Monolithic Optical Element Molding for Precise Beam Splitter Alignment
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Solution Overview
Problem
Existing optical systems for mixed and augmented reality displays are complex to manufacture, particularly in positioning curved beam splitters, and are sensitive to environmental factors like dust and moisture, with high reflection losses at element-air interfaces.
Innovation Solution
A method involving a two-part mold process where a lens forming fluid is solidified to create an intermediate product, coated with a different material to form an optical element, then embedded in additional lens forming fluid within a second mold cavity, allowing precise alignment and protection of multiple optical elements in a monolithic piece, minimizing reflection losses and environmental sensitivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple optical elements are assembled separately in pancake optics, then the optical system can be manufactured with conventional methods, but the manufacturing complexity increases and positioning precision deteriorates
Solution Approach 1:
The patent merges multiple optical elements (beam splitter, waveplates, polarizers) into a single monolithic optical component manufactured by injection molding. This combining approach eliminates the need for separate assembly steps, reduces the number of interfaces, and simplifies the overall manufacturing process while maintaining optical functionality.
Solution Approach 2:
The monolithic optical element performs multiple optical functions simultaneously - beam splitting, polarization control, and wave plate functionality are all integrated into one component. This multi-functionality approach reduces the total number of components needed and simplifies the optical system architecture.
2Volume of moving object
If curved beam splitters are positioned in conventional optical systems, then the optical path can be folded compactly, but the positioning precision deteriorates and sensitivity increases
Solution Approach 1:
The curved beam splitter is merged with other optical elements into a single monolithic component. The curved surface geometry is directly formed during injection molding, eliminating the need for separate positioning and mounting operations that would compromise precision.
Solution Approach 2:
The patent replaces mechanical positioning and mounting mechanisms with a direct injection molding process. The optical elements are positioned precisely through mold cavity design rather than mechanical adjustment, eliminating sensitivity to assembly variations.
3Device complexity
If optical elements are exposed to air in conventional systems, then the system structure remains simple, but reflection losses increase and environmental protection deteriorates
Solution Approach 1:
Multiple optical elements are combined into one monolithic component with no air gaps between interfaces. This eliminates reflection losses at element-air interfaces and removes the need for complex protective housing structures.
Solution Approach 2:
The patent uses a single molded material (or composite material with optimized refractive index) for the entire optical element, eliminating interfaces with air. This composite approach reduces reflection losses while maintaining structural integrity.
4Adaptability or versatility
If conventional assembly methods are used for optical elements, then manufacturing flexibility is maintained, but alignment precision and repeatability deteriorate
Solution Approach 1:
The patent replaces mechanical alignment and assembly processes with a single-step injection molding process. The mold cavities are designed to position optical elements with high precision during molding, ensuring consistent alignment without requiring manual adjustment or complex mechanical fixtures.
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
This method efficiently produces a compact, robust optical system with minimized reflection losses and environmental protection, ensuring precise alignment and integration of optical elements, suitable for use in mixed and augmented reality devices.
Implementation Method 1
providing a lens forming fluid in the first mold cavity and allowing the lens forming fluid to solidify, to produce an intermediate product with a surface
Implementation Method 2
coating at least a part of the surface of the intermediate product with a material to produce an optical element in the optical system
Implementation Method 3
providing lens forming fluid in the second mold cavity such that the coating applied in step c) becomes embedded in the lens forming fluid, and allowing the lens forming fluid to solidify
Implementation Method 4
embedding the elements in a lens material with a higher refractive index
Data Source
AI summary
There is provided a method for producing an optical system, whereby molds and coatings becomes embedded in the lens forming fluid, allowing the lens forming fluid to solidify.