Patent Grant
11726261
The present disclosure relates to optical waveguides and more particularly to waveguide displays using birefringent gratings.
Waveguides can be referred to as structures with the capability of confining and guiding waves (i.e., restricting the spatial region in which waves can propagate). One subclass includes optical waveguides, which are structures that can guide electromagnetic waves, typically those in the visible spectrum. Waveguide structures can be designed to control the propagation path of waves using a number of different mechanisms. For example, planar waveguides can be designed to utilize diffraction gratings to diffract and couple incident light into the waveguide structure such that the in-coupled light can proceed to travel within the planar structure via total internal reflection (“TIR”).
Fabrication of waveguides can include the use of material systems that allow for the recording of holographic optical elements within the waveguides. One class of such material includes polymer dispersed liquid crystal (“PDLC”) mixtures, which are mixtures containing photopolymerizable monomers and liquid crystals. A further subclass of such mixtures includes holographic polymer dispersed liquid crystal (“HPDLC”) mixtures. Holographic optical elements, such as volume phase gratings, can be recorded in such a liquid mixture by illuminating the material with two mutually coherent laser beams. During the recording process, the monomers polymerize and the mixture undergoes a photopolymerization-induced phase separation, creating regions densely populated by liquid crystal micro-droplets, interspersed with regions of clear polymer. The alternating liquid crystal-rich and liquid crystal-depleted regions form the fringe planes of the grating.
Waveguide optics, such as those described above, can be considered for a range of display and sensor applications. In many applications, waveguides containing one or more grating layers encoding multiple optical functions can be realized using various waveguide architectures and material systems, enabling new innovations in near-eye displays for augmented reality (“AR”) and virtual reality (“VR”), compact heads-up displays (“HUDs”) for aviation and road transport, and sensors for biometric and laser radar (“LIDAR”) applications.
Following below are more detailed descriptions of various concepts related to, and embodiments of, an inventive optical display and methods for displaying information. It should be appreciated that various concepts introduced above and discussed in greater detail below may be implemented in any of numerous ways, as the disclosed concepts are not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes. A more complete understanding of the invention can be obtained by considering the following detailed description in conjunction with the accompanying drawings, wherein like index numerals indicate like parts. For purposes of clarity, details relating to technical material that is known in the technical fields related to the invention have not been described in detail.
One embodiment includes a waveguide including at least one waveguide substrate, at least one birefringent grating; at least one birefringence control layer, a light source for outputting light, an input coupler for directing the light into total internal reflection paths within the waveguide, and an output coupler for extracting light from the waveguide, wherein the interaction of the light with the birefringence control layer and the birefringent grating provides a predefined characteristic of light extracted from the waveguide.
In another embodiment, the interaction of light with the birefringence control layer provides at least one of: an angular or spectral bandwidth variation, a polarization rotation, a birefringence variation, an angular or spectral dependence of at least one of beam transmission or polarization rotation, and a light transmission variation in at least one direction in the plane of the waveguide substrate.
In a further embodiment, the predefined characteristic varies across the waveguide.
In still another embodiment, the predefined characteristic results from the cumulative effect of the interaction of the light with the birefringence control layer and the birefringent grating along at least one direction of light propagation within the waveguide.
In a still further embodiment, the predefined characteristic includes at least one of: uniform illumination and uniform polarization over the angular range of the light.
In yet another embodiment, the birefringence control layer provides compensation for polarization rotation introduced by the birefringent grating along at least one direction of light propagation within the waveguide.
In a yet further embodiment, the birefringence control layer is a liquid crystal and polymer material system.
In another additional embodiment, the birefringence control layer is a liquid crystal and polymer system aligned using directional ultraviolet radiation.
In a further additional embodiment, the birefringence control layer is aligned by at least one of: electromagnetic radiation, electrical or magnetic fields, mechanical forces, chemical reaction, and thermal exposure.
In another embodiment again, the birefringence control layer influences the alignment of LC directors in a birefringent grating formed in a liquid crystal and polymer system.
In a further embodiment again, the birefringence control layer has an anisotropic refractive index.
In still yet another embodiment, the birefringence control layer is formed on at least one internal or external optical surface of the waveguide.
In a still yet further embodiment, the birefringence control layer includes at least one stack of refractive index layers disposed on at least one optical surface of the waveguide, wherein at least one layer in the stack of refractive index layers has an isotropic refractive index and at least one layer in the stack of refractive index layers has an anisotropic refractive index.
In still another additional embodiment, the birefringence control layer provides a high reflection layer.
In a still further additional embodiment, the birefringence control layer provides optical power.
In still another embodiment again, the birefringence control layer provides an environmental isolation layer for the waveguide.
In a still further embodiment again, the birefringence control layer has a gradient index structure.
In yet another additional embodiment, the birefringence control layer is formed by stretching a layer of an optical material to spatially vary its refractive index in the plane of the waveguide substrate.
In a yet further additional embodiment, the light source provides collimated light in angular space.
In yet another embodiment again, at least one of the input coupler and output coupler includes a birefringent grating.
In a yet further embodiment again, the birefringent grating is recorded in a material system including at least one polymer and at least one liquid crystal.
In another additional embodiment again, the at least one birefringent grating includes at least one birefringent grating for providing at least one of the functions of: beam expansion in a first direction, beam expansion in a second direction and light extraction from the waveguide, and coupling light from the source into a total internal reflection path in the waveguide.
In a further additional embodiment again, the light source includes a laser, and the alignment of LC directors in the birefringent grating spatially vary to compensate for illumination banding.
A still yet another additional embodiment includes a method of fabricating a waveguide, the method including providing a first transparent substrate, depositing a layer of grating recording material, exposing the layer of grating recording material to form a grating layer, forming a birefringence control layer, and applying a second transparent substrate.
In a still yet further additional embodiment, the layer of grating recording material is deposited onto the substrate, the birefringence control layer is formed on the grating layer, and the second transparent substrate is applied over the birefringence control layer.
In yet another additional embodiment again, the layer of grating recording material is deposited onto the substrate, the second transparent substrate is applied over the grating layer, and the birefringence control layer is formed on second transparent substrate.
