Integrated Depth Sensor Window Lens With Opaque Light Dam
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing head-mounted displays (HMDs) face challenges in integrating depth sensors with precise optical lenses, particularly in maintaining optical clarity and aesthetics while ensuring minimal light leakage and reflection, which affect depth measurement accuracy and device appearance.
Innovation Solution
A two-shot injection molding process is used to create a depth sensor window lens for HMDs, combining optically clear lenses for the sensor and illuminator with an opaque dam, achieving a seamless joint with a surface finish of less than 10 nm, using precise tooling and controlled injection to form a single, integral part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate components are used for sensor lens and illuminator lens, then manufacturing flexibility is improved, but assembly precision and optical alignment are worsened
Solution Approach 1:
The patent combines the sensor lens and illuminator lens into a single integrated window lens component. This merging eliminates the need for separate assembly of multiple lenses, thereby maintaining manufacturing flexibility through unified molding while achieving superior assembly precision and optical alignment as a single monolithic structure.
Solution Approach 2:
The integrated window lens serves multiple functions simultaneously: it acts as both the sensor lens and illuminator lens, while also providing structural support and optical isolation through the opaque dam. This multi-functionality resolves the contradiction by achieving precision through integration while maintaining ease of manufacture through a single-component design.
2Measurement precision
If optical isolation is increased to prevent light leakage, then depth measurement accuracy is improved, but device appearance and aesthetics are worsened
Solution Approach 1:
The patent applies optical isolation selectively through an opaque dam positioned between the sensor lens and illuminator lens. This local application of opacity prevents light leakage and improves depth measurement accuracy only in the critical region where light isolation is needed, while the rest of the window lens maintains its optically clear appearance and aesthetic quality.
Solution Approach 2:
The opaque dam acts as an intermediary element that mediates between the conflicting requirements of optical isolation and aesthetics. It provides the necessary light blocking function to improve measurement precision while being integrated into the overall lens structure in a way that minimizes impact on device appearance.
3Ease of repair
If multiple separate parts are used for sensor lens and illuminator lens, then ease of repair is improved, but manufacturing complexity is worsened
Solution Approach 1:
The patent merges the sensor lens and illuminator lens into a single integrated window lens, which simplifies manufacturing by eliminating the need for complex multi-component assembly processes. While this reduces ease of repair compared to separate replaceable components, it achieves manufacturing simplicity through unified molding and reduces overall device complexity.
Data Source
AI summary
A method of making an integrated depth sensor window lens, such as for an augmented reality (AR) head set, the depth sensor window lens comprising a sensor lens and an illuminator lens separated by an opaque dam. The method uses a two-shot injection molding process, a first shot comprising an optically clear polymeric material to form the sensor lens and the illuminator lens and the second shot comprising an opaque polymeric material to form the separator of the two.