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WO2024257096A2 - Procédés de fabrication d'éléments optiques de conduit de lumière - Google Patents

Procédés de fabrication d'éléments optiques de conduit de lumière Download PDF

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Publication number
WO2024257096A2
WO2024257096A2 PCT/IL2024/050577 IL2024050577W WO2024257096A2 WO 2024257096 A2 WO2024257096 A2 WO 2024257096A2 IL 2024050577 W IL2024050577 W IL 2024050577W WO 2024257096 A2 WO2024257096 A2 WO 2024257096A2
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WO
WIPO (PCT)
Prior art keywords
optical element
optical
partially
frame
facets
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/IL2024/050577
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English (en)
Other versions
WO2024257096A3 (fr
Inventor
Elad SHARLIN
Ido FUCHS
Tsion EISENFELD
Yochay Danziger
Ronen Chriki
Amir Shapira
Eitan RONEN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Lumus Ltd
Original Assignee
Lumus Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Lumus Ltd filed Critical Lumus Ltd
Publication of WO2024257096A2 publication Critical patent/WO2024257096A2/fr
Publication of WO2024257096A3 publication Critical patent/WO2024257096A3/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

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Classifications

    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/01—Head-up displays
    • G02B27/017—Head mounted
    • G02B27/0172—Head mounted characterised by optical features
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/28—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00 for polarising
    • G02B27/283—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00 for polarising used for beam splitting or combining

Definitions

  • the present disclosure relates to optical systems, and, in particular, it concerns methods for fabricating optical devices including light-guide optical elements.
  • Optical arrangements for near eye display (NED), head mounted display (HMD) and head up display (HUD) require large aperture to cover the area where the observer’s (user’s) eye is located (commonly referred to as the eye-motion box - or EMB).
  • EMB eye-motion box
  • the image that is to be projected into the observer’s eye is generated by a small optical image generator (projector) having a small optical aperture.
  • the image from the image projector is conveyed to the eye by an optical combiner, which can be implemented as a light-guide optical element (LOE) having one or more sets of mutually-parallel partially-reflecting internal surfaces, which expands (multiplies) the image in one or two dimensions to generate a large aperture.
  • LOE light-guide optical element
  • the present disclosure provides methods for fabricating optical devices including lightguide optical elements (LOEs).
  • LOEs lightguide optical elements
  • a method for fabricating an optical device comprises: obtaining at least one optical element; obtaining a frame; arranging the at least one optical element within the frame according to a spatial configuration that defines a position of the at least one optical element in the frame and an orientation of the at least one optical element relative to the frame; bonding the at least one optical element to the frame to fix the spatial configuration; and filling regions of the frame unoccupied by the at least one optical element with a transparent optical material.
  • the method further comprises: prior to filling the regions of the frame with the transparent optical material, arranging the frame between a pair of parallel surfaces such that the at least one optical element is located between the parallel surfaces.
  • the method further comprises: curing the transparent optical material.
  • the at least one optical element is constructed from a material that is the same as the transparent optical material.
  • the at least one optical element is constructed from a glass material having a low glass-transition temperature or a plastic or polymer material having a high glass-transition temperature.
  • arranging the at least one optical element within the frame includes deploying a device that places each optical element of the at least one optical element according to the spatial configuration.
  • the at least one optical element has an embedded material internal to the at least one optical element that is sensitive to at least one of an electric field or a magnetic field.
  • arranging the at least one optical element within the frame is performed at least in part by applying at least one of an electric field or a magnetic field to the embedded material internal to the at least one optical element.
  • the embedded material includes at least one of a ferromagnetic material or a dielectric material.
  • the at least one optical element includes a planar partially-reflecting surface.
  • the at least one optical element includes a lens.
  • the at least one optical element includes a polarizing beam splitter.
  • the at least one optical element includes an optical retarder.
  • the at least one optical element includes a reflective surface.
  • the at least one optical element includes a plurality of optical elements.
  • the plurality of optical elements includes a first plurality of planar partially- reflecting surfaces.
  • the orientation defined by the spatial configuration is such that the first plurality of partially-reflecting surfaces are obliquely inclined relative to a pair of parallel surfaces between which the frame is located.
  • the orientation defined by the spatial configuration is such that the first plurality of partially-reflecting surfaces are perpendicular to a pair of parallel surfaces between which the frame is located.
  • the orientation defined by the spatial configuration is such that the first plurality of partially-reflecting surfaces are mutually parallel.