In a yet further additional embodiment again, the birefringence control layer is formed on the first transparent substrate, the layer of grating recording material is deposited onto the birefringence control layer, and the second transparent substrate is applied over the grating layer.
In still yet another embodiment again, the method further includes depositing a layer of liquid crystal polymer material and aligning the liquid crystal polymer material using directional UV light, wherein the layer of grating recording material is deposited onto the substrate and the second transparent substrate is applied over the aligned liquid crystal polymer layer.
In a still yet further embodiment again, the layer of liquid crystal polymer material is deposited onto one of either the grating layer or the second transparent substrate.
In still yet another additional embodiment again, the layer of liquid crystal polymer material is deposited onto the first transparent substrate, the layer of grating recording material is deposited onto the aligned liquid crystal polymer material, and the second transparent substrate is applied over the grating layer.
Additional embodiments and features are set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the specification or may be learned by the practice of the invention. A further understanding of the nature and advantages of the present invention may be realized by reference to the remaining portions of the specification and the drawings, which forms a part of this disclosure.
These and other features and advantages of the present invention will be better understood by reference to the following detailed description when considered in conjunction with the accompanying data and figures, wherein:
For the purposes of describing embodiments, some well-known features of optical technology known to those skilled in the art of optical design and visual displays have been omitted or simplified in order to not obscure the basic principles of the invention. Unless otherwise stated, the term “on-axis” in relation to a ray or a beam direction refers to propagation parallel to an axis normal to the surfaces of the optical components described in relation to the invention. In the following description the terms light, ray, beam, and direction may be used interchangeably and in association with each other to indicate the direction of propagation of electromagnetic radiation along rectilinear trajectories. The term light and illumination may be used in relation to the visible and infrared bands of the electromagnetic spectrum. Parts of the following description will be presented using terminology commonly employed by those skilled in the art of optical design. In the following description, the term grating may be used to refer to any kind of diffractive structure used in a waveguide, including holograms and Bragg or volume holograms. The term grating may also encompass a grating that includes of a set of gratings. For example, in some embodiments the input grating and output grating each include two or more gratings multiplexed into a single layer. For illustrative purposes, it is to be understood that the drawings are not drawn to scale unless stated otherwise.
Referring generally to the drawings, systems and methods relating to waveguide applications incorporating birefringence control in accordance with various embodiments of the invention are illustrated. Birefringence is the optical property of a material having a refractive index that depends on the polarization and propagation direction of light. A birefringent grating can be referred to as a grating having such properties. In many cases, the birefringent grating is formed in a liquid crystal polymer material system such as but not limited to HPDLC mixtures. The polarization properties of such a grating can depend on average relative permittivity and relative permittivity modulation tensors.
Many embodiments in accordance with the invention are directed towards waveguides implementing birefringence control. In some embodiments, the waveguide includes a birefringent grating layer and a birefringence control layer. In further embodiments, the birefringence control layer is compact and efficient. Such structures can be utilized for various applications, including but not limited to: compensating for polarization related losses in holographic waveguides; providing three-dimensional LC director alignment in waveguides based on Bragg gratings; and spatially varying angular/spectral bandwidth for homogenizing the output from a waveguide. In some embodiments, a polarization-maintaining, wide-angle, and high-reflection waveguide cladding with polarization compensation is implemented for grating birefringence. In several embodiments, a thin polarization control layer is implemented for providing either quarter wave or half wave retardation. In a number of embodiments, a polarization-maintaining, wide-angle birefringence control layer is implemented for modifying the polarization output of a waveguide to balance the birefringence of an external optical element used with the waveguide.
In many embodiments, the waveguide includes at least one input grating and at least one output grating. In further embodiments, the waveguide can include additional gratings for various purposes, such as but not limited to fold gratings for beam expansion. The input grating and output grating may each include multiplexed gratings. In some embodiments, the input grating and output grating may each include two overlapping gratings layers that are in contact or vertically separated by one or more thin optical substrate. In some embodiments, the grating layers are sandwiched between glass or plastic substrates. In some embodiments two or more such gratings layers may form a stack within which total internal reflection occurs at the outer substrate and air interfaces. In some embodiments, the waveguide may include just one grating layer. In some embodiments, electrodes may be applied to faces of the substrates to switch gratings between diffracting and clear states. The stack may further include additional layers such as beam splitting coatings and environmental protection layers. The input and output gratings shown in the drawings may be provided by any of the above described grating configurations. Advantageously, the input and output gratings can be designed to have common surface grating pitch. In cases where the waveguide contains grating(s) in addition to the input and output gratings, the gratings can be designed to have grating pitches such that the vector sum of the grating vectors is substantially zero. The input grating can combine gratings orientated such that each grating diffracts a polarization of the incident unpolarized light into a waveguide path. The output gratings can be configured in a similar fashion such that the light from the waveguide paths is combined and coupled out of the waveguide as unpolarized light. Each grating is characterized by at least one grating vector (or K-vector) in 3D space, which in the case of a Bragg grating is defined as the vector normal to the Bragg fringes. The grating vector can determine the optical efficiency for a given range of input and diffracted angles. In some embodiments, the waveguide includes at least one surface relief grating. Waveguide gratings structures, materials systems, and birefringence control are discussed below in further detail.
