US20220269098A1 - Optical System - Google Patents

Optical System Download PDF

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Publication number
US20220269098A1
US20220269098A1 US17/640,004 US202117640004A US2022269098A1 US 20220269098 A1 US20220269098 A1 US 20220269098A1 US 202117640004 A US202117640004 A US 202117640004A US 2022269098 A1 US2022269098 A1 US 2022269098A1
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Prior art keywords
coupling
loe
prism
partially
region
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Abandoned
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US17/640,004
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English (en)
Inventor
Yochay Danziger
Shimon GRABARNIK
Ronen CHRIKI
Eitan Ronen
Elad Sharlin
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Lumus Ltd
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Lumus Ltd
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Priority to US17/640,004 priority Critical patent/US20220269098A1/en
Assigned to LUMUS LTD. reassignment LUMUS LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GRABARNIK, Shimon, RONEN, Eitan, CHRIKI, RONEN, DANZIGER, YOCHAY, SHARLIN, Elad
Publication of US20220269098A1 publication Critical patent/US20220269098A1/en
Priority to US19/350,104 priority patent/US20260029659A1/en
Abandoned legal-status Critical Current

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    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/0081—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00 with means for altering, e.g. enlarging, the entrance or exit pupil
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00663—Production of light guides
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/0018—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00 with means for preventing ghost images
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/01—Head-up displays
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/01—Head-up displays
    • G02B27/017—Head mounted
    • G02B27/0172—Head mounted characterised by optical features
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/10—Beam splitting or combining systems
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/10—Beam splitting or combining systems
    • G02B27/14—Beam splitting or combining systems operating by reflection only
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/10—Beam splitting or combining systems
    • G02B27/14—Beam splitting or combining systems operating by reflection only
    • G02B27/143—Beam splitting or combining systems operating by reflection only using macroscopically faceted or segmented reflective surfaces
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/10—Beam splitting or combining systems
    • G02B27/14—Beam splitting or combining systems operating by reflection only
    • G02B27/145—Beam splitting or combining systems operating by reflection only having sequential partially reflecting surfaces
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/0001—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems
    • G02B6/0011—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems the light guides being planar or of plate-like form
    • G02B6/0013—Means for improving the coupling-in of light from the light source into the light guide
    • G02B6/0023—Means for improving the coupling-in of light from the light source into the light guide provided by one optical element, or plurality thereof, placed between the light guide and the light source, or around the light source
    • G02B6/0031—Reflecting element, sheet or layer
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/0001—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems
    • G02B6/0011—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems the light guides being planar or of plate-like form
    • G02B6/0033—Means for improving the coupling-out of light from the light guide
    • G02B6/005—Means for improving the coupling-out of light from the light guide provided by one optical element, or plurality thereof, placed on the light output side of the light guide
    • G02B6/0055—Reflecting element, sheet or layer
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24—Coupling light guides
    • G02B6/26—Optical coupling means
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03B—APPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR
    • G03B21/00—Projectors or projection-type viewers; Accessories therefor
    • G03B21/005—Projectors using an electronic spatial light modulator but not peculiar thereto
    • G03B21/006—Projectors using an electronic spatial light modulator but not peculiar thereto using LCD's
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03B—APPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR
    • G03B21/00—Projectors or projection-type viewers; Accessories therefor
    • G03B21/14—Details
    • G03B21/142—Adjusting of projection optics
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03B—APPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR
    • G03B33/00—Colour photography, other than mere exposure or projection of a colour film
    • G03B33/10—Simultaneous recording or projection
    • G03B33/12—Simultaneous recording or projection using beam-splitting or beam-combining systems, e.g. dichroic mirrors
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/01—Head-up displays
    • G02B27/0101—Head-up displays characterised by optical features
    • G02B2027/0123—Head-up displays characterised by optical features comprising devices increasing the field of view
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/01—Head-up displays
    • G02B27/0101—Head-up displays characterised by optical features
    • G02B2027/013—Head-up displays characterised by optical features comprising a combiner of particular shape, e.g. curvature
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/01—Head-up displays
    • G02B27/0149—Head-up displays characterised by mechanical features
    • G02B2027/015—Head-up displays characterised by mechanical features involving arrangement aiming to get less bulky devices
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/01—Head-up displays
    • G02B27/0189—Sight systems

Definitions

  • the present invention relates to optical systems and, in particular, it concerns an optical system for two-dimensional expansion of an image from an image projector for display to a user.
  • a near eye display optical engine is shown in FIG. 1A , including an image projector 200 that projects image light having an angular field through transmissive coupling prism 202 T and through vertical aperture 203 V into waveguide 204 .
  • the light propagates in the waveguide, being reflected by total internal reflection.
  • Partial reflectors 206 embedded in the waveguide reflect the image out of the waveguide (dashed arrows) towards the observer having eyeball center 208 .
  • FIG. 1B shows an alternative way of coupling into the waveguide by using reflective coupling prism 202 R having mirror on its back side.
  • FIG. 1C shows schematically a front view of a 2D aperture expansion waveguide.
  • image projector 200 injects an image through coupling prism 202 through lateral aperture 203 L ( 203 V is also present, but not visible from this orientation) into waveguide 204 .
