VR Eyecup Alignment Structure for Adjustable Optical Positioning

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Solution Overview

Problem

The increasing optical alignment tolerances in virtual reality (VR) headsets due to advancements in pixel density and viewing optics make the 6-axis alignment of optical components a multi-step, inefficient process, and once aligned, components cannot be easily adjusted if errors are made, leading to potential misalignment issues.

Innovation Solution

An eyecup assembly with a laminated plastic frame and alignment structures that allows for adjustable alignment with a coupling interface, enabling the electronic display to be re-aligned without discarding components, using detachable rigid mounting points for precise adjustment and re-alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If optical components are fixed into a particular position, then alignment stability is improved, but adaptability deteriorates (cannot be adjusted later if wrong position or alignment is lost)

Engineering Contradiction:

Improvealignment stabilityVSAvoidadjustability

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The frame is divided into multiple portions (first portion, second portion, third portion) that can be independently positioned and aligned. Each portion can be separately adjusted relative to the others, allowing fine-tuning of optical component positions while maintaining overall structural integrity. This segmentation enables both stability (once positioned) and adaptability (can be repositioned if needed).

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The alignment structure transitions from a static fixed-position design to a dynamic multi-position capability. The frame portions can be moved between different positions during assembly and adjustment, then fixed once optimal alignment is achieved. This dynamic capability resolves the contradiction between initial adjustability and final stability.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If a multi-step alignment process is used, then manufacturing precision is improved, but productivity deteriorates (inefficient for large scale production)

Engineering Contradiction:

Improvealignment precisionVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The frame portions are pre-configured with alignment features and reference marks during manufacturing. This preliminary preparation allows workers to quickly perform alignment by simply positioning components relative to pre-established references, rather than performing complex multi-step alignment procedures during assembly. The precision is maintained through pre-engineered alignment features while productivity improves through simplified assembly steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The alignment structure serves as an intermediary component that facilitates precise alignment between different frame portions and optical components. It provides reference surfaces, alignment marks, and mechanical guides that mediate the positioning process, enabling accurate alignment to be achieved rapidly without complex multi-step procedures.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If alignment structures are made detachable, then adaptability is improved (allowing realignment), but device complexity increases (additional alignment structures needed)

Engineering Contradiction:

ImproverealignabilityVSAvoidstructure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The alignment structures serve multiple functions: they provide mechanical attachment between frame portions, establish precise alignment references, and enable both initial assembly and subsequent realignment operations. This multi-functionality reduces the need for separate dedicated alignment features, thereby limiting the increase in structural complexity while maximizing adaptability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The detachable alignment structures are designed to be reusable rather than single-use. When realignment is needed, existing alignment structures can be detached and reattached in new positions, or reference marks can be reused for new alignment configurations. This recoverability approach enables adaptability without requiring entirely new structural components, thus limiting complexity increase.

Inventive Principle:

Principle #34Discarding and recovering

Data Source

PatentUS9995940B2Laminated alignment structure for eyecup assemblies in a virtual reality headset

Publication Date: 2018.06.12 META PLATFORMS TECHNOLOGIES LLC

AI summary

An eyecup assembly includes an electronic display element of a head-mounted display (HMD), a transparent plastic frame, an eyecup of the HMD, and a coupling interface. The plastic frame is laminated to the electronic display element and includes a center portion and a peripheral portion. The center portion includes an optical component and the peripheral portion including at least two protruding alignment structures. The eyecup includes alignment structures coupled to the at least two protruding alignment structures on the frame. The coupling interface interfaces with an alignment system. The alignment system is configured to align the eyecup assembly to the electronic display by adjusting a position of the electronic display relative to the eyecup so that a test image displayed by the electronic display after transmission through the optical component in the frame and an aperture of the eyecup is within a threshold value of a reference image.