Switchable Bragg Gratings
Optical structures recorded in waveguides can include many different types of optical elements, such as but not limited to diffraction gratings. In many embodiments, the grating implemented is a Bragg grating (also referred to as a volume grating). Bragg gratings can have high efficiency with little light being diffracted into higher orders. The relative amount of light in the diffracted and zero order can be varied by controlling the refractive index modulation of the grating, a property that is can be used to make lossy waveguide gratings for extracting light over a large pupil. One class of gratings used in holographic waveguide devices is the Switchable Bragg Grating (“SBG”). SBGs can be fabricated by first placing a thin film of a mixture of photopolymerizable monomers and liquid crystal material between glass plates or substrates. In many cases, the glass plates are in a parallel configuration. One or both glass plates can support electrodes, typically transparent tin oxide films, for applying an electric field across the film. The grating structure in an SBG can be recorded in the liquid material (often referred to as the syrup) through photopolymerization-induced phase separation using interferential exposure with a spatially periodic intensity modulation. Factors such as but not limited to control of the irradiation intensity, component volume fractions of the materials in the mixture, and exposure temperature can determine the resulting grating morphology and performance. As can readily be appreciated, a wide variety of materials and mixtures can be used depending on the specific requirements of a given application. In many embodiments, HPDLC material is used. During the recording process, the monomers polymerize and the mixture undergoes a phase separation. The LC molecules aggregate to form discrete or coalesced droplets that are periodically distributed in polymer networks on the scale of optical wavelengths. The alternating liquid crystal-rich and liquid crystal-depleted regions form the fringe planes of the grating, which can produce Bragg diffraction with a strong optical polarization resulting from the orientation ordering of the LC molecules in the droplets.
The resulting volume phase grating can exhibit very high diffraction efficiency, which can be controlled by the magnitude of the electric field applied across the film. When an electric field is applied to the grating via transparent electrodes, the natural orientation of the LC droplets can change, causing the refractive index modulation of the fringes to lower and the hologram diffraction efficiency to drop to very low levels. Typically, the electrodes are configured such that the applied electric field will be perpendicular to the substrates. In a number of embodiments, the electrodes are fabricated from indium tin oxide (“ITO”). In the OFF state with no electric field applied, the extraordinary axis of the liquid crystals generally aligns normal to the fringes. The grating thus exhibits high refractive index modulation and high diffraction efficiency for P-polarized light. When an electric field is applied to the HPDLC, the grating switches to the ON state wherein the extraordinary axes of the liquid crystal molecules align parallel to the applied field and hence perpendicular to the substrate. In the ON state, the grating exhibits lower refractive index modulation and lower diffraction efficiency for both S- and P-polarized light. Thus, the grating region no longer diffracts light. Each grating region can be divided into a multiplicity of grating elements such as for example a pixel matrix according to the function of the HPDLC device. Typically, the electrode on one substrate surface is uniform and continuous, while electrodes on the opposing substrate surface are patterned in accordance to the multiplicity of selectively switchable grating elements.
One of the known attributes of transmission SBGs is that the LC molecules tend to align with an average direction normal to the grating fringe planes (i.e., parallel to the grating or K-vector). The effect of the LC molecule alignment is that transmission SBGs efficiently diffract P polarized light (i.e., light with a polarization vector in the plane of incidence), but have nearly zero diffraction efficiency for S polarized light (i.e., light with the polarization vector normal to the plane of incidence). As a result, transmission SBGs typically cannot be used at near-grazing incidence as the diffraction efficiency of any grating for P polarization falls to zero when the included angle between the incident and reflected light is small. In addition, illumination light with non-matched polarization is not captured efficiently in holographic displays sensitive to one polarization only.
HPDLC Material Systems
HPDLC mixtures in accordance with various embodiments of the invention generally include LC, monomers, photoinitiator dyes, and coinitiators. The mixture (often referred to as syrup) frequently also includes a surfactant. For the purposes of describing the invention, a surfactant is defined as any chemical agent that lowers the surface tension of the total liquid mixture. The use of surfactants in HPDLC mixtures is known and dates back to the earliest investigations of HPDLCs. For example, a paper by R. L Sutherland et al., SPIE Vol. 2689, 158-169, 1996, the disclosure of which is incorporated herein by reference, describes a PDLC mixture including a monomer, photoinitiator, coinitiator, chain extender, and LCs to which a surfactant can be added. Surfactants are also mentioned in a paper by Natarajan et al, Journal of Nonlinear Optical Physics and Materials, Vol. 5 No. I 89-98, 1996, the disclosure of which is incorporated herein by reference. Furthermore, U.S. Pat. No. 7,018,563 by Sutherland; et al., discusses polymer-dispersed liquid crystal material for forming a polymer-dispersed liquid crystal optical element including: at least one acrylic acid monomer; at least one type of liquid crystal material; a photoinitiator dye; a coinitiator; and a surfactant. The disclosure of U.S. Pat. No. 7,018,563 is hereby incorporated by reference in its entirety.
The patent and scientific literature contains many examples of material systems and processes that can be used to fabricate SBGs, including investigations into formulating such material systems for achieving high diffraction efficiency, fast response time, low drive voltage, and so forth. U.S. Pat. No. 5,942,157 by Sutherland, and U.S. Pat. No. 5,751,452 by Tanaka et al. both describe monomer and liquid crystal material combinations suitable for fabricating SBG devices. Examples of recipes can also be found in papers dating back to the early 1990s. Many of these materials use acrylate monomers, including:
Acrylates offer the benefits of fast kinetics, good mixing with other materials, and compatibility with film forming processes. Since acrylates are cross-linked, they tend to be mechanically robust and flexible. For example, urethane acrylates of functionality 2 (di) and 3 (tri) have been used extensively for HPDLC technology. Higher functionality materials such as penta and hex functional stems have also been used.
Overview of Birefringence
Holographic waveguides based on HPDLC offer the benefits of switching capability and high index modulation, but can suffer from the inherent birefringence resulting from the alignment of liquid crystal directors along grating vectors during the LC-polymer phase separation. While this can lead to a large degree of polarization selectivity, which can be advantageous in many applications, adverse effects such as polarization rotation can occur in gratings designed to fold and expand the waveguided beam in the plane of the waveguide (known as fold gratings). This polarization rotation can lead to efficiency losses and output light nonuniformity.
Two common approaches for modifying the alignment of LC directors include rubbing and the application of an alignment layer. Typically, by such means, LC directors in a plane parallel to the alignment layer can be realigned within the plane. In HPDLC Bragg gratings, the problem is more challenging owing to the natural alignment of LC directors along grating K-vectors, making director alignment in all but the simplest gratings a complex three-dimensional problem and rendering conventional techniques using rubbing or polyamide alignment layers impractical. Other approaches can include applying electric fields, magnetic fields, and mechanical pressure during curing. These approaches have been shown to have limited success when applied to reflection gratings. However, such techniques typically do not easily translate to transmission Bragg grating waveguides.
