transmitted to one or more MR systems. For example, an MR system may use image recognition and / or location data to recognize that it is located in a room with corresponding standard persistent coordinate data (e.g., from the fact that another MR system has previously mapped the room). In some embodiments, an MR system may receive standard persistent coordinate data corresponding to its location from the remote server.

[0045] In relation to Figures 1A and 1B, the environment / world coordinate system 108 defines a shared coordinate space for both the real environment 100 and the virtual environment 130. In the illustrated example, the coordinate space has its origin at point 106. Furthermore, the coordinate space is defined by the same three orthogonal axes (108X, 108Y, 108Z). Thus, a first location in the real environment 100 and a second corresponding location in the virtual environment 130 can be described with respect to the same coordinate space. This simplifies the identification and representation of corresponding locations in the real and virtual environments, as the same coordinates can be used to identify both locations. However, in some examples, the corresponding real and virtual environments do not need to use a shared coordinate space. For example, in some examples (not shown), matrices (which may include translational matrices and quaternion matrices or other rotation matrices), or other suitable representations, can characterize transformations between the real environment coordinate space and the virtual environment coordinate space.

[0046] Figure 1C shows an exemplary MRE 150 that simultaneously presents aspects of the real environment 100 and the virtual environment 130 to the user 110 via the mixed reality system 112. In the illustrated example, the MRE 150 simultaneously presents to the user 110 real objects 122A, 124A, 126A, and 128A from the real environment 100 (e.g., via the transparent portion of the display of the mixed reality system 112) and virtual objects 122B, 124B, 126B, and 132 from the virtual environment 130 (e.g., via the active display portion of the display of the mixed reality system 112). As described above, the origin 106 functions as the origin of the coordinate space corresponding to the MRE 150, and the coordinate system 108 defines the x, y, and z axes of the coordinate space.

[0047] In the illustrated example, the mixed reality object includes corresponding pairs of real and virtual objects (i.e., 122A / 122B, 124A / 124B, and 126A / 126B) that occupy corresponding positions in coordinate space 108. In some examples, both the real and virtual objects may be visible to the user 110 simultaneously. This may be desirable, for example, when the virtual object presents information designed to extend the view of the corresponding real object (such as in a museum application where the virtual object presents a missing piece of an old, damaged sculpture). In some examples, the virtual object (122B, 124B, and / or 126B) may be displayed in a way that obscures the corresponding real object (122A, 124A, and / or 126A) (e.g., via active pixelated occlusion using a pixelated occlusion shutter). This may be desirable, for example, when the virtual object acts as a visual replacement for the corresponding real object (such as in an interactive storytelling application where an inanimate real object becomes a “living” character).

[0048] In some examples, real-world objects (e.g., 122A, 124A, 126A) may be associated with virtual content or helper data that does not necessarily constitute a virtual object. Virtual content or helper data can facilitate the processing or handling of virtual objects in a mixed reality environment. For example, such virtual content may include a two-dimensional representation of the corresponding real-world object; a custom asset type associated with the corresponding real-world object; or statistical data associated with the corresponding real-world object. This information can enable or facilitate calculations involving real-world objects without incurring unnecessary computational overhead.

[0049] In some examples, the presentation described above may also incorporate audio modes. For example, in MRE150, the virtual monster 132 may be associated with one or more audio signals, such as footsteps generated when the monster walks around MRE150. As will be further described below, the processor of the mixed reality system 112 may compute an audio signal corresponding to the mixture and processed synthesis of all such sounds within MRE150 and present the audio signal to the user 110 via one or more speakers included in the mixed reality system 112 and / or one or more external speakers.

[0050] Exemplary Mixed Reality System An exemplary mixed reality system 112 may include a wearable head device (e.g., a wearable augmented reality or mixed reality head device) comprising: displays (which may comprise left and right transmissive displays, which may be near-eye displays, and associated components for coupling light from the displays to the user's eyes); left and right speakers (e.g., positioned adjacent to the user's left and right ears, respectively); an inertial measuring unit (IMU) (e.g., mounted on the temple arms of the head device); an orthogonal coil electromagnetic receiver (e.g., mounted on the left temple piece); left and right cameras (e.g., depth (time-of-flight) cameras) oriented away from the user; and left and right eye cameras oriented towards the user (e.g., for detecting the user's eye movements). However, the mixed reality system 112 may incorporate any suitable display technology and any suitable sensors (e.g., optical, infrared, acoustic, LiDAR, EOG, GPS, magnetic). Furthermore, the mixed reality system 112 may incorporate networking capabilities (e.g., Wi-Fi capabilities) for communicating with other devices and systems, including other mixed reality systems. The mixed reality system 112 may further include a battery (which may be mounted in an auxiliary unit such as a belt pack designed to be worn around the user's waist), a processor, and memory. The wearable head device of the mixed reality system 112 may include a tracking component, such as an IMU or other suitable sensor, configured to output a set of coordinates of the wearable head device relative to the user's environment. In some examples, the tracking component may provide input to a processor that performs simultaneous localization and mapping (SLAM) and / or visual odometry algorithms. In some examples, the mixed reality system 112 may also include a handheld controller 300 and / or auxiliary unit 320, which may be a wearable belt pack, as further described below.

[0051] Figures 2A to 2D show components of an exemplary mixed reality system 200 (which may correspond to mixed reality system 112) that may be used to present an MRE (which may correspond to MRE150) or other virtual environment to a user. Figure 2A shows a perspective view of a wearable head device 2102 included in the exemplary mixed reality system 200. Figure 2B shows a plan view of the wearable head device 2102 mounted on the user's head 2202. Figure 2C shows a front view of the wearable head device 2102. Figure 2D shows an end view of an exemplary eyepiece 2110 of the wearable head device 2102. As shown in Figures 2A to 2C, the exemplary wearable head device 2102 includes an exemplary left eyepiece (e.g., a left transparent waveguide set eyepiece) 2108 and an exemplary right eyepiece (e.g., a right transparent waveguide set eyepiece) 2110. Each eyepiece 2108 and 2110 may include a transmissive element from which the real environment can be viewed, as well as a display element for presenting a display that overlaps with the real environment (e.g., via imagewise modulated light). In some examples, such a display element may include a surface diffractive optical element for controlling the flow of imagewise modulated light. For example, the left eyepiece 2108 may include a left internally coupled grating set 2112, a left orthogonal pupillary dilation (OPE) grating set 2120, and a left exit (output) pupillary dilation (EPE) grating set 2122. As used herein, pupil may refer to the emission of light from an optical element such as a grating set or reflector. Similarly, the right eyepiece 2110 may include a right internally coupled grating set 2118, a right OPE grating set 2114, and a right EPE grating set 2116. Imagewise modulated light can be transmitted to the user's eye via the internally coupled gratings 2112 and 2118, OPE 2114 and 2120, and EPE 2116 and 2122. Each internally coupled grating set 2112, 2118 can be configured to deflect light toward its corresponding OPE grating set 2120, 2114.Each OPE grating set 2120, 2114 can be designed to gradually deflect light downward toward its associated EPE 2122, 2116, thereby extending the formed exit pupil horizontally. Each EPE 2122, 2116 can be configured to gradually redirect at least a portion of the light received from its corresponding OPE grating set 2120, 2114 toward the user's eyebox position (not shown) defined behind the eyepieces 2108, 2110, thereby extending the formed exit pupil vertically toward the eyebox. Alternatively, instead of the internal coupling grating sets 2112 and 2118, OPE grating sets 2114 and 2120, and EPE grating sets 2116 and 2122, the eyepieces 2108 and 2110 may include other arrangements of gratings and / or refractive and reflective mechanisms to control the coupling of imagewise-modulated light to the user's eye.

