Integrated Depth Sensor Window Lens with Opaque Separation Dam
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Solution Overview
Problem
Existing head-mounted displays (HMDs) face challenges in integrating depth sensors due to issues with optical precision, stray light interference, and aesthetic design, particularly in compact form factors, which affect the user experience and industrial design.
Innovation Solution
A depth sensor window lens for HMDs is manufactured using a two-shot injection molding process, combining optically clear lenses for the sensor and illuminator with an opaque dam, ensuring precise optical separation and a seamless appearance by controlling tooling tolerances to within 10 nm, resulting in an integral, optically clear IR lenses with an opaque frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate components are used for sensor lens and illuminator lens, then optical precision can be maintained, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines the sensor lens and illuminator lens into a single integrated window lens component manufactured via injection molding. This merging eliminates the need for separate components and their associated alignment mechanisms, reducing device complexity while maintaining optical precision through the molding process that creates optically clear regions with precise geometric separation
Solution Approach 2:
The window lens serves multiple functions simultaneously: it acts as both the sensor lens and illuminator lens, provides structural support, creates optical separation through the opaque dam, and ensures seamless appearance. This multi-functionality reduces the overall component count and simplifies the device architecture
2Manufacturing precision
If optically clear material is used for the window lens, then optical precision is improved, but stray light interference increases
Solution Approach 1:
The window lens employs local quality by having different optical properties in different regions: the sensor lens region and illuminator lens region are optically clear to maintain precision, while the dam region is opaque to block stray light. This spatial variation in material properties allows simultaneous achievement of optical precision and stray light rejection
Solution Approach 2:
The window lens is segmented into distinct functional regions: optically clear regions for the sensor lens and illuminator lens, and an opaque region forming the dam. This segmentation allows each region to perform its specific function optimally - clear regions transmit light for precise sensing and illumination, while the opaque segment blocks stray light interference
3Shape
If tight tooling tolerances are applied, then seamless appearance is achieved, but manufacturing complexity increases
Solution Approach 1:
The window lens and frame are combined into a single injection molded part, eliminating the need for separate assembly operations and associated tolerances. This integration achieves seamless appearance at the interface between the window lens and frame while simplifying manufacturing to a single molding process
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 provides enhanced optical performance and aesthetic appeal by minimizing stray light interference, maintaining optical precision, and achieving a compact, seamless design suitable for HMDs, thereby improving the user experience and industrial design.
Implementation Method 1
injecting an optically clear polymeric material into a first mold to form a sensor lens and an illuminator lens; injecting an opaque polymeric material into a second mold subsequent to the operation of injecting an optically clear polymeric material
Data Source
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AI summary
A method of making an integrated depth sensor window lens (114, 214, 314, 414, 840), such as for an augmented reality (AR) head set, the depth sensor window lens (114, 214, 314, 414, 840) comprising a sensor lens (116, 216, 316, 416, 516) and an illuminator lens (118, 218, 318, 418, 518) separated by an opaque dam (117, 217, 317, 417, 517). The method uses a two-shot injection molding process, a first shot comprising an optically clear polymeric material to form the sensor lens (116, 216, 316, 416, 516) and the illuminator lens (118, 218, 318, 418, 518) and the second shot comprising an opaque polymeric material to form the separator of the two.