A major design challenge in waveguides is the coupling of image content from an external projector into the waveguide efficiently and in such a way that the waveguide image is free from chromatic dispersion and brightness non-uniformity. To overcome chromatic dispersion and to achieve the respectable collimation, the use of lasers can be implemented. However, lasers can suffer from the problem of pupil banding artifacts, which manifest themselves as output illumination non-uniformity. Banding artifacts can form when the collimated pupil is replicated (expanded) in a TIR waveguide. In basic terms, the light beams diffracted out of the waveguide each time the beam interacts with the grating can have gaps or overlaps, leading to an illumination ripple. In many cases, the degree of ripple is a function of field angle, waveguide thickness, and aperture thickness. The effect of banding can be smoothed by the dispersion typically exhibited by broadband sources such as LEDs. However, LED illumination is not entirely free from the banding problem and, moreover, tends to result in bulky input optics and an increase in the thickness of the waveguide. Debanding can be minimized using a pupil shifting technique for configuring the light coupled into the waveguide such that the input grating has an effective input aperture that is a function of the TIR angle. Techniques for performing pupil-shifting in international application No. PCT/US2018/015553 entitled “Waveguide Device with Uniform Output Illumination,” the disclosure of which is hereby incorporated by reference in its entirety.
In some cases, the polarization rotation that takes place in fold gratings (described above) can compensate for illumination banding in waveguides that uses laser illumination. The mechanism for this is that the large number of grating interactions in a fold grating combined with the small polarization rotation at each interaction can average out the banding (arising from imperfect matching of TIR beams and other coherent optical effects such as but not limited to those arising from parasitic gratings left over from the recording process, stray light interactions with the grating and waveguide surfaces, etc.). The process of compensating for the birefringence can be aided by fine tuning the spatial variation of the birefringence (alignment of the LC directors) in the fold grating.
A further issue that arises in waveguide displays is that contact with moisture or surface combination can inhibit waveguide total internal reflection (TIR), leading to image gaps. In such cases, the scope for using protective outer layers can be limited by the need for low index materials that will provide TIR over the waveguide angular bandwidth. A further design challenge in waveguides is maintaining high efficiency over the angular bandwidth of the waveguide. One exemplary solution would be a polarization-maintaining, wide-angle, and high-reflection waveguide cladding. In some applications, polarization balancing within a waveguide can be accomplished using either a quarter wave retarding layer or a half wave retarder layer applied to one or both of the principal reflecting surfaces of the waveguide. However, in some cases, practical retarder films can add unacceptable thickness to the waveguide. Thin film coatings of the required prescription will normally entail an expensive and time-consuming vacuum coating step. One exemplary method of implementing a coating includes but not limited to the use of an inkjet printing or industry-standard spin-coating procedure. In many embodiments, the coating could be applied directly to a printed grating layer. Alternatively, the coating could be applied to an external optical surface of the assembled waveguide.
In some applications, waveguides are combined with conventional optics for correcting aberrations. Such aberrations may arise when waveguides are used in applications such as but not limited to a car HUD, which projects an image onto a car windscreen for reflection into the viewer's eyebox. The curvatures of the windscreen can introduce significant geometric aberration. Since many waveguides operate with collimated beams, it can be difficult to pre-compensate for the distortion within the waveguide itself. One solution includes mounting a pre-compensating optical element near the output surface of the waveguides. In many cases, the optical element is molded in plastic and can introduce severe birefringence, which should be balanced by the waveguide.
In view of the above, many embodiments of the invention are directed towards birefringence control layers designed to address one or more of the issues posed above. For example, in many embodiments, a compact and efficient birefringence control layer is implemented for compensating for polarization related losses in holographic waveguides, for providing three-dimensional LC director alignment in waveguides based on Bragg gratings, for spatially varying angular/spectral bandwidth for homogenizing the output from a waveguide, and/or for isolating a waveguide from its environment while ensuring confinement of wave-guided beams. In some embodiments, a polarization-maintaining, wide-angle, and high-reflection waveguide cladding with polarization compensation is implemented for grating birefringence. In several embodiments, a thin polarization control layer is implemented for providing either quarter wave or half wave retardation. A polarization control layer can be implemented as a thin layer directly on top of the grating layer or to one or both of the waveguide substrates using a standard spin coating or inkjet printing process. In a number of embodiments, a polarization-maintaining, wide-angle birefringence control layer is implemented for modifying the polarization output of a waveguide to balance the birefringence of an external optical element used with the waveguide. Other implementations and specific configurations are discussed below in further detail.
Waveguide Applications Incorporating Birefringence Control
Waveguides and waveguide displays implementing birefringence control techniques in accordance with various embodiments of the invention can be achieved using many different techniques. In some embodiments, the waveguide includes a birefringent grating layer and a birefringence control layer. In further embodiments, a compact and efficient birefringence control layer is implemented. A birefringence control layer can be implemented for various functions such as but not limited to: compensating for polarization related losses in holographic waveguides; providing three-dimensional LC director alignment in waveguides based on Bragg gratings; and efficient and cost-effective integration within a waveguide for spatially varying angular/spectral bandwidth for homogenizing the output from the waveguide. In any of the embodiments to be described, the birefringence control layer may be formed on any optical surface of the waveguide. For the purposes of understanding the invention, an optical surface of the waveguide may be one of the TIR surfaces, a surface of the grating layer, a surface of the waveguide substrates sandwiching the grating layer, or a surface of any other optical substrate implemented within the waveguide (for example, a beam-splitter layer for improving uniformity).