[0052] In some examples, the wearable head device 2102 may include a left temple arm 2130 and a right temple arm 2132, the left temple arm 2130 including a left speaker 2134, and the right temple arm 2132 including a right speaker 2136. The orthogonal coil electromagnetic receiver 2138 may be located within the left temple piece or in another suitable location within the wearable head unit 2102. The inertial measurement unit (IMU) 2140 may be located within the right temple arm 2132 or in another suitable location within the wearable head device 2102. The wearable head device 2102 may also include a left depth (e.g., time-of-flight) camera 2142 and a right depth camera 2144. The depth cameras 2142 and 2144 may be appropriately oriented in different directions to cover a wider field of view together.

[0053] In the examples shown in Figures 2A to 2D, the left source 2124 of imagewise modulated light can be optically coupled to the left eyepiece 2108 via the left internal coupling grating set 2112, and the right source 2126 of imagewise modulated light can be optically coupled to the right eyepiece 2110 via the right internal coupling grating set 2118. The imagewise modulated light sources 2124 and 2126 can include, for example, fiber optic scanners; projectors including electronic optical modulators such as digital light processing (DLP) chips or liquid crystal on silicon (LCoS) modulators; or light-emitting displays such as micro light-emitting diodes (μLEDs) or micro organic light-emitting diode (μOLED) panels coupled to the internal coupling grating sets 2112 and 2118 using one or more lenses on each side. The input coupling grating sets 2112 and 2118 can deflect the light from the imagewise modulated light sources 2124 and 2126 to an angle exceeding the critical angle of total internal reflection (TIR) ​​of the eyepieces 2108 and 2110. The OPE grid sets 2114 and 2120 gradually deflect the light propagating by TIR downwards toward the EPE grid sets 2116 and 2122. The EPE grid sets 2116 and 2122 gradually fuse the light toward the user's face, including the pupil of the user's eye.

[0054] In some examples, as shown in Figure 2D, each of the left eyepiece 2108 and the right eyepiece 2110 includes multiple waveguides 2402. For example, each eyepiece 2108, 2110 may include multiple individual waveguides, each dedicated to its respective color channel (e.g., red, blue, and green). In some examples, each eyepiece 2108, 2110 may include multiple sets of such waveguides, each set configured to impart a different wavefront curvature to the emitted light. The wavefront curvature may be convex to the user's eye, for example, to present a virtual object positioned at a distance in front of the user (e.g., only a distance corresponding to the reciprocal of the wavefront curvature). In some examples, the EPE grid sets 2116, 2122 may include curved grid grooves that achieve convex wavefront curvature by changing the Poynting vector of the emitted light crossing each EPE.

[0055] In some examples, stereoscopically adjusted left and right eye images can be presented to the user through imagewise optical modulators 2124, 2126 and eyepieces 2108, 2110 to create the perception that the displayed content is three-dimensional. The perceived presence of the three-dimensional virtual object can be enhanced by selecting waveguides (and thus corresponding to wavefront curvature) so that the virtual object is displayed at a distance close to the distance indicated by the stereoscopic left and right images. This technique can also reduce motion sickness experienced by some users, which may be caused by the difference between the depth perception cue provided by the stereoscopic left and right eye images and the autonomic nervous system regulation of the human eye (e.g., focus depending on object distance).

[0056] Figure 2D shows a top-down end view of the right eyepiece 2110 of an exemplary wearable head device 2102. As shown in Figure 2D, the multiple waveguides 2402 can include a first subset 2404 of three waveguides and a second subset 2406 of three waveguides. The two subsets of waveguides 2404, 2406 can be distinguished by different EPE gratings featuring different grating line curvatures to impart different wavefront curvatures to the emitted light. Within each subset of waveguides 2404, 2406, each waveguide can be used to couple different spectral channels (e.g., one of the red, green, and blue spectral channels) to the user's right eye 2206. (Although not shown in Figure 2D, the structure of the left eyepiece 2108 is similar to that of the right eyepiece 2110.)

[0057] Figure 3A shows an exemplary handheld controller component 300 of the mixed reality system 200. In some examples, the handheld controller 300 includes a grip portion 346 and one or more buttons 350 arranged along the top surface 348. In some examples, the buttons 350 may be configured to be used as optical tracking targets for tracking, for example, six-degree-of-freedom (6DOF) motion of the handheld controller 300, together with a camera or other optical sensor (which may be mounted on the head unit of the mixed reality system 200 (e.g., a wearable head device 2102)). In some examples, the handheld controller 300 includes a tracking component (e.g., an IMU or other suitable sensor) for detecting position or orientation, such as position or orientation relative to the wearable head device 2102. In some examples, such a tracking component may be located within the handle of the handheld controller 300 and / or mechanically coupled to the handheld controller. The handheld controller 300 can be configured to provide one or more output signals corresponding to one or more of the following: the state of a button being pressed; or the position, orientation, and / or movement of the handheld controller 300 (e.g., via the IMU). Such output signals can be used as inputs to the processor of the mixed reality system 200. Such inputs may correspond to the position, orientation, and / or movement of the handheld controller (and, by extension, the position, orientation, and / or movement of the user's hand holding the controller). Such inputs may also correspond to the user pressing button 350.

[0058] Figure 3B shows an exemplary auxiliary unit 320 of the mixed reality system 200. The auxiliary unit 320 may include a battery to supply energy to operate the system 200 and may include a processor to run programs to operate the system 200. As shown, the exemplary auxiliary unit 320 includes a clip 2128 for attaching the auxiliary unit 320 to a user's belt, for example. Other form factors, including form factors that do not involve attaching the unit to a user's belt, may be suitable for the auxiliary unit 320 and will become apparent. In some examples, the auxiliary unit 320 is coupled to a wearable head device 2102 via a multi-conduit cable that may include, for example, electric wires and optical fibers. Wireless connectivity between the auxiliary unit 320 and the wearable head device 2102 may also be used.

[0059] In some examples, the mixed reality system 200 may include one or more microphones for detecting sound and providing corresponding signals to the mixed reality system. In some examples, the microphones may be attached to or integrated with the wearable head device 2102 and may be configured to detect the user's voice. In some examples, the microphones may be attached to or integrated with the handheld controller 300 and / or auxiliary unit 320. Such microphones may be configured to detect ambient sounds, surrounding noise, the voice of the user or a third party, or other sounds.

[0060] Figure 4 shows an exemplary functional block diagram that may correspond to exemplary mixed reality systems, such as the mixed reality system 200 described above (which may correspond to mixed reality system 112 relating to Figure 1). As shown in Figure 4, the exemplary handheld controller 400B (which may correspond to the handheld controller 300 ("Totem")) includes a totem-to-wearable head device 6-degree-of-freedom (6DOF) totem subsystem 404A, and the exemplary wearable head device 400A (which may correspond to wearable head device 2102) includes a totem-to-wearable head device 6DOF subsystem 404B. In this example, the 6DOF totem subsystem 404A and the 6DOF subsystem 404B work together to determine the six coordinates of the handheld controller 400B relative to the wearable head device 400A (e.g., three translational offsets and three rotations along axes). The six degrees of freedom may be expressed relative to the coordinate system of the wearable head device 400A. The three translational offsets can be represented as X, Y, and Z offsets in such a coordinate system, as a translational matrix, or as any other representation. The rotational degrees of freedom can be represented as a sequence of yaw, pitch, and roll rotations, as a rotation matrix, as a quaternion, or as any other representation. In some examples, a wearable head device 400A; one or more depth cameras 444 (and / or one or more non-depth cameras) included in the wearable head device 400A; and / or one or more optical targets (e.g., button 350 on the handheld controller 400B described above, or a dedicated optical target included in the handheld controller 400B) can be used for 6DOF tracking. In some examples, the handheld controller 400B may include a camera as described above, and the wearable head device 400A may include an optical target for optical tracking in conjunction with the camera. In some examples, the wearable head device 400A and the handheld controller 400B each include a set of three orthogonally oriented solenoids used to wirelessly transmit and receive three identifiable signals.The 6DOF of the wearable head device 400A relative to the handheld controller 400B can be determined by measuring the relative magnitudes of three identifiable signals received in each of the coils used for receiving. Furthermore, the 6DOF totem subsystem 404A may include an inertial measurement unit (IMU) that is useful for providing improved accuracy and / or more timely information regarding the rapid movement of the handheld controller 400B.

