JP2024096247A - Improved Manufacturing for Virtual and Augmented Reality Systems and Components - Google Patents

Abstract

The present invention provides improved manufacturing for virtual and augmented reality systems and components.
An improved diffractive structure for a 3D display system is disclosed. The improved diffractive structure includes an intermediate layer between a waveguide substrate and an upper grating surface. The upper grating surface comprises a first material corresponding to a first refractive index value, the underlayer comprises a second material corresponding to a second refractive index value, and the substrate comprises a third material corresponding to a third refractive index value. According to additional embodiments, an improved approach is provided for implementing the deposition of a transfer material onto a substrate, which allows for very precise distribution and deposition of different transfer patterns onto any number of substrate surfaces.
[Selection] Figure 19

Description

This disclosure relates to virtual reality and augmented reality imaging and visualization systems.

Modern computing and display technologies have facilitated the development of systems for so-called "virtual reality" or "augmented reality" experiences in which digitally reproduced images or parts thereof are presented to a user in a manner that appears or can be perceived as real. Virtual reality, or "VR", scenarios typically involve the presentation of digital or virtual image information without transparency to other actual real-world visual inputs. Augmented reality, or "AR", scenarios typically involve the presentation of digital or virtual image information as an extension of the user's surrounding real-world visualization. For example, referring to FIG. 1, an augmented reality scene (4) is depicted in which a user of AR technology sees a real-world park-like setting (6) featuring people, trees, buildings as a background, and a concrete platform (1120). In addition to these items, a user of the AR technology also perceives that they "see" a robotic figure (1110) standing on a real-world platform (1120) and a flying cartoon-like avatar character (2) that appears to be an anthropomorphic bumblebee, although these elements (2, 1110) do not exist in the real world. In conclusion, the human visual perception system is highly complex, and it is difficult to create VR or AR technology that facilitates a comfortable, natural-like, and sensory-rich presentation of virtual image elements among other virtual or real-world image elements.

There are numerous challenges when presenting 3D virtual content to a user of an AR system. A major premise of presenting 3D content to a user involves the generation of multiple depth perceptions. In other words, it may be desirable for some virtual content to appear closer to the user, while other virtual content appears to occur further away. Therefore, to achieve a 3D perception, the AR system should be configured to deliver virtual content at different focal planes to the user.

For a 3D display to provide a true sensation of depth, and more specifically, a simulated sensation of surface depth, it is desirable to generate, for each point in the display's field of view, an accommodation response that corresponds to that point's virtual depth. If the accommodation response to a display point does not correspond to that point's virtual depth, as determined by the binocular depth cues of convergence and stereopsis, the human visual system may experience accommodative conflicts, resulting in unstable imaging, deleterious eye strain, headaches, and, in the absence of accommodative information, a near-complete lack of surface depth.

Therefore, there is a need for improved techniques for implementing 3D displays that address these and other problems of conventional approaches. The systems and techniques described herein are configured to work with the typical human visual configuration and address these challenges.

Embodiments of the present invention are directed to devices, systems, and methods for facilitating virtual reality and/or augmented reality interactions for one or more users.

According to some embodiments, an augmented reality (AR) display system for delivering augmented reality content to a user includes an image source for providing one or more frames of image data, an optical modulator for transmitting light associated with the one or more frames of image data, and a diffractive optical element (DOE) for receiving the light associated with the one or more frames of image data and directing the light toward an eye of a user, the DOE comprising a diffractive structure having a waveguide substrate corresponding to a waveguide refractive index, a surface grating, and an intermediate layer (also referred to herein as a "lower layer") disposed between the waveguide substrate and the surface grating, the lower layer corresponding to a lower layer diffraction index different from the waveguide refractive index.

According to some embodiments of the present invention, a diffractive structure is employed for the DOE, which includes an underlayer between a waveguide substrate and an upper grating surface. The upper grating surface comprises a first material corresponding to a first refractive index value, the underlayer comprises a second material corresponding to a second refractive index value, and the substrate comprises a third material corresponding to a third refractive index value.

Any combination of the same or different materials may be employed to implement each of these portions of the structure, for example, all three materials are different (and all three materials correspond to different refractive index values), or two of the layers share the same material (for example, two of the three materials are the same and therefore share a common refractive index value that is different from the refractive index value of the third material). Any suitable set of materials may be used to implement any layer of the improved diffractive structure.

Thus, various combinations are available, where an underlayer of one refractive index is combined with an overlayer grating of another refractive index along with a substrate of a third refractive index, and adjustment of these relative values provides much variation in the dependence of diffraction efficiency on the angle of incidence. Layered waveguides with layers of different refractive index are presented. Various combinations and permutations are presented along with associated performance data to illustrate functionality. Benefits include increased angle, which provides increased output angle with a grating and therefore increased field of view with an eyepiece. Additionally, the ability to counter the normal decrease in diffraction efficiency with angle is functionally beneficial.

According to additional embodiments, improved approaches are provided for implementing deposition of transfer material onto a substrate along with transfer of the transfer material into a pattern to implement diffraction. These approaches allow for very precise distribution, deposition, and/or formation of different transfer materials/patterns onto any number of substrate surfaces. According to some embodiments, a patterned distribution of transfer material (e.g., patterned inkjet distribution) is performed to implement deposition of transfer material onto a substrate. This approach using patterned inkjet distribution allows for very precise volumetric control over the material to be deposited. Additionally, this approach can serve to provide a smaller, more uniform underlayer beneath the grating surface.

In some embodiments, a template is provided having a first set of deeper depth structures along with a second set of shallower depth structures. When depositing the transfer material onto the transfer receiver, a relatively larger volume of the transfer material is deposited corresponding to the deeper depth structures of the template. In addition, a relatively smaller volume of the transfer material is deposited corresponding to the shallower depth structures of the template. This approach allows for simultaneous deposition of materials of different thicknesses for different features to be formed on the transfer receiver. This approach can be taken to generate distributions that are intentionally non-uniform for structures with different depths and/or feature parameters, e.g., feature structures are on the same substrate but have different thicknesses. This can be used, for example, to generate spatially distributed volumes of transfer material that allow for simultaneous transfer of structures of variable depths with the same underlayer thickness.

Some embodiments relate to an approach for implementing simultaneous deposition of multiple types of transfer materials onto a substrate. This allows materials with optical properties to be simultaneously deposited across multiple portions of a substrate at once. This approach also provides the ability to tailor local areas associated with specific functions (e.g., to act as an internal coupling grating, an orthogonal pupil expansion element (OPE) grating, or an exit pupil expansion element (EPE) grating). The different types of materials may include the same material with different optical properties (e.g., two variants of the same material with different refractive indices) or two entirely different materials. Any optical properties of the materials, such as refractive index, opacity, and/or absorbance, can be considered and selected when employing the present technique.

According to another embodiment, multi-sided transfer may be employed to transfer to multiple sides of the optical structure. This allows transfers to occur on different sides of the optical element, implementing multiplexing of functions throughout the base layer volume. In this way, different eyepiece functions can be implemented without adversely affecting the grating structure function. A first template may be used to generate one transfer on side "A" of the substrate/transfer receiver, forming a first pattern with a first material on side A of the structure. Another template may be used to generate a second transfer on side "B" of the same substrate, which forms a second pattern with a second material on side B of the substrate. Sides A and B may have the same or different patterns and/or may have the same or different types of materials.

Additional embodiments relate to multi-layer overlay transfer and/or multi-layer separation/offset substrate integration. In either/both of these approaches, a previously transferred pattern can be jetted and printed again. An adhesive can be jetted onto the first layer, a second substrate can be bonded to it (possibly with an air gap), and a subsequent jetting process can deposit and transfer onto the second substrate. A series of transferred patterns can be bonded to each other sequentially in a roll-to-roll process. It should be noted that approaches implementing multi-layer overlay transfer can be used in conjunction with or instead of the multi-layer separation/offset substrate integration approach. For multi-layer overlay transfer, a first transfer material can be deposited and transferred onto a substrate, followed by deposition of a second transfer material, resulting in a composite multi-layer structure having both the first and second transfer materials. For multi-layer separation/offset substrate integration, both the first substrate 1 and the second substrate 2 can be transferred with a transfer material, and then substrate 1 and substrate 2 can be sandwiched and bonded, in one embodiment, possibly with offset features (also transferred) that provide an air gap between the active structures of substrate 2 and the backside of substrate 1. Transferred spacers can be used to create the air gap.

According to yet another embodiment, an approach is disclosed for implementing a variable volume deposition of a material distributed across a substrate, which may rely on a priori knowledge of the surface non-uniformity. This compensates for surface non-uniformity of the substrate that may result in undesired parallelism and poor optical performance. Variable volume deposition of transfer material may be employed to provide a horizontal distribution of the transfer material to be deposited independent of the underlying topography or physical feature set. For example, the substrate may be pulled flat by a vacuum chuck and in-situ metrology may be performed to assess the surface height, for example, using a low-coherence or laser-based contact measurement probe. The dispensed volume of the transfer material may be varied in response to the measurement data, resulting in a more uniform layer in response to the reproduction. Any type of non-uniformity, such as thickness variations and/or the presence of dips, peaks, or other anomalies or features associated with local locations on the substrate, may also be addressed by this embodiment of the invention.