  • the image light ray 220 A propagates laterally in the waveguide as it reflects by TIR between the waveguide faces.
  • two sets of facets are used: set 206 L expand the aperture laterally by reflecting the guided image progressively to a different guided direction 220 B while facets set 206 V expand the aperture vertically by progressively coupling the image out from area 210 on the waveguide onto the observer's eye.
  • the present invention is an optical system for directing image illumination injected at a coupling-in region to an eye-motion box for viewing by a user.
  • an optical system for directing image illumination injected at a coupling-in region to an eye-motion box for viewing by an eye of a user, the optical system comprising a light-guide optical element (LOE) formed from transparent material, the LOE comprising: (a) a first region containing a first set of planar, mutually-parallel, partially-reflecting surfaces having a first orientation; (b) a second region containing a second set of planar, mutually-parallel, partially-reflecting surfaces having a second orientation non-parallel to the first orientation; (c) a set of mutually-parallel major external surfaces, the major external surfaces extending across the first and second regions such that both the first set of partially-reflecting surfaces and the second set of partially-reflecting surfaces are located between the major external surfaces, wherein the second set of partially-reflecting surfaces are at an oblique angle to the major external surfaces so that a part of image illumination propagating within
  • LOE light-guide optical element
  • the coupling-in region comprises a coupling-in prism having a first planar surface that is a continuation of one of the major external surfaces in the first region, the coupling-in prism having a thickness dimension measured perpendicular to the major external surfaces that is greater than a thickness of the LOE.
  • the coupling-in prism presents a coupling-in surface and a transition line between the coupling-in prism as the LOE, the coupling-in surface defining an optical aperture of the coupling-in prism in a dimension parallel to the major external surfaces and the transition line defining an optical aperture of the coupling-in prism in a dimension perpendicular to the major external surfaces.
  • the first set of partially-reflecting surfaces further comprises at least one partially-reflecting surface located within a volume of the coupling-in prism.
  • an optical system for directing image illumination injected at a coupling-in region to an eye-motion box for viewing by an eye of a user, the optical system comprising a light-guide optical element (LOE) formed from transparent material, the LOE comprising: (a) a first region containing a first set of planar, mutually-parallel, partially-reflecting surfaces having a first orientation; (b) a second region containing a second set of planar, mutually-parallel, partially-reflecting surfaces having a second orientation non-parallel to the first orientation; (c) a set of mutually-parallel major external surfaces, the major external surfaces extending across the first and second regions such that both the first set of partially-reflecting surfaces and the second set of partially-reflecting surfaces are located between the major external surfaces, wherein the second set of partially-reflecting surfaces are at an oblique angle to the major external surfaces so that a part of image illumination propagating
  • LOE light-guide optical element
  • the first set of partially-reflecting surfaces further comprises at least one partially-reflecting surface located within a volume of the coupling-in prism.
  • an optical system for directing image illumination injected at a coupling-in region to an eye-motion box for viewing by an eye of a user, the optical system comprising a light-guide optical element (LOE) formed from transparent material, the LOE comprising: (a) a first region containing a first set of planar, mutually-parallel, partially-reflecting surfaces having a first orientation; (b) a second region containing a second set of planar, mutually-parallel, partially-reflecting surfaces having a second orientation non-parallel to the first orientation; (c) a set of mutually-parallel major external surfaces, the major external surfaces extending across the first and second regions such that both the first set of partially-reflecting surfaces and the second set of partially-reflecting surfaces are located between the major external surfaces, wherein the second set of partially-reflecting surfaces are at an oblique angle to the major external surfaces so that a part of image illumination propagating
  • LOE light-guide optical element
  • the coupling-in prism presents a coupling-in surface and a transition line between the coupling-in prism as the LOE, the coupling-in surface defining an optical aperture of the coupling-in prism in a dimension parallel to the major external surfaces and the transition line defining an optical aperture of the coupling-in prism in a dimension perpendicular to the major external surfaces.
  • the coupling-in prism is bonded to the LOE at an edge surface of the LOE.
  • the coupling-in prism may be bonded to one of the major external surfaces of the LOE.
