HMD Frame Warping for Digital Projector Optical Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing head-mounted displays face challenges in aligning optical components such as digital projector assemblies with precision, leading to perceptible optical quality deviations and user experience issues due to manufacturing variabilities and tolerances.
Innovation Solution
A method involving coupling digital projector assemblies to an HMD frame, warping the frame to align the assemblies optically, and securing them in place using an enclosure to achieve precise alignment within predetermined thresholds, reducing the need for expensive alignment equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional alignment methods using optical benches are used, then alignment precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The frame structure itself serves as the alignment mechanism through its deformable geometry. The frame is designed to be warped into a target geometry that automatically aligns the optical components, eliminating the need for external optical benches and complex alignment equipment. The frame's geometric properties enable self-alignment when deformed to the target configuration.
Solution Approach 2:
The frame's geometric parameters are changed by warping it from its initial geometry to a target geometry. This deformation alters the spatial relationships and orientations of the mounted optical components, achieving precise alignment through parameter transformation rather than through complex mechanical adjustment mechanisms.
2Manufacturing precision
If expensive alignment equipment is used, then alignment precision is improved, but capital expenditures increase
Solution Approach 1:
The patent replaces expensive, durable alignment equipment (optical benches) with a disposable or single-use frame deformation approach. The frame itself becomes the alignment tool, and once warped to the target geometry and components are secured, the alignment function is completed without requiring ongoing use of costly equipment.
Solution Approach 2:
The frame geometry acts as an intermediary between the mounting structure and the optical components. By warping the frame to a predetermined target geometry, the alignment is achieved through this intermediate geometric configuration rather than through direct mechanical adjustment using expensive equipment.
3Ease of manufacture
If components are mounted before alignment, then manufacturing simplicity is improved, but alignment precision may worsen
Solution Approach 1:
The frame is prepared with mounting features in its initial geometry, allowing components to be mounted before the warping operation. The preliminary mounting is then followed by the geometric transformation that achieves precise alignment, combining the simplicity of early mounting with the precision of subsequent geometric adjustment.
Solution Approach 2:
The frame transitions from a static initial geometry to a dynamic warped target geometry. This dynamic transformation occurs after component mounting, allowing the system to evolve from a simple mounting state to a precisely aligned state through controlled geometric deformation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Improves optical component alignment, enhances user experience by minimizing optical deviations, and reduces capital and operating expenditures by simplifying the alignment process.
Implementation Method 1
the frame may then be warped and the warped HMD frame may be fixed in place to optically align the two digital projector assemblies to each other
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Methods of assembling a head-mounted display (HMD) may include coupling a first digital projector assembly to an HMD frame, coupling a second digital projector assembly to the HMD frame, and then warping the HMD frame to optically align the first digital projector assembly with the second digital projector assembly. The warped HMD frame may be fixed such that the first digital projector assembly and the second digital projector assembly are optically aligned to within a predetermined threshold. Various other methods and systems are also disclosed.