[0061] In some embodiments, the wearable system 400 may include a microphone array 407 that includes one or more microphones positioned on a headgear device 400A. In some embodiments, the microphone array 407 may include four microphones. Two microphones may be positioned on the front of the headgear 400A, and two microphones may be positioned on the back of the headgear 400A (e.g., one on the left rear and one on the right rear). In some embodiments, the signals received by the microphone array 407 may be transmitted to a DSP 408. The DSP 408 may be configured to perform signal processing on the signals received from the microphone array 407. For example, the DSP 408 may be configured to perform noise reduction, acoustic echo rejection, and / or beamforming on the signals received from the microphone array 407. The DSP 408 may be configured to transmit the signals to a processor 416.

[0062] In some cases, for example, to compensate for the movement of the wearable head device 400A relative to coordinate system 108, it may be necessary to transform the coordinates from local coordinate space (e.g., a coordinate space fixed relative to the wearable head device 400A) to inertial coordinate space (e.g., a coordinate space fixed relative to the real environment). For example, such a transformation may be necessary to maintain the illusion that a virtual object exists in the real environment (e.g., a virtual person sitting in a real chair and facing forward, regardless of the position and orientation of the wearable head device), so that the display of the wearable head device 400A presents the virtual object in a position and orientation that would be expected relative to the real environment (e.g., the same position in the lower right corner of the display) and orientation, rather than a fixed position and orientation on the display (and, for example, so that it does not appear unnaturally positioned in the real environment when the wearable head device 400A moves and rotates). In some cases, the compensatory transformation between coordinate spaces can be determined by processing images from the depth camera 444 using SLAM and / or visual odometry procedures to determine the transformation of the wearable head device 400A relative to coordinate system 108. In the example shown in Figure 4, the depth camera 444 can be coupled to the SLAM / visual odometry block 406 and provide images to the block 406. The implementation of the SLAM / visual odometry block 406 may include a processor configured to process these images and determine the position and orientation of the user's head, which can be used to identify transformations between the head coordinate space and another coordinate space (e.g., inertial coordinate space). Similarly, in some examples, additional information about the user's head pose and position is obtained from the IMU 409. The information from the IMU 409 can be integrated with the information from the SLAM / visual odometry block 406 to provide improved accuracy and / or more timely information regarding the rapid adjustment of the user's head pose and position.

[0063] In some examples, the depth camera 444 can supply 3D images to a hand gesture tracker 411, which may be implemented in the processor of a wearable head device 400A. The hand gesture tracker 411 can identify the user's hand gestures, for example, by matching the 3D images received from the depth camera 444 with stored patterns representing hand gestures. Other suitable techniques for identifying the user's hand gestures will become apparent.

[0064] In some examples, one or more processors 416 may be configured to receive data from the wearable head device's 6DOF headgear subsystem 404B, IMU 409, SLAM / visual odometry block 406, depth camera 444, and / or hand gesture tracker 411. The processor 416 may also send and receive control signals from the 6DOF totem system 404A. The processor 416 may be wirelessly coupled to the 6DOF totem system 404A, as in an example where the handheld controller 400B is not connected. The processor 416 may further communicate with additional components such as an audiovisual content memory 418, a graphical processing unit (GPU) 420, and / or a digital signal processor (DSP) voice spatializer 422. The DSP voice spatializer 422 may be coupled to a head-related transfer function (HRTF) memory 425. The GPU 420 may include a left channel output coupled to the left source of imagewise modulated light 424 and a right channel output coupled to the right source of imagewise modulated light 426. The GPU 420 can output stereoscopic image data to the sources of imagewise modulated light 424, 426, for example, as described above with reference to Figures 2A to 2D. The DSP audio spatializer 422 can output audio to the left speaker 412 and / or the right speaker 414. The DSP audio spatializer 422 can receive an input from the processor 419 indicating a direction vector from the user to a virtual sound source (which may be moved by the user, for example, via the handheld controller 320). Based on the direction vector, the DSP audio spatializer 422 can determine the corresponding HRTF (for example, by accessing an HRTF or by interpolating multiple HRTFs). Next, the DSP audio spatializer 422 can apply the determined HRTF to an audio signal, such as an audio signal corresponding to a virtual sound generated by a virtual object.This can enhance the realism and presence of virtual sounds by incorporating the user's relative position and orientation to virtual sounds in a mixed reality environment; that is, by presenting virtual sounds that match the user's expectations of how those virtual sounds would sound if they were real sounds in a real environment.

[0065] In some examples, as shown in Figure 4, one or more of the processor 416, GPU 420, DSP voice spatializer 422, HRTF memory 425, and audiovisual content memory 418 may be included in an auxiliary unit 400C (which may correspond to the auxiliary unit 320 described above). The auxiliary unit 400C may include a battery 427 for powering its components and / or for powering the wearable head device 400A or the handheld controller 400B. Including such components in an auxiliary unit that can be worn on the user's waist can limit the size and weight of the wearable head device 400A, and thus reduce fatigue in the user's head and neck.

[0066] Figure 4 shows elements corresponding to various components of an exemplary mixed reality system, but various other suitable arrangements of these components will become apparent to those skilled in the art. For example, the elements shown in Figure 4 as associated with the auxiliary unit 400C could instead be associated with the wearable head device 400A or the handheld controller 400B. Furthermore, some mixed reality systems may completely omit the handheld controller 400B or the auxiliary unit 400C. Such variations and modifications should be understood to fall within the scope of the disclosed examples.

[0067] Encapsulation layer for illumination layer An exemplary mixed reality system (e.g., mixed reality system 200) wearable head device or head-mounted display may include an optical system for presenting images to the user via the display. The exemplary optical system may further include eye-tracking capabilities. For example, Figures 5 and 6A-6B show examples of optical systems and / or illumination layers that may be used in a wearable head device (e.g., wearable head device 2102) according to embodiments of the present disclosure.

[0068] Figure 5 shows an exemplary optical system 500 that may be used in a wearable head device (e.g., wearable head device 2102). As shown in the figure, the optical system 500 may include multiple optical components arranged in layers. For example, the optical system 500 may include one or more of the following: an outer lens 501, a dimmer 503, an eyepiece 505, an inner lens 507, an IR illumination layer 510, and a corrective prescription insert 509. The optical system 500 may be configured to present a digital image to the user's eye 520, present a view of the user's environment, and / or track the user's eye movements. The outer and inner lenses may provide a focused view of the user's environment and / or a digital image. A dimmer 503 may be provided to adjust the amount of light entering the optical system from the user's environment. An eyepiece 505 may be provided to present digital content to the user. An IR illumination layer 510 (also referred to herein as an illumination layer) may be provided to enhance eye-tracking capabilities. The orthodontic prescription insert 509 may be provided to tailor the optical system to the vision of a particular user. The drawings are included for illustrative purposes only and may not necessarily be to scale, and may show the relative thickness of the layers and / or the actual dimensions of the layers.

