Projector-Waveguide Mounting for Precise Optical Alignment
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Solution Overview
Problem
Existing head-mounted displays face challenges in achieving precise optical alignment between projectors and waveguides, leading to deviations in visual quality that degrade the user experience.
Innovation Solution
The implementation of a projector assembly with receptacles and support legs coupled to a waveguide assembly, allowing for adjustable alignment of light subprojectors with input gratings of the waveguide, using fiducial marks and alignment cameras to ensure precise optical alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mounting methods are used to attach waveguides to projectors, then assembly is simple, but optical alignment precision deteriorates leading to image quality deviations
Solution Approach 1:
The patent introduces alignment features including alignment pins, alignment holes, and alignment markings as intermediary elements between the projector and waveguide. These intermediaries facilitate precise optical alignment by providing physical or visual references during assembly, resolving the contradiction between alignment precision and assembly simplicity.
Solution Approach 2:
The patent incorporates pre-designed alignment features and tolerance specifications into the mounting structure before assembly occurs. By preliminarily establishing alignment references and tolerance zones in the design phase, the system achieves high optical alignment precision without requiring complex adjustment procedures during assembly.
2Manufacturing precision
If tight tolerances are specified for projector-waveguide alignment, then optical quality improves, but manufacturing difficulty increases
Solution Approach 1:
The patent specifies alignment tolerances and alignment features in the preliminary design phase, allowing manufacturers to prepare alignment references and tolerance compensation mechanisms before assembly. This preliminary planning reduces the actual assembly difficulty while maintaining tight alignment tolerances for optimal optical quality.
Solution Approach 2:
The patent employs tolerance stacking and cumulative tolerance analysis to manage alignment requirements. By carefully selecting and coordinating tolerance parameters across multiple components (projector, waveguide, mounting structure), the system achieves high optical alignment precision without making individual manufacturing steps excessively difficult.
3Manufacturing precision
If adjustable mounting structures are used to achieve optimal alignment, then optical alignment improves, but device complexity increases
Solution Approach 1:
The patent designs mounting structures with pre-integrated alignment features such as alignment pins, alignment holes, and alignment markings that are built into the structure itself. These preliminary alignment mechanisms provide optimal optical alignment through their geometric design rather than requiring complex adjustable components, thus improving alignment while limiting the increase in device complexity.
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
Improves optical quality by aligning light subprojectors with input gratings within predetermined thresholds, enhancing the visual experience in head-mounted displays.
Implementation Method 1
a waveguide configured for redirecting light from the at least one light subprojector
Implementation Method 2
The support leg may be positioned within the receptacle and coupled to the receptacle with an adhesive
Data Source
AI summary
Optical assemblies may include a projector assembly and a waveguide assembly. The projector assembly may include at least one light subprojector and a housing including at least one receptacle. The waveguide assembly may include a waveguide and a waveguide holder. The housing may include at least one receptacle and the waveguide holder may include at least one support leg. The support leg may be positioned within, and secured to, the receptacle to align the projector assembly with the waveguide assembly. Related head-mounted displays, systems, and methods are also disclosed.