Optical Component Overmolding for Eye Tracking and Optical Power
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Solution Overview
Problem
Existing fabrication techniques for optical components with eye-tracking features and optical power are inefficient and costly, particularly in head-mounted devices like smartglasses or VR/AR headsets, due to the use of multiple layers and adhesives.
Innovation Solution
A refractive polymer layer is overmolded onto an illumination layer with integrated light sources, forming a lens curvature that provides optical power through subtractive processes or molding, reducing the number of steps and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple layers and adhesives are used to fabricate optical components with eye-tracking features and optical power, then the component can achieve both eye-tracking functionality and optical power, but the fabrication process becomes inefficient and costly
Solution Approach 1:
The patent merges the illumination layer with light sources and the lens layer into a single integrated optical component. The refractive polymer layer is overmolded directly onto the illumination layer, eliminating the need for separate adhesive bonding and multiple discrete layers. This integration maintains both eye-tracking functionality and optical power while reducing fabrication complexity
Solution Approach 2:
The refractive polymer layer serves multiple functions simultaneously: it acts as the lens structure providing optical power, serves as the encapsulant for the light sources, and forms the curved surface for eye-tracking. This multi-functionality reduces the number of separate components needed and simplifies the overall device structure
2Adaptability or versatility
If multiple layers and adhesives are used in fabrication, then eye-tracking features and optical power can be integrated, but the fabrication process becomes costly
Solution Approach 1:
By combining the illumination layer and lens layer into a single molded component, the patent reduces the number of fabrication steps and material costs. The overmolding process integrates multiple functions into one manufacturing operation, eliminating the need for separate adhesive materials and assembly steps
Solution Approach 2:
The illumination layer is prepared with integrated light sources and electrical traces before the refractive polymer layer is overmolded. This preliminary integration of components simplifies subsequent fabrication steps and reduces overall manufacturing cost by preparing components in advance
3Device complexity
If light sources are integrated within the refractive layer, then fabrication is simplified and costs are reduced, but noticeable occlusions may occur
Solution Approach 1:
The patent applies local quality by making the refractive polymer layer transparent or translucent in specific regions where light sources are integrated, while maintaining appropriate optical properties in other areas. This localized transparency allows light to pass through without creating noticeable occlusions, while still providing structural support and optical power
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 simplifies the fabrication process, reduces expenses, and minimizes noticeable occlusions by integrating light sources within the refractive layer, ensuring seamless integration of eye-tracking and optical power in optical components.
Implementation Method 1
A refractive polymer layer is overmolded onto an illumination layer with integrated light sources, forming a lens curvature that provides optical power
Data Source
AI summary
An illumination layer is coupled with a glass substrate. A refractive layer is overmolded over the illumination layer. The refractive layer may encapsulate light sources and electrical traces of the illumination layer. A lens curvature is formed in the refractive layer.