  • the method further comprises: obtaining a second plurality of planar partially- reflecting surfaces; and arranging the second plurality of partially-reflecting surfaces within the frame according to a second spatial configuration that defines a position of the second plurality of partially-reflecting surfaces in the frame and an orientation of the second plurality of partially- reflecting surfaces relative to the frame, and the orientation defined by the second spatial configuration is such that the second plurality of partially-reflecting surfaces are mutually parallel and non-parallel to the first plurality of partially-reflecting surfaces.
  • the at least one optical element includes a plurality of planar partially-reflecting surfaces
  • obtaining the at least one optical element includes: obtaining a production plate formed from glass having low glass-transition temperature or a plastic or polymer material having a high glass-transition temperature, coating the production plate with a partially-reflecting coating, and slicing the coated production plate to produce a plurality of coated plates, each coated plate being a planar partially-reflecting surface.
  • the at least one optical element includes a plurality of planar partially-reflecting surfaces
  • obtaining the at least one optical element includes: obtaining a plurality of production plates, each production plate formed from glass having a low glass-transition temperature or a plastic or polymer material having a high glass-transition temperature, coating each of the production plates with a partially-reflecting coating, stacking the coated production plates in a stack and temporarily bonding together the coated production plates with a temporary adhesive, and slicing the stack and removing the temporary adhesive to produce a plurality of coated plates, each coated plate being a planar partially-reflecting surface.
  • obtaining the at least one optical element includes: obtaining an amount of a material that is sensitive to at least one of an electric field or a magnetic field, and embedding the amount of the material in an optical material to form the at least one optical element.
  • the at least one optical element includes a polarizing beam splitter.
  • optical materials are low index material, medium index materials, and high index material.
  • an optical material is considered to be a high index material if the refractive index of the optical material is greater than or equal to approximately 1.7.
  • an optical material is considered to be a low index material if the refractive index of the optical material is in a range between approximately 1 and approximately 1.53.
  • an optical material is considered to be a medium index material if it is neither a low index material nor a high index material, in other words the refractive index of the optical material is in a range between approximately 1.53 and 1.7.
  • FIG. 14 is a graph showing reflectance curves for p-polarized light and s-polarized light at a particular angular range of between 40° and 60°.
  • FIGS. 1 and 2 illustrate certain particularly preferred examples of optical devices for which the fabrication methods of the present disclosure are particularly relevant, although the fabrication methods are not limited to such applications.
  • the LOE 12 is formed from transparent (i.e., light-transmitting) material, and includes a set (pair) of mutually-parallel major external surfaces 14, 16 and a set of planar, mutually-parallel, partially-reflecting surfaces (“facets”) 18.
  • the facets 18 are internal to the LOE 12, i.e., they are located between the major external surfaces 14, 16, and are obliquely inclined relative to the major external surfaces 14, 16.
  • a compact image projector 20 is optically coupled with the LOE 12 via a suitable optical coupling configuration 22 (represented in the drawings as a coupling prism, but may be of other suitable forms such as a coupling reflector) so as to inject image illumination (corresponding to a collimated image) 19 into the LOE 12 within which the image light is trapped by internal reflection at the major external surfaces 14, 16.
  • the propagating image light (represented as rays 24) interacts with the facets 18, which progressively deflect (couples-out) a proportion of the image illumination (represented as rays 30) out of the LOE 12 towards the eye 26 of an observer located within a region defined as the eye-motion box (EMB) 28, thereby achieving expansion of the optical aperture in one dimension.
  • EMB eye-motion box
  • the regions 13 and 15 may be immediately juxtaposed so that they meet at a boundary, which may be a straight boundary or some other form of boundary, or there may be one or more additional LOE region interposed between those regions, to provide various additional optical or mechanical function, depending upon the particular application.
  • a boundary which may be a straight boundary or some other form of boundary, or there may be one or more additional LOE region interposed between those regions, to provide various additional optical or mechanical function, depending upon the particular application.
  • particularly high quality major external surfaces are achieved by employing continuous external plates between which the separately formed regions 13 and 15 are sandwiched to form the compound LOE structure.
  • the compact image projector 20 is optically coupled with the LOE 12’ so as to inject image illumination into the LOE region 13 via the coupling prism 22 within which the image light is trapped (propagates) by internal reflection at the major external surfaces 14, 16.
  • the propagating image illumination (rays 24) impinges on the facets 17 in the region 13, with each successive facet deflecting a proportion of the image illumination into a deflected direction, also trapped/guided by internal reflection within the LOE 12’. This partial reflection at successive facets achieves a first dimension of optical aperture expansion.