It should be noted that any of the above-mentioned embodiments may be combined together. Furthermore, additional and other objects, features, and advantages of the present invention are set forth in the detailed description, drawings, and claims.
For example, the present application provides the following:
(Item 1)
1. A method of manufacturing a diffractive optical element, comprising the steps of:
depositing a set of one or more materials onto a substrate;
identifying a template, the template having an imprint pattern formed thereon;
and transferring the transfer pattern into the set of one or more materials on the substrate using the template;
The method, wherein the transferred pattern comprises a diffractive pattern for the diffractive optical element.
(Item 2)
the set of one or more materials on the substrate comprises a first portion of material and a second portion of material;
the template comprises a first set of depth structures and a second set of depth structures, the first set of depth structures having a different depth than the second set of depth structures;
the transfer pattern comprises a first pattern and a second pattern;
2. The method of claim 1, further comprising forming the first pattern and the second pattern simultaneously on the substrate, the template transferring the first pattern with the first set of depth structures onto the first portion of the material, and the template transferring the second pattern with the second set of depth structures onto the second portion of the material.
(Item 3)
3. The method of any of items 1 to 2, wherein the first pattern corresponds to a first diffraction grating pattern and the second pattern corresponds to a second diffraction grating pattern.
(Item 4)
4. The method of any of items 1 to 3, wherein the first and second portions of the material correspond to a non-uniform distribution of the material on the substrate.
(Item 5)
5. The method of any of items 1 to 4, wherein the substrate forms an underlayer of uniform thickness, and the first and second patterns form variable depth structures on the underlayer of uniform thickness.
(Item 6)
6. The method of claim 1, wherein the set of one or more materials on the substrate comprises a first portion of material and a second portion of material, the first portion of material having different optical properties than the second portion of material.
(Item 7)
7. The method of any of items 1 to 6, wherein the different optical properties between the first portion of material and the second portion of material correspond to different refractive indices, opacities, or absorbances.
(Item 8)
8. The method of any of the preceding claims, wherein the first portion of the material is deposited above the second portion of the material prior to transfer.
(Item 9)
the set of one or more materials on the substrate comprises a first portion of material and a second portion of material, the first portion of material being on a first side of the substrate and the second portion of material being on a second side of the substrate;
transferring a first pattern into a first portion of the material on the first side of the substrate;
transferring a second pattern into a second portion of the material on the second side of the substrate;
The method according to any one of items 1 to 8.
(Item 10)
10. The method of any of items 1 to 9, wherein the first pattern is different from the second pattern.
(Item 11)
11. The method of any of the preceding claims, wherein the first portion of material is a different material than the second portion of material.
(Item 12)
12. The method of any of the preceding claims, wherein the set of one or more materials on the substrate comprises a first portion of material and a second portion of material, the first portion of material being deposited and transferred prior to deposition of the second portion of material.
(Item 13)
13. The method of any of the preceding claims, wherein transfer is performed onto the second portion of the material.
(Item 14)
14. The method according to any of items 1 to 13, wherein the first substrate having a first transferred pattern is superimposed onto the second substrate having a second transferred pattern.
(Item 15)
Item 15. The method according to any of items 1 to 14, wherein the first substrate having the first transferred pattern is bonded to the second substrate having the second transferred pattern.
(Item 16)
Item 16. The method of any of items 1 to 15, wherein a spacer forms a gap between the first substrate having the first transferred pattern and the second substrate having the second transferred pattern.
(Item 17)
17. The method of any of the preceding claims, wherein varying levels of the set of one or more materials are deposited on the substrate.
(Item 18)
18. The method of any of the preceding claims, wherein the variable levels of the set of one or more materials deposited on the substrate are identified by measuring variability in a surface uniformity of the substrate.
(Item 19)
19. The method of any of the preceding claims, wherein the set of one or more materials is deposited on the substrate by inkjet deposition.
(Item 20)
20. A diffractive optical element formed using the method of any of items 1 to 19.

FIG. 1 illustrates a user's view of augmented reality (AR) through a wearable AR user device in one illustrated embodiment. FIG. 2 illustrates a conventional stereoscopic 3D simulation display system. FIG. 3 illustrates an improved approach for implementing a stereoscopic 3D simulation display system according to some embodiments of the present invention. 4A-4D illustrate various systems, subsystems, and components to address the objective of providing a high quality, comfortably perceived display system for human VR and/or AR. 4A-4D illustrate various systems, subsystems, and components to address the objective of providing a high quality, comfortably perceived display system for human VR and/or AR. 4A-4D illustrate various systems, subsystems, and components to address the objective of providing a high quality, comfortably perceived display system for human VR and/or AR. 4A-4D illustrate various systems, subsystems, and components to address the objective of providing a high quality, comfortably perceived display system for human VR and/or AR. FIG. 5 illustrates a plan view of an exemplary configuration of a system utilizing an improved diffractive structure. FIG. 6 illustrates a stacked waveguide assembly. FIG. 7 illustrates a DOE. 8 and 9 illustrate exemplary diffraction patterns. 8 and 9 illustrate exemplary diffraction patterns. 10 and 11 illustrate two waveguides into which the beams are launched. 10 and 11 illustrate two waveguides into which the beams are launched. FIG. 12 illustrates a stack of waveguides. FIG. 13A illustrates an example approach for implementing a diffractive structure having a waveguide substrate and a top grating surface, but no underlayer. FIG. 13B shows a chart of exemplary simulation results. FIG. 13C shows an annotated version of FIG. 13A. FIG. 14A illustrates an example approach for implementing a diffractive structure having a waveguide substrate, an underlayer, and an upper grating surface. FIG. 14B illustrates an example approach for implementing a diffractive structure having a waveguide substrate, an underlayer, a grating surface, and an upper surface. FIG. 14C illustrates an example approach for implementing a stack of diffractive structures having a waveguide substrate, an underlayer, a grating surface, and a top surface. FIG. 15A illustrates an example approach for implementing a diffractive structure having a high index waveguide substrate, a low index underlayer, and a low index top grating surface. FIG. 15B shows a chart of exemplary simulation results. FIG. 16A illustrates an example approach for implementing a diffractive structure having a low index waveguide substrate, a high index underlayer, and a low index top grating surface. FIG. 16B shows a chart of exemplary simulation results. FIG. 17A illustrates an example approach for implementing a diffractive structure having a low index waveguide substrate, a medium index underlayer, and a high index upper grating surface. FIG. 17B shows a chart of exemplary simulation results. 18A-D illustrate modification of the underlayer properties. 18A-D illustrate modification of the underlying properties. 18A-D illustrate modification of the underlying properties. 18A-D illustrate modification of the underlying properties. FIG. 19 illustrates an approach for implementing precise variable volume deposition of transferred material onto a single substrate. FIG. 20 illustrates an approach and transfer steps for implementing directional co-deposition of multiple different transfer materials into the same layer, according to some embodiments. 21A-B illustrate an example approach for implementing two-sided printing in the context of a total internal reflection diffractive optical element. FIG. 22 illustrates a structure formed using the approach shown in FIGS. 21A-B. FIG. 23 illustrates an approach for implementing multi-layer overprinting. FIG. 24 illustrates an approach for implementing multi-layer isolation/offset substrate integration. FIG. 25 illustrates an approach for implementing variable volume deposition of distributed material across a substrate to address surface non-uniformities.

According to some embodiments of the present invention, a diffractive structure is employed, the diffractive structure including an underlayer/intermediate layer between a waveguide substrate and an upper grating surface. The upper grating surface comprises a first material corresponding to a first refractive index value, the underlayer comprises a second material corresponding to a second refractive index value, and the substrate comprises a third material corresponding to a third refractive index value.

One advantage of this approach is that by appropriate selection of the relative refractive indices for the three layers, the structure can obtain a wider field of view for a wider range of incident light due to the fact that the minimum total internal reflection angle is reduced as the refractive index is increased. The diffraction efficiency can be increased, allowing for a "brighter" light output to the display of the image viewing device.

Various combinations are available, where a bottom layer of one refractive index is combined with a top grating of another refractive index along with a substrate of a third refractive index, and adjusting these relative values provides much variation in the dependence of diffraction efficiency on the angle of incidence. Layered waveguides with layers of different refractive index are presented. Various combinations and permutations are presented along with associated performance data to illustrate functionality. Benefits include increased angle, which provides increased output angle with a grating and therefore increased field of view with an eyepiece. Additionally, the ability to counter the normal decrease in diffraction efficiency with angle is functionally beneficial.

Display Systems According to Some Embodiments
This portion of the disclosure describes exemplary display systems that can be used with the improved diffractive structures of the present invention.

Figure 2 illustrates a conventional stereoscopic 3D simulation display system that typically has separate displays 74 and 76 for each eye 4 and 6, respectively, at a fixed radial focal distance 10 from the eye. This conventional approach fails to take into account many of the useful cues utilized by the human eye and brain to detect and interpret depth in three dimensions, including accommodation cues.

