Lensed Beam-Splitter Prism Array for See-Through HMDs
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Solution Overview
Problem
Current see-through head-mounted display systems face challenges in effectively overlaying a display image onto a real scene without compromising image quality or user experience, particularly in consumer-oriented micro-optics manufacturing.
Innovation Solution
A lensed beam-splitter prism array is developed, comprising a beam-splitter substrate with thin-film coatings and a lens form layer, where the substrate is bonded and cut at an oblique angle to form a stack slice, and a lens form layer is applied on top of the thin-film coatings, enabling efficient light polarization and reflection for simultaneous display of virtual and real scenes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional beam-splitter substrates are used without oblique cutting, then manufacturing is simpler, but image quality and light polarization efficiency deteriorate
Solution Approach 1:
The substrate is divided into multiple stack slices by cutting at oblique angles, creating multiple thin-film coating interfaces that work together to improve light polarization efficiency and image quality while maintaining manufacturability through systematic segmentation
Solution Approach 2:
The substrate is cut at an oblique angle rather than perpendicular to the surface, introducing a dimensional change in the cutting orientation. This oblique cutting creates multiple coating interfaces that enhance light polarization efficiency and image quality
2Reliability
If multiple thin-film coatings are applied at oblique angles, then light polarization efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process segments the substrate into multiple stack slices, each with thin-film coatings applied at oblique angles. This segmentation allows for improved light polarization efficiency through multiple interfaces while managing complexity through systematic processing of divided components
Solution Approach 2:
Thin-film coatings are applied to substrates before the oblique cutting process. This preliminary action ensures that the coatings are properly formed on flat surfaces, and the subsequent oblique cutting creates the desired multiple interfaces without requiring post-processing coating operations
3Manufacturing precision
If lens forms are added to the beam-splitter substrate, then display image quality improves, but device complexity increases
Solution Approach 1:
Lens forms are integrated directly into the beam-splitter substrate structure, merging the beam-splitting function with the focusing function. This combination improves display image quality by enabling precise optical control while reducing device complexity by eliminating separate lens components
Solution Approach 2:
The beam-splitter substrate is designed to perform multiple functions: beam splitting through oblique thin-film coatings and image focusing through integrated lens forms. This multi-functionality improves display image quality while reducing the number of separate components needed in the system
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 allows for high-quality overlay of virtual images onto real scenes, enhancing user experience in see-through head-mounted displays by effectively combining and polarizing light for clear, unobstructed viewing of both virtual and real-world elements.
Implementation Method 1
enabling efficient light polarization and reflection for simultaneous display of virtual and real scenes
Implementation Method 2
a beam-splitter substrate having a planar top substrate surface and a bottom substrate surface. The beam-splitter substrate has a plurality of planar and parallel thin-film coatings each spanning the top substrate surface and the bottom substrate surface and making an oblique angle therebetween
Implementation Method 3
enabling efficient light polarization and reflection for simultaneous display of virtual and real scenes
Implementation Method 4
a lens form layer formed on the top substrate surface and having a plurality of lens forms, each lens form being above one of the plurality of thin-film coatings
Implementation Method 5
A lensed beam-splitter prism array is developed, comprising a beam-splitter substrate with thin-film coatings and a lens form layer
Data Source
AI summary
A lensed beam-splitter prism array includes a beam-splitter substrate with a plurality of planar and parallel thin-film coatings each spanning a top substrate surface and a bottom substrate surface, and making an oblique angle therebetween, and a lens form layer formed on the top surface and having a plurality of lens forms, each lens form being above one of the plurality of coatings. A method for fabricating a lensed beam-splitter prism includes bonding a plurality of substrates to form a substrate stack having a coating between each adjacent substrate pair. The method also includes forming a stack slice by applying a plurality of parallel cuts at an oblique angle with respect to each coating. Each coating spans a first stack-slice surface and a second stack-slice surface opposing the first stack-slice surface. The method also includes forming a lens form layer on the first stack-slice surface spanning one or more coatings.