  • the set of facets 17 in the region 13 are orthogonal to the major external surfaces 14, 16 of the LOE 12’.
  • the facets 18, whose orientation is such that the facets 18 are obliquely inclined relative to the major external surfaces 14, 16, progressively couple out a proportion of the image illumination 25 propagating within the LOE 12’ by internal reflection at the major external surfaces 14, 16 from the region 13 into the region 15, towards the eye of the observer located in the EMB 28, thereby achieving a second dimension of optical aperture expansion.
  • the coupled-out illumination is represented as rays 30.
  • the frame 102 is shown in the drawings as having a rectangular cross-section and as being formed from rectangular sidewalls, various sidewall arrangements and geometries can be used to construct the frame, including, for example, polygonal or non-polygonal side walls.
  • the frame is formed from curved sidewalls so that the frame has a non-polygonal cross-section in the plane of the paper.
  • the at least one optical element 104 is also obtained.
  • the at least one optical element 104 is implemented as a set (plurality) of planar partially-reflecting surfaces (referred to hereinafter as “facets”).
  • the facets 104 are preferably of equal size and dimension, and can be constructed from a base element, such as an optical plate, having a partially-reflecting coating applied thereto.
  • all of the facets are formed from a base element with a partially-reflecting coating applied to one side of the base element (referred to as one-side or single-side coated facets).
  • the optical performance of the optical device is largely dependent on properly arranging of the optical elements 104 according to the appropriate spatial configuration. In practice, misalignment of the optical elements may lead to decreased optical performance.
  • Various methods can be used to arrange the facets (or generally the optical element) 104 in the frame 102 according to the spatial configuration with high accuracy. According to certain embodiments of the present disclosure, a device is deployed to arrange the facets 104 according to the spatial configuration.
  • an optical element magazine can be used to temporarily store the optical element(s) in a temporary spatial configuration prior to placement in the frame 102, and the magazine can be positioned relative to the frame such that the optical element(s), when stored in the in the magazine, are relatively positioned in their final positions so that the optical element(s) can be quickly dumped into the frame in the correct spatial configuration.
  • FIG. 6 illustrates an embodiment that employs multiple facet magazines 160, each temporarily storing a set of facets 104 that are to be placed in corresponding frames.
  • a first of the frames 102a is complete (i.e., all of the facets 104a in the frame 102a are properly placed and bonded), a next one of the frames 102b is in progress of being filled by one of the facet magazines 160 (i.e., some of the facets 104b are properly placed and bonded), and a next one of the frames 102c is empty, awaiting filling from another one of the facet magazines 160.
  • LOEs which can be ID LOEs such the LOE illustrated in FIG. 1, as well as 2D LOEs such as the LOE illustrated in FIG. 2.
  • the spatial configuration of the facets in the frame can be chosen according to the type of LOE and the required position and orientation of the facets in the final LOE product.
  • the facets 104 should be placed in the frame 102 so that the orientation of the facets defined by the spatial configuration is such that the facets 104 are mutually parallel, and preferably such that the facets 104 are obliquely inclined to pair of parallel surfaces 114a and 114b or planes 103a and 103b between which the frame is located.
  • the facets 104 can be placed in the frame 102 so that the orientation of the facets defined by the spatial configuration is such that the facets 104 are mutually parallel, and optionally such that the facets 104 are obliquely inclined to the pair of parallel surfaces 114a and 114b or planes 103a and 103b or such that the facets 104 are perpendicular to the pair of parallel surfaces 114a and 114b or planes 103a and 103b.
  • a first set of the facets 104 (corresponding to the facets 18) can be arranged according to a first spatial configuration so that they are mutually parallel and are obliquely inclined relative to the pair of parallel surfaces 114a and 114b or planes 103a and 103b, and a second set of the facets 104 (corresponding to the facets 17) can be arranged according to a second spatial configuration so that they are mutually parallel and have an orientation (defined by the second spatial configuration) that is non-parallel to the orientation of the first set of facets.
  • each of the facets has an embedded material, that is internal to the facet, that is sensitive to at least one of an electric field or a magnetic field.
  • the embedded material can be, for example, a magnetic material, such as a ferromagnetic particle or particles, and a dielectric material.
  • the facet bulk material can be any optical material that exhibits partially reflective properties, such as, for example optical glue, glass, plastic, or polymer.