[0069] Figure 6A shows an exemplary illumination layer 610A according to an embodiment of the present disclosure. The illumination layer 610A may be included in an optical system, for example, an optical system 500. As shown in the figure, the illumination layer 610A may include a substrate 612 and one or more LEDs 614A. In some embodiments, the illumination layer may include one or more metal traces (not shown) connected to one or more LEDs 614A. The LEDs 614A may be IR LEDs corresponding to wavelengths in the IR range. As shown in the figure, one or more LEDs 614A may be arranged on the back surface 618 of the substrate 612. The LEDs 614A may provide IR illumination light 616 to the user's eye 620. The IR illumination light may be reflected from the surface of the eye 620 to form IR eye reflected light 622. A portion of the IR reflected light 622 may be received by a light sensor 624. In some embodiments, the light sensor 624 may be located near the outer edge of the illumination layer 610A, for example, near the edge of the optical system stack 500. In some examples, the light sensor 624 may be part of the optical system, but it does not have to be physically positioned on the illumination layer. The received portion of the IR reflected light 622 can be processed by an MR system to track the eye movements of the eye 620.

[0070] Figure 6B shows an exemplary illumination layer 610B according to an embodiment of the present disclosure. The illumination layer 610B may be included in an optical system, for example, optical system 500. As shown in the figure, the illumination layer 610B may include a substrate 612 and one or more LEDs 614B. As shown in the figure, one or more LEDs 614B may be arranged on the front surface 626 of the substrate 612. In some embodiments, the illumination layer may include one or more metal traces (not shown) connected to one or more LEDs 614B. The LEDs 614B may provide IR illumination light 616 to the user's eye, as described with respect to Figure 6A. The LEDs 614B may be IR LEDs corresponding to wavelengths in the IR range.

[0071] In some embodiments, the substrate 612 may be a flexible or rigid substrate formed from a polymer layer laminated on a carrier plate, such as a glass carrier plate. For example, the substrate may include polycarbonate (PC), polyethylene terephthalate (PET), and / or triacetate cellulose (TAC) laminated on a glass carrier plate. While the polymer materials forming the substrate 612 may be relatively inexpensive and mechanically reliable, the substrate 612 may be susceptible to light transmission loss due to reflection and / or haze, as well as light transmission loss at inter-material interfaces, such as the polymer / glass interface. Furthermore, polymer materials may be prone to processing problems such as surface chemical attack and swelling, and may have poor scratch resistance, which can contribute to reduced light transmission and increased haze. The loss of light transmission and haze can affect the amount of ambient light passing through the optical system, such as optical system 500, and thus affect the quality of the digital image presented to the user.

[0072] Figures 7A and 7B are photographs of portions of polymer layers, such as polymer illumination layers, showing haze on the surface of the polymer layer that can affect transmittance. For example, polymer layer 710A may correspond to a magnified view of polymer layer 710B. As shown in the figures, the surfaces of polymer layers 710A and 710B may be rough and / or non-uniform, which can contribute to their hazy appearance. For example, the surface may include numerous irregular undulations that contribute to a non-uniform surface texture. In some examples, polymer layers, e.g., 710A and 710B, may have a measured haze value of about 1.00–1.65%. In comparison, a glass illumination layer may have a measured haze value of about 0.24%.

[0073] Figure 7C shows the profile of an illumination layer according to an embodiment of the present disclosure. As shown in the figure, the illumination layer 710C may include a substrate 712C which may have a rough or uneven top surface 718C. For example, the surface may include numerous irregular undulations that contribute to an uneven surface texture. An uneven surface may contribute to a visible cloudy appearance (see, for example, Figures 7A and 7B) and may contribute to reduced transmittance. Figure 7D shows an illumination layer according to an embodiment of the present disclosure. As shown in the figure, the illumination layer 710D may include a substrate 712D which may have a rough or uneven top surface 718D and a bottom surface 720D with respect to the surface 718C as described above.

[0074] Figures 8A and 8B are photographs of a portion of a polymer illumination layer, including an encapsulation layer, according to embodiments of the present disclosure. In some examples, polymer layer 810A may correspond to a magnified view of polymer layer 810B. As shown in the figures, the surface texture of polymer layers 810A and 810B may be relatively smoother compared to the surface texture of polymer layers 710A and 710B. For example, a polymer layer including an encapsulation layer, e.g., 810A and 700B, may have a measured haze value of about 0.11%.

[0075] Figure 8C shows a profile of the illumination layer 810C according to an embodiment of the present disclosure. For example, as shown in Figure 8C, the illumination layer 810C may include an encapsulation layer 830C located on the top surface 818C and / or bottom surface 820C of the substrate 812C of the illumination layer 810C. Although the encapsulation layer is shown on both the top and bottom surfaces, those skilled in the art will understand that according to embodiments of the present disclosure, the encapsulation layer may be located on either the top or bottom surface.

[0076] Figure 8D may correspond to a detailed view of the illumination layer 810C according to an embodiment of the present disclosure. For example, as shown in this figure, an encapsulation layer 830D may be provided to planarize the surface 818D of the substrate 812D. As used herein, the term planarization may refer to the smoothing, filling, and / or flattening of an uneven surface texture. In some embodiments, the encapsulation layer, e.g., 830C, 830D, may include an anti-reflective nanopattern 832D that planarizes the surface 818 of the substrate, e.g., 812C, 812D. The encapsulation layer may improve transmittance and reduce haze by planarizing the irregular undulations of the surface. Furthermore, the encapsulation layer may function as a protective scratch-resistant layer on the substrate (e.g., 812C, 812D) of the illumination layer 810.

[0077] Figure 9 is a graph illustrating an example of improved transmittance of the illumination layer when the encapsulation layer described above embeds one or more LEDs. Line 910 shows the transmittance over various wavelengths of an illumination layer without an encapsulation layer, e.g., illumination layers 610A and 610B. Line 920 shows the transmittance over various wavelengths of an illumination layer including an encapsulation layer, e.g., illumination layer 810. Figure 10 shows a schematic difference between the planarized portion 1030 and the non-planarized portion 1018 of the illumination layer 1010. As shown, the planarized portion 1030 can be relatively more transmittance compared to the non-planarized portion 1018. For example, the transmittance of the non-planarized portion 1018 may correspond to line 910 in Figure 9, while the transmittance of the planarized portion 1010 may correspond to line 920.

[0078] Figures 11 to 16 show exemplary illumination layers for an MR system according to embodiments of the present disclosure. The illumination layer may include a substrate, one or more LEDs, and an encapsulation layer. In some embodiments, the substrate may include an anti-reflective coating disposed on the substrate. In some embodiments, the illumination layer may include a second encapsulation layer. In some embodiments, the second encapsulation layer may have a radius of curvature.

[0079] Figure 11 shows an exemplary illumination layer for an MR system according to an embodiment of the present disclosure. As shown in the figure, the illumination layer 1110 may include a substrate 1112, one or more LEDs 1114, and an encapsulation layer 1130. In one or more examples, one or more LEDs 1114 may be mounted on the back surface of the substrate 1112. One or more LEDs may be configured to project light 1116 through the substrate 1112 toward the user's eye (not shown). The illumination layer 1110 may be characterized as a backlit illumination layer.

[0080] As shown in the figure, the substrate 1112 of the illumination layer 1110 may include a polymer layer 1134 disposed on a carrier plate (CP) 1136. The polymer layer 1134 may be formed from, for example, PET, PC, and TAC. In some embodiments, the carrier plate 1136 may be formed from a glass plate. The carrier plate 1136 may provide additional rigidity to the substrate 1112. In some embodiments, a refractive index matching layer 1138 may be disposed between the polymer layer 1134 and the carrier plate 1136. The refractive index matching layer 1138 may be provided to reduce undesirable reflection and / or refraction at the interface between the polymer layer 1134 and the carrier plate 1136. In some embodiments, the illumination layer 1110 may include an anti-reflective coating 1140 disposed on the front surface of the substrate, for example, opposite the encapsulation layer 1130. In some embodiments, a second refractive index matching layer 1142 may be disposed between the carrier plate 1136 and the anti-reflective coating 1140.