Many different types of optical elements can be used as the coupler. For example, in some embodiments, the coupler is a grating. In several embodiments, the coupler is a birefringent grating. In many embodiments, the coupler is a prism. The apparatus further includes at least one birefringent grating 208 for providing beam expansion in a first direction and light extraction from the waveguide and at least one birefringence control layer 209 with anisotropic refractive index properties. In the embodiments to be discussed, the source 204 can be an input image generator that includes a light source, a microdisplay panel, and optics for collimating the light. As can readily be appreciated, various input image generators can be used, including those that output non-collimated light. In many embodiments, the input image generator projects the image displayed on the microdisplay panel such that each display pixel is converted into a unique angular direction within the substrate waveguide. The collimation optics may include lens and mirrors, which can be diffractive lenses and mirrors. In some embodiments, the source may be configured to provide illumination that is not modulated with image information. In several embodiments, the light source can be a laser or LED and can include one or more lenses for modifying the illumination beam angular characteristics. In a number of embodiments, the image source can be a micro-display or an image scanner.
The interaction of the light with the birefringence control layer 209 and the birefringent grating 208 integrated along the total internal reflection path for any direction of the light can provide a predefined characteristic of the light extracted from the waveguide. In some embodiments, the predefined characteristic includes at least one of a uniform polarization or a uniform illumination over the angular range of the light.
Implementing Birefringence Control Layers
Various materials and fabrication processes can be used to provide a birefringence control layer. In many embodiments, the birefringent control layer has anisotropic index properties that can be controlled during fabrication to provide a spatial distribution of birefringence such that the interaction of the light with the birefringence control layer and the birefringent grating integrated along the total internal reflection path for any direction of the light provides a predefined characteristic of the light extracted from the waveguide. In some embodiments, the layer may be implemented as a thin stack that includes more than one layer.
Alignment of HPDLC gratings can present significant challenges depending on the grating configuration. In the simplest case of a plane grating, polarization control can be confined to a single plane orthogonal to the grating plane. Rolled K-vector gratings can require the alignment to vary across the grating plane. Fold gratings, particularly ones with slanted Bragg fringes, can have much more complicated birefringence, requiring 3D alignment and, in some cases, more highly spatially resolved alignment.
The following examples of birefringence control layers for use with the invention are illustrative only. In each case, it is assumed that the layer is processed such that the properties vary across the surface of the layer. It is also assumed that the birefringence control layer is configured within the waveguide or on an optical surface of the waveguide containing the grating. In some embodiments, the birefringence control layer is in contact with the grating layer. In several cases, the birefringence control layer spits into separate sections and are disposed on different surfaces of the waveguide. In a number of embodiments, a birefringence layer may include multiple layers.
In some embodiments, the invention provides a thin polarization control layer that can provide either quarter wave or half wave retardation. The polarization control layer can be implemented as a thin layer directly on top of the grating layer or to one or both of the waveguide substrates using a standard spin coating or ink jet printing process.
In one group of embodiments, the birefringence control layer is formed using materials using liquid crystal and polymer networks that can be aligned in 3D using directional UV light. In some embodiments, the birefringence control layer is formed at least in part from a Liquid Crystal Polymer (LCP) Network. LCPs, which have also been referred to in the literature as reactive mesogens, are polymerizable liquid crystals containing liquid crystalline monomers that include, for example, reactive acrylate end groups, which polymerize with one another in the presence of photo-initiators and directional UV light to form a rigid network. The mutual polymerization of the ends of the liquid crystal molecules can freeze their orientation into a three-dimensional pattern. The process typically includes coating a material system containing liquid crystal polymer onto a substrate and selectively aligning the LC directors using directionally/spatially controllable UV source prior to annealing. In some embodiments, the birefringence control layer is formed at least in part from a Photo-Alignment Layer, also referred to in the literature as a linearly polymerized photopolymer (LPP). An LPP can be configured to align LC directors parallel or perpendicular to incident linearly polarized UV light. LPP can be formed in very thin layers (typically 50 nm) minimizing the risks of scatter or other spurious optical effect. In some embodiments, the birefringence control layer is formed from LCP, LPP, and at least one dopant. Birefringence control layers based on LCPs and LPPs can be used align LC directors in the complex three-dimensional geometries characteristic of fold gratings and rolled K-vector gratings formed in thin film (2-4 microns). In some embodiments, a birefringence control layer based on LCPs or LPPs further includes dichroic dyes, chiral dopants to achieve narrow or broadband cholesteric filters, twisted retarders, or negative c-plate retarders. In many embodiments, birefringence control layers based on LCPs or LPPs provide quarter or half-wave retardation layers.
In some embodiments, the birefringence control layer is formed by a multilayer structure combining isotropic and anisotropic index layers (as shown in
A birefringent grating will typically have polarization rotation properties that are functions of angle wavelength. The birefringence control layer can be used to modify the angular, spectral, or polarization characteristics of the waveguide. In some embodiments, the interaction of light with the birefringence control layer can provide an effective angular bandwidth variation along the waveguide. In many embodiments, the interaction of light with the birefringence control layer can provide an effective spectral bandwidth variation along the waveguide. In several embodiments, the interaction of light with the birefringence control layer can provide a polarization rotation along the waveguide. In a number of embodiments, the grating birefringence can be made to vary across the waveguide by spatially varying the composition of the liquid crystal polymer mixture during grating fabrication. In some embodiments, the birefringence control layer can provide a birefringence variation in at least one direction in the plane of the waveguide substrate. The birefringence control layer can also provide a means for optimizing optical transmission (for different polarizations) within the waveguide. In many embodiments, the birefringence control layer can provide a transmission variation in at least one direction in the plane of the waveguide substrate. In several embodiments, the birefringence control layer can provide an angular dependence of at least one of beam transmission or polarization rotation in at least one direction in the plane of the waveguide substrate. In a number of embodiments, the birefringence control layer can provide a spectral dependence of at least one of beam transmission or polarization rotation in at least one direction in the plane of the waveguide substrate.
In many embodiments, birefringent gratings may provide input couplers, fold gratings, and output gratings in a wide range of waveguide architectures.
In some embodiments, the invention provides a polarization-maintaining, wide angle birefringence control layer for modifying the polarization output of a waveguide to balance the birefringence of an external optical element used with the waveguide.
