Patent Grant
12352960
The present invention generally relates to apparatuses and methods for displays and more specifically to apparatuses and methods for waveguide displays.
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.
One embodiment includes a waveguide display including a waveguide including a holographic polymer dispersed liquid crystal mixture (HPDLC) layer sandwiched between first and second transparent substrates, wherein the HPDLC layer includes an input grating, a fold grating, and an output grating, and an input image node optically coupled to the waveguide, wherein the input grating is configured to receive light from the input image node and to cause the light to travel within the waveguide via total internal reflection to the fold grating, the fold grating is configured to direct the light towards the output grating, and the output grating is configured to cause the light to exit the waveguide.
In another embodiment, the input image node is coupled to the waveguide by an opto-mechanical interface that allows the waveguide to be mechanically disconnected from the input image node.
In a further embodiment, the waveguide is configured to direct light received from the input image node towards a vehicular windshield.
In still another embodiment, the waveguide is configured to distort the light exiting the waveguide such that the distorted light compensates for the curvature of the vehicular windshield.
In a still further embodiment, the input grating and the output grating are configured to be reverse reciprocal of each other.
In yet another embodiment, the input image node includes a transparent prism for coupling light into the waveguide.
In a yet further embodiment, the transparent prism includes a first surface for coupling light from the input image node into the prism, a second surface for coupling light out of the prism towards the waveguide, a third surface for providing an internal reflection, and a fourth surface opposing the third surface.
In another additional embodiment, the third surface is configured to totally internally reflect the light, wherein the third and fourth surfaces provide a window for viewing an external scene.
In a further additional embodiment, the waveguide display further includes a second waveguide, wherein the two waveguides are configured to form a binocular waveguide display.
In another embodiment again, at least one of the input grating and the output grating is a multiplexed grating.
In a further embodiment again, the waveguide further includes a second fold grating, wherein the multiplexed grating is configured to direct a portion of incident light towards the first fold grating and to direct another portion of incident light towards the second fold grating.
In still yet another embodiment, the multiplexed gratings provided by at least one of the input grating and the output grating is configured to increase the field of view of the waveguide display by providing a first waveguide path for light forming a first portion of the field of view and a second waveguide path for light forming a second portion of the field of view.
In a still yet further embodiment, the input and output gratings each multiplex first and second gratings, wherein a second fold grating is provided, wherein the first grating multiplexed into the input grating, the fold grating and the first grating multiplexed into the output grating together provide a first waveguide path for in-coupling, beam expanding and extracting a first field of view portion, wherein the second grating multiplexed into the input grating, the second fold grating and the second grating multiplexed into the output grating together provide a second waveguide path for in-coupling, beam expanding, and extracting a second field of view portion.
In still another additional embodiment, the waveguide further includes a quarter wave coating for rotating polarization of incoming light.
In a still further additional embodiment, the fold grating is configured to provide pupil expansion in a first direction and the output grating is configured to provide pupil expansion in a second direction different than the first direction.
In still another embodiment again, at least one of the input grating, fold grating, and output grating includes a rolled K-vector grating.
In a still further embodiment again, the input image node includes a light source.
In yet another additional embodiment, the input image node further includes a microdisplay panel.
In a yet further additional embodiment, the waveguide display further includes an eye tracker.
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.
The description and claims will be more fully understood with reference to the following figures and data graphs, which are presented as exemplary embodiments of the invention and should not be construed as a complete recitation of the scope of the invention. It will apparent to those skilled in the art that the present invention may be practiced with some or all of the present invention as disclosed in the following description.
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. As used herein, the term grating may encompass a grating comprised of a set of gratings in some embodiments. For illustrative purposes, it is to be understood that the drawings are not drawn to scale unless stated otherwise.
Turning now to the drawings, systems and methods for generating displays using waveguides incorporating Bragg gratings in accordance with various embodiments of the invention are illustrated. In many embodiments, the waveguide structures are designed to be optical waveguides, which are structures that can confine and guide electromagnetic waves in the visible spectrum, or light. These optical waveguides can be implemented for use in a number of different applications, such as but not limited to helmet mounted displays, head mounted displays (“HMDs”), and HUDs. The term HUD is typically utilized to describe a class of devices that incorporates a transparent display that presents data without requiring users to change their usual visual field. Optical waveguides can integrate various optical functions into a desired form factor depending on the given application.
Optical waveguides in accordance with various embodiments can be designed to manipulate light waves in a controlled manner using various methods and waveguide optics. For example, optical waveguides can be implemented using materials with higher refractive indices than the surrounding environment to restrict the area in which light can propagate. Light coupled into optical waveguides made of such materials at certain angles can be confined within the waveguide via total internal reflection. In a planar waveguide, the angles at which total internal reflection occurs can be given by Snell's law, which can determine whether the light is refracted or entirely reflected at the surface boundary.