  • FIGS. 1A and 1B are schematic side views of a conventional near-eye waveguide-based display illustrating two geometries for coupling-in of image illumination into the waveguide;
  • FIG. 1C is a front view of a conventional near-eye waveguide-based display illustrating the use of first and second sets of partially-reflecting internal surfaces to expand an optical aperture of an image projector in two dimensions;
  • FIG. 1D is a schematic isometric view of a waveguide similar to that of FIG. 1C and corresponding to FIG. 5A of publication WO 2020/049542 A1;
  • FIGS. 2A-2C are isometric, top and side views, respectively, of an angular representation of the image propagation through an optical system according to the teachings of the present invention
  • FIG. 3A is a schematic front view of a light-guide optical element (LOE, or waveguide), constructed and operative according to the teachings of an aspect of the present invention, illustrating propagation of image illumination from a coupling-in region to a first set of partially-reflecting surfaces (facets), and from the first set of facets to a second set of facets;
  • LOE light-guide optical element
  • FIG. 3B is a view similar to FIG. 3A illustrating a theoretical locus of facet locations required for providing a field of view (FOV) to a single viewing point;
  • FOV field of view
  • FIG. 3C is a view similar to FIG. 3B illustrating a corresponding set of loci for facet locations to provide a FOV across an “eye-motion box” (EMB) of permitted viewing locations;
  • EMB eye-motion box
  • FIG. 3D is a view similar to FIG. 3A illustrating the required facet positions and dimensions in order to span the loci illustrated in FIG. 3C ;
  • FIG. 3E is a view similar to FIG. 3C where the loci are further increased according to the geometrical requirements resulting from using an obliquely-angled first set of facets;
  • FIG. 3F is a schematic representation of the LOE of FIG. 3D where the facet-containing regions are demarcated by corresponding polygons, with the first set of facets demarcated by a concave polygon;
  • FIG. 3G is a view similar to FIG. 3F in which the concave polygon containing the first set of facets is subdivided into a number of non-concave blocks or slices;
  • FIG. 3H is a schematic isometric view illustrating how such blocks can be assembled to produce the structure of FIG. 3G , for subsequent slicing to form a plurality of LOEs;
  • FIG. 4A is a view similar to FIG. 3A illustrating exemplary dimensions for an implementation generating a rectangular field of view with angular dimensions as illustrated in FIG. 4B ;
  • FIG. 4C is a view similar to FIG. 3A illustrating exemplary dimensions for an implementation generating a trapezoidal field of view with angular dimensions as illustrated in FIG. 4D ;
  • FIG. 5A is a view similar to FIG. 4A illustrating an image projector and a coupling-in prism for introducing image illumination into the LOE;
  • FIG. 5B is a schematic isometric view of the coupling-in prism of FIG. 5A ;
  • FIG. 5C is a side view of the coupling-in prism of FIG. 5A illustrating the required dimensions for an exemplary implementation of the present invention
  • FIG. 5D illustrates a variant implementation of the present invention employing a coupling-in prism which is attached to a major external surface of the LOE;
  • FIG. 6A is a schematic front view similar to FIG. 5A illustrating the use of an integrated laser-scanning image projector integrated with a coupling-in prism;
  • FIG. 6B is a schematic side view of the integrated laser-scanning image projector integrated with a coupling-in prism of FIG. 6A ;
  • FIG. 7A is a schematic side view of a coupling-in arrangement employing an inclined reflector coupling arrangement and a coupling-in prism, and employing external collimating optics;
  • FIG. 7B is a view similar to FIG. 7A in which the inclined reflector coupling arrangement and the coupling-in prism are combined and reduced in size;
  • FIG. 7C is a view similar to FIG. 7A employing a polarized beam splitter and integrating reflective collimating optics into the reflective coupling-in arrangement;
  • FIG. 7D is a view similar to FIG. 7C but using external collimating optics
  • FIG. 8A is a view similar to FIG. 5A , but where a coupling-in prism is integrated with part of the waveguide;
  • FIG. 8B is a schematic isometric view of the coupling-in prism of FIG. 8A ;
  • FIG. 9A is a schematic side view of the coupling-in prism of FIG. 8A implemented as a coupling-in prism bonded to the LOE at an edge surface of the LOE;
  • FIGS. 9B and 9C are schematic isometric views of the coupling-in prism of FIG. 9A showing inclusion of full or partial partially-reflective facets, respectively, within the prism;
  • FIG. 9D is a schematic side view of the coupling-in prism of FIG. 8A implemented as a coupling-in prism bonded to one of the major external surfaces of the LOE;
  • FIGS. 9E and 9F are schematic isometric views of the coupling-in prism of FIG. 9D showing inclusion of full or partial partially-reflective facets, respectively, within the prism;
  • FIG. 10A is a side view of an angular representation similar to FIG. 2C illustrating two specific points within a field of view of the projected image;
  • FIG. 10B is a partial view similar to FIG. 4A illustrating the image light propagation paths corresponding to the two points of FIG. 10A ;
  • FIGS. 10C and 10D are side views of a coupling-in prism indicating the injection angle of these two field point, respectively, and the corresponding desired location of the first reflective facet they should encounter;
  • FIGS. 11A-11C are views similar to FIGS. 7A, 7C and 7D , respectively, illustrating implementations of these geometries with partially-reflective facets within the coupling prisms;
  • FIG. 11D is a view similar to FIG. 6B illustrating an implementation of this geometry with partially-reflective facets within the coupling prism;
  • FIG. 12A is a schematic isometric view of a series of plates with selectively-deployed partially-reflecting coatings, each according to a pattern required for a different plane of the LOE of FIG. 3D , for assembly according to a production method of the present invention
  • FIG. 12B is a schematic isometric view of a stack of plates formed by bonding together the series of plates of FIG. 12A ;
  • FIG. 12C is a schematic isometric view of a block formed by slicing the stack of FIG. 12B along the indicated dashed lines;
  • FIG. 12D is a schematic isometric view of (a part of) an LOE formed by slicing the block of FIG. 12C along the indicated dashed lines;
  • FIG. 13 is a schematic side view of a coupling-in configuration employing an air gap and a mirror surface
  • FIGS. 14A and 14B are views similar to FIGS. 2A and 2C , respectively, showing the image propagation through the optical system in the case of an obliquely oriented first set of partially-reflecting surfaces;
  • FIG. 14C is a view similar to FIG. 3F for an implementation of the LOE optimized for the image propagation described in FIGS. 14A and 14B ;
  • FIG. 15 is a schematic side view of a side coupling-in configuration employing a beam-splitter to fill the waveguide with the injected image and its conjugate;
  • FIG. 16A is a side view of an angular representation of the image propagation through the second region of an LOE according to a variant implementation of the present invention employing a high-inclination second set of partially-reflecting surfaces;
  • FIG. 16B is a schematic side view of the second region of the LOE implemented according to the optical geometry of FIG. 16A ;
  • FIG. 16C is a graph indicating schematically the preferred angle dependence of reflectance of the facets for the implementation of FIG. 16B ;
  • FIG. 17A is a schematic isometric view of a plate with selectively-deployed partially-reflecting coatings, similar to the plates of FIG. 12A ;
  • FIG. 17B is an enlarged schematic side view illustrating a coated region implemented with an abrupt edge
  • FIG. 17C is a schematic illustration of the use of a raised mask to generate a coating with a marginal region of gradually-varying thickness
  • FIG. 17D is a schematic illustration of the use of the principle of FIG. 17C to deposit a multi-layer coating with a marginal region of gradually-varying thickness;
  • FIG. 17E is a schematic illustration of the use of a second raised mask to generate a complementary transparent coating in regions not coated by the first process.
