阅读说明：本技术 一种柔性近眼显示波导光机系统的制作方法 (Manufacturing method of flexible near-to-eye display waveguide optical-mechanical system ) 是由 梁海锋 焦新光 蔡长龙 张颖莉 于 2021-08-07 设计创作，主要内容包括：本发明公开了一种柔性近眼显示波导光机系统的制作方法,包括：波导片；所述波导片由波导基底、耦入区域和耦出区域构成；所述波导片的一侧斜面位置设置有所述耦入区域,在所述耦入区域设置有用于折光以及成像的第一折光区域和第二折光区域,将光线折转于所述第二折光区域内,将光线折转于所述波导片内部；所述波导片中部为传输区域,光线全反射于所述波导片内部,最终传输进入所述耦出区域；所述波导片的另一侧设置有用于二维扩瞳的所述耦出区域；该方法设计合理、解决了工业量产技术问题、可以采用模板压印和材料喷覆技术实现柔性波导片的制作；制作生成的波导片具有一定的延展性和弯曲性,增加了工作场所的灵活性。(The invention discloses a method for manufacturing a flexible near-to-eye display waveguide optical-mechanical system, which comprises the following steps: a waveguide sheet; the waveguide sheet is composed of a waveguide substrate, a coupling-in area and a coupling-out area; the coupling-in area is arranged at the inclined surface of one side of the waveguide sheet, a first refraction area and a second refraction area for refraction and imaging are arranged in the coupling-in area, light is refracted in the second refraction area, and the light is refracted in the waveguide sheet; the middle part of the waveguide sheet is a transmission area, and light is totally reflected inside the waveguide sheet and finally transmitted into the coupling-out area; the other side of the waveguide sheet is provided with the coupling-out region for the two-dimensional pupil expansion; the method has reasonable design, solves the technical problem of industrial mass production, and can realize the manufacture of the flexible waveguide sheet by adopting the template imprinting and material spraying technology; the produced waveguide slice has certain ductility and flexibility, and the flexibility of a workplace is increased.)

1. A method for manufacturing a flexible near-to-eye display waveguide optical-mechanical system is characterized by comprising the following steps:

a waveguide sheet (1); the waveguide sheet (1) is composed of a waveguide substrate (11), a coupling-in region (12) and a coupling-out region (13);

the coupling-in area (12) is arranged at the inclined surface of one side of the waveguide sheet (1), a first refraction area (2) and a second refraction area (3) for refraction and imaging are arranged in the coupling-in area (12), the first refraction area (2) is a semi-reflecting and semi-transparent system and is used for folding light rays into the second refraction area (3), and the second refraction area (3) is an imaging lens system and is used for folding light rays into the waveguide sheet (1);

the middle part of the waveguide sheet (1) is a transmission area, light is totally reflected inside the waveguide sheet (1) and finally transmitted into the coupling-out area (13);

the other side of the waveguide sheet (1) is provided with the coupling-out region (13) for the two-dimensional pupil expansion, and different materials can be adopted to coat each micromirror or carry out film system plating.

2. The method of claim 1, wherein the waveguide substrate (11) is made of a flexible material.

3. The method of claim 1, wherein the coupling-in region (12), the coupling-out region (13) and the waveguide sheet (1) are formed by photolithography, imprinting, and material coating/film coating.

4. The method for manufacturing the flexible near-to-eye display waveguide optical-mechanical system according to claim 1, wherein the method is applied to the system according to claim 1, and comprises the following steps:

step 1: firstly, establishing an optical-mechanical system meeting the requirement of a design index by applying optical design software, carrying out simulation analysis on the optical performance of the system, and finally determining the geometric parameters of the optical system by adjusting design parameters to obtain the structural size of the original optical-mechanical system;

step 2: applying a simulation flow module to establish optical, structural and thermal integrated coupling analysis for simulating working parameters of the structural template;

and step 3: processing the template by adopting a photoetching technology;

and 4, step 4: transferring the pattern by adopting a nano-imprinting process;

and 4, step 4: respectively spraying or depositing a film on each micromirror by adopting different materials for the micromirror pattern generated by imprinting to realize a specific film system structure;

and 5: and (5) filling materials to finish the manufacture of the flexible waveguide sheet.

5. The method as claimed in claim 4, wherein the flexible waveguide optical-mechanical system has a field angle of 30 ° (H:19 ° V:24 °), an eye movement range of 8mm x 8mm, and an exit pupil diameter of 13 mm.

Technical Field

The invention belongs to the field of Augmented Reality (AR) technology, and particularly relates to a design and manufacturing method of an optical-mechanical system based on a flexible optical waveguide.

Technical Field

In recent years, optical waveguide technology has been the core of the AR field, and has gained much attention due to its wide application prospect and visible technological breakthrough. The optical waveguide device is based on total reflection propagation of the whole optical field in the optical waveguide, and essentially corresponds to a transparent periscope with only one entrance pupil and can have a single or a plurality of exit pupils. The core of this is the arrangement of waveguide in and out couplers, which can be simple prisms, microprism arrays, embedded mirror arrays, surface relief gratings, holographic gratings, super-surface or spatial light modulators, but these methods have certain advantages and limitations.

In order to better serve users, the problems to be solved are as follows: 1. the traditional optical waveguide process is difficult in mass production, complex in process and expensive in product price; 2. the waveguide material is a glass substrate, so that the adaptability is poor, and the waveguide material does not have the bending regulation capability; 3. the size of the optical machine is too large, and the volume and the weight of the device need to be further reduced.

Disclosure of Invention

In view of this, the present invention provides a method for manufacturing a flexible near-eye display waveguide optical-mechanical system.