In many embodiments, waveguides incorporating Bragg gratings are implemented for HUD applications. HUDs can be incorporated in any of a variety of applications including (but not limited to) near-eye applications. HUDs that utilize planar waveguides incorporating Bragg gratings in accordance with various embodiments of the invention can achieve significantly larger fields of view and have lower volumetric requirements than HUDs implemented using conventional optical components. In some embodiments, the HUDs include at least one waveguide incorporating a number of gratings. In further embodiments, the waveguide incorporates at least three Bragg gratings that can be implemented to provide various optical functions, such as but not limited to dual-axis beam expansion. For example, in a number of embodiments, the waveguide incorporates an input grating, a fold grating, and an output grating. HUDs utilizing waveguides can be implemented using varying numbers of waveguide. In many embodiments, a HUD is implemented using a single waveguide. In other embodiments, the HUD is implemented using a stack of waveguides. Multiple waveguides can be stacked and implemented to provide different optical functions, such as but not limited to implementing color displays. In several embodiments, the HUDs incorporate three separate waveguides, one waveguide for each of a Red, Green, and Blue color channel.
Waveguides utilizing Bragg gratings in accordance with various embodiments of the invention can be designed to have different types of fringes. Use of multiple waveguides having the same surface pitch sizes but different grating slanted angles can increase the overall couple-in angular bandwidth of the waveguide. In a number of embodiments, one or more of the gratings within the waveguide incorporate a rolling K-vector and/or a slant angle that varies across the grating to modify the diffraction efficiency of the grating. The K-vector can be defined as a vector orthogonal to the plane of the associated grating fringe, which can determine the optical efficiency for a given range of input and diffracted angles. By incorporating a grating with rolled K-vectors (“RKVs”), the gratings can be designed to vary diffraction efficiency in a manner that achieves desirable characteristics across the eyebox of the HUD display. Configurations of grating fringes (such as RKVs) and other aspects relating to the structures and implementations of waveguides for use in HUDs are discussed below in further detail.
Optical waveguides can incorporate different optical elements to manipulate the propagation of light waves. As can readily be appreciated, the type of grating selected can depend on the specific requirements of a given application. 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. By strategically placing volume Bragg gratings within a waveguide, the propagation of light within the waveguide can be affected in a controlled manner to achieve various effects. The diffraction of light incident on the grating can be determined by the characteristic of the light and the grating. As can readily be appreciated, volume Bragg gratings can be constructed to have different characteristics depending on the specific requirements of the given application. In a number of embodiments, the volume Bragg grating is designed to be a transmission grating. In other embodiments, the volume Bragg grating is designed to be a reflection grating. In transmission gratings, incident light meeting the Bragg condition is diffracted such that the diffracted light exits the grating on the side which the incident light did not enter. For reflection gratings, the diffracted light exits on the same side of the grating as where the incident light entered.
Waveguide structures in accordance with various embodiments of the invention can implement gratings in a number of different ways. In addition to volume gratings, gratings can be implemented as surface relief gratings. As the name suggests, surface relief gratings can be implemented by physically forming grooves or periodic patterns on the surface of the substrate. The periodicity and angles formed by the grooves can determine the efficiency and other characteristics of the grating. Any of a number of methods can be used to form these grooves, such as but not limited to etching and photolithography.
Although
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.
Typically, the SBG elements are switched clear in 30 μs with a longer relaxation time to switch ON. Note that the diffraction efficiency of the device can be adjusted, by means of the applied voltage, over a continuous range. In many cases, the device exhibits near 100% efficiency with no voltage applied and essentially zero efficiency with a sufficiently high voltage applied. In certain types of HPDLC devices, magnetic fields can be used to control the LC orientation. In some HPDLC applications, phase separation of the LC material from the polymer can be accomplished to such a degree that no discernible droplet structure results. An SBG can also be used as a passive grating. In this mode, its chief benefit is a uniquely high refractive index modulation. SBGs can be used to provide transmission or reflection gratings for free space applications. SBGs can be implemented as waveguide devices in which the HPDLC forms either the waveguide core or an evanescently coupled layer in proximity to the waveguide. The glass plates used to form the HPDLC cell provide a total internal reflection (“TIR”) light guiding structure. Light can be coupled out of the SBG when the switchable grating diffracts the light at an angle beyond the TIR condition.
In waveguide cell designs, in addition to the components described above, adhesives and spacers can be disposed between the substrates to affix the layers of the elements together and to maintain the cell gap, or thickness dimension. In these devices, spacers can take many forms, such as but not limited to materials, sizes, and geometries. Materials can include, for example, plastics (e.g., divinylbenzene), silica, and conductive spacers. They can take any suitable geometry, such as but not limited to rods and spheres. The spacers can take any suitable size. In many cases, the sizes of the spacers range from 1 to 30 μm. While the use of these adhesive materials and spacers can be necessary in LC cells using conventional materials and methods of manufacture, they can contribute to the haziness of the cells degrading the optical properties and performance of the waveguide and device.
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 PDLC mixtures is known and dates back to the earliest investigations of PDLCs. 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 comprising: 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.
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).