[0081] The encapsulation layer 1130 may include a nanopatterned surface 1132. As shown in the figure, the nanopatterned surface 1132 may be located on the back surface of the encapsulation layer 1130. As described above, the nanopatterned surface 1132 of the encapsulation layer 1130 can flatten and reduce transmission loss associated with surface imperfections and irregularities of the substrate 1112, for example, the polymer layer 1134 of the substrate 1112. For example, the nanopatterned surface 1132 can reduce visible light reflection, for example, reduce haze and improve transmittance. Various pattern types will be described in more detail below. However, those skilled in the art will understand that any suitable nanopatterned surface having anti-reflective properties can be used without departing from the scope of this disclosure. Furthermore, the encapsulation layer 1130 can improve the mechanical stability of the substrate 1112A by adding further rigidity to the illumination layer 1110.

[0082] In some embodiments, the encapsulation layer 1130 may be positioned on the back surface of the substrate 1112 such that the encapsulation layer 1130 is positioned on one or more LEDs 1114, i.e., one or more LEDs 1114 are covered by the encapsulation layer 1130. In some embodiments, the illumination layer 1110 may include one or more leads (not shown). One or more leads may connect one or more LEDs 1114 to other circuits, such as a power supply not positioned on the illumination layer 1110. One or more leads may be formed from copper, silver, and / or other suitable materials known in the art.

[0083] As shown in the figure, the encapsulation layer 1130 can cover one or more LEDs 1114 and / or lead wires. In this way, the encapsulation layer 1130 can further function to passivate one or more LEDs 1114 and / or lead wires. Briefly referring to the illumination layers 610A and 610B, one or more LEDs 614A, 614B and lead wires (not shown) placed on the substrate 612 are exposed to air and ambient conditions and humidity, which can cause corrosion. Corrosion due to exposure to ambient conditions can be undesirable as it can lead to a decrease in the performance of the components. In comparison, the illumination layers according to embodiments of the present disclosure can include an encapsulation layer 1130 that can cover one or more LEDs 1114 and lead wires (not shown), thereby sealing these components from exposure to ambient conditions. For example, if one or more LEDs have a height of about 250 μm, the encapsulation layer 1130 may have a height of about 300 μm. Therefore, the encapsulation layer 1130 can embed and passivate one or more LEDs 1114 and / or lead wires.

[0084] Therefore, the encapsulation layer 1130 can improve the transmittance of the illumination layer 1110 and reduce fogging. Furthermore, the encapsulation layer 1130 can improve the mechanical stability of the substrate 1112. In addition, the encapsulation layer 1130 can embed and passivate one or more LEDs 1114 and / or lead wires.

[0085] Figure 12 shows an exemplary illumination layer 1210 for an exemplary MR system according to an embodiment of the present disclosure. The illumination layer 1210 may include a substrate 1212, one or more LEDs 1214, and an encapsulation layer 1230. In some embodiments, the substrate 1212 may be formed from a polymer layer 1234. For example, compared to the illumination layer 1110, the illumination 1210 does not need to include a carrier plate, such as a carrier plate 1136. In this way, the illumination layer 1210 may have greater flexibility compared to the illumination layer 1110.

[0086] In some embodiments, one or more features of the illumination layer 1210 (apart from the substrate 1112) may be the same as those of the illumination layer 1110. For example, as shown in the figure, the encapsulation layer 1230 may be positioned on the back surface of the substrate 1212 such that the encapsulation layer 1230 is positioned on one or more LEDs 1214, i.e., one or more LEDs 1214 are covered by the encapsulation layer 1230. The encapsulation layer 1230 may include a rear patterned surface 1232. The patterned surface 1232 may be the same as the patterned surfaces 832, 1132 described above. In some embodiments, the illumination layer 1210 may include one or more leads (not shown). In some embodiments, the illumination layer 1210 may include an anti-reflective coating 1240 positioned on the front surface of the substrate, for example, opposite to the encapsulation layer 1230. Thus, the illumination layer 1210 may provide improved transmittance and reduced haze compared to, for example, illumination layers 610A, 610B. Furthermore, the encapsulation layer 1230 of the illumination layer 1210 can improve the mechanical stability of the substrate 1212 by an additional bonded material layer. In addition, the encapsulation layer 1230 of the illumination layer 1210 can embed and passivate one or more LEDs 1214 and / or lead wires.

[0087] Figure 13 shows an exemplary illumination layer 1310 for an exemplary MR system according to an embodiment of the present disclosure. The illumination layer 1310 may include a substrate 1312, one or more LEDs 1314, a first encapsulation layer 1330, and a second encapsulation layer 1350. The illumination layer 1310 may be a front-illumination layer. In some embodiments, the substrate 1312 may be formed from a polymer layer 1334, similar to the substrate 1212.

[0088] In some embodiments, the features of the illumination layer 1310 may be similar to those of illumination layers 1310 and 1210. For example, as shown in the figure, the first encapsulation layer 1330 may be positioned on the back surface of the substrate 1312 so that the first encapsulation layer 1330 can be placed on one or more LEDs 1314, i.e., so that one or more LEDs 1314 can be covered by the first encapsulation layer 1330. The first encapsulation layer 1330 may include a first patterned surface 1332. The patterned surface may be similar to the patterned surface 832 described above, and for example, the patterned surface 1332 may have anti-reflective properties. In some embodiments, the illumination layer 1310 may include one or more lead wires (not shown). Thus, the illumination layer 1310 may provide improved transmittance and reduced fogging compared to, for example, illumination layers 610A and 610B. Furthermore, the first encapsulation layer 1330 of the illumination layer 1310 can improve the mechanical stability of the illumination layer 1310 by increasing its thickness. Additionally, the encapsulation layer 1330 of the illumination layer 1310B can embed and passivate one or more LEDs 1314 and / or lead wires.

[0089] The illumination layer 1310 may include a second encapsulation layer 1350. For example, the second encapsulation layer 1350 may be located on the front surface of the substrate 1312, for example, on the surface opposite to the encapsulation layer 1330. In some embodiments, the second encapsulation layer 1350 may have a radius of curvature. For example, the radius of curvature may be selected to provide refractive lens power. Although the illumination layer 1310 is shown having a second encapsulation layer 1350 located on the front surface of the substrate 1312, those skilled in the art will understand that an encapsulation layer having a radius of curvature may be located on the rear surface of the substrate 1312. Due to the radius of curvature of the second encapsulation layer 1350, a separate refractive optical component may be redundant. For example, referring to an optical system 500 in which refractive power can be provided by an inner lens 507, the refractive power provided by the second encapsulation layer 1350 may make the inner lens 507 redundant. Therefore, embodiments including a second encapsulation layer 1350 having a radius of curvature can eliminate the inner lens 507 (and / or similar components providing optical power) from the stack of the optical system 500. This can reduce the total number of optical components and optical interfaces and improve the optical image quality presented to the user.

[0090] As shown in the figure, the second encapsulation layer 1350 may include a second patterned surface 1352. The second patterned surface 1352 may be positioned along the radius of curvature of the second encapsulation layer 1350. The second patterned surface 1352 can reduce the manufacturing time and cost associated with applying an additional anti-reflective coating to the curved surface. In some embodiments, the second patterned surface 1352 may include the same pattern as the first patterned surface 1332. In some embodiments, the second patterned surface 1352 may include a different pattern from the first patterned surface 1332. Those skilled in the art will understand that the specific patterns of the first and second patterned surfaces are not intended to limit the scope of this disclosure.