  • an amount of the embedded material 190 (implemented in the example as ferromagnetic material) is placed on a carrier plate, 192, which is preferably a flat plate.
  • a magnet (not shown) can be used to move the ferromagnetic material 190 to a requisite position on the carrier plate 192.
  • an amount of facet bulk material (represented in the figure as dotted region 194), for example optical glue, is placed on the carrier plate 192 such that the ferromagnetic material 190 is embedded within the bulk material 194, i.eix is internal to the bulk material 194.
  • facet bulk material represented in the figure as dotted region 194
  • optical glue for example optical glue
  • another flat plate 192a can be placed on top of the bulk material 194 so that the bulk material 194, with the ferromagnetic material 190 embedded therein, is sandwiched between the plates 192 and 192a.
  • the plates 192 and 192a can be pressed together, which can aid in flattening out the bulk material 194 to the desired thickness.
  • the bulk material 194 can be cured, for example via UV and/or heat curing (e.g., via a UV lamp and/or a heat lamp) so that the bulk material 194 solidifies / hardens.
  • FIG. 8D shows the bulk material post-curing, represented as cross-hatching 194’.
  • the top flat plate 192a can be removed, and then a portion of the cured material, having the ferromagnetic material 190 embedded therein, is removed from the carrier plate 192 to form facet 104, as shown in FIG. 8E.
  • the facet 104 can be trimmed down in size and/or dimension, as shown in FIG. 8F.
  • a coating layer or layers 195 for example a thin film coating (which can be a multi-layer coating) and/or one or more optical sheets (for example available from 3M), can be applied to the cured bulk material 194’, before or after removal from the carrier plate 192, and before or after trimming down the facet in size and/or dimension.
  • the coating layer(s) 195 can be partially-reflecting coating that provide the facet 104 with its partial reflectivity.
  • partial reflectivity of the facet can be effectuated by utilizing a high index or medium index optical glue as the facet bulk material 194’, and utilizing a lower index material (either a medium index material, or a low index material) as the LOE bulk material.
  • a high index material in a lower index bulk LOE material to affect facet partial reflectivity will be discussed in further detail below in the context of another embodiment, and with reference to FIGS. 13A and 13B.
  • FIGS. 8A - 8F can be expanded for larger-scale production of facets, as will now be discussed with reference to FIGS. 9A - 9F.
  • FIG. 9A multiple particles of ferromagnetic material 190 are placed on the carrier plate 192, and can be aligned and distributed to requisite positions via a magnet.
  • FIG. 9B shows the aligned ferromagnetic material 190 on the carrier plate 192.
  • FIG. 9C shows optical glue 194 (or other suitable partially-reflecting bulk material) placed on the carrier plate 192 such that the aligned ferromagnetic material 190 is embedded in the optical glue 194.
  • an amount of dielectric material can be embedded within the facet, in addition to, or instead of, ferromagnetic material.
  • the embedding can be achieved using the same or similar techniques described above for embedding ferromagnetic material.
  • the orientation of the embedded magnetic and/or dielectric material can be adjusted prior to curing of the bulk material.
  • the embodiments discussed above with reference to FIGS. 8A - 9E were described within the non-limiting example context of the facet bulk material being high refractive index or medium refractive index optical glue, embodiments in which other materials are used to form the facet bulk are contemplated herein, for example, embodiments in which high or medium refractive index glass, plastic, or polymer, are used to form the facet bulk.
  • the glass, plastic, or polymer material can be placed on the carrier plate 192 as a resin, and then cured to harden.
  • the facet material is index matched to the LOE bulk material and can be used for manipulating the optical coating(s) / optical sheets (e.g., from 3M) (that effectuates partial-reflectivity) to achieve the desired spatial orientation.
  • facets with embedded magnetic material and/or dielectric material can be produced using a frame structure.
  • an amount of magnetic material and/or dielectric material can be placed in a frame structure that is sized and dimensioned corresponding to the size and dimension of a single facet, or sized and dimensioned corresponding to the size and dimension of a plurality of adjoined facets (e.g., facets arranged side by side).
  • the frame structure can then be filled with a facet bulk material, for example, optical glue, glass resin, plastic resin, polymer resin.
  • the bulk material can then be cured to harden, and the facet structure, with embedded magnetic material and/or dielectric material can be removed from the frame.
  • the apparatus 200 includes a stage 202 that supports the frame 102, and a device 204 configured to produce controlled electric fields 206a and/or magnetic fields 206b of controllable magnitude.