In fact, a typical human eye can interpret multiple layers of depth based on radial distance, for example, about 12 layers of depth. A near vision limit of about 0.25 meters is approximately the closest depth of focus, and a far vision limit of about 3 meters means that any item more than about 3 meters away from the human eye will receive infinite focus. The layers of focus become thinner and thinner the closer to the eye. In other words, the eye can perceive very small differences in focal length relatively close to the eye, and this effect dissipates as the object becomes more distant from the eye. At an infinite object location, the depth of focus/dioptric spacing value is about 1/3 diopter.

Figure 3 illustrates an improved approach to implementing a stereoscopic 3D simulation display system according to some embodiments of the present invention, where two composite images are displayed, one for each eye 4 and 6, and various radial focal depths (12) for various sides (14) of each image can be utilized to provide the perception of three-dimensional depth layering in the image perceived by each eye. Since multiple focal planes (e.g., 12 focal planes) exist between the user's eyes and infinity, data within these focal planes and the depicted relationships can be utilized to position virtual elements within an augmented reality scenario for the user's viewing, since the human eye is constantly moving around and utilizes focal planes to perceive depth. It should be noted that while this figure shows a specific number of focal planes at various depths, implementations of the present invention may use any number of focal planes as needed for the particular application desired, and the present invention is therefore not limited to devices having only the specific number of focal planes shown in any of the figures in this disclosure.

With reference to Figures 4A-4D, some general component options are illustrated according to some embodiments of the present invention. In the portion of the detailed description that follows the discussion of Figures 4A-4D, various systems, subsystems, and components are presented to address the objective of providing a high quality, comfortably perceived display system for human VR and/or AR.

As shown in FIG. 4A, an AR system user (60) is depicted wearing a frame (64) structure coupled to a display system (62) positioned in front of the user's eyes. Speakers (66), in the depicted configuration, are coupled to the frame (64) and positioned adjacent the user's ear canals (in one embodiment, another speaker, not shown, is positioned adjacent the user's other ear canal to provide stereo/shapeable sound control). The display (62) is operatively coupled (68), such as by wired or wireless connection, to a local processing and data module (70), which may be mounted in a variety of configurations, such as fixedly attached to the frame (64), fixedly attached to a helmet or hat (80) as shown in the embodiment of FIG. 4B, embedded within headphones, removably attached to the torso (82) of the user (60) in a backpack-style configuration as shown in the embodiment of FIG. 4C, or removably attached to the waist (84) of the user (60) in a belt-coupled configuration as shown in the embodiment of FIG. 4D.

The local processing and data module (70) may include a low power processor or controller and digital memory, such as flash memory, both of which may be utilized to aid in processing, caching, and storing data. The data may be a) data captured from sensors, such as image capture devices (such as cameras), microphones, inertial measurement units, accelerometers, compasses, GPS units, wireless devices, and/or gyroscopes, that may be operably coupled to the frame (64), and/or b) data acquired and/or processed using a remote processing module (72) and/or a remote data repository (74), possibly for processing or retrieval and then passing to the display (62). The local processing and data module (70) may be operably coupled to the remote processing module (72) and the remote data repository (74) via wired or wireless communication links, etc. (76, 78), and these remote modules (72, 74) are operably coupled to each other and available as resources to the local processing and data module (70).

In one embodiment, the remote processing module (72) may comprise one or more relatively powerful processors or controllers configured to analyze and process the data and/or image information. In one embodiment, the remote data repository (74) may comprise a relatively large digital data storage facility that may be available through the Internet or other networking configurations in a "cloud" resource configuration. In one embodiment, all data is stored and all calculations are performed in the local processing and data module, allowing for fully autonomous use from any remote module.

The perception of Z-axis difference (i.e., linear distance from the eye along the optical axis) can be facilitated by using a waveguide with a variable focus optics configuration. Image information from a display can be collimated and injected into a waveguide and distributed in a large exit pupil fashion using any suitable substrate-guided optics method known to those skilled in the art, and then the variable focus optics capabilities can be utilized to change the focus of the wavefront of the light emerging from the waveguide and provide the eye with the perception that the light emerging from the waveguide is from a particular focal distance. In other words, since the incoming light is collimated to avoid the issues in total internal reflection waveguide configurations, it exits in a collimated manner, requiring the viewer's eye to accommodate to a far point and focus it on the retina, which will necessarily be interpreted as being from optical infinity unless some other intervention causes the light to be refocused and perceived as being from a different viewing distance. One such suitable intervention is a variable focus lens.

In some embodiments, the collimated image information is launched into a piece of glass or other material at an angle such that it undergoes total internal reflection and is passed into an adjacent waveguide. The waveguide may be configured such that the collimated light from the display is distributed to exit approximately uniformly across a distribution of reflectors or diffractive features along the length of the waveguide. Upon exiting towards the eye, the exiting light is passed through a variable focus lens element, and depending on the controlled focus of the variable focus lens element, the light exiting the variable focus lens element and entering the eye will have different levels of focus (a collimated flat wavefront represents optical infinity, and larger beam divergence/wavefront curvature represents closer viewing distances to the eye 58).

In a "frame sequential" configuration, a stack of sequential two-dimensional images may be fed sequentially to the display in a manner similar to how computed tomography systems use stacked image slices to represent three-dimensional structures over time, creating a three-dimensional perception. A series of two-dimensional image slices may be presented to the eye, each at a different focal length relative to the eye, and the eye/brain will integrate such stacks into the perception of a coherent three-dimensional volume. Depending on the display type, row-by-row or even pixel-by-pixel sequencing may be performed to create the perception of three-dimensional viewing. For example, in a scanning optical display (such as a scanning fiber display or a scanning mirror display), the display presents the waveguide one line or one pixel at a time in a sequential manner.

With reference to FIG. 6, a stacked waveguide assembly (178) may be utilized to provide a three-dimensional perception to the eye/brain by having multiple waveguides (182, 184, 186, 188, 190) and multiple weak lenses (198, 196, 194, 192) configured together to transmit image information to the eye with various levels of wavefront curvature for each waveguide level that indicates the focal length to be perceived for that waveguide level. Multiple displays (200, 202, 204, 206, 208), or in another embodiment, a single multiplexed display, may be utilized to inject collimated image information into the waveguides (182, 184, 186, 188, 190), each of which may be configured to distribute the incoming light substantially equally over the length of each waveguide for output to the eye, as previously described.

The waveguide (182) closest to the eye is configured to deliver collimated light to the eye that may represent an optical infinity focal plane as it is launched into such waveguide (182). The next upper waveguide (184) is configured to transmit collimated light that passes through a first weak lens (192; e.g., a weak negative lens) before it can reach the eye (58). Such a first weak lens (192) may be configured to create a slight convex wavefront curvature such that the eye/brain interprets the light emerging from the next upper waveguide (184) as originating from a first focal plane closer to optical infinity inward toward the person. Similarly, the third upper waveguide (186) passes its output light through a first (192) and second (194) lenses before reaching the eye (58). The combined refractive power of the first (192) and second (194) lenses can be configured to create another incremental amount of wavefront divergence such that the eye/brain interprets the light emerging from the upper third waveguide (186) as emerging from a second focal plane that is closer to optical infinity and even more inward toward the person than the light from the next upper waveguide (184).

The other waveguide layers (188, 190) and weak lenses (196, 198) are similarly configured, with the highest waveguide (190) in the stack sending its output through all of the weak lenses between it and the eye for a total focal power that represents the focal plane closest to the person. To compensate the stack of lenses (198, 196, 194, 192) when viewing/interpreting light originating from the world (144) on the other side of the stacked waveguide assembly (178), a compensation lens layer (180) is placed on top of the stack to compensate for the total refractive power of the lower lens stack (198, 196, 194, 192). Such a configuration again provides a relatively large exit pupil configuration for as many perceived focal planes as there are waveguide/lens pairs available, as previously described. Both the reflective sides of the waveguides and the focusing sides of the lenses can be static (i.e., not dynamic or electroactive). In an alternative embodiment, which is dynamic and uses electro-active features as described above, a small number of waveguides may be multiplexed in a time-sequential manner to generate a larger number of effective focal planes.

Various diffractive configurations can be employed to focus and/or redirect a collimated beam. For example, passing a collimated beam through a linear diffraction pattern, such as a Bragg grating, will deflect, or "steer," the beam. Passing a collimated beam through a radially symmetric diffraction pattern, i.e., a "Fresnel zone plate," will change the focus of the beam. A combination diffraction pattern having both linear and radial elements can be employed to produce both deflection and focusing of a collimated input beam. These deflection and focusing effects can be produced in reflective as well as transmissive modes.

These principles can be applied with waveguide configurations to allow for additional optical system control. As shown in FIG. 7, a diffraction pattern (220), i.e., a "diffractive optical element" (or "DOE"), is embedded within a planar waveguide (216) such that as a collimated beam is totally internally reflected along the planar waveguide (216), it intersects the diffraction pattern (220) at multiple locations. The structure can also include another waveguide (218) into which a beam can be launched (e.g., by a projector or display), with a DOE (221) embedded within this other waveguide (218).