Volume gratings can be recorded in a waveguide cell using many different methods in accordance with various embodiments of the invention. The recording of optical elements in optical recording materials can be achieved using any number and type of electromagnetic radiation sources. Depending on the application, the exposure source(s) and/or recording system can be configured to record optical elements using varying levels of exposure power and duration. As discussed above with regards to SBGs, techniques for recording volume gratings can include the exposure of an optical recording material using two mutually coherent laser beams, where the superimposition of the two beams create a periodic intensity distribution along the interference pattern. The optical recording material can form grating structures exhibiting a refractive index modulation pattern matching the periodic intensity distribution. In HPDLC mixtures, the light intensity distribution results in diffusion and polymerization of monomers into the high intensity regions and simultaneous diffusion of liquid crystal into the dark regions. This phase separation creates alternating liquid crystal-rich and liquid crystal-depleted regions that form the fringe planes of the grating. The grating structures can be formed with slanted or non-slanted fringes depending on how the recording beams are configured.
Another method for recording volume gratings in an optical recording material includes the use of a single beam to form an interference pattern onto the optical recording material. This can be achieved through the use of a master grating. In many embodiments, the master grating is a volume grating. In some embodiments, the master grating is an amplitude grating. Upon interaction with the master grating, the single beam can diffract. The first order diffraction and the zero order beam can overlap to create an interference pattern, which can then expose the optical recording material to form the desired volume grating. A single-beam recording process utilizing an amplitude grating in accordance with an embodiment of the invention is conceptually illustrated in
Although specific methods of recording volume gratings are discussed and shown in
In addressing the limited range of wavelengths and angles over which diffraction occurs in volume Bragg gratings, several methods can be utilized to increase the diffraction bandwidth of the gratings. In many embodiments, gratings can employ fringes that vary with respect to their K-vectors. In a number of embodiments, the change across the rolled K-vectors is typically such that the direction of the change in K-vectors is out of plane with the waveguide or grating element. Varying fringes, or rolled K-vectors, can be implemented in a number of different ways. In some embodiments, fringes of gratings are designed to vary in a progressive manner across the grating. In other embodiments, different discrete sets of gratings with different fringes are place serially. Gratings with rolled K-vectors can be designed and configured in a variety of ways. In many embodiments, the rolled K-vectors are designed such that the peak diffraction efficiency of each grating segment is optimized for its corresponding output angle at that position. In some embodiments, the peak diffraction efficiency of each grating at different positions is at an offset with its corresponding output angle at that position. It has been shown that by introducing this offset, eyebox homogeneity can be improved. In several embodiments, offsets can improve total image brightness by a factor of two compared to just matching the peak diffraction efficiencies at different positions.
Rolled K-vector gratings can be used to maximize the peak diffraction efficiency of in-couple light in accordance with an embodiment of the invention. The use of rolled k-vectors enables high efficiency input coupling into a grating, and also allows the beam spread angle to be optimized to minimize the thickness of the waveguide; this may need balancing the waveguide thickness, the angular bandwidth of the grating, and the spread of field angles at any given point on the grating. The low angular response of gratings as the K-vector is rolled (and surface pitch maintained) can prevent output coupling, allowing the waveguide thickness to be minimized. In a number of embodiments, the design aim is to ensure maximum input coupling at a point and to minimize the angular diversity such that the grating thickness can be minimized without reciprocally out-coupling at different point.
In many embodiments, different sets of discrete fringes are superimposed into the same grating, creating a multiplexed grating with essentially multiple gratings inside the same volume that work independently and without interfering with each other. For example, if two volume gratings are recorded in the same device for two different Bragg wavelengths at the same incidence angle, the device can diffract the two selected wavelengths into different output directions with limited crosstalk. Multiplexing can be used to produce improved angular profiles by combining two gratings of similar prescription to extend the diffraction efficiency angular bandwidth and give better luminance uniformity and color balance across the exit pupil and field of view. Multiplexing can also be used to encode two distinct diffraction prescriptions which can be design to project light into distinct field of regions or diffract light of two different wavelengths into a given field of view region. Steps can be taken to ensure that there is no competition between gratings during recording leading to unequal diffraction efficiencies and crosstalk between gratings in playback. Multiplexing can also offer the significant benefit of reducing the number of layers in the waveguide structure. In some embodiments, at least one of the input, fold, or output gratings can combine two or more angular diffraction prescriptions to expand the angular bandwidth. Similarly, in several embodiments, at least one of the input, fold, or output gratings can combine two or more spectral diffraction prescriptions to expand the spectral bandwidth. For example, a color multiplexed grating may be used to diffract two or more of the primary colors.
Although specific grating structures with varying fringes are discussed above, any of a number of fringe configurations can be utilized in accordance with specific requirements of a given application. For example, any number of gratings can be multiplexed as allowed by manufacturing constraints. Rolled K-vector gratings can be designed to have K-vectors rolled in any discrete unit.
