Monolithic Optical System Embedding Waveguides in Lens
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Solution Overview
Problem
Current optical systems for mixed reality, augmented reality, and virtual reality displays are complex and difficult to manufacture, particularly in aligning and protecting sensitive components like curved beam splitters, and require time-consuming assembly of multiple components.
Innovation Solution
A method involving the use of mold parts and lens forming fluid to create a monolithic optical system with embedded optical elements, where the elements are aligned and protected within a higher refractive index lens material, minimizing reflection losses and environmental exposure, and utilizing thin film deposition for coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple optical components are assembled separately, then each component can be optimized individually, but the assembly process becomes time-consuming and alignment is difficult
Solution Approach 1:
The patent merges multiple separate optical components (beam splitter, waveguides, displays, protective layers) into a single monolithic optical element formed by casting lens forming fluid in a mold. This integration eliminates the need for time-consuming assembly and alignment of multiple separate components while maintaining optical precision.
Solution Approach 2:
The monolithic optical element performs multiple functions simultaneously: beam splitting, waveguiding, display presentation, and protective coverage. This multi-functionality is achieved by incorporating different optical layers and elements within a single cast structure, eliminating the need for separate components.
2Adaptability or versatility
If multiple components are assembled together, then functional complexity is achieved, but the system becomes sensitive to environmental factors and requires careful protection
Solution Approach 1:
By combining all optical components into a single monolithic element with internal layers, the patent eliminates exposed interfaces between components. The entire assembly is protected by an outer surface that seals the internal structure, preventing dust, water, sweat, and salt from entering and damaging sensitive internal components.
Solution Approach 2:
The patent uses a protective outer layer formed as part of the monolithic structure to shield internal optical elements. This integrated protective layer acts as a barrier against environmental harmful factors while maintaining the functional complexity of internal components.
3Ease of manufacture
If optical elements are exposed to air interfaces, then manufacturing is simpler, but reflection losses increase
Solution Approach 1:
The patent uses lens forming fluid with a higher refractive index than air to embed the optical elements. This composite material approach eliminates air interfaces within the optical path, reducing reflection losses while maintaining manufacturing simplicity through the casting process.
4Manufacturing precision
If curved beam splitters are used, then optical performance is improved, but positioning and alignment become difficult
Solution Approach 1:
The patent combines the curved beam splitter with the mold structure itself during the casting process. The beam splitter is formed as an integrated part of the monolithic optical element, eliminating the need for separate positioning and alignment operations that would be required if it were a separate component.
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 approach simplifies the production of complex optical systems, ensures precise alignment and protection of components, reduces reflection losses, and provides a compact, low-birefringence design suitable for polarized light handling, enhancing the durability and performance of the optical system.
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
reflection losses of element-air interfaces can be minimized by embedding the elements in a lens material with a higher refractive index
Data Source
AI summary
An optical system and method for producing the same comprising molding components including a waveguide directly within a lens, by placing the components within a UV transparent mold.