Preferably, the DOE (220) has a relatively low diffraction efficiency so that only a portion of the light in the beam is deflected toward the eye (58) with each intersection of the DOE (220), while the remainder continues to travel through the planar waveguide (216) via total internal reflection. The light carrying the image information is thus split into several related light beams that exit the waveguide at multiple locations, and the result is a very uniform pattern of exit emission toward the eye (58) for this particular collimated beam bouncing within the planar waveguide (216), as shown in FIG. 8. The exit beam toward the eye (58) is shown in FIG. 8 as substantially parallel, since in this case the DOE (220) has only a linear diffraction pattern. However, variations to this linear diffraction pattern pitch can be exploited to controllably deflect the exiting parallel beam, thereby creating scanning or tiling functionality.

Referring to FIG. 9, as the radially symmetric diffraction pattern components of the embedded DOE (220) change, the output beam pattern becomes more divergent, which requires the eye to accommodate to closer distances and focus the output beam pattern onto the retina, and the output beam pattern will be interpreted by the brain as light from a viewing distance closer to the eye than optical infinity.

Referring to FIG. 10, with the addition of another waveguide (218) into which a beam may be launched (e.g., by a projector or display), a DOE (221) embedded within this other waveguide (218), such as a linear diffraction pattern, may function to spread the light throughout the larger planar waveguide (216), which, depending on the particular DOE configuration in operation, may function to provide a very large incident field of the incident light exiting the larger planar waveguide (216), e.g., a large eyebox, at the eye (58).

Although the DOEs (220, 221) are depicted as bisecting the associated waveguides (216, 218), this need not be the case. They can be placed closer to or on either side of either of the waveguides (216, 218) to have the same functionality. Thus, as shown in FIG. 11, with the injection of a single collimated beam, the entire field of cloned collimated beams can be directed towards the eye (58). In addition, in a combined linear diffraction pattern/radially symmetric diffraction pattern scenario such as the one described above, beam distribution waveguide optics with Z-axis focusing capability (due to functionality such as functional expansion of the exit pupil, in a configuration such as that of FIG. 11, the exit pupil can be as large as the optical element itself, which can be a very significant advantage for user comfort and ergonomics) are presented, where the divergence angle of the cloned beams and the wavefront curvature of each beam both represent light originating from a point closer than optical infinity.

In one embodiment, one or more DOEs are switchable between an "on" state in which they actively diffract and an "off" state in which they do not significantly diffract. For example, a switchable DOE may comprise a layer of polymer-dispersed liquid crystal in which microdroplets comprise a diffractive pattern within a host medium, and the refractive index of the microdroplets can be switched to substantially match that of the host material (in which case the pattern does not significantly diffract incident light) or to a refractive index that does not match that of the host medium (in which case the pattern actively diffracts incident light). Additionally, with dynamic changes to the diffraction terms, beam scanning or tiling functionality can be achieved. As previously mentioned, it is desirable to have a relatively low diffraction grating efficiency in each of the DOEs (220, 221). This is because it facilitates the distribution of light, and further because the light coming through the waveguide that is desirably transmitted (e.g., in an augmented reality configuration, light originating from the world 144 towards the eye 58) is less affected by the lower diffraction efficiency of the DOE (220) that it intersects, and therefore a better view of the real world is achieved through such a configuration.

Configurations such as those illustrated herein are preferably driven with the input of image information in a time-sequential approach, with frame-sequential driving being the simplest to implement. For example, an image of the sky at optical infinity can be input at time 1, and a diffraction grating can be utilized to keep the light collimated. An image of a closer tree branch can then be input at time 2, while the DOE controllably applies a focus change, say one diopter or one meter away, to provide the eye/brain with the perception that the branch's light information is coming from a closer focal distance. This kind of paradigm can be repeated in a fast time-sequential manner such that the eye/brain perceives the input as being all parts of the same image. This is just an example of two focal planes. Preferably, the system would include more focal planes, providing a smoother transition between the object and its focal distance. This kind of configuration generally assumes that the DOE is switched relatively slowly (i.e., in sync with the frame rate of the display inputting the image, in the range of tens to hundreds of cycles per second).

The polar opposite could be a configuration in which the DOE elements can shift focus at tens to hundreds of MHz or more, facilitating switching of the focus state of the DOE elements on a pixel-by-pixel basis as the pixels are scanned into the eye (58) using a scanning light display type approach. This is desirable because it means that the overall display frame rate can be kept very low (low enough to ensure that "flicker" is not an issue (in the range of about 60-120 frames/sec)).

Between these ranges, if the DOE can be switched at KHz rates, the focus on each scan line can be adjusted on a row-by-row basis, which can give the user a visible advantage, for example, in terms of temporal artifacts in eye movement relative to the display. For example, different focal planes in a scene can be interleaved in this manner to minimize visible artifacts in response to head movement (as discussed in detail later in this disclosure). The row-by-row focus modulator can be operatively coupled to a line-scanning display, such as a grating light valve display, in which a linear array of pixels is swept to form an image. The row-by-row focus modulator can be operatively coupled to a scanning light display, such as a fiber scanning display and a mirror scanning light display.

A stacked configuration similar to that of FIG. 6 can provide multi-plane focusing simultaneously using a dynamic DOE. For example, with three simultaneous focal planes, a primary focal plane (e.g., based on measured ocular accommodation) can be presented to the user, and + and - margins (i.e., one closer, one farther) can be utilized to provide a large range of focus to which the user can accommodate before a plane update is required. This increased focus range can provide a time advantage if the user switches to a closer or farther focus (i.e., as determined by accommodation measurements), the new focal plane can be brought to the center depth of focus, and the + and - margins are again prepared for a fast switch to either side while the system catches up.

Referring to FIG. 12, a stack (222) of planar waveguides (244, 246, 248, 250, 252) is shown, each with a reflector (254, 256, 258, 260, 262) at each end, configured so that collimated image information launched at one end by a display (224, 226, 228, 230, 232) bounces back by total internal reflection to the reflector, at which point some or all of the light is reflected toward the eye or other target. Each of the reflectors may have a slightly different angle to all reflect the outgoing light toward a common destination, such as the pupil. Lenses (234, 236, 238, 240, 242) may be inserted between the display and the waveguide for beam steering and/or focusing.

As mentioned before, an object at optical infinity creates a substantially plane wavefront, while an object closer, say 1m from the eye, creates a curved wavefront (with a convex radius of curvature of about 1m). The optical system of the eye needs to have enough refractive power to bend the incoming ray of light so that it is ultimately focused on the retina (the convex wavefront is turned into a concave one, which then leads to a focus on the retina). These are the basic functions of the eye.

In many of the aforementioned embodiments, the light directed to the eye is treated as part of one continuous wavefront, some portion of which will impinge on the pupil of a particular eye. In another approach, the light directed to the eye can be effectively discretized or split into multiple beamlets or individual rays, each of which has a diameter of less than about 0.5 mm and a unique propagation path, as part of a larger aggregate wavefront that can be functionally created by an aggregation of beamlets or rays. For example, a curved wavefront can be approximated by aggregating multiple individual, nearby collimated beams that each approach the eye from an appropriate angle to represent an origin that coincides with the center of the radius of curvature of the desired aggregate wavefront.

If the beamlets have a diameter of about 0.5 mm or less, it is as if they are coming through a pinhole lens configuration, which means that each individual beamlet is always at a relative focus on the retina, independent of the accommodation state of the eye, however the trajectory of each beamlet will be affected by the accommodation state. For example, if the beamlets approach the eye parallel and represent a discretized collimated collective wavefront, an eye that is correctly accommodated to infinity will deflect the beamlets so that they all converge to the same shared spot on the retina, and will appear in focus. If the eye accommodates to, say, 1 m, the beams will converge to a spot in front of the retina, cross paths, and hit multiple nearby or partially overlapping spots on the retina, appearing blurred.

If the beamlets approach the eye in a divergent configuration, with the shared origin 1 meter from the viewer, then 1 meter of accommodation will steer the beam to a single spot on the retina, which will appear in focus. If the viewer accommodates to infinity, the beamlets will converge to a spot behind the retina, producing multiple nearby or partially overlapping spots on the retina, producing a blurred image. More generally, the eye's accommodation determines the degree of overlap of the spots on the retina, and a given pixel is "in focus" if all of the spots are directed to the same spot on the retina, and "out of focus" if the spots are offset from each other. This concept that beamlets of diameter 0.5 mm or less can all be assembled to be perceived by the eye/brain as being in focus at all times and substantially identical to a coherent wavefront can be exploited in generating configurations for comfortable 3D virtual or augmented reality perception.

In other words, a set of multiple narrow beams can be used to mimic the conditions with a larger diameter variable focus beam, and if necessary, the beamlet diameter can be kept to a maximum of about 0.5 mm, and the beamlet angular trajectories can be selected to create an effect similar to a larger defocused beam in order to maintain a relatively static focus level and generate the perception of defocus (such a defocus process may not be identical to a Gaussian blur process as for larger beams, but would create a multimodal point spread function that can be interpreted in a similar manner to a Gaussian blur).