Gratings can be implemented in waveguides in a variety of different ways. In some embodiments, the gratings reside on the outer surface of the waveguide. In other embodiments, volume gratings are implemented inside the waveguide. Gratings can also be implemented to perform different optical functions, such as but not limited to coupling light, directing light, and preventing the transmission of light.
In many embodiments, diffraction gratings can be used to preserve eye box size while reducing lens size by effectively expanding the exit pupil of a collimating optical system. The exit pupil can be defined as a virtual aperture where only the light rays which pass though this virtual aperture can enter a user's eyes.
Expanding upon the ideas in
In many embodiments, the optical waveguide utilizes a fold grating, which can provide exit pupil expansion in one dimension while directing the light within the waveguide. In further embodiments, the fold grating directs the light towards an output grating, which can provide exit pupil expansion in a second dimension that is different from the first direction and also couples the light out of the waveguide. By using the fold grating, the waveguide display can require fewer layers than other systems and methods of displaying information. In addition, by using 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. As a result, a two-dimension exit pupil expansion can be achieved using a single waveguide.
Although the discussions above relating to
Waveguides in accordance with various embodiments of the invention can be stacked together to implement certain optical functions. For example, in many embodiments, the device can include a stack of RGB diffracting layers, each layer comprising input and output gratings. In each layer the SBGs are recorded to provide peak diffraction efficiency vs. wavelength characteristics (along the waveguide) shifted by small increments from the peak wavelength. In some embodiments, RGB SBG layers are used and can be switched sequentially and synchronously with RGB LEDs image sources.
Although
Waveguide displays in accordance with various embodiments of the invention can be implemented and constricted in many different ways. For example, waveguide displays can contain a varying number of waveguide layers and different exit pupil expansion scheme.
In the illustrative embodiment, the light path from the source to the waveguide via the IIN is indicated by rays 1408-1411. The input grating 1405A, 1405B of each grating layer can couple a portion of the light into a TIR path in the waveguide 1404, such path being represented by the rays 1412, 1413. The output gratings 1407A, 1407B can diffract light out of the waveguide into angular ranges of collimated light 1414, 1415 respectively for viewing by the eye 1416. The angular ranges, which correspond to the field of view of the display, can be defined by the IIN optics. In some embodiments, the waveguide gratings can encode optical power for adjusting the collimation of the output. In several embodiments, the output image is at infinity. In other embodiments, the output image may be formed at distances of several meters from the eye box. Typically, the eye is positioned within the exit pupil or eye box of the display.
Different IIN implementations and embodiments can be utilized as discussed and taught in 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, the disclosures of which are hereby incorporated by reference in their entireties. In some embodiments, the IIN contains a beamsplitter for directing light onto a microdisplay and transmitting the reflected light towards the waveguide. In many embodiments, the beamsplitter is a grating recorded in HPDLC and uses the intrinsic polarization selectivity of such gratings to separate the light illuminating the display and the image modulated light reflected off the display. In several embodiments, the beam splitter is a polarizing beam splitter cube. In a number of embodiments, the IIN incorporates a despeckler. Despecklers are discussed in U.S. Pat. No. 8,565,560, entitled Laser Illumination Device, the disclosure of which is hereby incorporated by reference in its entirety.
The light source can be a laser or LED and can include one or more lenses for modifying the illumination beam angular characteristics. The image source can be a micro-display or laser based display. LED can provide better uniformity than laser. If laser illumination is used, there is a risk of illumination banding occurring at the waveguide output. In many embodiments, laser illumination banding in waveguides can be overcome using the techniques and teachings disclosed in U.S. patent application Ser. No. 15/512,500, entitled Method and Apparatus for Generating Input Images for Holographic Waveguide Displays, the disclosure of which is hereby incorporated by reference in its entirety. In some embodiments, the light from the light source is polarized. In several embodiments, the image source is a liquid crystal display (LCD) micro display or liquid crystal on silicon (LCoS) micro display.
In some embodiments, similar to the one shown in
In many embodiments, the fold grating's angular bandwidth can be enhanced by designing the grating prescription to provide dual interaction of the guided light with the grating. Exemplary embodiments of dual interaction fold gratings are disclosed in U.S. patent application Ser. No. 14/620,969, entitled Waveguide Grating Device, the disclosure of which is hereby incorporated in its entirety.
In many embodiments, the grating layer can be broken up into separate layers. For example, in some embodiments, a first layer includes the fold grating while a second layer includes the output grating. In further embodiments, a third layer can include the input grating. In such embodiments, the number of layers can then be laminated together into a single waveguide substrate. In several embodiments, the grating layer includes a number of 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 can be separated by optical glue or other transparent material of refractive index matching or substantially similar that of the pieces.
In many embodiments, the grating layer can 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 some embodiments, the cell can be 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 several embodiments, one cell can be made with multiple apertures such that the separate apertures are filled with different pockets of SBG material. Any intervening spaces can then be separated by a separating material (e.g., glue, oil, etc.) to define separate areas. In a number of embodiments, the SBG material can be spin-coated onto a substrate and then covered by a second substrate after curing of the material.
