Optical Device Reflective Unit Integration for AR
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Solution Overview
Problem
The manufacturing of small-sized reflective units for augmented reality devices is challenging due to difficulties in precise cutting and contamination issues, and existing methods result in diffraction phenomena and residual reflections, affecting the quality and durability of optical devices.
Innovation Solution
A method involving the preparation of first and second optical elements with corresponding surfaces, forming a reflective unit on one element, and bringing them into close contact with an adhesive of the same refractive index to create an optical device, which minimizes residual reflections and diffraction by integrating the reflective unit inside the optical element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large reflective unit is prepared and only a small reflective portion is left by painting other areas, then a mask is fabricated, but diffraction phenomenon occurs, boundary portion cannot be clearly distinguished, and the reflective unit may be easily contaminated
Solution Approach 1:
The patent extracts only the necessary small reflective portion from a large reflective unit by forming a patterned reflective layer directly on the optical element surface, eliminating the need for painting masks that cause diffraction. The reflective layer is formed only in the required areas through selective deposition or coating processes, avoiding the harmful effects of mask-based fabrication.
Solution Approach 2:
The patent introduces a non-reflective intermediate layer or protective coating around the reflective portions to prevent contamination while maintaining clear boundaries. This intermediary layer acts as a barrier that protects the reflective units during subsequent manufacturing processes without causing diffraction effects.
2Manufacturing precision
If a large reflective unit is prepared and the remaining area is cut out while leaving only a small reflective area, then a reflective unit is obtained, but precise cutting is difficult due to unintentional curvature or wear and the reflective unit may be easily contaminated
Solution Approach 1:
The patent replaces mechanical cutting processes with direct formation methods such as selective coating, deposition, or lithographic patterning of the reflective layer. This substitution eliminates mechanical wear, curvature issues, and contamination risks associated with cutting while achieving precise reflective unit geometry through controlled material deposition.
Solution Approach 2:
The patent performs preliminary patterning of the reflective layer formation process before final assembly, creating precise reflective units through pre-defined masks or direct writing methods. This preliminary action ensures accurate positioning and shape control without requiring subsequent cutting or trimming operations.
3Adaptability or versatility
If conventional lens modules are used in HMDs, then augmented reality is implemented, but the structures are complicated, making manufacturing very difficult and resulting in large sizes and heavy weights
Solution Approach 1:
The patent merges the reflective unit functionality directly into the optical element structure by forming the reflective layer on the optical element surface. This integration combines multiple functions (optical guidance and reflection) into a single component, eliminating the need for separate lens modules and reducing overall device complexity, size, and weight while maintaining augmented reality functionality.
Solution Approach 2:
The patent creates an optical element that serves multiple functions simultaneously: it acts as both the optical guiding element and the reflective surface for virtual image formation. This multi-functional design eliminates the need for separate dedicated reflective components, simplifying the overall HMD structure while maintaining full augmented reality capability.
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 enables the production of optical devices with improved durability and reduced ghost images, maintaining the pinhole effect and depth of field, suitable for augmented reality applications, and facilitates mass production with lower costs.
Implementation Method 1
forming an optical device by bringing the first and second optical elements into close contact with each other and fastening them to each other... using an adhesive made of a material having the same refractive index as the first and second optical elements
Data Source
AI summary
The present invention relates to a method of manufacturing an optical device, and provides a method of manufacturing an optical device, which includes: preparing first and second optical elements having a pair of corresponding surfaces; forming a reflective unit on the surface of the first optical element selected from the pair of corresponding surfaces; and forming an optical device by bringing the first and second optical elements into close contact with each other and fastening them to each other.