  • FIG. 17F is a schematic side view illustrating a partially-reflecting region resulting from the sequence of coating processes described with reference to FIGS. 17D and 17E .
  • the present invention is an optical system for directing image illumination injected at a coupling-in region to an eye-motion box for viewing by a user.
  • the present invention relates to a number of aspects which facilitate shallow-angle implementations of such a display, which presents certain design challenges, particularly with regard to coupling-in configurations. It should be noted, however, that various aspects of the invention described herein are not limited to shallow-angle implementations, and may also be applicable to other implementations.
  • FIGS. 2A-2C show an angular polar representation of an image as it propagates in the waveguide according to present invention.
  • FIG. 2A shows an isometric view
  • FIG. 2C a side view
  • FIG. 2B shows a top view (relative to FIG. 2A ) that corresponds to the view from the front of the waveguide.
  • the waveguide has total-internal-reflection (TIR) boundary circles 228 , indicating that images within these circles are not subject to TIR, and will be coupled-out so as to escape the waveguide.
  • TIR total-internal-reflection
  • Image 220 A 1 is coupled into the waveguide and propagates by TIR back and forth to 220 A 2 . These images propagate along a very shallow trajectory along the waveguide where the shallowest part of the image is only 7 degrees from the waveguide plane (shown as angle 221 in FIG. 2C ). Facets 224 (equivalent to 206 L of FIG. 1C ) in this implementation are perpendicular to the waveguide, and therefore reflect images 220 A 1 and 220 A 2 directly onto 220 B 1 and 220 B 2 , respectively. Images 220 B 1 and 220 B 2 are coupled by TIR as they propagate down the waveguide. In the second portion of the LOE, facets 226 (equivalent to 206 V in FIG. 1C ) couple image 220 B 2 out of the waveguide onto image 220 C towards the observer.
  • facets 226 (equivalent to 206 V in FIG. 1C ) couple image 220 B 2 out of the waveguide onto image 220 C towards the observer.
  • the illustrations shown herein relate primarily to an image having aspect of 4:3 and diagonal field of 70 degrees injected into a waveguide having refractive index on 1.6.
  • the design illustrated here generates a full image at an eyeball center 35 mm away from the waveguide (including eye-relief, eyeball-radius and margins).
  • Adaptations of these implementations for different fields of view and aspect ratios can readily be implemented by a person ordinarily skilled in the art on the basis of the description herein.
  • One aspect of the present invention relates to optimization of deployment of partially-reflecting surfaces (or “facets”) in the first part of the waveguide responsible for the first dimension of optical aperture expansion.
  • facets partially-reflecting surfaces
  • an optical system for directing image illumination injected at a coupling-in region 15 to an eye-motion box 26 for viewing by an eye of a user employs a light-guide optical element (LOE) 12 formed from transparent material having a first region 16 containing a first set of planar, mutually-parallel, partially-reflecting surfaces 17 having a first orientation, and a second region 18 containing a second set of planar, mutually-parallel, partially-reflecting surfaces 19 having a second orientation non-parallel to the first orientation.
  • LOE light-guide optical element
  • a set of mutually-parallel major external surfaces 24 extend across the first and second regions such that both the first set of partially-reflecting surfaces and the second set of partially-reflecting surfaces are located between the major external surfaces.
  • the second set of partially-reflecting surfaces 19 are at an oblique angle to the major external surfaces 24 so that a part of image illumination propagating within the LOE by internal reflection at the major external surfaces from the first region into the second region is coupled out of the LOE from a coupling-out region 28 towards the eye-motion box 26 .