In many embodiments, the input coupler, the fold grating, and the output grating 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. Additional, such optical elements can also be fabricated using any of the various methods described in the above sections.
In one embodiment, the input coupler, the fold grating, and the output grating embodied as SBGs can be Bragg gratings recorded in a holographic polymer dispersed liquid crystal (HPDLC) (e.g., a matrix of liquid crystal droplets), 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 many embodiments, the input coupler, the fold grating, and the output grating is made of 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 disclosure of which is hereby incorporated in its entirety. The grating can be recorded in any of the above material systems but used in a passive (non-switching) mode. The fabrication process is identical to that used for switched but with the electrode coating stage being omitted. LC polymer material systems are highly desirable in view of their high index modulation. In some embodiments, the gratings are recorded in HPDLC but are not switched.
In many embodiments, the input grating can be replaced by another type of input coupler, such as but not limited to a prism and a reflective surface. In some embodiments, the input coupler can be a holographic grating, such as an SBG grating or a passive grating, which can be a passive SBG grating. The input coupler can be configured to receive collimated light from a display source and to cause the light to travel within the waveguide via total internal reflection between the first surface and the second surface to the fold grating. The input coupler can be orientated directly towards or at an angle relative to the fold grating. For example, in several embodiments, the input coupler can be set at a slight incline in relation to the fold grating. In a number of embodiments, the fold grating can be oriented in a diagonal direction. The fold grating can be configured to provide pupil expansion in a first direction and to direct the light to the output grating via total internal reflection inside the waveguide.
In many embodiments, a longitudinal edge of each fold grating is oblique to the axis of alignment of the input coupler such that each fold grating is set on a diagonal with respect to the direction of propagation of the display light. The fold grating can be angled such that light from the input coupler is redirected to the output grating. In some embodiments, the fold grating is set at a forty-five-degree angle relative to the direction that the display image is released from the input coupler. This feature can cause the display image propagating down the fold grating to be turned into the output grating. For example, in several embodiments, the fold grating can cause the image to be turned 90 degrees into the output grating. In this manner, a single waveguide can provide dual axis pupil expansion in both the horizontal and vertical directions. In a number of embodiments, each of the fold grating can have a partially diffractive structure. In some embodiments, each of the fold gratings can have a fully diffractive structure.
The output grating can be configured to provide pupil expansion in a second direction different than the first direction and to cause the light to exit the waveguide from the first surface or the second surface. The output grating can receive the display image from the fold grating via total internal reflection and can provide pupil expansion in a second direction. In many embodiments, the output grating includes multiple layers of substrate, thereby comprising multiple layers of output gratings. Accordingly, there is no requirement for gratings to be in one plane within the waveguide, and gratings may be stacked on top of each other (e.g., cells of gratings stacked on top of each other).
In many embodiments, a quarter wave plate on the substrate waveguide rotates polarization of a light ray to maintain efficient coupling with the SBGs. The quarter wave plate can be coupled to or adhered to the surface of substrate waveguide. For example, in some embodiments, the quarter wave plate is a coating that is applied to substrate waveguide. The quarter wave plate can provide light wave polarization management. Such polarization management can help light rays retain alignment with the intended viewing axis by compensating for skew waves in the waveguide. The quarter wave plate is optional and can increase the efficiency of the optical design in implementations. In several embodiments, the waveguide does not include the quarter wave plate. The quarter wave plate may be provided as multi-layer coating.
In many embodiments, the waveguide display can be operated in monochrome. In some embodiments, the waveguide display can be operated in color. Operating in color can be achieved using a stack of monochrome waveguides of similar design to the one in
In many embodiments, a dual expansion waveguide display can further include a dynamic focusing element.
The dynamic focus device can provide a multiplicity of image surfaces 1902. In light field display applications, at least four image surfaces can be used. The dynamic focusing element can be based on dynamic focusing elements described in U.S. patent application Ser. No. 15/553,120 entitled, Electrically Focus Tunable Lens, the disclosure of which is hereby incorporated in its entirety. In some embodiments, a dual expansion waveguide display having a dynamic focusing element and an eye tracker can provide a light field display, such as those based on the teachings disclosed in U.S. patent application Ser. No. 15/543,013, entitled Holographic Waveguide Light Field Displays, the disclosure of which is hereby incorporated by reference in its entirety.
Although specific waveguide structures are discussed above, any of a number of waveguide structures can be implemented depending on the specific requirements of a given application. For example, in many waveguide configurations, the input, fold, and output gratings are formed in a single layer sandwiched by transparent substrates. Such a configuration is shown in
In many embodiments, the waveguide display is coupled to the IIN by an opto-mechanical interface that allows the waveguide to be easily retracted from the IIN assembly. The basic principle is conceptually illustrated in
In many embodiments, the microdisplay is a reflective device. In some embodiments, the microdisplay is a transmission device, typically a transmission LCoS device.
