Optical Waveguide Assembly Alignment and Protection
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Solution Overview
Problem
Optical waveguide assemblies in virtual and augmented reality systems face challenges with precise alignment and protection, leading to distorted images and potential damage due to misalignment and mechanical stress.
Innovation Solution
The use of an insert with precise alignment features and materials like metal or plastic, combined with Optically Clear Adhesive (OCA) tape or raised edges/areas, ensures accurate alignment and protection of optical waveguides, preventing damage during assembly and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If optical waveguides are made of glass with precision ridges, then optical reflection and image quality are improved, but the waveguides become easily damaged due to mechanical stress and misalignment
Solution Approach 1:
The patent introduces a frame structure as an intermediary component that holds and protects the glass waveguides. The frame absorbs mechanical stress and prevents direct contact between the fragile waveguides and external forces, thereby protecting the precision ridges while maintaining optical functionality.
Solution Approach 2:
The frame structure is designed beforehand to cushion and distribute mechanical stresses before they can reach the glass waveguides. This preventive protection allows the waveguides to maintain their precision ridges without being easily damaged during assembly or operation.
2Loss of information
If multiple optical waveguides are used for different colors, then color accuracy and image quality are improved, but alignment precision becomes more difficult to maintain
Solution Approach 1:
The frame structure serves multiple functions: it holds all color waveguides (red, green, blue) in a unified structure, provides common alignment references for all waveguides, and maintains their relative positions. This multi-functional design simplifies the alignment process while ensuring color accuracy.
Solution Approach 2:
The patent segments the multi-color waveguide system into individual waveguide components that are each precisely manufactured, then integrates them into a unified frame structure. This segmentation allows for precise manufacturing of each waveguide while the frame ensures their accurate relative alignment.
3Volume of moving object
If light projection engine is positioned close to waveguide for compact design, then device size is reduced, but alignment sensitivity increases leading to image distortion
Solution Approach 1:
The frame structure is designed with pre-established alignment features and reference surfaces that guide the positioning of both the waveguides and the light projection engine. This preliminary alignment structure ensures that even in a compact configuration, the components maintain precise relative positions, reducing sensitivity to manufacturing variations.
Data Source
AI summary
Methods and systems are provided to assemble an optical waveguide assembly. An optical waveguide assembly may be used in a virtual reality headset or other type of projection system. The optical waveguide assembly includes a front lens, one or more optical waveguides, and a back lens. In one embodiment, an insert is used that is the same width as the optical waveguides to prevent cracking of the optical waveguides. In another embodiment, the optical waveguide assembly includes Optically Clear Adhesive (OCA) tape between the different elements of the optical waveguide assembly to precisely align the optical waveguides. In another embodiment, the optical waveguide assembly has cover portions or a frame that protect the optical waveguides in the optical waveguide assembly.