In some embodiments, the beamlets are not mechanically deflected to create this collective focus effect; rather, the eye receives a superset of many beamlets that includes both multiple angles of incidence and multiple locations where the beamlets intersect the pupil. To represent a given pixel from a particular viewing distance, some of the beamlets from the superset that have the appropriate angles of incidence and intersection points with the pupil (as if emanating from the same shared origin in space) are turned on with a matching color and intensity to represent the collective wavefront, while beamlets in the superset that are not consistent with the shared origin are not turned on with that color and intensity (although some of them may be turned on with some other color and intensity level, e.g., to represent a different pixel).

5, an exemplary embodiment 800 of an AR system using an improved diffractive structure is now described. The AR system generally includes an image generation processor 812, at least one FSD 808 (fiber scanning device), an FSD circuit 810, coupling optics 832, and at least one optical assembly (DOE assembly 802) having a waveguide stacked together with the improved diffractive structure described below. The system may also include an eye tracking subsystem 806. As shown in FIG. 5, the FSD circuit may include an image generation processor 812 having a Maxim chip CPU 818, a temperature sensor 820, a piezoelectric driver/transducer 822, a red laser 826, a blue laser 828, a green laser 830, and a circuit 810 in communication with a fiber combiner that combines all three lasers 826, 828, 830. It should be noted that other types of imaging technologies may also be used in place of the FSD device. For example, high resolution liquid crystal display ("LCD") systems, backlit ferroelectric panel displays, and/or high frequency DLP systems may all be used in some embodiments of the present invention.

The image generation processor is responsible for generating the virtual content that is ultimately displayed to the user. The image generation processor may convert images or videos associated with the virtual content into a format that can be projected to the user in 3D. For example, in generating 3D content, the virtual content may need to be formatted so that some of a particular image is displayed on a particular depth plane, while others are displayed on other depth planes. Or the images may all be generated at a particular depth plane. Or the image generation processor may be programmed to feed slightly different images to the right and left eyes so that when viewed together, the virtual content appears coherent and comfortable to the user's eyes. In one or more embodiments, the image generation processor 812 delivers the virtual content to the optical assembly in a time-sequential manner. A first portion of the virtual scene may be delivered first, such that the optical assembly projects the first portion in the first depth plane. Then, the image generation processor 812 may deliver another portion of the same virtual scene, such that the optical assembly projects the second portion in the second depth plane, and so on. Here, the Alvarez lens assembly can be translated laterally quickly enough to generate multiple lateral translations (corresponding to multiple depth planes) on a frame-by-frame basis.

The image generation processor 812 may further include memory 814, a CPU 818, a GPU 816, and other circuitry for image generation and processing. The image generation processor may be programmed with desired virtual content to be presented to a user of the AR system. It should be understood that in some embodiments, the image generation processor may be stored within the wearable AR system. In other embodiments, the image generation processor and other circuitry may be stored within a belt pack that is coupled to the wearable optics.

The AR system also includes coupling optics 832 for directing light from the FSD to the optical assembly 802. The coupling optics 832 may refer to one or more conventional lenses used to direct the light into the DOE assembly. The AR system also includes an eye tracking subsystem 806 configured to track the user's eyes and determine the user's focus.

In one or more embodiments, software blurring may be used to induce blur as part of the virtual scene. A blur module may be part of the processing circuitry in one or more embodiments. The blur module may blur portions of one or more frames of image data being fed into the DOE. In such an embodiment, the blur module may completely blur portions of a frame that are not intended to be rendered at a particular depth frame. An exemplary approach that may be used to implement the aforementioned image display system and components therein is described in U.S. Patent Application Serial No. 14/555,585.

Improved Diffractive Structure
As previously mentioned, a diffraction pattern can be formed on the planar waveguide such that a collimated beam is totally internally reflected along the planar waveguide and the beam intersects the diffraction pattern at multiple locations. This arrangement can be stacked to provide image objects at multiple focal planes in a stereoscopic 3D simulation display system according to some embodiments of the present invention.

Figure 13A illustrates one possible approach that can be taken to implement a structure 1300 of a waveguide 1302 (also referred to herein as a "light guide", "substrate", or "waveguide substrate"), where an outcoupling grating 1304 is formed directly on the top surface of the waveguide 1302, for example as a combined monolithic structure, and/or both are formed from the same material (even if not constructed from the same monolithic structure). In this approach, the index of refraction of the grating material is the same as that of the waveguide 1302. The refractive index n (or "index of refraction") of a material describes the degree to which light propagates through that medium and is defined as n = c/v, where c is the speed of light in a vacuum and v is the phase velocity of light in the medium. The index of refraction determines the degree to which light is bent or refracted when entering the material.

Figure 13B shows a chart 1320 of example simulation results for a single polarization of the efficiency of light exiting the structure 1300 as a function of the angle at which the light is propagating in the waveguide. The chart shows that the diffraction efficiency of light outcoupled to the structure 1300 decreases at higher angles of incidence. As can be seen, at an angle of about 43 degrees, the efficiency drops off relatively sharply on the depicted plot due to the total internal reflectance variation with angle of incidence in a medium with a uniform refractive index.

The usable range of configuration 1300 is therefore somewhat limited and therefore undesirable as the bounce spacing may decrease at higher angles of incidence, which may further reduce the brightness seen by the observer at those angles. The diffraction efficiency will be lower at the shallowest angles of incidence, which is quite undesirable as the bounce spacing between interactions with the top surface (see FIG. 13C) is so far away that there is very little opportunity for light to outcouple. Thus, a dimming signal with fewer outcoupled samples would result from this arrangement, and this problem would be exacerbated by a grating that has a lower diffraction efficiency at these high angles with this polarization orientation. Note that as used herein and in the figures, "1T" refers to the first transmitted diffraction order.

In some embodiments of a waveguide-based or substrate-guided optical system such as those described above, different pixels in the substrate-guided image are represented by beams propagating at different angles in the waveguide, with light propagating along the waveguide by total internal reflection (TIR). The range of beam angles that remain trapped in the waveguide by TIR is a function of the difference in refractive index between the waveguide and the medium outside the waveguide (e.g., air). The higher the difference in refractive index, the greater the number of beam angles. In some embodiments, the range of beam angles propagating along the waveguide correlates with the field of view of the image coupled out of the face of the waveguide by the diffractive element, and correlates with the image resolution supported by the optical system. In addition, the range of angles over which total internal reflection occurs is dictated by the refractive index of the waveguide. In some embodiments, the minimum is about 43 degrees and the practical maximum is about 83 degrees, thus in the range of 40 degrees.

14A illustrates an approach to address this problem according to some embodiments of the present invention, where the structure 1400 includes an intermediate layer 1406 (referred to herein as "lower layer 1406") between the substrate 1302 and the upper grating surface 1304. The upper surface 1304 comprises a first material corresponding to a first refractive index value, the lower layer 1406 comprises a second material corresponding to a second refractive index value, and the substrate 1302 comprises a third material corresponding to a third refractive index value. Note that any combination of the same or different materials may be employed to implement each of these portions of the structure 1400, e.g., all three materials are different (and all three materials correspond to different refractive index values), or two of the layers share the same material (e.g., two of the three materials are the same and therefore share a common refractive index value that is different from the refractive index value of the third material). Any combination of refractive index values may be employed. For example, one embodiment includes a low refractive index for the underlayer and uses higher refractive index values for the surface grating and substrate. Other exemplary configurations having other illustrative combinations of refractive index values are described below. Any suitable set of materials may be used to implement structure 1500. For example, polymer, glass, and sapphire are all examples of materials that may be selected to implement any of the layers of structure 1400.

15A, in some embodiments, it may be desirable to implement the structure 1500 using a relatively higher index substrate as the waveguide substrate 1302, with a relatively lower index underlayer 1406 and a relatively lower index upper grating surface 1304. This is because it may be possible to obtain a wider field of view from the fact that the minimum total internal reflection angle is reduced as the index is increased through the relationship n1×sin(θ1)=n2×sin(90). For a substrate with an index of refraction of 1.5, the critical angle is 41.8 degrees. However, for a substrate index of 1.7, the critical angle is 36 degrees.

Gratings formed on a substrate of higher refractive index can be utilized to outcouple light even if it itself has a lower refractive index, as long as the layer of material that makes up the grating is not too thick between the grating and the substrate. This is related to the fact that with such a configuration, one can have a wider range of angles for total internal reflection ("TIR"). In other words, the TIR angle drops to a lower value with such a configuration. In addition, it is noted that many of the current etching processes may not be well suited for extending to high index glasses. In some embodiments, it is desirable to replicate the outcoupling layer reliably and inexpensively.

The configuration of the underlayer 1406 can be adjusted to modify the performance characteristics of the structure 1500, for example, by changing the thickness of the underlayer 1406. The configuration of FIG. 15A (wherein the structure includes a lattice structure 1304 on top comprising a relatively low refractive index material with an associated lower refractive index underlayer 1406, which also includes an associated high refractive index light guiding substrate 1302) can be modeled to yield data such as that depicted in FIG. 15B. With reference to this figure, the left plot 1502a is associated with a configuration with a zero thickness underlayer 1502. The center plot 1502b shows data for a 0.05 micron thick underlayer 1502. The right plot 1502c shows data for a 0.1 micron thick underlayer 1502.