In some embodiments, the birefringence control layer can be provided by various techniques using mechanical, thermal, or electro-magnetic processing of substrates. For example, in some embodiments, the birefringence control layer is formed by applying spatially varying mechanical stress across the surface of an optical substrate.
Fabrication of Waveguides Implementing Birefringence Control Layers
The present invention also provides methods and apparatus for fabricating a waveguide containing a birefringent grating and a birefringence control layer. The construction and arrangement of the apparatus and methods as shown in the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (for example, additional steps for improving the efficiency of the process and quality of the finished waveguide, minimizing process variances, monitoring the process and others.) Any process step referring to the formation of a layer should be understood to cover multiple such layers. For example, where a process step of recording a grating layer is described, this step can extend to recording a stack containing two or more grating layers. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions may be made in the design of the process apparatus, operating conditions and arrangement of the exemplary embodiments without departing from the scope of the present disclosure. For the purposes of explaining the invention, the description of the processes will refer to birefringence control layers based on liquid crystal polymer material systems as described above. However, it should be clear from the description that the processes may be based on any of the implementations of a birefringence control layer described herein.
In some embodiments, exposure of the grating recording material may use conventional cross beam recording procedures instead of the mastering process described above. In many embodiments, further processing of the grating layer may include annealing, thermal processing, and/or other processes for stabilizing the optical properties of grating layer. In some embodiments, electrodes coatings may be applied to the substrates. In many embodiments, a protective transparent layer may be applied over the grating layer after exposure. In a number of embodiments, the liquid crystal polymer material is based on the LCP, LPP material systems discussed above. In several embodiments, the alignment of the liquid crystal polymer can result in an alignment of the liquid crystal directors parallel to the UV beam direction. In other embodiments, the alignment is at ninety degrees to the UV beam direction. In some embodiments, the second transparent substrate may be replaced by a protective layer applied using a coating apparatus.
Although
Additional Embodiments and Applications
In some embodiments, a polarization-maintaining, wide angle, high reflection waveguide cladding with polarization compensation for grating birefringence can be implemented.
In many embodiments, a compact and efficient birefringence control layer for isolating a waveguide from its environment while ensuring efficient confinement of wave-guided beams can be implemented.
To clarify the embodiment of
The above description covers only some of the possible embodiments in which an LCP layer (or equivalent retarding layer) can be combined with an RMLCM layer in a waveguide structure. In many of the above described embodiments, the substrates can be fabricated from 0.5 mm thickness Corning Eagle XG glass. In some embodiments, thinner or thicker substrates can be used. In several embodiments, the substrates can be fabricated from plastic. In a number of embodiments, the substrates and optical layers encapsulated by the said substrates can be curved. Any of the embodiments can incorporated additional layers for protection from chemical contamination or damage incurred during processing and handling. In some embodiments, additional substrate layers may be provided to achieve a required waveguide thickness. In some embodiments, additional layers may be provided to perform at least one of the functions of illumination homogenization spectral filtering, angle selective filtering, stray light control, and debanding. In many embodiments, the bare LCP layer can be bonded directly to a bare exposed RMLCM layer. In several embodiments, an intermediate substrate can be disposed between the LCP layer and the RMLCM layer. In a number of embodiments, the LCP layer can be combined with an unexposed layer of RMLCM material. In many embodiments, layers of LCP, with or without encapsulation, can have haze characteristics <0.25%, and preferably 0.1% or less. It should be noted that the quoted haze characteristics are based on bulk material scatter and are independent of surface scatter losses, which are largely lost upon immersion. The LCP and encapsulation layers can survive 100 C exposure (>80 C for thermal UM exposures). In many embodiments, the LCP encapsulation layer can be drag wipe resistant to permit layer cleaning. In the embodiments described above, there can be constant retardance and no bubbles or voids within the film clear aperture. The LCP and adhesive layers can match the optical flatness criteria met by the waveguide substrates.
A color waveguide according to the principles of the invention would typically include a stack of monochrome waveguides. The design may use red, green, and blue waveguide layers or, alternatively, red and blue/green layers. In some embodiments, the gratings are all passive, that is non-switching. In some embodiments, at least one of the gratings is switching. In some embodiments, the input gratings in each layer are switchable to avoid color crosstalk between the waveguide layers. In some embodiments color crosstalk is avoided by disposing dichroic filters between the input grating regions of the red and blue and the blue and green waveguides. In some embodiments, the thickness of the birefringence control layer is optimized for the wavelengths of light propagating within the waveguide to provide the uniform birefringence compensation across the spectral bandwidth of the waveguide display. Wavelengths and spectral bandwidths bands for red, green, blue wavelengths typically used in waveguide displays are red: 626 nm±9 nm, green: 522 nm±18 nm and blue: 452 nm±11 nm. In some embodiments, the thickness of the birefringence control layer is optimized for trichromatic light.
In many embodiments, the birefringence control layer is provided by a subwavelength grating recorded in HPDLC. Such gratings are known to exhibit the phenomenon of form birefringence and can be configured to provide a range of polarization functions including quarter wave and half wave retardation. In some embodiments, the birefringence control layer is provided by a liquid crystal medium in which the LC directors are aligned by illuminating an azo-dye doped alignment layer with polarized or unpolarized light. In a number of embodiments, a birefringence control layer is patterned to provide LC director orientation patterns with submicron resolution steps. In same embodiments, the birefringence control layer is processed to provide continuous variation of the LC director orientations. In several embodiments, a birefringence control layer provided by combining one or more of the techniques described above is combined with a rubbing process or a polyimide alignment layer. In some embodiments, the birefringence control layer provides optical power. In a number of embodiments, the birefringence control layer provides a gradient index structure. In several embodiments, the birefringence control layer is provided by a stack containing at least one HPDLC grating and at least one alignment layer. In many embodiments, the birefringent grating may have rolled k-vectors. The K-vector is a vector aligned normal to the grating planes (or fringes) which determines the optical efficiency for a given range of input and diffracted angles. Rolling the K-vectors allows the angular bandwidth of the grating to be expanded without the need to increase the waveguide thickness. In many embodiments, the birefringent grating is a fold grating for providing exit pupil expansion. The fold grating may be based on any of the embodiments disclosed in PCT Application No.: PCT/GB2016000181 entitled WAVEGUIDE DISPLAY and embodiments discussed in the other references give above.