  • the first set of partially-reflecting surfaces 17 are oriented so that a part of image illumination propagating within the LOE by internal reflection at the major external surfaces from the coupling-in region is deflected towards the second region.
  • certain parts of the first region 16 of the LOE outside the envelope of useful facets are implemented as an optical continuum (i.e., without partially reflecting internal surfaces), thereby reducing unwanted “ghost” reflections.
  • the facets are implemented as filling the entire width of the convex polygon, as illustrated in the drawing.
  • the regions of facets required to deliver a given field of view to the eye-motion box is further refined to generate a concave polygon defining the required facet locations, thereby removing parts of the intermediate facets which would otherwise unnecessarily attenuate the image illumination directed to provide the part of the field reflected by facets furthest from the coupling-in region.
  • the first set of partially-reflecting surfaces includes a first partially-reflecting surface 17 A proximal to the coupling-in region 240 so as to contribute to a first part of a field of view (FOV) of the user as viewed at the eye-motion box, a third partially-reflecting surface 17 C distal to the coupling-in region so as to contribute to a third part of the FOV of the user as viewed at the eye-motion box, and a second partially-reflecting surface 17 B lying in a medial plane 22 between the first and the third partially-reflecting surfaces so as to contribute to a second part of the FOV of the user as viewed at the eye-motion box.
  • FOV field of view
  • facet 17 A contributes to the right side of the FOV
  • facet 17 C contributes to the left side of the FOV
  • facet 17 B contributes to the central region of the FOV.
  • the second partially-reflecting surface 17 B is deployed in a subregion of the medial plane 22 such that image illumination propagating from the coupling-in region to the third partially-reflecting surface (arrow 23 ) and contributing to the third part of the field of view of the user as viewed at the eye-motion box passes through the medial plane 22 without passing through the second partially-reflecting surface 17 B.
  • proximal distal
  • distal medial
  • proximal distal
  • distal medial
  • FIG. 3A shows front view of few selected beams of the projected image having parameters corresponding to the exemplary FOV mentioned above.
  • Solid lines represent beam of an image injected into the waveguide laterally and dashed lines represent beams after lateral aperture expansion and reflection as they propagate vertically. It should be noted throughout this document that any example describing lateral expansion followed by vertical expansion can be changed to vertical expansion followed by lateral without inherent change in structure. This can be exemplified simply by rotating the above figures by 90 degrees.
  • All beams are transmitted from entrance pupil of the coupling-in region 240 .
  • the beams propagate within the waveguide until being reflected by set of parallel embedded reflectors 206 L (facets).
  • the facets in this diagram are assumed to be perpendicular to the external faces of the waveguide. Therefore, every line (solid followed by dashed) represents a different lateral section of the projected image field onto the observer's eye.
  • the vertical field of every section is illuminated by plurality of overlapping beams (as viewed from front) propagating at different angles inclination (into the page) that are reflected by TIR (such internal reflection being illustrated in the side view of FIG. 1A ).
  • FIG. 3C shows schematically the curve for three lateral positions of the eyeball 208 as 244 A, 244 B and 244 C. To cover the required width of the eye-motion box, widening of the facets is required.
  • FIG. 3D shows the finite size facets 206 L appropriate for the above conditions.
  • the length of the facets can vary according to the facet spacing and other optical parameters such as refractive index, the size of the projected field and the location of image injection 240 .
  • the area of the lateral expanding facets is described at SL while the area of the ‘depression’ above it is SD and the vertical expanding facets area is SV. Due to the concave polygon form of SL, the light propagating laterally from the entrance 240 , propagates mostly in transparent area SD before being reflected downward in SL. The propagation in a transparent area reduces the loss of image illumination by reflection to undesired directions, thereby improving waveguide efficiency. Furthermore, there are no undesired reflections of the scenery by facets from SD, thereby substantially reducing glints and ghost images from the waveguide.
  • FIGS. 3G and 3H One possible method for producing the lateral expansion section SL with ‘depression’ SD is shown in FIGS. 3G and 3H .
  • the sections including SD and SL are subdivided into blocks as indicated by heavy outlines in the region designate 300 in FIG. 3G .
  • FIG. 3H illustrates how this structure can be assembled from a transparent prism 302 having appropriate face angles together with three plates having appropriate facet angles (shown as lines along the plates) that fit together against the corresponding surfaces of prism 302 and against each other to form the assembled structure as illustrated.
  • This structure is combined with additional clear prisms and the vertical-expansion portion of the LOE to generate the overall structure.
  • the combined prism and plates can be sliced, or can first be attached to another stack to be sliced together to generate the waveguide with all its sections.
  • FIG. 4A The size of the waveguide as described above is shown in FIG. 4A , resulting in an image field angular size as shown in FIG. 4B .
  • the most laterally-spread beams 250 illuminate only the lower corners of the image, thereby requiring a large waveguide area while contributing only to a small part of the image.
  • FIG. 4D there is shown an image which has the same total area as FIG. 4B (which is shown with dashed lines in FIG. 4D for comparison), but distributed as a trapezoid, with a wider field at the top than at the bottom.
  • FIG. 4C The LOE to generate this FOV is illustrated in FIG. 4C , with corresponding dimensions.
