Monocoque Optical Chassis for Precise AR Glasses Alignment
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Solution Overview
Problem
Traditional AR devices face challenges in maintaining precise optical alignment of components due to tolerance and assembly variations, leading to image distortion and stress-induced degradation, and current manufacturing methods are time-consuming and expensive.
Innovation Solution
An optical support system with a monocular chassis of integrated alignment features and monocoque construction, using materials with low thermal expansion and injection molding, integrates optical components into a single sub-assembly, decoupling them from frame stresses, and employs PSA tape for flexible bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If optical components are mounted in separate housings made of different materials, then assembly flexibility is improved, but alignment precision and structural integrity deteriorate due to tolerance variations and stress transmission
Solution Approach 1:
The patent integrates the projector housing and waveguide housing into a single integrated optical housing structure. This merging eliminates the interface between separate housings, thereby removing tolerance accumulation and misalignment issues that occur when multiple components are assembled together. The integrated structure ensures precise alignment of optical components while maintaining manufacturing feasibility through modular design of the overall AR device.
2Stability of the object's composition
If optical components are directly bonded to the device frame, then structural integration is improved, but optical performance deteriorates due to stress transmission degrading modulation transfer function
Solution Approach 1:
The patent segments the optical housing from the device frame, creating a distinct optical module that is not directly bonded to the frame. This segmentation isolates the optical components (projector and waveguide) from mechanical stresses transmitted through the frame, preventing stress-induced degradation of the modulation transfer function. The optical housing is instead integrated with the arms through a connection structure that minimizes stress transmission to the optical components.
3Manufacturing precision
If CNC machining from aluminum is used for imaging housings, then manufacturing precision is improved, but production time and cost increase
Solution Approach 1:
The patent changes the manufacturing approach from CNC machining to injection molding for producing the optical housing. This parameter change in the manufacturing process enables mass production of the housing with consistent precision suitable for optical component mounting. The injection molding process creates complex geometries efficiently, reducing production time and cost while maintaining the precision required for proper optical alignment through integrated alignment features molded into the housing.
Data Source
AI summary
The present disclosure relates to an optical support system for augmented reality (AR) eyewear, which includes a monocular chassis designed to integrate and precisely align optical components such as a projector, waveguide, and various other components. The monocular chassis is characterized by its monocoque construction, incorporating integrated alignment features that facilitate the accurate positioning of the optical elements for optimal device performance. In some examples, the chassis is constructed from materials with a low coefficient of thermal expansion and is manufactured using injection molding techniques, making it suitable for mass production. The design allows for the decoupling of the projector from stresses imparted by the eyewear frame, seeking to ensure the integrity of the optical path. Additionally, the waveguide is secured to the chassis using pressure-sensitive adhesive tape, providing a flexible yet strong bond. Disclosed examples offer a robust, precise, and scalable solution for the production of high-quality AR eyewear.