In many embodiments, the principles of the invention may be applied to an emissive display. Examples of emissive displays for use with the invention include ones based on LED arrays and light emitting polymers arrays.
In many embodiments, the microdisplay optics includes a polarizing beam splitter cube. In some embodiments, the microdisplay optics includes an inclined plate to which a beam splitter coating has been applied. In a number of embodiments, the microdisplay optics includes a waveguide device comprising a SBG, which acts as a polarization selective beam splitter. Details relating to such embodiments are discussed 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, the disclosures of which are hereby incorporated in their entireties. In several embodiments, the microdisplay optics contains at least one of a refractive component and curved reflecting surfaces or a diffractive optical element for controlling the numerical aperture of the illumination light. In some embodiments, the microdisplay optics contains spectral filters for controlling the wavelength characteristics of the illumination light. In a number of embodiments, the microdisplay optics contains apertures, masks, filter, and coatings for controlling stray light. In many embodiments, the microdisplay optics incorporate birdbath optics.
Although
Waveguides incorporating Bragg gratings similar to those described above can be utilized in a variety of applications including (but not limited to) HUDs in vehicular applications such as automotive and aerospace applications. In many embodiments, a waveguide is utilized to direct light incident on the waveguide from one or more projection sources toward a windshield, where the light is reflected toward the operator of the vehicle. Windshields are often curved. In several embodiments, the waveguides transmit incident light to compensate for distortions introduced by the curvature of a windshield (or other surface onto which light from the waveguide is projected). As is discussed further below, distortions introduced by curvature of a surface onto which light is projected can be compensated for by selection of the K-vector across the output grating of the waveguide and/or computationally by modifying the manner in which an input image is projected into the waveguide.
An HUD for vehicular applications in accordance with an embodiment of the invention is conceptually illustrated in
Projection of light into an eyebox by reflection off a curved windshield using a HUD system in accordance with an embodiment of the invention is conceptually illustrated in
Use of flat waveguides that incorporate Bragg gratings can significantly reduce the volumetric requirements of a HUD compared to conventional HUDs implemented using conventional refractive and/or reflective optical components. Furthermore, the field of view of a HUD that can be achieved using a waveguide can be significantly greater despite the reduction in volumetric requirements compared to a conventional HUD. A comparison of the field of view and volumetric requirements of a HUD implemented using a waveguide incorporating Bragg gratings and a conventional HUD is shown in
While various embodiments of HUDs incorporating waveguides including Bragg gratings are described above with reference to
Waveguides incorporating Bragg gratings can provide significant advantages when used in HUDs including (but not limited to) wide field of view displays and reduced volumetric requirements compared to HUDs implemented using conventional reflective and refractive optical components. In many embodiments, vehicular HUDS are implemented using one or more planar waveguides fabricated to incorporate at least volumetric Bragg gratings that couple incident light into the waveguide, fold the light within the waveguide and direct light from the waveguide. As noted above, the gratings can provide two dimensional exit pupil expansion.
A waveguide assembly including three separate waveguides for each of a Red, Green, and Blue color channel implemented in accordance with an embodiment of the invention is illustrated in
Input coupling gratings couple light from one or more illumination sources into a waveguide. Referring again to
A perspective view of a waveguide assembly incorporating separate input gratings for each waveguide is shown in
The input gratings for each of the waveguides can be slightly offset within the waveguide assembly as can be appreciated from the conceptual illustration of the placement of the input gratings relative to the waveguides shown in
While the waveguide assemblies illustrated above in
Coupling of light from a projection system into input gratings of a waveguide assembly in accordance with an embodiment of the invention is conceptually illustrated in
Referring again to
The dimensions of the fold and output gratings of a waveguide that can be utilized in a vehicular HUD in accordance with an embodiment of the invention is illustrated in
Impact of varying output grating slant angle in the manner shown in
HUD systems in accordance with several embodiments of the invention reflect light off a curved surface such as (but not limited to a windshield). Projection of light by a waveguide similar to the waveguide shown in
As noted above, the K-vectors and slant angles of the fringes within an output Bragg grating can be chosen to correct for curvature of the surface onto which the display is projected by the output grating. A windshield correction function that is utilized to modify the rolled K-vector prescription of an output grating in accordance with an embodiment of the invention is illustrated in
Referring again to
Referring again to
In many embodiments, incorporation of a fold grating that increases in width with distance from the input grating can enable the construction of a variety of waveguide shapes. Many of the waveguides illustrated above are largely rectangular. In many embodiments, the form factor of the waveguide can be reduced. A waveguide in which the output grating is contained within a region that can be cut with a taper (indicated with dashed lines) in accordance with an embodiment of the invention is illustrated in
A variety of illumination sources can be utilized to implement HUDs in accordance with various embodiments of the invention including (but not limited to) LED based and laser based projection systems. A HUD projection system that couples Red, Green, and Blue laser pulses into the respective Red, Green, and Blue waveguides of a waveguide assembly in accordance with an embodiment of the invention is conceptually illustrated in
Although specific projection systems are described above with reference to
Waveguides incorporating Bragg gratings similar to those described above can be utilized in a variety of applications, such as but not limited to monocular displays. Monocular displays can be implemented in a variety of different ways, including through the use of methods, components, and structures as described above. Additionally, it should be readily apparent that various aspects can be modified as appropriate to the specific requirements of a given application. For example, in many embodiments, it can be desirable for the monocular display to have an optical element that can facilitate the redirection of light from the light source onto the waveguide. This can be due to the spatial and angle positioning of the various components. In a number of embodiments, the monocular display is designed to be compact, resulting in forced positioning for the various components. An optical element used for redirecting light in such embodiments can include, but are not limited to, a prism. In several embodiments, a prism is used for PGU coupling and TIR redirection.