  • lateral edge light beams 252 illuminate vertically all the field (with corresponding different angles into the paper), therefore making much more efficient use of the LOE size. Consequently, the size of the waveguide of FIG. 4C is substantially smaller than that of FIG. 4A , as illustrated by the exemplary dimensions for the same overall FOV area.
  • FIG. 4C The subsequent description with illustrate further aspects of the invention in the non-limiting exemplary context of the configuration of FIG. 4A , but it should be appreciated that configurations such as that of FIG. 4C may be implemented using the same principles.
  • FIG. 5A shows the waveguide with lateral entrance pupil 203 L and coupling prism 202 M to scale.
  • the image projector 200 is illustrated schematically.
  • FIG. 5B is an isometric view of the coupling prism 202 M with vertical aperture 203 T and lateral aperture 203 L, both located at same plane so as to define a rectangular aperture.
  • FIG. 5C illustrates a side view of coupling prism 202 M which, for a 1.7 mm thick waveguide, requires a 14 mm-long coupling prism designed to couple light from all field angles into the waveguide.
  • Part of the beams 262 are reflected from the bottom of the prism before entering through pupil 203 V into waveguide 204 .
  • the height of prism 202 M above the waveguide is 6.4 mm, which is acceptable in many applications.
  • the size of projector 200 that is need to inject the image through prism 202 M also takes space and volume and, in many applications, will not be acceptable.
  • the prism 202 M (and others described herein) preferably has a lower face that is parallel to the waveguide faces for consistent reflection, while the upper and side faces do not need specific optical properties, so their shapes can be other than the ones shown in these figures.
  • FIG. 5D illustrates an alternative architecture where a coupling prism 202 L is located above the waveguide, and where the entrance pupil is the prism face 264 .
  • the prism and the required projector are larger than in FIGS. 5A-5C , making this configuration non-optimal.
  • FIGS. 6A and 6B illustrate integration of the image projector with the coupling prism.
  • a scanning laser image projector is illustrated here by way of a non-limiting example, but the same principles can be implemented using an image projector based on another type of image generator, such as employing an LCOS (liquid crystal on silicon) spatial light modulator, or a micro-LED image generator.
  • LCOS liquid crystal on silicon
  • FIG. 6A shows a coupling prism 202 P attached to waveguide 204 .
  • FIG. 6B shows a side view of the integrated (embedded) image projector.
  • Laser 270 directs a polarized beam onto scanning mirrors 272 that scan intermediate image plane across a micro-lens array (MLA) or diffuser 274 .
  • the scanned light passes through the diffuser and is reflected from polarizing-beam-splitter 276 onto collimating reflecting lens 278 (combined with a quarter-wave plate).
  • the reflected light passes through PBS 276 into coupling prism 202 P.
  • This coupling prism thus serves also as part of the PBS 276 .
  • Part of the light passes directly into the waveguide and part is reflected by the lower face 279 before entering the waveguide, thereby filling the aperture of the waveguide with both the image and its conjugate.
  • FIGS. 7A-7D Alternative architectures for combining the image projector with the coupling prism are shown in FIGS. 7A-7D .
  • FIG. 7A shows light from image generator (not shown, but as before, may be a scanned laser, LCOS or other) being collimated by a refractive lens 280 (beams in diagram from different fields points therefore not parallel), entering prism section 282 and being reflected by mirror 284 into prism section 202 Q and into waveguide 204 .
  • prism sections 282 and 202 Q can be combined to a single prism, as illustrated in FIG. 7B .
  • FIG. 7B employs an equivalent reflector architecture to FIG. 7A , but with smaller prism.
  • the prism length is of the order of 14 mm, similar to prism 202 M in FIG. 5C for similar output parameters.
  • the height will be only 3.2 mm, which is half that of 202 M.
  • the upper (non-reflecting) face of the prism 283 is preferably absorbing. It is drawn here according to the upper beam 260 (defined in FIG. 5C ), but since the upper surface is not optically significant, it can be higher and/or have other shapes.
  • This prism can also be provided with a coupling configuration including a lower refractive index part at its lower face equivalent to elements 286 or 228 described below with reference to FIGS. 7C and 7D .
  • the interface can be used to attached to a PBS as an image projector.
  • FIG. 7C shows injection of diverging polarized light corresponding to an image (originated from a MLA, scanning laser, LCOS or other image generator) passing through interface 286 into PBS section 290 and reflected by PBS 292 onto reflecting collimating lens 294 .
  • the reflected collimated light passes through PBS 292 into coupling prism 202 Q and into the waveguide 204 .
  • some of the light is reflected by the lower section of prisms 290 and 202 Q, therefore these surfaces need to have good image quality and to be continuous.
  • the interface 286 can be air, but also a low refractive index medium (relative to prism 290 ), so that TIR will occur for light reflected from 294.
  • FIG. 7D shows an arrangement similar to FIG. 7C , but with external optics (e.g., a refractive lens 296 ) that collimates the light and a flat reflector 298 .
  • external optics e.g., a refractive lens 296
  • FIGS. 8A and 8B illustrate an alternative configuration according to a further aspect of the present invention in which a coupling prism is integrated with part of the waveguide instead of as an extension shown in FIG. 5A .