As shown by the data in these plots, as the underlayer thickness is increased, the diffraction efficiency as a function of incidence angle becomes much more nonlinear and suppressed at high angles, which may be undesirable. Therefore, control of the underlayer is an important functional input in this case. Note, however, that with a zero-thickness underlayer and only the grating features themselves possessing a lower refractive index, the range of angles supported by the structure is governed by the TIR conditions in the higher index base material, not the lower index grating feature material.

Referring to FIG. 16A, an embodiment of a structure 1600 is illustrated that features a relatively high refractive index underlayer 1406 on a lower refractive index substrate 1302, with a top surface grating 1304 having a refractive index lower than the underlayer 1406 and comparable, though not necessarily equal, to that of the substrate 1302. For example, the top surface grating may correspond to a refractive index of 1.5, the underlayer may correspond to a refractive index of 1.84, and the substrate may correspond to a refractive index of 1.5. For this example, assume that the period is 0.43 μm and λ corresponds to 0.532 μm.

Simulations related to such configurations are presented in FIG. 16B. As shown in this figure, in chart 1602a with a 0.3 micron thick underlayer 1406, the diffraction efficiency drops as in the previous configuration, but then begins to rise at the higher end of the angular range. This is also true for the 0.5 micron thick underlayer 1406 configuration, as shown in chart 1602b. It is beneficial that in each of these (0.3 micron, 0.5 micron) configurations, the efficiency is relatively high at the higher extremes of the angular range. Such functionality may tend to counter the sparser bounce spacing concerns mentioned above. Also shown in this figure is chart 1602c for an embodiment featuring an example of 90 degree rotated polarization, where the diffraction efficiency is low as might be expected, but exhibits desirable behavior in providing better efficiency at steeper angles compared to shallower angles.

Indeed, in some embodiments, the diffraction efficiency versus angle may increase at high angles. This may be a desirable feature for some embodiments as it helps to compensate for the lower bounce spacing that may occur at higher propagation angles. Thus, the structural configuration of FIG. 16A may be preferred in embodiments where it is desirable to compensate for the lower bounce spacing (which occurs with higher propagation angles) as it promotes increased diffraction efficiency versus angle at higher angles, which is desirable relative to the monolithic configuration described above.

Referring to FIG. 17A, another structure 1700 is depicted in which the bottom layer 1406 has a refractive index substantially higher than that of the substrate 1302. The grating structure 1304 is on top, and the grating structure 1304 also has a refractive index higher than that of the bottom layer 1406. For example, the top surface grating may correspond to a refractive index of 1.86, the bottom layer may correspond to a refractive index of 1.79, and the substrate may correspond to a refractive index of 1.5. As before, for this example, assume that the period is 0.43 μm and λ corresponds to 0.532 μm.

Referring to FIG. 17B, chart 1702 shows simulation data illustrated for structure 1700 of FIG. 17A. As shown in chart 1702, the resulting plot of diffraction efficiency versus incidence angle demonstrates desirable general behavior that helps compensate for the aforementioned lower bounce spacing at relatively high incidence angles and generally retains reasonable diffraction efficiency over a wider range of angles.

It should be noted that underlayer 1406 need not be uniform across the substrate. Any property of underlayer 1406 may be varied at different locations of the substrate, such as differences in thickness, composition, and/or refractive index of underlayer 1406. One possible reason for varying the properties of underlayer 1406 is to promote uniform display properties in the presence of known variations in either the display image and/or non-uniform delivery of light within the display system.

For example, consider the case where a waveguide structure receives incident light at a single internal coupling location 1802 on the waveguide, as shown in FIG. 18A. If incident light is launched into the waveguide 1302, less and less light will remain as it propagates along the length of the waveguide 1302. This means that the output light near the internal coupling location 1802 may end up appearing "brighter" than the output light further along the length of the waveguide 1302. If the underlayer 1406 is uniform along the entire length of the waveguide 1302, the optical effect of the underlayer 1406 may enhance this non-uniform brightness level across the substrate.

The properties of the underlayer 1406 can be tailored across the substrate 1302 to make the output light more uniform. FIG. 18B illustrates an approach in which the thickness of the underlayer 1406 is varied across the length of the waveguide substrate 1302, with the underlayer 1406 being thinner near the internal coupling location 1802 and thicker the further away from location 1802. In this manner, the effect of the underlayer 1406 to promote better diffraction efficiency can, at least in part, ameliorate the effects of light loss along the length of the waveguide substrate 1302, thereby promoting a more uniform light output throughout the structure.

18C illustrates an alternative approach in which the thickness of the underlayer 1406 is not varied, but the refractive index of the underlayer 1406 is varied across the substrate 1302. For example, to address the problem that the output light near the location 1802 tends to be brighter away from the location 1802, the refractive index for the underlayer 1406 is configured to be the same or similar to the substrate 1302 close to the location 1802, but with an increasing difference in their refractive index values away from the location 1802. The composition of the underlayer 1406 material can be varied at different locations, resulting in different refractive index values. FIG. 18D illustrates a hybrid approach in which both the thickness and refractive index of the underlayer 1406 are varied across the substrate 1302. Note that this same approach can be done to vary the thickness and/or refractive index of the upper grating surface 1304 and/or the substrate 1302 in conjunction with or instead of varying the underlayer 1406.

Thus, various combinations are available, where a bottom layer 1406 of one refractive index is combined with a top grating 1304 of another refractive index, along with a substrate 1302 of a third refractive index, and tuning these relative values provides much variation in the dependence of the diffraction efficiency on the angle of incidence. Layered waveguides with layers of different refractive index are presented. Various combinations and permutations are presented with associated performance data to illustrate functionality. Benefits include increased angle, which provides increased output angle with the grating 1304, and therefore increased field of view with the eyepiece. Additionally, the ability to counter the normal decrease in diffraction efficiency with angle is functionally beneficial.

14B illustrates an embodiment in which another layer (top surface) of material 1409 is placed above the grating layer 1304. Layer 1409 can be implemented configurably to address different design goals. For example, layer 1409 can form an intervening layer between multiple stacked diffractive structures 1401a and 1401b, as shown in FIG. 14C. As shown in FIG. 14C, this intervening layer 1409 can be employed to eliminate any air gaps/gaps and provide a support structure for the stacked diffractive components. In this use case, layer 1409 can be formed from a material having a relatively low refractive index, for example, about 1.1 or 1.2. Although not shown in this figure, other layers (such as weak lenses) can also be placed between diffractive structures 1401a and 1401b.

In addition, layer 1409 can be formed from a material having a relatively high refractive index. In this situation, it is the grating on layer 1409, rather than grating surface 1304, that will provide the diffractive effect for all or a significant amount of the incident light.

As will be apparent, different relative combinations of refractive index values can be selected for different layers, including layer 1409, to achieve desired optical effects and results.

Such structures may be fabricated using any suitable fabrication technique. Certain high refractive index polymers, such as those known as "MR174," may be directly embossed, printed, or etched to produce the desired patterned structures, but there are challenges associated with the cure shrinkage, etc., of such layers. Thus, in another embodiment, another material may be transferred, embossed, or etched onto the high refractive index polymer layer (i.e., such as a layer of MR174) to produce a functionally similar result. Current state-of-the-art printing, etching (i.e., which may include resist stripping and patterning steps similar to those utilized in conventional semiconductor processes), and embossing techniques may be utilized and/or combined to accomplish such printing, embossing, and/or etching steps. For example, molding techniques similar to those utilized in DVD production may also be utilized for certain replication steps. Additionally, certain jetting or deposition techniques utilized in printing and other deposition processes may also be utilized to deposit certain layers with precision.

The following portion of the disclosure now describes improved approaches for implementing formation patterns for diffraction on a substrate, where the imprinting of deposited imprint material is performed in accordance with some embodiments of the present invention. These approaches allow for very precise distribution of the imprint material and very precise formation of different imprint patterns on any number of substrate surfaces. It should be noted that the following description can be used with and to implement the grating configurations described above. However, it should be noted that the deposition approach of the present invention can be used with other configurations as well.

According to some embodiments, a patterned distribution of the transfer material (e.g., a patterned inkjet distribution) is performed to implement the deposition of the transfer material onto the substrate. This approach using a patterned inkjet distribution allows for very precise volumetric control over the material to be deposited. In addition, this approach can serve to provide a smaller, more uniform base layer beneath the grating surface, and as previously mentioned, the base thickness of the layer can have a significant impact on the performance of the eyepiece/optical device.

19 illustrates an approach for implementing precise variable volume deposition of transfer material onto a single substrate. As shown in the figure, a template 1902 is provided having a first set of deeper depth structures 1904 and a second set of shallower (e.g., standard) depth structures 1906. When depositing the transfer material onto a transfer receiver 1908, a relatively larger volume of transfer material 1910 is deposited corresponding to portions of the template with the deeper depth structures 1904 of the template 1902. In contrast, a relatively smaller volume of transfer material 1912 is deposited corresponding to the shallower depth structures 1906 of the template 1902. The template is then used to transfer the first and second sets of depth structures into the transfer material, forming respective structures with different depths and/or patterns in the transfer material. This approach thus allows for the simultaneous formation of different features on the transfer receiver 1908.