In many embodiments, the monocular display includes a waveguide implementing at least an input grating, a fold grating, and an output grating. In some embodiments, the waveguide includes reciprocal grating prescriptions designed for zero-dispersion. Monocular displays can be designed to implement a variety of different types of gratings, including those described in the previous sections of this application. Positioning and orientation of the gratings can depend on the specific requirements of a given application. For example, in several embodiments, the gratings are designed such that the monocular display can implement a reverse reciprocal dual axis pupil expansion architecture where the waveguide receives and outputs light from the same side.
Monocular displays can be implemented using waveguides with properties described above, such as, and including, stacking waveguide layers in order to implement RGB color. As such, in many embodiments, the implemented waveguide can be made up of a stack of waveguide layers. In further embodiments, the waveguide stack includes two waveguide layers implementing a three-color system.
In many embodiments, the monocular display includes a compact PGU optical interface. In some embodiments, the monocular display utilizes a projector as a PGU. In several embodiments, the PGU can be an IIN module composed of several components.
The prismatic relay optics 4903 includes side walls 4903A, 4903B, an input surface 4903C and the output surface 4903D. The reflective surface 4903A can be a TIR surface or can alternatively support a reflection coating. The prismatic relay optics 4903 can guide light from the IIN towards the waveguide eye piece along ray paths that are refracted through the input surface (4903C), reflected at the surface 4903A and refracted through the output surface (4903D). Hence, the prismatic surface 4903A, 4903C, 4903D serve to steer the input beam into the waveguide eyepiece along a path that can be designed to be conformal with any display mounting arrangement while delivering the beam at the correct angle for diffraction at the input grating. When the surface 4903A is configured as a TIR surface, the side walls provide a window for viewing an external scene without obscuration.
Light from the prismatic relay optics can be coupled into the waveguide via the optical interface layer 4906, which in some embodiments provides polarization selectivity. In several embodiments, the optical interface layer provides one of spectral or angular selectivity. In a number of embodiments, the optical interface layer 4906 is a diffractive optical element. In a variety of embodiments, at least one of the transmitting or reflecting surfaces of the prismatic relay optics has optical power. In some embodiments, at least one of the transmitting or reflecting surfaces of the prismatic relay optics supports at least one coating for controlling at least one of polarization, reflection or transmission as a function of wavelength or angle. The image light from the IIN can be expanded in the prism to produce sufficient beam width aperture to enable a high efficiency RKV input aperture—thus preserving efficiency and brightness.
In some embodiments, the waveguide 4902 includes input, fold and output gratings disposes in separate red, green and blue diffracting layers or multiplexed into fewer layer as discussed above or disclosed in the references. For simplicity, the gratings in
Utilizing the techniques and methods as discussed above, monocular displays can be implemented in a wide variety of applications using various designs.
Waveguides incorporating Bragg gratings similar to those described above can be utilized in a variety of applications including (but not limited to) HUDs in wearable near-eye display applications such as eyeglasses, monocles, and visors. In many embodiments, a waveguide is utilized to direct light incident on the waveguide from one or more projection sources toward one or more lenses, where the light is reflected toward the wearer of the lens. In such embodiments, an important figure of merit is out-couple efficiency of the light in the eyebox. In several embodiments, the waveguides are configured to transmit incident light to maximize out-coupling of light onto the lens and to improve uniformity across the entire field of view (FOV) of the wearable device (or other surface onto which light from the waveguide is projected). As is discussed further below, out-couple efficiency can be maximized by selection of the features of the K-vectors across the output grating of the waveguide and/or implementing polarization recycling. Similarly, the uniformity of illumination across the FOV may be maximized by optimizing RKV slant angle and modulation.
An HUD in accordance with various embodiments of the invention can be implemented to be located within a near-eye display device, such as glasses or monocle. A projection system and a waveguide can be contained within the wearable device and light can be projected from the waveguide onto the lens of the near-eye display. The light can be reflected off the surface of the near-eye display device into a region that is commonly referred to as the eyebox of the HUD. The term eyebox is generally utilized to refer to a region in which the display is visible to the eye of a viewer. The display appears to the viewer as a virtual display on the opposite side of the lens of the near-eye display device to the viewer. The location of the display can be determined based upon projective geometry. Placement of the display within the field of view of the near-eye display device enables the wearer to view the surrounding environment and projected information simultaneously.
