Monolithic Polymer Waveguides for Precise AR Optical Coupling
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Solution Overview
Problem
Existing augmented reality (AR) technologies face challenges in providing a comfortable and natural-feeling presentation of virtual image elements amidst real-world imagery due to difficulties in aligning accommodative and vergence cues, leading to user discomfort.
Innovation Solution
The integration of waveguides with in-coupling optical elements, such as prisms and lenses, within AR systems to enhance light coupling efficiency, reduce ghosting, and simplify manufacturing, while providing uniform brightness and improved image quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate in-coupling optical elements are integrated with waveguides through assembly processes, then alignment precision and image quality improve, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the in-coupling optical element and waveguide into a single monolithic structure formed by one-piece molding. The optical element is integrated directly into the waveguide body, eliminating separate assembly steps and reducing alignment complexity while maintaining manufacturing precision through molded-in features.
Solution Approach 2:
The patent incorporates alignment features and optical element geometries directly into the mold cavity before the molding process. This preliminary preparation of alignment structures ensures precise positioning is achieved during molding itself, rather than requiring post-assembly alignment procedures.
2Ease of manufacture
If multiple separate components are assembled to form the waveguide system, then manufacturing flexibility improves, but manufacturing time and production complexity increase
Solution Approach 1:
The patent combines multiple components (waveguide body, in-coupling optical element, and alignment features) into a single molded part. This integration eliminates multiple assembly operations, reduces production time, and simplifies the manufacturing process while maintaining the flexibility to produce different configurations through mold design.
Solution Approach 2:
The patent segments the monolithic structure into functional zones (waveguide region, optical element region, alignment feature regions) that can be independently designed in the CAD model and controlled through different mold cavity sections, allowing manufacturing flexibility while maintaining single-step production.
3Adaptability or versatility
If conventional assembly processes are used to integrate optical elements with waveguides, then design adaptability improves, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent enables design adaptability by modifying mold cavity parameters (optical element geometry, waveguide dimensions, alignment feature locations) to produce different configurations. This approach maintains versatility while reducing manufacturing cost by eliminating assembly operations and utilizing high-volume injection molding processes.
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 enhances user comfort by aligning accommodative and vergence cues, resulting in a more realistic and comfortable AR experience with improved image quality and reduced manufacturing complexity.
Implementation Method 1
light containing image information can propagate through said polymer layer being guided therein by reflecting from said first and second major surfaces via total internal reflection
Implementation Method 2
couple light incident on said in-coupling optical element into said polymer layer for propagation therethrough
Implementation Method 3
couple light incident on said in-coupling optical element into said polymer layer for propagation therethrough by reflection from said second major surface
Data Source
AI summary
This disclosure describes optical devices, such as waveguides, and methods of manufacturing same. An example waveguide can include a polymer layer having substantially optically transparent material with first and second major surfaces configured such that light containing image information can propagate through the polymer layer being guided therein by reflecting from the first and second major surfaces via total internal reflection. The first surface can include first smaller and second larger surface portions monolithically integrated with the polymer layer and with each other. The first smaller surface portion can include at least a part of an in-coupling optical element configured to couple light incident on the in-coupling optical element into the polymer layer for propagation therethrough by reflection from the second major surface and the second larger surface portion of the first major surface.