  • FIG. 8A shows coupling prism 202 Y (dotted area) on top of waveguide 204 .
  • Image generator 200 is therefore located closer to the waveguide and has a smaller size. All of the light rays propagating in the waveguide continue to emerge from point 240 , therefore the lateral aperture 203 L 2 is located at same place as the previous embodiments.
  • the vertical aperture 203 V is here located at the end of the prism, where the thickened portion of the prism meets with the major external surface which defines the main portion of the LOE.
  • FIG. 8B shows the shape of the coupling prism in an isometric view.
  • the two apertures 203 L 2 and 203 V 2 have same width as previously described but because of the separation of location the prism becomes vertically elongated at 203 L 2 .
  • FIG. 8A it is apparent from FIG. 8A that some of the facets (here represented as 206 A and 206 B) are located within the prism. A number of possible implementations of these facets in prism 202 Y are illustrated in FIGS. 9A-9F . For clarity of presentation, the facets lying within the main part of the LOE have been omitted here.
  • FIG. 9A shows prism 202 Y attached to the edge of the waveguide
  • FIG. 9B shows in isometry the placement of the facets in the prism.
  • FIG. 9C shows the reflecting parts (shaded area) to be only a part of the corresponding plane within the prism.
  • FIG. 9D shows an alternative configuration where prism 202 Y is formed by attaching a correspondingly-shaped block on top of waveguide 204 (facets in 204 are not shown).
  • FIG. 9E the same structure is illustrated with facets across the entire cross-section of 202 Y above the LOE thickness, while in FIG. 9F , the reflective area is implemented only as the shaded region, corresponding to only the optimal required area.
  • FIGS. 6A-7D it is possible to combine the earlier-mentioned integrated image projector ( FIGS. 6A-7D ) together with the LOE-integrated coupling prism of FIGS. 8A-9F . Certain geometrical considerations in such an implementation are illustrated with reference to FIGS. 10A-10D .
  • FIG. 10A shows a side view of an angular distribution equivalent to FIG. 2C , but with markings of two field points associated with facets 206 A (circle) and 206 B (square). Same field points are shown in FIG. 10B .
  • FIG. 10C shows a side view of the waveguide-overlapping coupling prism where the shaded area represents a preferred location for the facets associated with 206 A and FIG. 10D shows the preferred location for the facets for 206 B.
  • the PBS 292 is shown here for reference. It is apparent that the preferred location for the facets in the overlapping coupling prism should be above the PBS plane. Implementation of facets at before the PBS plane would cause distortion to the transmitted image.
  • FIGS. 11A-11D are side views illustrating implementations of facets to coupling prisms incorporating projector optics.
  • FIGS. 11A, 11B and 11C show integration of facet section 202 T (marked as a shaded area) into configurations which are otherwise similar to those of FIGS. 7A, 7C and 7D , respectively.
  • the 3D representation remains as was described with reference to 10 A- 10 D.
  • FIG. 11D parallels FIG. 6B , and illustrates that, where the PBS orientation is opposite, the facet section 202 T 2 is best implemented only partially after the PBS plane.
  • the coupling prism will therefore extend slightly further outside lateral aperture plane 203 L 2 (illustrated in FIGS. 8A-8B ).
  • facets 202 T 2 as illustrated in FIG. 11D will also be suitable for configurations employing the waveguide architecture of FIGS. 4C and 4D .
  • the facet patterns of FIG. 3D or 3F can be produced based on stacking and slicing selectively-coated plates.
  • the plates are coated in a predefined pattern as shown in FIG. 12A , which shows a set of plates shown from the front 300 F that are coated in predefined patterns 302 F. These patters have width and position according to required coated facets shown in 112 .
  • These patterns are preferably produced by masking the uncoated part of the waveguide while coating. It is also possible to coat only the other part of the face of the plates in 304 F by coating a non-reflective coating in order to maintain flat surface or to preserve the phase of transmitted light through 304 to be equivalent to phase of transmitted light through 302 .
  • FIG. 12B illustrates a stack formed by bonding together the partially coated plates, where the dashed line shows the slicing planes across the stack.
  • FIG. 12C shows one slice having side view of the plates 300 S and the reflective patterns 302 S. Another slice is done as shown by the dashed lines in FIG. 12C to generate the final upper section of FIG. 12D , corresponding to the upper part of the LOE of FIG. 3D .
  • FIGS. 12A-12D are highly schematic, and that a larger number of plates are typically used.
  • FIG. 13 illustrates an extreme case of this concept where 202 M is replaced with air-gap and mirror 310 that is in-plane with lower waveguide plane 312 .
  • the light from projecting optics 308 is directed onto perpendicular entrance 306 to waveguide 204 and onto mirror plane 310 .
  • angles of the beams change and consequently the length of the mirror is shorter than length of prism 202 M.
  • the angle of the lower beam 262 is now 11.5 degrees instead of 7 before. Consequently, the mirror length is now 8.5 mm instead of 14 mm in FIG. 5C .
  • As the beam enter the waveguide its angular distribution is as in FIG. 5C .
  • the mirror can overlap the waveguide for mechanical attachment.
  • a conceptually-similar approach of employing low refractive index material can be implemented using a low refractive index glass prism.