Use of flat waveguides that incorporate Bragg gratings can significantly reduce the volumetric requirements of a HUD compared to conventional HUDs implemented using conventional optical components. Furthermore, the field of view of a HUD that can be achieved using a waveguide can be significantly greater despite the reduction in volumetric requirements compared to a conventional HUD.
Waveguides incorporating Bragg gratings can provide significant advantages when used in HUDs including (but not limited to) wide field of view displays and reduced volumetric requirements compared to HUDs implemented using conventional reflective and refractive optical components. In many embodiments, near-eye wearable HUDS are implemented using one or more planar waveguides fabricated to incorporate at least volume Bragg gratings that couple incident light into the waveguide, fold the light within the waveguide and direct light from the waveguide. As noted above, the gratings can provide two dimensional exit pupil expansion.
A waveguide assembly including three types of gratings, an input, fold and output, implemented in accordance with an embodiment of the invention is illustrated in
Input coupling gratings couple light from one or more illumination sources into a waveguide. Referring again to
Regardless of the specific input grating design the gratings may be formed in layers of polymer using techniques similar to those described in PCT Application Serial No. PCT/GB2012/000680, the relevant disclosure from which is incorporated by reference herein in its entirety. In many embodiments, the polymer layers that contain the waveguides are separated by layers of glass.
Coupling of light from a projection system into input gratings of a waveguide assembly can be implemented in many different ways. The projector can direct light toward a mirror or prism that reflects the light into the input gratings. In other embodiments, the projector can directly project light into the input gratings, and/or a waveguide can be utilized to direct light from the projection system into the input gratings.
Referring again to
Gratings and exemplary dimensions thereof, according to embodiments capable of supporting 25 degree and 50 degree Field of view using an output grating having an aperture size of 25 mm×25 mm at a near-eye relief from the eyebox (reflected via a transparent lens element) are shown in
HUD systems in accordance with several embodiments of the invention reflect light off a curved surface such as (but not limited to a wearable lens). Projection of light by a waveguide is conceptually illustrated in
As noted above, the K-vectors and slant angles of the fringes within an output Bragg grating can also be chosen to correct for curvature of the surface onto which the display is projected by the output grating. Rolled K-vector prescriptions for all three gratings in accordance with an embodiment of the invention is illustrated in
Referring again to
Referring again to
As shown in
Depending on nature of the grating, light may be p or s polarized, and the nature of that polarization can have an effect on the efficiency of overall coupling efficiency, and therefore overall efficiency of the waveguide embodiments, as shown in
Once again it is to be noted that the out-couple efficiency of the light that finally hits the eyebox is the important metric to determine efficiency of the waveguide system. This value can be characterized by a percentage of coupled light. Turning to
In addition to these birefringence effects, coatings and films may be implemented in embodiments of the invention to increase the capture of light that might be rejected because of the polarization selectivity of the waveguide. For example, in some embodiments a QWP film may be implemented to suppress odd interactions. In other embodiments, a HWP film may be implemented to collect s-polarized light. Such implementations may be referred to as polarization recycling. A conceptual illustration of an implementation of such a coating is provided in
Embodiments of near-eye waveguide devices may incorporate one or more of the input, output and fold grating structures discussed above. Embodiments may comprise any number of input and output layers, these layers may be bifurcated, and these layers may incorporate other optical features such as QWP or HWP films, MUX gratings, and combinations thereof. Exemplary embodiments of various combinations may be found in
One exemplary embodiment of an implementation of an architecture according to the above is illustrated in
Embodiments are also directed to methods of manufacturing multiplex (MUX) gratings. In many embodiments a multiplex grating comprises multiple prescriptions disposed in the same grating. As shown in
Although specific systems and methods are discussed above, many different embodiments can be implemented in accordance with the invention. It is therefore to be understood that the present invention can be practiced in ways other than specifically described, without departing from the scope and spirit of the present invention. Thus, embodiments of the present invention should be considered in all respects as illustrative and not restrictive. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their equivalents. Although specific 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. 17/167,903 entitled “Waveguide Architectures and Related Methods of Manufacturing,” filed Feb. 4, 2021, which is a continuation of U.S. patent application Ser. No. 16/242,979 entitled “Waveguide Architectures and Related Methods of Manufacturing,” filed Jan. 8, 2019, which claims the benefit of and priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 62/614,947 entitled “Monocular Waveguide Displays,” filed Jan. 8, 2018, U.S. Provisional Patent Application No. 62/614,949 entitled, “Vehicular Waveguide Displays,” filed Jan. 8, 2018, and U.S. Provisional Patent Application No. 62/615,000 entitled “Near-Eye Waveguide Displays,” filed Jan. 8, 2018, the disclosures which are incorporated herein by reference in their entireties.
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| Parent | 16242979 | Jan 2019 | US |
| Child | 17167903 | US |