In order to solve the technical problems, the invention adopts the following technical scheme:

a method for manufacturing a flexible near-to-eye display waveguide optical-mechanical system is characterized by comprising the following steps: the waveguide sheet is composed of a waveguide substrate, a coupling-in area and a coupling-out area;

the coupling-in area is arranged at the inclined surface of one side of the waveguide sheet, a first light folding area and a second light folding area are arranged in the coupling-in area and used for folding light and imaging, the first light folding area is a semi-reflecting and semi-transparent system and used for folding light into the second light folding area, the second light folding area is an imaging lens system and used for folding light into the waveguide sheet, the middle of the waveguide sheet is a transmission area, the light is totally reflected into the waveguide sheet and finally transmitted into the coupling-out area; the other side of the waveguide sheet is provided with the coupling-out area for the two-dimensional pupil expansion, and different materials can be adopted to coat each micromirror or carry out film system coating;

preferably, the waveguide substrate is made of a flexible material.

Preferably, the coupling-in region, the coupling-out region and the waveguide plate are formed by photolithography, stamping, material spraying/film coating.

Preferably, the method for manufacturing the flexible near-eye display waveguide optical-mechanical system includes the following steps:

step 1: firstly, establishing an optical-mechanical system meeting the requirement of a design index by applying optical design software, carrying out simulation analysis on the optical performance of the system, and finally determining the geometric parameters of the optical system by adjusting design parameters to obtain the structural size of the original optical-mechanical system;

step 2: applying a simulation flow module to establish optical, structural and thermal integrated coupling analysis for simulating working parameters of the structural template;

and step 3: processing the template by adopting a photoetching technology;

and 4, step 4: transferring the pattern by adopting a nano-imprinting process;

and 4, step 4: respectively spraying or depositing a film on each micromirror by adopting different materials for the micromirror pattern generated by imprinting to realize a specific film system structure;

and 5: and (5) filling materials to finish the manufacture of the flexible waveguide sheet.

Preferably, the flexible waveguide sheet has a field angle of 30 ° (H:19 ° V:24 °), an eye movement range of 8mm × 8mm, and an exit pupil diameter of 13 mm.

Compared with the prior art, the invention has the following technical effects:

the invention combines the flexible spray coating technology and the graphic mask technology to realize the integration of the flexible AR optical machine on the same substrate. The integrated waveguide sheet has simple manufacturing process and high yield, can be matched with pixels of a display to form a flexible AR optical machine system, and can be widely applied to near-to-eye display. The flexible near-eye display optical-mechanical system has the advantages that: the process difficulty and the yield are greatly improved compared with the traditional beveling type waveguide plate by adopting an embossing method; the material is a flexible material and has a certain bending degree; a plurality of film series channels can be formed in a micro area by adopting a spraying and coating method to form a large visual field pupil of the human eye.

Drawings

Fig. 1 is a schematic view of a waveguide structure of a method for manufacturing a flexible near-eye display waveguide optical-mechanical system according to the present invention.

Fig. 2 is a schematic diagram of nanoimprint lithography for a method of manufacturing a flexible near-to-eye display waveguide optical-mechanical system according to the present invention.

Fig. 3 is a schematic view of the reflective layer processing of the method for manufacturing the flexible near-eye display waveguide optical-mechanical system according to the present invention.

Fig. 4 is a schematic diagram of a gluing tool of a manufacturing method of a flexible near-to-eye display waveguide optical-mechanical system according to the present invention.

Fig. 5 is an inventive schematic diagram of a method for manufacturing a flexible near-eye display waveguide optical-mechanical system according to the present invention.

In the figure: 1. a waveguide sheet; 2. a first light refraction area; 3. a second light-folding area; 11. a waveguide substrate; 12. a coupling-in region; 13. a coupling-out region.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

Example 1:

referring to fig. 1-5, the invention discloses a method for manufacturing a flexible near-eye display waveguide optical-mechanical system, which improves the existing AR optical waveguide manufacturing technology and provides a design and manufacturing scheme of a near-eye display waveguide optical-mechanical system based on flexibility, thereby reducing the process difficulty of manufacturing and processing. The waveguide sheet 1 is composed of a waveguide substrate 11, an incoupling region 12 and an outcoupling region 13, the waveguide sheet 1 may be polymethyl methacrylate (PDMS) with specific configuration or a flexible material prepared and generated to meet design requirements, and the waveguide sheet 1 may be formed by photolithography, imprinting and spray coating.

As shown in fig. 1, the coupling-in region 12 is responsible for coupling light into the waveguide and is shaped as a 10mm 5.05mm 4.24mm half-mirror and a spherical mirror with R-62.66

As shown in fig. 1, the waveguide region is responsible for transmitting light into the out-coupling 13 region, which is a 10mm x 3mm triangular prism and a 30mm x 57mm x 2mm rectangular waveguide substrate 11.

As shown in fig. 1, the coupling-out 13 region is responsible for the light pupil at the human eye, and has the shape: 3mm 30mm 1.4mm inclination 32.4 degree equispaced micro-mirror, which is coated with anisotropic material layer or different reflectivity film layer.

As shown in fig. 2, a template complementary to the waveguide plate is prepared, and PDMS is used to perform nanoimprint and pattern transfer on the template to prepare the primary waveguide structure.

As shown in fig. 3, each micromirror structure is individually coated with a different material.

The imprint pattern is filled with PDMS and the incoupling 12 portion is glued to the other side of the waveguide as shown in fig. 4.

As shown in fig. 5, which is a schematic diagram of the present invention, the light emitted from the OLED microdisplay is transmitted through the flexible waveguide sheet, and then the final expanded pupil is imaged on the human eye.

The above description is only a preferred embodiment of the present invention, and is not intended to limit the technical scope of the present invention, so that any minor modifications, equivalent changes and decorations made on the above embodiment according to the technical spirit of the present invention are still within the technical scope of the present invention.