  • the device 204 produces controlled electric fields 206a and/or magnetic fields 206b to controllably manipulate the position and orientation of the facet in three-dimensional space so as to place the facet in the frame 102 according to the requisite spatial configuration.
  • the device 204 typically includes a computerized control system, implemented, for example, as a computerized processor or controller coupled to a storage memory (e.g., memory), that controls the device 204 to produce the electric fields and/or magnetic fields.
  • control system can actuate the device 204 to produce the electric fields and/or magnetic fields and can vary the magnitude / strength of the produced electric fields and/or magnetic fields, for example by varying an applied voltage in time and space.
  • the placement of the facet in the frame 102 according to the requisite spatial configuration can be aided by the stage 202, which can be implemented as a moveable stage that is moveable along two or three axes of movement and preferably also tiltable about two or three tilt axes.
  • the device 204 and the stage 202 can have separate control systems, or more preferably a single control system can be used to control both the production of the electric fields and/or magnetic fields by the device 204 and the movement of the stage 202.
  • Various types of devices can be used to produce controlled electric fields and magnetic fields, including, for example, stepper motors, which are well-known in the art.
  • the injected resin can be allowed to solidify / harden, preferably using curing, for example via UV and/or heat curing (e.g., via a UV lamp and/or a heat lamp), to speed up the hardening process, thereby forming the bulk of the optical device.
  • curing for example via UV and/or heat curing (e.g., via a UV lamp and/or a heat lamp), to speed up the hardening process, thereby forming the bulk of the optical device.
  • the steps for fabricating optical devices have generally included placing fabricated facets (or other optical elements) in a frame structure at a prescribed position and orientation (spatial configuration), bonding the facets to the frame, and then adding a bulk material (e.g., low or high T g material resin) to the frame.
  • a bulk material e.g., low or high T g material resin
  • the bulk portion of the optical device is preconstructed, preferably as a single piece, and has defined openings configured for receiving optical elements (e.g., facets, etc.), and the optical elements (e.g., facets, etc.) are placed in the openings and bonded to the bulk portion. Embodiments of such methods will now be described, with reference to FIGS. 11A - 11D.
  • the openings 304a, 304b are hollow openings that extend between opposite faces (sides) of the block 302 (only one face 308 is shown in the drawings).
  • the openings can be slits, slots, channels, or hollow grooves, formed in the block 302.
  • the facets 104a, 104b can be manufactured, for example, using any of the techniques previously described, or any other suitable technique.
  • all of the facets 104a, 104b are formed from transparent plates, each coated on one side with a partially- reflecting coating (i.e., single-side coated facets).
  • some of the facets 104a, 104b are double-side coated facets and some of the facets 104a, 104b are un-coated facets.
  • the optical device being fabricated is a 2D FOE having two sets of facets, where the facets of a set are mutually parallel but the two sets of facets have non-parallel orientations.
  • the block 302 has a first set of parallel openings 304a for receiving a first set of facets 104a, and has a second set of parallel openings 304b, non-parallel to the openings 304a, for receiving a second set of facets 104b.
  • FIGS. 12A - 12C there is illustrated a method for fabricating an LOE according to another embodiment of the present disclosure in which a set of facets is inserted into appropriate places between two similarly shaped and dimensioned optical structures, which are bonded together.
  • a first optical structure 402a has a sawtooth configuration that defines a set of surfaces 406a.
  • Each surface 406a has a spatial configuration that defines a position of the surface 406a in the optical structure 402a and an orientation of the surface 406a relative to an external face of the optical structure 402a, for example face 404.
  • the surfaces 406a are configured to receive a corresponding set of facets 104, which can be bonded to the surfaces 406a. Once the facets 104 are placed on the corresponding surfaces 406a, the facets 104 assume the spatial configuration of the surfaces 406a. As illustrated in FIG. 12C, a second optical structure 402b, that is generally similar to the optical structure 402a, is then mated with the first optical structure 402a, and the two optical structures 402a and 402b are bonded together to form a bonded structure 408 having the facets 104 embedded therein.
  • the facets 104 can be constructed from a high index material, and the optical structures 402a and 402b can be constructed from a low or medium index optical material.
  • the facets 104 can be single-side coated facets, whereas in other embodiments a first set of the facets can be double-side coated facets and a second set of the facets can be un-coated facets, and the first and second sets of facets are arranged in an alternating configuration, similar to as discussed previously.
  • FIGS. 13A and 13B there is illustrated a method for fabricating an LOE according to another embodiment of the present disclosure.