[0091] Therefore, the encapsulation layers 1330 and 1350 can improve the transmittance of the illumination layer 1310 and reduce fogging. Furthermore, the encapsulation layers 1330 and 1350 can improve the mechanical stability of the illumination layer 1310 by providing additional rigidity to the substrate 1312. In addition, the first encapsulation layer 1330 can embed and passivate one or more LEDs 1314 and / or lead wires. Finally, the second encapsulation layer 1350 can reduce the size of the optical system, for example, optical system 500, by eliminating the need to include a separate optical component that provides light power.

[0092] Figure 14 shows an exemplary illumination layer 1410 for an exemplary MR system according to an embodiment of the present disclosure. As shown in the figure, the illumination layer 1410 may include a substrate 1412, one or more LEDs 1414, a first encapsulation layer 1430, and a second encapsulation layer 1450. Compared to the illumination layer 1310, one or more LEDs 1414 may be mounted on the surface of the substrate 1412. As shown, one or more LEDs 1414 may be configured to project light 1416 away from the substrate 1412 toward the eyes of a user (not shown). Thus, the illumination layer 1410 may be characterized as a front-illuminated illumination layer.

[0093] As shown in the figure, the first encapsulation layer 1430 may be located on the rear surface of the illumination layer 1410. In some embodiments, the first encapsulation layer 1430 may include a patterned surface 1432. For example, as shown in the figure, the first patterned surface 1432 may be located on the back surface of the encapsulation layer 1430 and / or the illumination layer 1410. As described above, the patterned surface 1432 of the encapsulation layer 1430 can flatten and reduce transmission loss associated with surface defects and irregularities of the polymer layer 1434 of the substrate 1412, for example. For example, the encapsulation layer 1430 may include a patterned surface 1432 that can reduce visible light reflection, for example, reduce haze and improve transmittance.

[0094] In some embodiments, the illumination layer 1410 may include a second encapsulation layer 1450 positioned on the front surface of the substrate 1412. Since the illumination layer 1410 includes one or more LEDs 1414 mounted on the front surface of the substrate 1412, the second encapsulation layer 1450 may be positioned on top of the one or more LEDs 1414, i.e., one or more LEDs 1414 and / or lead wires (not shown) are covered by the encapsulation layer 1130. In some embodiments, the illumination layer 1410 may include one or more leads (not shown).

[0095] In some embodiments, the second encapsulation layer 1450 may have a radius of curvature. As described above with respect to the illumination layer 1410, the radius of curvature may be selected to provide refractive lens power. Thus, in embodiments including a second encapsulation layer 1450 having a radius of curvature, the inner lens 507 can be eliminated from the stacking of the optical system 500, which can reduce the total number of optical components as well as the number of optical interfaces of the optical system. Furthermore, in one or more examples, the radius of curvature of the second encapsulation layer 1452 can be associated with a height of about 200 to 300 microns. Thus, when a second encapsulation layer 1452 having a radius of curvature is placed on one or more LEDs 1414, the illumination layer 1410 may be thinner than in embodiments where a substantially flat encapsulation layer is used to cover one or more LEDs, for example, the illumination layer 1310. This can be confirmed by comparing the thicknesses of the illumination layer 1310 and the illumination layer 1410.

[0096] Therefore, the encapsulation layers 1430 and 1450 can improve the transmittance of the illumination layer 1310 and reduce fogging. Furthermore, the encapsulation layers 1430 and 1450 can improve the mechanical stability of the illumination layer 1410 by providing additional rigidity to the substrate 1412. In addition, the first encapsulation layer 1430 can embed and passivate one or more LEDs 1414 and / or lead wires. Finally, the second encapsulation layer 1450 can reduce the size of the optical system, for example, optical system 500, by eliminating the need to include a separate optical component that provides light power.

[0097] Figure 15 shows an exemplary illumination layer 1510 for an exemplary MR system according to an embodiment of the present disclosure. As shown in the figure, the illumination layer 1510 may include a substrate 1512, one or more LEDs 1514, a first encapsulation layer 1530, and a refractive lens 1558. As shown in the figure, the illumination layer 1510 may be a backlit illumination layer. In one or more embodiments, the encapsulation layer 1530 may be similar to, for example, encapsulation layers 1130 and 1230.

[0098] As shown in the figure, the substrate 1512 of the illumination layer 1510 may include a polymer layer 1534 disposed on a carrier plate 1536. The polymer layer 1534 may be formed from, for example, PET, PC, and TAC. In some embodiments, the carrier plate 1136 may be formed from a glass plate. In some embodiments, a refractive index matching layer 1538 may be disposed between the polymer layer 1534 and the carrier plate 1536. In some embodiments, the illumination layer 1510 may include a refractive lens 1558 disposed on the front surface of the substrate 1512, for example, opposite the encapsulation layer 1530. In some embodiments, the refractive lens 1558 may be coated with an anti-reflective surface 1556.

[0099] In some embodiments, a second refractive index matching layer 1542 may be positioned between the carrier plate 1536 and the refractive lens 1558. Since the illumination layer may include a refractive lens mounted on the front surface of the substrate 1512, a separate refractive optical component may be redundant. For example, referring to an optical system 500 in which refractive power can be provided by an inner lens 507, the refractive power provided by the second encapsulation layer 1550 may form the inner lens 507.

[0100] Therefore, the encapsulation layer 1530 can improve the transmittance of the illumination layer 1510 and reduce fogging. Furthermore, the encapsulation layer 1530 can improve the mechanical stability of the substrate 1512 by improving the rigidity of 1510. In addition, the encapsulation layer 1530 can embed and passivate one or more LEDs 1514 and / or lead wires. Finally, the refractive lens 1558 can reduce the size of the optical system, for example, optical system 500, by eliminating the need to include a separate optical component that provides light power.

[0101] Figure 16 shows an exemplary illumination layer 1610 for an exemplary MR system according to an embodiment of the present disclosure. As shown in the figure, the illumination layer 1610 may include a substrate 1612, one or more LEDs 1614, a first encapsulation layer 1630, and a refractive lens 1658. In some embodiments, the substrate 1612 may be formed from a polymer layer 1634. Unlike the illumination layer 1610, for example, the illumination 1510 does not need to include a carrier plate, such as a carrier plate 1536.

[0102] In some embodiments, the features of the illumination layer 1610 (apart from the substrate 1612) may be similar to those of the illumination layer 1510. For example, as shown in the figure, the encapsulation layer 1630 may be positioned on the back surface of the substrate 1612 such that the encapsulation layer 1630 is positioned on one or more LEDs 1614, i.e., one or more LEDs 1614 are covered by the encapsulation layer 1630. The encapsulation layer 1630 may include a rear patterned surface 1632. The patterned surface 1632 may be similar to the patterned surface described above. In some embodiments, the illumination layer 1610 may include one or more leads (not shown). In some embodiments, the illumination layer 1610 may include an anti-reflective coating 1640 positioned on the front surface of the substrate, for example, opposite to the encapsulation layer 6230. Thus, the illumination layer 1610 may provide improved transmittance and reduced haze compared to, for example, illumination layers 610A, 610B. Furthermore, the encapsulation layer 1630 of the illumination layer 1610 can improve the mechanical stability of the substrate 1612 by adding additional materials, such as the encapsulation layer 1630. Additionally, the encapsulation layer 1630 of the illumination layer 1610 can embed and passivate one or more LEDs 1614 and / or lead wires. Furthermore, the refractive lens 1658 can reduce the size of the optical system, such as the optical system 500, by eliminating the need to include separate optical components to provide light power.

