HMD Projector Assembly Alignment Using Altered Frame Mating Structure
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Solution Overview
Problem
Existing head-mounted displays suffer from optical deviations due to variations between light projectors, leading to suboptimal user experiences, as slight differences in projector alignment can be glaringly apparent to users.
Innovation Solution
A method and system for determining the optical angle of a display projector assembly relative to its base, altering a mating structure within a frame to align the output along a predetermined optical axis, and mating the assembly to the frame using an altered mating structure, ensuring precise optical alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard manufacturing tolerances are used for projector assemblies, then manufacturing cost and complexity are reduced, but optical alignment precision deteriorates leading to visible deviations
Solution Approach 1:
The patent applies preliminary action by pre-determining the optical angle of each projector assembly before final assembly. The system measures and records the specific optical angle of each projector relative to its base, then uses this pre-determined information to calculate and alter the mating structure accordingly. This preliminary measurement and documentation of optical characteristics enables precise alignment to be achieved during assembly without requiring complex real-time adjustment mechanisms.
Solution Approach 2:
The patent implements parameter changes by physically altering the mating structure based on the determined optical angle. The system modifies geometric parameters of the mating structure (such as angle, position, or orientation) to compensate for variations in projector optical output. This parameter adjustment of the mating structure transforms the alignment process from requiring high-precision mechanical manufacturing to allowing standard tolerances while achieving precise optical alignment through controlled parameter modification.
2Manufacturing precision
If individual optical compensation is implemented for each projector variation, then optical quality is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent replaces complex mechanical alignment adjustment mechanisms with a computational and structural modification approach. Instead of using adjustable mechanical components or manual alignment procedures during assembly, the system uses predetermined optical angle measurements combined with pre-calculated mating structure alterations. This substitution of mechanical adjustment systems with pre-computed structural solutions maintains high optical precision while enabling rapid assembly without time-consuming manual alignment procedures.
Solution Approach 2:
The system implements self-service by having each projector assembly determine its own optical angle characteristics, which then automatically informs the modification of its corresponding mating structure. The projector assembly essentially 'specifies' its own alignment requirements through the measurement process, and the mating structure is tailored to match these self-determined parameters. This self-service approach eliminates the need for external alignment expertise or complex adjustment procedures during assembly.
3Stability of the object's composition
If thicker bonding structures are used to ensure alignment, then structural stability is improved, but device thickness and weight increase
Solution Approach 1:
The patent applies parameter changes by modifying the geometric parameters of the mating structure rather than increasing its physical dimensions. By adjusting angle, position, or orientation parameters of the mating structure based on predetermined optical measurements, the system achieves precise optical alignment and stable composition without requiring thicker bonding structures. This parameter-based approach maintains optical stability while keeping the device thin and lightweight.
Data Source
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AI summary
Disclosed methods of aligning display projector assemblies included in head-mounted displays may include (1) determining an optical angle of an output of a display projector assembly relative to a base of the display projector assembly, (2) physically altering, based on the determined optical angle of the output of the display projector assembly, a mating structure included within a frame such that, when the base of the display projector assembly is mated to the frame via the mating structure, the output of the display projector assembly is optically aligned with the frame along a predetermined optical axis, and (3) mating the base of the display projector assembly to the frame via the altered mating structure. Various other methods, systems, and apparatuses are also disclosed.