This approach can be utilized to generate distributions that are intentionally non-uniform for structures with different depths and/or feature parameters, e.g., feature structures on the same substrate but with different thicknesses. This can be used to generate spatially distributed volumes of transfer material, for example, allowing simultaneous transfer of structures of variable depths with the same underlayer thickness.

19 illustrates a structure 1920 formed using the deposition technique/apparatus described above, with the underlayer 1922 having a uniform thickness despite differences in pattern depth and volume. It can be seen that the transfer material has been deposited with a non-uniform thickness within the structure 1920. Here, the top layer 1924 includes a first portion 1926 having a first set of layer thicknesses, while the second portion 1928 has a second set of layer thicknesses. In this example, the portion 1926 corresponds to a thicker layer compared to the standard/shallower thickness of the portion 1928. However, it should be noted that any combination of thicknesses can be constructed using the concepts of the present invention, with thicknesses formed on the underlayer that are either/both thicker and/or thinner than the standard thickness.

This capability can be used, for example, to deposit larger volumes of material to act as spacer elements, for example, to aid in the construction of multi-layer diffractive optical elements.

Some embodiments relate to an approach for implementing simultaneous deposition of multiple types of transfer materials onto a substrate. This allows materials with optical properties to be simultaneously deposited across multiple portions of the substrate at once. This approach also provides the ability to tailor local areas associated with specific functions (e.g., to serve as an internal coupling grating, an orthogonal pupil expansion element (OPE) grating, or an exit pupil expansion element (EPE) grating).

Figure 20 illustrates an approach and transfer steps for implementing directional co-deposition of multiple different transfer materials into the same layer, according to some embodiments. As shown in the figure, a template 2002 is provided for transferring a pattern into different types of transfer materials 2010 and 2012 on a transfer receiver 2008. Materials 2010 and 2012 may comprise the same material with different optical properties (e.g., two versions of the same material with different refractive indices) or two entirely different materials.

Any optical properties of the materials can be considered and selected when employing this technique. For example, as shown in the embodiment of FIG. 20, material 2010 corresponds to a high refractive index material deposited in one section of the transfer receiver 2008, while at the same time, material 2012 corresponds to a lower refractive index material deposited in an area of a second section.

As shown in the resulting structure 2020, this forms a multi-function diffractive optical element having a high refractive index portion 2026 and a lower refractive index portion 2028. In this case, the high refractive index portion 2026 for a first function and the portion 2028 for a second function were transferred simultaneously.

While this example illustratively identifies the refractive index of the materials as the optical property to "tune" when simultaneously depositing materials, it should be noted that other optical properties may also be considered when identifying types of materials for deposition into different portions of a structure. For example, opacity and absorbance are other properties that may be used to identify materials for deposition into different portions of a structure and tune the local properties of the final product.

In addition, one type of material may be deposited above/below another material prior to transfer. For example, one refractive index material may be deposited directly below a second refractive index material immediately prior to transfer to create a refractive index gradient to form a diffractive optical element. This may be used, for example, to implement the structure shown in FIG. 17A (or any of the other related structures described above or in the figures).

According to another embodiment, multi-sided printing can be employed to print onto multiple sides of the optical structure. This allows printing to occur on different sides of the optical element, implementing multiplexing of functions throughout the base layer volume. In this way, different eyepiece functions can be implemented without adversely affecting the grating structure function.

Figures 21A-B illustrate an example approach for implementing two-sided transfer in the context of a total internal reflection diffractive optical element. As illustrated in Figure 21A, a first template 2102a can be used to generate an transfer on side "A" of a substrate/transfer receiver 2108. This forms a first pattern 2112 having a first material on side A of the structure.

As illustrated in FIG. 21B, template 2102b can be used to generate a second transfer onto side "B" of the same substrate. This forms a second pattern 2114 having a second material on side B of the substrate.

Note that sides A and B may have the same or different patterns and/or the same or different types of materials. In addition, the patterns on each side may have various layer thicknesses (e.g., using the approach of FIG. 19) and/or different material types on the same side (e.g., using the approach of FIG. 20).

22, a first pattern 2112 is transferred onto side A of substrate 2108, and a second pattern 2114 is transferred onto the opposite side B. A composite function of the resulting two-sided transferred element 2200 can now be realized. In particular, when incident light is applied to the two-sided transferred element 2200, some light exits the element 2200 and implements a first function 1, while other light exits and implements a second function 2.

Additional embodiments relate to multi-layer overlay transfer and/or multi-layer separation/offset substrate integration. In either/both of these approaches, a previously transferred pattern can be jetted and printed again. Adhesive can be jetted onto a first layer, a second substrate can be bonded to it (possibly with an air gap), and a subsequent jetting process can deposit and transfer onto the second substrate. A series of transferred patterns can be bonded to each other sequentially in a roll-to-roll process. It should be noted that approaches implementing multi-layer overlay transfer can be used in conjunction with or instead of the multi-layer separation/offset substrate integration approach.

Figure 23 illustrates an approach for implementing multi-layer over-transfer. Here, a first transfer material 2301 can be deposited and transferred onto a substrate 2308. This is followed by deposition (and possible transfer) of a second transfer material 2302. This results in a composite multi-layer structure having both the first transfer material 2301 and the second transfer material 2302. In one embodiment, a subsequent transfer can be implemented for the second transfer material 2302. In an alternative embodiment, a subsequent transfer is not implemented for the second transfer material 2302.

Figure 24 illustrates an approach for implementing multi-layer separation/offset substrate integration. Here, both a first substrate 1 and a second substrate 2 can be deposited with a transfer material and then transferred. Substrates 1 and 2 can then be sandwiched and bonded, in one embodiment, possibly with offset features (also transferred) that provide an air gap 2402 between the active structures of substrate 2 and the backside of substrate 1. Transferred spacers 2404 can be used to create the air gap 2402.

According to yet another embodiment, an approach is disclosed for implementing variable volume deposition of distributed material across a substrate, which may rely on a priori knowledge of surface non-uniformity. To illustrate, consider substrate 2502 shown in FIG. 25. As shown, surface non-uniformity of substrate 2502 may result in undesirable parallelism, resulting in poor optical performance. In this case, substrate 2502 (or a previously transferred layer) may be measured for variability.

Variable volume deposition of transfer material can be employed to provide a horizontal distribution of the transfer material to be deposited independent of the underlying topography or physical feature set. For example, the substrate can be pulled flat by a vacuum chuck and in-situ metrology can be performed to assess the surface height, for example, using a low-coherence or laser-based contact measurement probe. The dispensed volume of the transfer material can be varied in response to the measurement data to provide a more uniform layer upon reproduction. In this example, portion 2504a of the substrate has the highest level of variation, portion 2504b has an intermediate level of variation, and portion 2504c has the lowest level of variation. Thus, a large volume of transfer material can be deposited in portion 2504a, a medium volume of transfer material is deposited in portion 2504b, and a small/standard volume of transfer material is deposited in portion 2504c. As shown by the resulting product 2506, this results in a more uniform overall substrate/transfer material/transfer pattern thickness, which in turn can tailor or benefit the performance of the transferred device.

Note that while the examples show variations due to thickness non-uniformities, other types of non-uniformities may also be addressed by this embodiment of the invention. In another embodiment, such variations may be due to the presence of dips, peaks, or other anomalies or features associated with a local location on the substrate.

In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will be apparent, however, that various modifications and changes can be made therein without departing from the broader spirit and scope of the invention. For example, the foregoing process flows have been described with reference to a particular sequence of process actions. However, the sequence of many of the described process actions can be changed without affecting the scope or operation of the invention. The specification and drawings are therefore to be regarded in an illustrative rather than a restrictive sense.

Various exemplary embodiments of the present invention are described herein. Reference is made to these examples in a non-limiting sense. They are provided to illustrate the broader and more appreciable aspects of the present invention. Various changes may be made to the described invention, and equivalents may be substituted without departing from the true spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation, material, composition of matter, process, process acts, or steps to the objective, spirit, or scope of the present invention. Moreover, as will be understood by those skilled in the art, each of the individual variations described and illustrated herein has discrete components and features that may be readily separated from or combined with the features of any of the other several embodiments without departing from the scope or spirit of the present invention. All such modifications are intended to be within the scope of the claims associated with this disclosure.

The present invention includes methods that may be performed using the subject devices. The methods may include the act of providing such a suitable device. Such providing may be performed by an end user. In other words, the act of "providing" merely requires the end user to obtain, access, access, locate, configure, activate, power on, or otherwise act to provide the requisite device in the subject method. The methods described herein may be performed in any order of the described events that is logically possible, as well as in the described order of events.

Exemplary aspects of the invention have been described above, along with details regarding material selection and manufacturing. As to other details of the invention, these may be understood in conjunction with the above-referenced patents and publications, and may generally be known or understood by those skilled in the art. The same may be true with respect to method-based aspects of the invention in terms of additional acts as would typically or logically be adopted.

In addition, while the present invention has been described with reference to several embodiments that optionally incorporate various features, the present invention is not limited to those described and indicated as being considered with respect to each variation of the present invention. Various modifications may be made to the invention described, and equivalents (whether described herein or not included for some simplicity) may be substituted without departing from the true spirit and scope of the present invention. In addition, when a range of values is provided, it is to be understood that all intervening values between the upper and lower limits of that range, and any other stated or intervening values within that stated range, are encompassed within the present invention.