[0103] Figures 17A to 17C show exemplary patterns of the encapsulation layer as described above, according to embodiments of the present disclosure. In some embodiments, the pattern may include at least one selected from lines and spaces, pillars, and holes. Figures 17A to 17C show cross-sectional views of exemplary line and space patterns. In some embodiments, the pitch of the line and space pattern may be about 100 to 150 nm. As shown in the figures, the lines may have different shapes. For example, as shown in Figure 17A, the exemplary line and space pattern may include lines having a substantially rectangular cross-section. Figure 17B shows an exemplary line and space pattern having a tapered shape with a truncated triangular cross-section, relatively compared to, for example, 1700A. Figure 17C shows an exemplary tapered line and space pattern having a triangular cross-section, relatively compared to, for example, 1700A and 1700B.

[0104] Figure 17D shows an exemplary pillar pattern. In some embodiments, the pitch of the pillar pattern can be about 100–150 nm. As shown in the figure, the pillars can have a cylindrical shape, but other shapes can be used without departing from the scope of this disclosure. In some embodiments, the pillars can have a diameter of about 10–140 nm. Figure 17E shows an exemplary hole pattern. In some embodiments, the pitch of the hole pattern can be about 100–150 nm.

[0105] Figure 17F is a graph showing exemplary transmittances of various pattern types, including an illumination layer without a patterned surface or other anti-reflective coating 1701, an illumination layer with an anti-reflective surface 1703, an illumination layer with an encapsulation layer without a patterned surface 1705, an illumination layer with an encapsulation layer having a pillar-type patterned surface 1707, an illumination layer with an encapsulation layer having a second pillar-type patterned surface 1709, and an illumination layer with an encapsulation layer having a perforated patterned surface 1711. As shown in the figure, illumination layers with patterned surfaces can have a transmittance of approximately 5-7% higher than that of visible light.

[0106] Manufacturing of the encapsulation layer for the illumination layer Figure 18 shows a process 1800 for manufacturing an exemplary illumination layer for an exemplary MR system according to an embodiment of the present disclosure. As shown in the figure, illumination layers, such as the 1100, 1200, 1300, 1400, 1500, and 1600 described above, can be manufactured using jet and flash imprint lithography (J-FIL) processes. The following description of process 1800 will also be described with reference to Figure 19, which is a flowchart 1900 illustrating an exemplary process for manufacturing an exemplary illumination layer for an exemplary MR system according to an embodiment of the present disclosure. For example, flowchart 1900 may describe the steps shown in process 1800.

[0107] In one or more examples of this disclosure, the process 1800 shown in Figure 18 can be initiated in step 1901, in which case the resin 1862 can be deposited on the upper surface 1818 of the substrate 1812. In some embodiments, the resin 1862 can be an ultraviolet-curable resin. In some embodiments, the resin 1862 can be deposited on the upper surface 1818 of the substrate 1812 by a print head. In some embodiments, the resin can be deposited as a single droplet. In some embodiments, the resin 1862 can be deposited as multiple droplets, each droplet being deposited separately.

[0108] In one or more examples, after the resin 1862 is deposited, the mold 1860 may be moved to come into contact with the resin 1862 (step 1903). The resin 1862 may conform to the shape of the mold 1860 once the mold 1860 is moved to come into contact with the resin 1862, as shown in 1800B. In some embodiments, the mold may be an encoded resist template (CRT). In some embodiments, the encoded resist template may include a plurality of nanofeatures 1868. The plurality of nanofeatures may be configured to impart a nanopattern to generate a patterned surface on the encapsulation layer, e.g., patterned surfaces 832 and 1132-1632. The patterned surfaces may correspond to the various patterns described with respect to Figures 17A-17xx. Those skilled in the art will understand that the scope of this disclosure is not intended to be limited by the patterns shown in Figures 17A-17xx.

[0109] In one or more examples, as shown in 1800B, excess resin 1864 may fill the mold nano-features 1868 (step 1905). For example, the nano-features 1868 may facilitate capillary action that allows excess resin 1864 to flow into the narrow spaces between the nano-features 1868. In this way, the illumination layer manufactured according to embodiments of the present disclosure may have clean edges, i.e., because excess resin 1864 may not flow down the sides of the illumination layer. This may allow the illumination layer to be cut to size before the encapsulation layer is deposited. In some embodiments, one or more illumination layers may be cut to size after the encapsulation layer has been deposited.

[0110] In one or more embodiments, once the mold 1860 is moved into contact with the resin 1860 (step 1903), the resin 1860 can be cured (step 1907). In some embodiments, the resin can be cured by exposure to UV light. In one or more embodiments, the resin can be exposed to heat and / or a combination of heat and UV light. For example, the resin can be preheated and / or exposed to heat before exposure to UV light. In such embodiments, thermal exposure can improve the crosslinking density of the resin. In some embodiments, the resin can be exposed to heat after exposure to UV light, with or without preheating. In one or more embodiments, the mold 1860 can be removed from the illumination layer (step 1909). In some embodiments, the mold 1860 can be removed after the resin has cured. In some embodiments, excess resin 1864 can be removed by the mold 1860. In some embodiments, excess resin 1864 can be deposited on a sacrificial surface so that the mold 1860 can be reused. In some embodiments, when the mold 1860 is removed, excess resin may evaporate from the mold.

[0111] Process 1800 shows a substantially flat mold 1860, but in some embodiments, mold 1860 may include a flexible and / or curved mold. For example, the mold may be a flexible mold, such as those described in Nanoimprint Lithography Methods on Curved Substrates, which is incorporated herein by reference in whole. A curved mold, such as those described in Nanoimprint Lithography Methods on Curved Substrates, may allow those skilled in the art to form encapsulation layers having a finite radius of curvature, e.g., encapsulation layers 1550, 1650, as described above with respect to Figures 18 and 19.

[0112] Figures 20A and 20B show illumination layers 2010 manufactured according to processes 1800 and 1900. Figure 20A shows a plan view of illumination layer 2010, which may be a substantially transparent component having the improved transmittance described above. In some embodiments, illumination layer 2010 may include one or more LEDs 2014 and one or more metal traces 2016. Figure 20B shows an exemplary cross-sectional view of illumination layer 2010. As shown in the figure, illumination layer 2010 may be similar to illumination layer 1310. For example, as shown in the figure, illumination layer 2010 may include a substrate 2012, one or more LEDs 2014, one or more lead wires 2016, a first encapsulation layer 2030, and a second encapsulation layer 2050. As shown in the figure, the second encapsulation layer 2050 may have light power.

[0113] Therefore, the illumination layer 2010 manufactured according to the embodiments of this disclosure may provide improved transmittance and reduced fogging. Furthermore, the encapsulation layers 2030, 2050 may improve the mechanical stability of the illumination layer 2010 by providing additional rigidity to the substrate 2012. In addition, the first encapsulation layer 2030 may embed and passivate one or more LEDs 2014 and / or lead wires 2016. Finally, the second encapsulation layer 2050 may provide an illumination layer having light power.

[0114] Embodiments of the present disclosure can provide a display including an infrared illumination layer, wherein the infrared illumination layer comprises a substrate, one or more LEDs disposed on a first surface of the substrate, and a first encapsulation layer disposed on the first surface of the substrate, the first encapsulation layer may include a nanopatterned surface. In some examples, the nanopatterned surface may be configured to improve the visible light transmittance of the illumination layer.

[0115] In some examples, one or more LEDs may be covered by a first encapsulation layer. In some examples, the first encapsulation layer may have a finite radius of curvature. In some examples, the radius of curvature may be configured to increase the refractive power of the illumination layer. In some examples, the first encapsulation layer may be substantially planar. In some examples, the display may include a second encapsulation layer, the second encapsulation layer may have a second geometric shape different from the first geometric shape of the first encapsulation layer. In some examples, the substrate may include a carrier plate and a polymer layer disposed on a first surface of the carrier plate. In some examples, the nanopatterned surface may include at least one nanopattern selected from line-and-space patterns, pillar patterns, and pore patterns. In some examples, the selected nanopattern may have a pitch in the range of approximately 100–150 nm.