In some embodiments, the apparatus is used in a waveguide design to overcome the problem of laser banding. A waveguide according to the principles of the invention can provide a pupil shifting means for configuring the light coupled into the waveguide such that the input grating has an effective input aperture which is a function of the TIR angle. Several embodiments of the pupil shifting means will be described. The effect of the pupil shifting means is that successive light extractions from the waveguide by the output grating integrate to provide a substantially flat illumination profile for any light incidence angle at the input grating. The pupil shifting means can be implemented using the birefringence control layers to vary at least one of amplitude, polarization, phase, and wavefront displacement in 3D space as a function of incidence light angle. In each case, the effect is to provide an effective aperture that gives uniform extraction across the output grating for any light incidence angle at the input grating. In some embodiments, the pupil shifting means is provided at least in part by designing the optics of the input image generator to have a numerical aperture (NA) variation ranging from high NA on one side of the microdisplay panel varying smoothly to a low NA at the other side according to various embodiments, such as those similar to ones disclosed in PCT Application No.: PCT/GB2016000181 entitled WAVEGUIDE DISPLAY, the disclosure of which is hereby incorporated in its entirety. Typically, the microdisplay is a reflective device.
In some embodiments, the grating layer may be broken up into separate layers. The number of layers may then be laminated together into a single waveguide substrate. In many embodiments, the grating layer contains several pieces, including the input coupler, the fold grating, and the output grating (or portions thereof) that are laminated together to form a single substrate waveguide. The pieces may be separated by optical glue or other transparent material of refractive index matching that of the pieces. In several embodiments, the grating layer may be formed via a cell making process by creating cells of the desired grating thickness and vacuum filling each cell with SBG material for each of the input coupler, the fold grating and the output grating. In one embodiment, the cell is formed by positioning multiple plates of glass with gaps between the plates of glass that define the desired grating thickness for the input coupler, the fold grating and the output grating. In one embodiment, one cell may be made with multiple apertures such that the separate apertures are filled with different pockets of SBG material. Any intervening spaces may then be separated by a separating material (e.g., glue, oil, etc.) to define separate areas. In one embodiment, the SBG material may be spin-coated onto a substrate and then covered by a second substrate after curing of the material. By using a fold grating, the waveguide display advantageously requires fewer layers than previous systems and methods of displaying information according to some embodiments. In addition, by using a fold grating, light can travel by total internal refection within the waveguide in a single rectangular prism defined by the waveguide outer surfaces while achieving dual pupil expansion. In another embodiment, the input coupler, the gratings can be created by interfering two waves of light at an angle within the substrate to create a holographic wave front, thereby creating light and dark fringes that are set in the waveguide substrate at a desired angle. In some embodiments, the grating in a given layer is recorded in stepwise fashion by scanning or stepping the recording laser beams across the grating area. In some embodiments, the gratings are recorded using mastering and contact copying process currently used in the holographic printing industry.
In many embodiments, the gratings are Bragg gratings recorded in holographic polymer dispersed liquid crystal (HPDLC) as already discussed, although SBGs may also be recorded in other materials. In one embodiment, SBGs are recorded in a uniform modulation material, such as POLICRYPS or POLIPHEM having a matrix of solid liquid crystals dispersed in a liquid polymer. The SBGs can be switching or non-switching in nature. In its non-switching form a SBG has the advantage over conventional holographic photopolymer materials of being capable of providing high refractive index modulation due to its liquid crystal component. Exemplary uniform modulation liquid crystal-polymer material systems are disclosed in United State Patent Application Publication No.: US2007/0019152 by Caputo et al and PCT Application No.: PCT/EP2005/006950 by Stumpe et al., both of which are incorporated herein by reference in their entireties. Uniform modulation gratings are characterized by high refractive index modulation (and hence high diffraction efficiency) and low scatter. In some embodiments at least one of the gratings is a surface relief grating. In some embodiments at least one of the gratings is a thin (or Raman-Nath) hologram,
In some embodiments, the gratings are recorded in a reverse mode HPDLC material. Reverse mode HPDLC differs from conventional HPDLC in that the grating is passive when no electric field is applied and becomes diffractive in the presence of an electric field. The reverse mode HPDLC may be based on any of the recipes and processes disclosed in PCT Application No.: PCT/GB2012/000680, entitled IMPROVEMENTS TO HOLOGRAPHIC POLYMER DISPERSED LIQUID CRYSTAL MATERIALS AND DEVICES. The grating may be recorded in any of the above material systems but used in a passive (non-switching) mode. The fabrication process can be identical to that used for switched but with the electrode coating stage being omitted. LC polymer material systems may be used for their high index modulation. In some embodiments, the gratings are recorded in HPDLC but are not switched.
In many embodiments, a waveguide display according to the principles of the invention may be integrated within a window, for example, a windscreen-integrated HUD for road vehicle applications. In some embodiments, a window-integrated display may be based on the embodiments and teachings disclosed in U.S. Provisional Patent Application No. 62/125,064 entitled OPTICAL WAVEGUIDE DISPLAYS FOR INTEGRATION IN WINDOWS and U.S. patent application Ser. No. 15/543,016 entitled ENVIRONMENTALLY ISOLATED WAVEGUIDE DISPLAY. In some embodiments, a waveguide display according to the principles of the invention may incorporate a light pipe for providing beam expansion in one direction based on the embodiments disclosed in U.S. patent application Ser. No. 15/558,409 entitled WAVEGUIDE DEVICE INCORPORATING A LIGHT PIPE. In some embodiments, the input image generator may be based on a laser scanner as disclosed in U.S. Pat. No. 9,075,184 entitled COMPACT EDGE ILLUMINATED DIFFRACTIVE DISPLAY. The embodiments of the invention may be used in wide range of displays including HMDs for AR and VR, helmet mounted displays, projection displays, heads up displays (HUDs), Heads Down Displays, (HDDs), autostereoscopic displays and other 3D displays. Some of the embodiments and teachings of this disclosure may be applied in waveguide sensors such as, for example, eye trackers, fingerprint scanners and LIDAR systems and in illuminators and backlights.