  • the partially reflecting layers (i.e., facets) of the LOE are implemented by a high index optical adhesive embedded within a low index transparent optical material, such as low index glass or low index plastic.
  • a plurality of optical plates 502 are obtained, each having a pair of parallel major external surfaces 503a, 503b.
  • the optical plates 502 are bonded together to form a bonded stack 500.
  • the optical plates 502 are bonded together by providing one or more layers of optical adhesive 504 between adjacent plates 502.
  • the partially reflecting layers can be formed from a high index optical adhesive, similar to the embodiment described above with reference to FIGS. 13A and 13B, but in contrast to the above-described embodiment the LOE bulk material can be formed from a low index optical adhesive instead of optical plates.
  • both the low index and high index adhesives can be injected into molds.
  • the low index adhesive can be injected into a first set of molds that can correspond in form to the optical plates 502 of FIGS. 13A and 13B
  • the high index adhesive can be injected into a second set of molds situated between adjacent molds of the first set of molds.
  • a moveable stage (that is moveable along two or three axes of movement and preferably also tiltable about two or three tilt axes) can be used in the injection process in order to situate the molds in the correct position relative to the adhesive injectors.
  • a UV source having one or more focused lasers can be used to cure the adhesives, providing higher resolution during the curing process.
  • the materials can be deposited onto a carrier plate that is placed on a moveable stage, or can be deposited directly onto the moveable stage itself, wherein the moveable stage is moveable along two or three axes of movement and preferably also tiltable about two or three tilt axes.
  • the fabrication process can employ cycles of material placement (e.g., low index bulk and/or high index facet deposition), curing (e.g., UV / heat curing), cleaning or washing of residue materials (e.g., non-condensed portions of the high or low index materials), and drying.
  • the stage can be moved (for example via a control system) to orient the stage (and hence the LOE under construction) in the proper orientation so that the facets assume the proper spatial configuration.
  • the curing process can employ a UV source having one or more focused lasers for curing the low index and high index materials, to provide higher resolution during the curing process.
  • the LOE can be fabricated by building up the LOE bulk via deposition of optical bulk material and deposition of optical materials as resin in thin layers in the LOE bulk material. The deposited thin layers of optical material within the LOE bulk material mimic the optical behavior of thin film multi-layer partial reflective coatings in conventional LOE fabrication.
  • the optical materials have different refractive indices and are deposited in thin layers (preferably on the sub micrometer scale, e.g., layer thickness below 10 nanometers and more preferably below 5 nanometers, but can also reach thickness of 1-2 microns or more) on or in the bulk material, one on top of the other, to achieve partial reflective functionality.
  • the LOE bulk is partially built-up by depositing multiple layers of optical bulk material (having a refractive index, for example 1.5) on a carrier plate placed on the moveable stage or directly on the moveable stage.
  • a first thin layer of a first optical material e.g., optical glue
  • a first refractive index e.g., 1.34
  • a second thin layer of a second optical material e.g., optical glue
  • a second refractive index e.g., 1.6
  • the low/high layers (1.34/1.6) can iterate to fulfill the optical requirements or for example other refractive index can also iterate with a third layer of optical glue having a third refractive index (e.g., 1.5) deposited on the second thin layer, and a fourth layer of optical glue having a fourth refractive index (e.g., 1.7) deposited on the third thin layer.
  • the optical material can be cured and then cleaned or washed (as discussed above).
  • the moveable stage can be controllably moved to orient the stage (and hence the LOE under construction) in the proper orientation so that the thin layers (which together become a facet) assume the proper spatial configuration. This multiple thin layer and bulk material deposition can be repeated as necessary for each facet and until the LOE is completely built-up.

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Abstract

Dispositif optique fabriqué en ayant recours à au moins un élément optique et d'un cadre. L'au moins un élément optique est disposé dans le cadre selon une configuration spatiale qui définit une position de l'au moins un élément optique dans le cadre et une orientation de l'au moins un élément optique par rapport au cadre. L'au moins un élément optique est lié au cadre pour fixer la configuration spatiale, et des régions du cadre inoccupées par l'au moins un élément optique sont remplies d'un matériau optique transparent.
PCT/IL2024/050577 2023-06-16 2024-06-10 Procédés de fabrication d'éléments optiques de conduit de lumière Pending WO2024257096A2 (fr)

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CA2960629C (fr) * 2017-03-14 2017-10-03 Lukas Ross Un dispositif d'eclairage de forme plate dote d'un module de fixation moule simple et methode associee
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