[0116] Embodiments relating to this disclosure can provide a display including an illumination layer. In one or more examples, the illumination layer may include a substrate, one or more LEDs disposed on a first surface of the substrate, and a first encapsulation layer disposed on the first surface of the substrate, the first encapsulation layer including a patterned surface, the patterned surface may be configured to improve the visible light transmittance of the illumination layer. In some examples, the illumination layer further includes a second encapsulation layer, the second encapsulation layer having a second geometric shape different from the first geometric shape of the first encapsulation layer. In some examples, the display may include an eyepiece configured to present digital content. In some examples, the first encapsulation layer has a finite radius of curvature. In some examples, the radius of curvature may be configured to increase the refractive power of the eyepiece. In some examples, one or more LEDs may be covered by the first encapsulation layer. In some examples, the display may include a light sensor, the light sensor may be configured to detect light reflected from the user's eye, and the light may be emitted by one or more LEDs.

[0117] Embodiments of the present disclosure can provide a method comprising depositing a resin on a first surface of a substrate, wherein the substrate includes an outer perimeter having one or more edges. The method may include bringing the first surface of a mold into contact with the resin. The method may include forming an encapsulation layer having a patterned surface on the first surface of the substrate using a first volume of resin. The method may include introducing a second volume of resin to the outer perimeter of the first substrate, wherein at least one of a plurality of nanofeatures can be located in the second portion. The method may include filling the second portion of the first surface of the mold with the second volume of resin, wherein at least one nanofeatures located in the second portion of the first surface of the mold. The method may include curing the resin to bond the encapsulation layer to the substrate. The method may include removing the mold from the substrate, wherein the second volume of resin is removed together with the mold. In some examples, the first surface of the mold may be configured to include a plurality of nanofeatures. In some examples, the first surface of the mold may include a first portion configured to overlap the substrate and a second portion configured to extend beyond the outer perimeter of the substrate. In some examples, the mold may include a flexible mold, the first surface of the mold may have a finite radius of curvature, and the encapsulation layer may be formed with a radius of curvature such that the encapsulation layer can have refractive power. In some examples, the substrate may include one or more LEDs placed on the first surface, and the encapsulation layer may cover one or more LEDs.

[0118] In some examples, the method may further include depositing a resin onto a second surface of a substrate. In some examples, the method may further include bringing a first surface of a mold into contact with the second resin. In some examples, the method may further include using a third volume of resin to form a second encapsulation layer having a second patterned surface on the second surface of the substrate. In some examples, the method may further include introducing a fourth volume of resin to the outer periphery of the substrate. In some examples, the method may further include filling at least one nano-feature located on a second portion of the first surface of the mold with the fourth volume of resin. In some examples, the method may further include curing the second resin to bond the second encapsulation layer to the substrate. In some examples, the method may further include removing the mold from the substrate, with the fourth volume of resin being removed along with the mold.

[0119] While the disclosed examples are adequately illustrated with reference to the accompanying drawings, it should be noted that various variations and modifications will be apparent to those skilled in the art. For example, elements and / or components shown in the drawings may not be to scale and / or may be exaggerated for illustrative purposes. As another example, elements of one or more implementations may be combined, deleted, modified, or supplemented to form further implementations. Other combinations and modifications should be understood to fall within the scope of the disclosed examples as defined by the accompanying claims.

Claims

1. A display including an infrared illumination layer, The infrared illumination layer is Substrate and One or more LEDs are disposed on the first surface of the substrate, A first encapsulation layer disposed on the first surface of the substrate, wherein the first encapsulation layer includes a nanopatterned surface, and the nanopatterned surface increases the visible light transmittance of the illumination layer. A display equipped with a screen.

2. The display according to claim 1, wherein one or more LEDs are covered by the first encapsulation layer.

3. The display according to claim 1, wherein the first encapsulation layer has a finite radius of curvature.

4. The display according to claim 3, wherein the radius of curvature of the first encapsulation layer is configured to increase the refractive power of the illumination layer.

5. The display according to claim 1, wherein the first encapsulation layer is substantially planar.

6. The display according to claim 1, further comprising a second encapsulation layer disposed on a second surface of the substrate, wherein the second encapsulation layer has a second geometric shape different from the first geometric shape of the first encapsulation layer.

7. The display according to claim 1, wherein the substrate comprises a carrier plate, and the substrate further comprises a polymer layer disposed on a first surface of the carrier plate.

8. The display according to claim 1, wherein the nanopatterned surface includes at least one nanopattern selected from line-and-space patterns, pillar patterns, and pore patterns.

9. The display according to claim 8, wherein the nanopattern has a pitch in the range of 100 nm to 150 nm.

10. It is a display, The aforementioned display includes an illumination layer, The aforementioned illumination layer is Substrate and One or more LEDs are disposed on the first surface of the substrate, A first encapsulation layer disposed on the first surface of the substrate, wherein the first encapsulation layer includes a patterned surface, and the patterned surface increases the visible light transmittance of the illumination layer. A display equipped with a screen.

11. The display according to claim 10, wherein the illumination layer further comprises a second encapsulation layer on the second surface of the substrate, and the second encapsulation layer has a second geometric shape different from the first geometric shape of the first encapsulation layer.

12. The display according to claim 10, further comprising an eyepiece, the eyepiece being configured to present digital content.

13. The display according to claim 12, wherein the first encapsulation layer has a finite radius of curvature.

14. The display according to claim 13, wherein the radius of curvature is configured to increase the refractive power of the eyepiece.

15. The display according to claim 10, wherein one or more LEDs are covered by the first encapsulation layer.

16. The display according to claim 10, further comprising a light sensor configured to detect light reflected from the user's eye, wherein the light is emitted by one or more LEDs.

17. It is a method, The method involves depositing a resin onto a first surface of a substrate, wherein the substrate includes an outer periphery having one or more edges. Bringing the first surface of the mold into contact with the resin, Using a first volume of resin, an encapsulation layer having a patterned surface is formed on the first surface of the substrate, A second volume of resin is introduced to the outer periphery of the substrate, wherein the first surface of the mold is configured to include a plurality of nano-features, the first surface of the mold includes a first portion configured to overlap the substrate and a second portion configured to extend beyond the outer periphery of the substrate, and at least one of the plurality of nano-features is located on the second portion. Filling the at least one nano-feature located on the second portion of the first surface of the aforementioned type with the second volume of resin, By curing the resin, the encapsulation layer is adhered to the substrate, The process involves removing the mold from the substrate, wherein the second volume of resin is removed together with the mold. Includes, A method comprising: the substrate comprising one or more LEDs disposed on the first surface, and the encapsulation layer covering the one or more LEDs.

18. The method according to claim 17, wherein the mold comprises a soft mold, the first surface of the mold has a finite radius of curvature, and the encapsulation layer is formed to have the radius of curvature such that the encapsulation layer has refractive power.

19. The method described above is: Depositing a second resin on the second surface of the substrate, The first surface of the aforementioned type is brought into contact with the second resin, Using a third volume of resin, a second encapsulation layer having a second patterned surface is formed on the second surface of the substrate, A fourth volume of resin is introduced to the outer periphery of the substrate, Filling the at least one nano-feature located on the second portion of the first surface of the aforementioned type with the fourth volume of resin, By curing the second resin, the second encapsulation layer is bonded to the substrate, The process involves removing the mold from the substrate, wherein the fourth volume of resin is removed together with the mold. The method according to claim 17, further comprising:

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