  • a low refractive index glass prism it is possible to compensate some of the dispersion generated by the angle in incidence of the light entering face 306 .
  • the facets employed 206 L employed for the first set of facets have been orthogonal to the major external surfaces of the LOE, as detailed in FIGS. 2A-2C .
  • the first set of facets is implemented using obliquely angle facets 336 .
  • FIG. 14A shows an isometric angular representation of such system used to transmit shallow angle images
  • FIG. 14B shows a corresponding partial side view of the angular representation.
  • This non-limiting example employs a trapezoidal FOV, equivalent to the image for minimal size shown in FIGS. 4C and 4D , although this structure could clearly also be used for a rectangular FOV.
  • the initial laterally propagating image 334 A 1 is coupled with 334 A 2 by TIR reflections. Only 334 A 2 is redirected towards the second region of the LOE 334 B 1 by tilted facets 336 , which are at an oblique angle relative to waveguide faces. Facets 336 are preferably coated with multilayer dielectric coatings, as is known in the art, to provide the desired degree of partial reflectivity for the range of incident angles corresponding to image 334 A 2 (as in all of the above embodiments), while being primarily transparent to the range of incident angles corresponding to image 334 A 1 , so as to minimize energy losses and formation of undesired reflections.
  • the image 334 B 1 is coupled to 334 B 1 by TIR as it propagates at shallow angle along the second region of the waveguide.
  • Image 334 B 2 is then coupled out to 334 C by facets 338 (shown only in FIG. 14A ), in a manner equivalent to facets 226 of FIGS. 2A-2C .
  • FIG. 14C illustrates the waveguide footprint that is equivalent to FIG. 4C , where shaded region 340 is the optimal area for the first set of facets 336 , and area 342 is the optimal area for output coupling facets 338 .
  • waveguide 370 has a coupling region 372 that has a partial reflector 374 along a center plane of the waveguide.
  • the partial reflector 374 is most preferably implemented as an 50% reflector, preferably insensitive to angle and achromatic, such as a partially-silvered surface.
  • FIG. 15 three beams are shown associated with the lowest point in the field, and are therefore the shallowest beams of the image illumination.
  • the lower beam (solid arrow) passes through collimating optics 376 and a coupling prism 378 and enters the waveguide. After one reflection, it experiences partial reflection by 374 and is split into two beams.
  • the central beam (dashed line) is split at the entrance and the top beam (dash-dot line) is split half way along combiner 372 . It is apparent that after the beams are split (thereby splitting the image illumination between the image and its conjugate), the waveguide is illuminated uniformly. Therefore, uniform image is expected after light is coupled out.
  • the waveguide will be illuminated uniformly.
  • the aperture of the illuminating optics 376 is very small since the optics is almost adjacent to the entrance of the waveguide, resulting in a small thickness of the optical assembly.
  • FIGS. 16A-16C this illustrates an alternative scheme for coupling-out of the image in the second region of the LOE toward the eye-motion box for viewing by the eye of the user.
  • the angular representation of FIG. 16A is similar to FIG. 2C , but in this case, the output coupling facets 390 have a steep angle.
  • image 220 B 1 is coupled out to 220 C (instead of 220 B 1 as in FIG. 2C ).
  • the images 220 B can be taller and are not limited by the angle of the facets 390 .
  • FIG. 16B shows schematically how such a configuration looks in real space. As the beam propagates downward (in this drawing), it is partially reflected by the facets downward out of the waveguide. In such a configuration it is preferable to have the facets closely spaced in order to ensure a uniform image.
  • FIG. 16C shows schematically the preferred reflectivity of facets for such configuration.
  • low reflectivity is desired at the low incidence angles (close to perpendicular) and higher reflectivity (for output coupling) at higher angles.
  • such properties are readily achieved using appropriately designed multilayer dielectric coatings, as is well-known in the art.
  • FIGS. 17A-17F various of the preferred embodiments described herein require partial selective application of reflective coatings on only part of a plate which is then assembled into a stack from which part or all of the LOE is then sliced. Partial coating of facets as illustrated in FIG. 17A could potentially introduce scattering effects at the edges of the coating, due to the physical discontinuity in coating as illustrated in schematic cross section in FIG. 17B . Additionally, this mechanical discontinuity may cause mechanical stress on the plates when stacked (as in FIG. 12B ).
  • FIGS. 17C-17F illustrate a preferred production method according to an aspect of the present invention for overcoming these limitations.
  • FIG. 17C illustrates the principles of coating characteristics when a mask 394 is placed close to plate surface 300 F but slightly spaced from the surface. When implementing coating (thick arrow), it will coat the plate where there is no mask but close to the mask a gradual decree in coating thickness will be generated around the edge of the mask 396 .
  • FIG. 17D illustrates schematically how this characteristic can be used to generate a gradual decrease (“tail-off”) of the coating pattern 302 F at the periphery of the desired region.
  • this configuration of gradual thinning of the coating may be sufficient.
  • the mask of FIG. 17E is typically not the exact inverse of the mask of FIG. 17D , since it is preferably increased around the boundary by an amount corresponding to the tailing-off region (which can be determined empirically).

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