It is also envisioned that any optional features of the described variations of the invention may be described and claimed independently or in combination with any one or more of the features described herein. Reference to a singular item includes the possibility that the same items are present in plural. More specifically, as used herein and in the claims associated herewith, the singular forms "a," "an," "said," and "the" include plural referents unless otherwise specified. In other words, the use of articles allows for "at least one" of the subject item in the above description as well as in the claims associated herewith. Furthermore, it should be noted that such claims may be drafted to exclude any optional element. Thus, this statement is intended to serve as a predicate for the use of exclusive terms such as "solely," "only," and the like, or the use of "negative" limitations in connection with the recitation of claim elements.

Without using such exclusive terms, the term "comprising" in the claims associated with this disclosure shall be construed as allowing for the inclusion of any additional elements, regardless of whether a given number of elements are recited in such claims or whether the addition of features can be considered as a change in the nature of the elements recited in such claims. Except as specifically defined herein, all technical and scientific terms used herein shall be given the broadest possible commonly understood meaning while maintaining the validity of the claims.

The scope of the present invention is not limited to the examples and/or subject specification provided, but rather is limited only by the scope of the language of the claims associated with this disclosure.

The above description of the illustrated embodiments is not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. Although specific embodiments and examples have been described herein for illustrative purposes, various equivalent modifications can be made without departing from the spirit and scope of the present disclosure, as will be recognized by those skilled in the art. The teachings provided herein of the various embodiments can be applied to other devices that implement virtual or AR or hybrid systems and/or employ user interfaces, not necessarily the exemplary AR system generally described above.

For example, the foregoing detailed description describes various embodiments of devices and/or processes through the use of block diagrams, schematic diagrams, and examples. To the extent that such block diagrams, schematic diagrams, and examples contain one or more functions and/or operations, it will be understood by those skilled in the art that each function and/or operation within such block diagrams, flow diagrams, or examples may be implemented, individually and/or collectively, by a wide range of hardware, software, firmware, or virtually any combination thereof.

In one embodiment, the subject matter may be implemented via an application specific integrated circuit (ASIC). However, those skilled in the art will recognize that the embodiments disclosed herein may equally be implemented in standard integrated circuits, in whole or in part, as one or more computer programs executed by one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs executed by one or more controllers (e.g., microcontrollers), as one or more programs executed by one or more processors (e.g., microprocessors), as firmware, or as virtually any combination thereof, and that designing circuits and/or writing code for the software and/or firmware would be well within the skill of one of ordinary skill in the art in light of the teachings of the present disclosure.

When logic is implemented as software and stored in memory, the logic or information can be stored on any computer-readable medium for use by or in association with any processor-related system or method. In the context of this disclosure, memory is a computer-readable medium that is electronic, magnetic, optical, or other physical device or means that contains or stores a computer and/or processor program. The logic and/or information can be embodied in any computer-readable medium for use by or in association with an instruction execution system, apparatus, or device, such as a computer-based system, processor-containing system, or other system that can fetch instructions from the instruction execution system, apparatus, or device and execute the instructions associated with the logic and/or information.

In the context of this specification, a "computer-readable medium" can be any element that can store programs associated with logic and/or information for use by or in connection with an instruction execution system, apparatus, and/or device. A computer-readable medium can be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device. More specific examples (non-exhaustive list) of computer-readable media would include portable computer diskettes (magnetic, compact flash cards, secure digital, or equivalent), random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM, EEPROM, or flash memory), portable compact disc read-only memory (CDROM), digital tape, and other non-transitory media.

Many of the methods described herein can be performed with variations. For example, many of the methods can include additional acts, omit certain acts, and/or be performed in a different order than illustrated or described.

The various embodiments described above can be combined to provide further embodiments. All U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications, and non-patent publications mentioned herein and/or listed in the Application Data Sheet are incorporated herein by reference in their entirety, to the extent not inconsistent with the specific teachings and definitions of this specification. Aspects of the embodiments can be modified, where necessary, to utilize systems, circuits, and concepts of the various patents, applications, and publications to provide still further embodiments.

These and other changes can be made to the embodiments in light of the description detailed above. Generally, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and claims, but should be construed to include all possible embodiments, along with the full scope of equivalents to which such claims are entitled. Therefore, the claims are not limited by this disclosure.

Furthermore, the various embodiments described above can be combined to provide further embodiments. Moreover, aspects of the embodiments can be modified, if necessary, to employ concepts from the various patents, applications, and publications to provide further embodiments.

These and other changes can be made to the embodiments in light of the description detailed above. Generally, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and claims, but should be construed to include all possible embodiments, along with the full scope of equivalents to which such claims are entitled. Therefore, the claims are not limited by this disclosure.

Claims (20)

1. A diffractive optical element for use in a three dimensional virtual reality and/or augmented reality display system, comprising:
The diffractive optical element comprises:
a first substrate, the first substrate having a first region and a second region;
a first layer disposed on the first substrate;
Equipped with
The first layer comprises:
a first diffractive optical element having a first depth, the first diffractive optical element being disposed on the first region of the first substrate;
a second diffractive optical element having a second depth, the second diffractive optical element being disposed on the second region of the first substrate; and
having
The first depth is different from the second depth. the first diffractive optical element has a first optical index;
The diffractive optical element of claim 1 , wherein the second diffractive optical element has a second optical index different from the first optical index. the first diffractive optical element has a first diffractive pattern;
The diffractive optical element of claim 1 , wherein the second diffractive optical element has a second diffractive pattern that is different from the first diffractive pattern. the first diffractive optical element has a first optical function;
The diffractive optical element of claim 1 , wherein the second diffractive optical element has a second optical function. the first optical function is internal coupling;
The diffractive optical element of claim 4 , wherein the second optical function is orthogonal pupil expansion or exit pupil expansion. the first diffractive optical element is an internal coupling grating;
The diffractive optical element of claim 1 , wherein the second diffractive optical element is an orthogonal pupil expander or an exit pupil expander. the first diffractive optical element has a first refractive index;
The diffractive optical element of claim 1 , wherein the second diffractive optical element has a second refractive index different from the first refractive index. the first substrate has a substrate refractive index;
the first refractive index value is less than the second refractive index value and the substrate refractive index of the first substrate;
The diffractive optical element of claim 7 , wherein the substrate refractive index value is less than the second refractive index value. the diffractive optical element further comprises a second layer disposed above the first layer;
The second layer comprises:
a first region including a first material having a first refractive index;
a second region including a second material having a second refractive index;
Equipped with
the first substrate includes a third material having a third refractive index;
2. The diffractive optical element of claim 1, wherein the first refractive index value, the second refractive index value, and the third refractive index value are selected based at least in part on a first requirement for diffraction efficiency or a second requirement for a field of view provided by the diffractive optical element. An eyepiece comprising a diffractive optical element according to claim 1. The eyepiece lens is
a first lens stacked on top of the diffractive optical element; and
a second diffractive optical element stacked on top of the first lens; and
Further equipped with
The eyepiece of claim 10 , wherein the diffractive optical element is closer to the viewer's eye than the second diffractive optical element. the diffractive optical element defines a first focal plane with a first focal length;
the second diffractive optical element comprises a second substrate, the second diffractive optical element defining a second focal plane with a second focal length that is smaller than the first focal length;
The eyepiece of claim 11 , wherein the second diffractive optical element is separated from the first diffractive optical element by the first lens. The eyepiece lens is
a second lens stacked on top of the second diffractive optical element; and
a third diffractive optical element stacked on top of the second lens; and
Further equipped with
The eyepiece of claim 12 , wherein the third diffractive optical element is positioned farther from the viewer's eye than the second diffractive optical element. The eyepiece of claim 13 , wherein the third diffractive optical element defines a third focal plane with a third focal length that is smaller than the second focal length. the eyepiece further comprises a compensation lens stacked on top of the third diffractive optical element;
The eyepiece of claim 13 , wherein the compensation lens is selected based at least in part on the total refractive index of the first lens and the second lens. The eyepiece lens is
an additional lens stacked on top of the third diffractive optical element; and
one or more additional diffractive optical elements stacked on top of the additional lens;
The eyepiece of claim 13 further comprising: the eyepiece further comprises a compensating lens stacked on top of the one or more additional diffractive optical elements;
17. The eyepiece of claim 16, wherein the compensating lens is selected based at least in part on the total refractive index of lenses separating diffractive optical layers in the eyepiece. 14. The eyepiece of claim 13, wherein at least two of the diffractive optical element, the second diffractive optical element, and the third diffractive optical element are multiplexed to create at least one additional focal plane in addition to the first focal plane, the second focal plane, and the third focal plane. the first substrate has a first transfer pattern;
The eyepiece of claim 12 , wherein the second substrate has a second transfer pattern. the eyepiece further comprises a second layer disposed on an opposing surface opposite the surface on which the first layer is disposed;
The second layer comprises:
a first region including a first material having a first refractive index;
a second region including a second material having a second refractive index;
The eyepiece of claim 10, comprising: