In-Coupler Grating Line Offset for AR Waveguide Aberration

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Solution Overview

Problem

Augmented reality waveguide displays face issues with blurry virtual images due to projector output imperfections, such as phase deviations from flat wavefronts, which degrade the modulation transfer function and sharpness, making small text or lines unreadable.

Innovation Solution

Implementing a grating line offset (GLO) in the in-coupler (IC) of the waveguide to apply phase shifts to the diffracted light, compensating for projector aberrations by calculating phase offsets based on measured wavefront deviations across multiple wavelengths and field of view points, and applying these offsets to specific grating lines to redirect light through the waveguide.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a conventional in-coupler is used without grating line offset, then the device complexity is low, but the image sharpness and modulation transfer function are degraded due to projector phase deviations

Engineering Contradiction:
Improveimage sharpnessVSAvoidin-coupler structure
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies different grating line offsets to different regions of the in-coupler grating structure. Specifically, the in-coupler includes a first grating line offset for a first region and a second grating line offset for a second region, allowing each region to be optimized for its specific field of view requirements. This local differentiation improves image sharpness and modulation transfer function without requiring complete redesign of the entire system.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The in-coupler is segmented into multiple regions (first region, second region, etc.), each with its own optimized grating line offset. This segmentation allows the system to address phase deviations at different field of view points independently, improving overall image quality while maintaining a manageable structural complexity through modular design.

Inventive Principle:
Principle #1Segmentation

2Reliability

If grating line offset is applied to compensate for phase deviations, then the modulation transfer function is improved, but the manufacturing precision requirements increase

Engineering Contradiction:
Improvemodulation transfer functionVSAvoidgrating line fabrication
Core Design Contradiction:
ReliabilityVSManufacturing precision

Solution Approach 1:

The patent calculates and determines the optimal grating line offsets before the actual manufacturing process. By pre-calculating the required offsets based on measured wavefront deviations and phase errors, the system establishes precise manufacturing targets in advance. This preliminary action allows manufacturers to fabricate gratings with specific offset values, improving modulation transfer function while providing clear manufacturing guidance.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent replaces complex mechanical adjustment mechanisms with a fixed grating line offset structure. Instead of using movable or adjustable components to compensate for phase deviations, the solution embeds the compensation directly into the grating geometry through predetermined offsets. This substitution simplifies the manufacturing process while maintaining reliable modulation transfer function performance.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If multiple grating line offsets are used for different field of view points, then the adaptability is improved, but the device complexity increases

Engineering Contradiction:
Improvefield of view coverageVSAvoidin-coupler design
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent implements region-specific grating line offsets where each region of the in-coupler is optimized for its corresponding field of view point. The in-coupler includes a first grating line offset for a first region and a second grating line offset for a second region, allowing the system to adapt to different field of view requirements while maintaining a unified grating structure. This approach improves adaptability without requiring multiple separate components.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent merges multiple field of view compensations into a single integrated in-coupler structure. By combining multiple grating line offsets within one grating element, the system achieves adaptability across different field of view points while avoiding the complexity of multiple separate optical components. The unified structure simplifies alignment and reduces the overall device complexity.

Inventive Principle:
Principle #5Merging (Combining)

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

The solution effectively reduces the effects of projector aberrations, resulting in a sharper virtual image by compensating for phase deviations, thereby improving the modulation transfer function and user experience in augmented reality displays.

Implementation Method 1

An in-coupler (IC) of a waveguide combiner diffracts light from a projector into total internal reflection (TIR)

Methodology Applied
Scientific EffectDiffraction: Diffraction Grating

Implementation Method 2

diffracts light from a projector into total internal reflection (TIR)

Methodology Applied
Scientific EffectTotal internal reflection: Total Internal Reflection

Data Source

PatentUS20250013041A1Projector compensation with incoupler grating line offset
Publication Date: 2025.01.09 APPLIED MATERIALS INC
  • US20250013041A1 patent drawing
  • US20250013041A1 patent drawing
  • US20250013041A1 patent drawing

AI summary

Certain aspects of the present disclosure include an optical device. The optical device generally includes an in-coupler (IC) configured to receive light from a projector, where the IC includes at least one grating line offset (GLO) associated with one or more phase deviations of the light from the projector. The device also includes a waveguide and an output coupler (OC), where the IC is configured to redirect the light from the projector to the OC through the waveguide.