It should be emphasized that the drawings are exemplary and that the dimensions have been exaggerated. For example, thicknesses of the SBG layers have been greatly exaggerated. Optical devices based on any of the above-described embodiments may be implemented using plastic substrates using the materials and processes disclosed in PCT Application No.: PCT/GB2012/000680, entitled IMPROVEMENTS TO HOLOGRAPHIC POLYMER DISPERSED LIQUID CRYSTAL MATERIALS AND DEVICES. In some embodiments, the dual expansion waveguide display may be curved.
Although the description has provided specific embodiments of the invention, additional information concerning the technology may be found in the following patent applications, which are incorporated by reference herein in their entireties: U.S. Pat. No. 9,075,184 entitled COMPACT EDGE ILLUMINATED DIFFRACTIVE DISPLAY, U.S. Pat. No. 8,233,204 entitled OPTICAL DISPLAYS, PCT Application No.: US2006/043938, entitled METHOD AND APPARATUS FOR PROVIDING A TRANSPARENT DISPLAY, PCT Application No.: GB2012/000677 entitled WEARABLE DATA DISPLAY, U.S. patent application Ser. No. 13/317,468 entitled COMPACT EDGE ILLUMINATED EYEGLASS DISPLAY, U.S. patent application Ser. No. 13/869,866 entitled HOLOGRAPHIC WIDE ANGLE DISPLAY, and U.S. patent application Ser. No. 13/844,456 entitled TRANSPARENT WAVEGUIDE DISPLAY, U.S. patent application Ser. No. 14/620,969 entitled WAVEGUIDE GRATING DEVICE, U.S. patent application Ser. No. 15/553,120 entitled ELECTRICALLY FOCUS TUNABLE LENS, U.S. patent application Ser. No. 15/558,409 entitled WAVEGUIDE DEVICE INCORPORATING A LIGHT PIPE, U.S. patent application Ser. No. 15/512,500 entitled METHOD AND APPARATUS FOR GENERATING INPUT IMAGES FOR HOLOGRAPHIC WAVEGUIDE DISPLAYS, U.S. Provisional Patent Application No. 62/123,282 entitled NEAR EYE DISPLAY USING GRADIENT INDEX OPTICS, U.S. Provisional Patent Application No. 62/124,550 entitled WAVEGUIDE DISPLAY USING GRADIENT INDEX OPTICS, U.S. Provisional Patent Application No. 62/125,064 entitled OPTICAL WAVEGUIDE DISPLAYS FOR INTEGRATION IN WINDOWS, U.S. patent application Ser. No. 15/543,016 entitled ENVIRONMENTALLY ISOLATED WAVEGUIDE DISPLAY, U.S. Provisional Patent Application No. 62/125,089 entitled HOLOGRAPHIC WAVEGUIDE LIGHT FIELD DISPLAYS, U.S. Pat. No. 8,224,133 entitled LASER ILLUMINATION DEVICE, U.S. Pat. No. 8,565,560 entitled LASER ILLUMINATION DEVICE, U.S. Pat. No. 6,115,152 entitled HOLOGRAPHIC ILLUMINATION SYSTEM, PCT Application No.: PCT/GB2013/000005 entitled CONTACT IMAGE SENSOR USING SWITCHABLE BRAGG GRATINGS, PCT Application No.: PCT/GB2012/000680, entitled IMPROVEMENTS TO HOLOGRAPHIC POLYMER DISPERSED LIQUID CRYSTAL MATERIALS AND DEVICES, PCT Application No.: PCT/GB2014/000197 entitled HOLOGRAPHIC WAVEGUIDE EYE TRACKER, PCT/GB2013/000210 entitled APPARATUS FOR EYE TRACKING, PCT Application No.:GB2013/000210 entitled APPARATUS FOR EYE TRACKING, PCT/GB2015/000274 entitled HOLOGRAPHIC WAVEGUIDE OPTICALTRACKER, U.S. Pat. No. 8,903,207 entitled SYSTEM AND METHOD OF EXTENDING VERTICAL FIELD OF VIEW IN HEAD UP DISPLAY USING A WAVEGUIDE COMBINER, U.S. Pat. No. 8,639,072 entitled COMPACT WEARABLE DISPLAY, U.S. Pat. No. 8,885,112 entitled COMPACT HOLOGRAPHIC EDGE ILLUMINATED EYEGLASS DISPLAY, U.S. patent application Ser. No. 16/086,578 entitled METHOD AND APPARATUS FOR PROVIDING A POLARIZATION SELECTIVE HOLOGRAPHIC WAVEGUIDE DEVICE, U.S. Provisional Patent Application No. 62/493,578 entitled WAVEGUIDE DISPLAY APPARATUS, PCT Application No.: PCT/GB2016000181 entitled WAVEGUIDE DISPLAY, U.S. Patent Application No. 62/497,781 entitled APPARATUS FOR HOMOGENIZING THE OUTPUT FROM A WAVEGUIDE DEVICE, U.S. Patent Application No. 62/499,423 entitled WAVEGUIDE DEVICE WITH UNIFORM OUTPUT ILLUMINATION.
The construction and arrangement of the systems and methods as shown in the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (for example, variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.). For example, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the scope of the present disclosure.
The current application is a continuation of U.S. patent application Ser. No. 16/906,872 entitled “Holographic Waveguides Incorporating Birefringence Control and Methods for Their Fabrication,” filed Jun. 19, 2020, which is a continuation of U.S. patent application Ser. No. 16/357,233 entitled “Holographic Waveguides Incorporating Birefringence Control and Methods for Their Fabrication,” filed Mar. 18, 2019, which claims the benefit of and priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 62/643,977 entitled “Holographic Waveguides Incorporating Birefringence Control and Methods for Their Fabrication,” filed Mar. 16, 2018. The disclosures which are hereby incorporated by reference in their entireties for all purposes.
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