Method of making a self-aligned light guide screen

Provided is a method of making a self-aligned light guide screen. More specifically, in a particular embodiment, fabrication may commence by providing a first ribbon section of light guides with at least one self alignment feature. A second ribbon section of light guides is provided with at least one self alignment feature configured to mate with the at least one self alignment feature of the first ribbon section. The ribbon sections are then stacked, the alignment features aligning the first and second ribbon sections.

RELATED APPLICATION

This application is related to commonly owned U.S. patent application Ser. No. 10/698,829, filed on Oct. 31, 2003 by inventors Huei Pei Kuo, Lawrence M. Hubby, Jr. and Steven L. Naberhuis and entitled “Light Guide Apparatus For Use In Rear Projection Display Environments”, herein incorporated by reference.

FIELD

This invention relates generally to the field of display devices and, in particular, to an improved method of making a self-aligned light guide screen.

BACKGROUND

Socially and professionally, most people rely upon video displays in one form or another for at least a portion of their work and/or recreation. With a growing demand for large screens and high definition television (HDTV), cathode ray tubes (CRTs) have largely given way to displays composed of liquid crystal devices (LCDs), plasma display panels (PDPs), and front and rear projection systems.

A CRT operates by scanning electron beam(s) that excite phosphor materials on the back side of a transparent screen, wherein the intensity of each pixel is commonly tied to the intensity of the electron beam. With a PDP, each pixel is an individual light-emitting device capable of generating its own light. With an LCD, each pixel is a transient light-emitting device, individually adjusted to permit light to shine through the pixel.

As neither system utilizes a large tube, LCD and PDP screens may be quite thin and often are lighter than comparable CRT displays. However, the manufacturing process for LCDs, PDPs, and most other flat panel displays is much more complex and intensive with respect to both equipment and materials than that of CRTs, typically resulting in higher selling prices.

Projection systems offer alternatives to PDP and LCD based systems. In many cases, projection display systems are less expensive than comparably sized PDP or LCD display systems. With a front projection system, the image is projected onto a screen from the same side as the viewer. If the viewer stands, sits or otherwise blocks the projection the image will be compromised. Front projection systems are therefore often suspended from the ceiling or mounted high upon a rear wall.

To accommodate the projector, one or more lenses, and reflectors, rear projection displays are typically 18 to 20 inches deep and not suitable for on-wall mounting. A typical rear projection system offering a 55-inch HDTV screen may weigh less than a comparable CRT, but at 200+ pounds it may be difficult and awkward to install and support.

Often, rear projection display devices exhibit average or below-average picture quality in certain environments. For example, rear projection displays may be difficult to see when viewed from particular angles within a room setting or when light varies within the environment. Aside from a theatrical setting, light output and contrast are constant issues in most settings and viewing environments.

Despite advancements in projectors and enhanced lens elements, the lens and reflector design remains generally unchanged and tends to be a limiting factor in both picture quality and overall display system thickness.

A developing variation of rear projection displays utilizes light guides, such as optical fibers, to route an image from an input location to an output location, and magnify the image. However, in certain configurations, light guide screens may lose a percentage of light and, thus, the brightness of the image, by permitting the light to venture off in directions other than substantially towards the viewing audience. This loss of light may in some instances amount to fifty percent (50%) of the light provided to the input ends of the light guides.

In addition, in some configurations, the viewing angle of the complete screen may be limited to the angular range corresponding to the acceptance angle of the light guides used in construction of the screen. With respect to light guides, the acceptance angle is the half-angle of the cone within which incident light is totally internally reflected by the fiber core. Further, this range of viewing angles may not be out in front of the screen, but may be more heavily concentrated to the right, left, top or bottom, depending on the direction the light guides approach the screen from behind.

Weight, thickness, durability, cost, aesthetic appearance, and quality are key considerations for rear projection display systems and display screens. As such, there is a need for some device to reduce this loss of light that is likely with a light guide screen.

Hence, there is a need for a fiber optic rear projection display device that overcomes one or more of the drawbacks identified above. And there is a need for a technique for fabricating this type of device.

SUMMARY

This invention provides a method of making a light guide screen.

In particular, and by way of example only, according to an embodiment of the present invention, this invention provides a method of making a self-aligned light guide screen including: providing a first ribbon section of light guides with at least one self alignment feature; providing a second ribbon section of light guides with at least one self alignment feature configured to mate with the at least one self alignment feature of the first ribbon section; and stacking the first and second ribbon sections, the alignment features aligning the first and second ribbon section.

DETAILED DESCRIPTION

Before proceeding with the detailed description, it is to be appreciated that the present teaching is by way of example, not by limitation. The concepts herein are not limited to use or application with a specific fiber optic rear projection display system. Thus, although the instrumentalities described herein are for the convenience of explanation, shown and described with respect to exemplary embodiments, it will be appreciated that the principles herein may be applied equally in other types fiber optic rear projection display systems.

Referring now to the drawings, the provided figures conceptually illustrate a method for making a self-aligned light guide screen. It will be appreciated that the described process need not be performed in the order in which it is herein described, but that this description is merely exemplary of one preferred process of one preferred method of making a self-aligned light guide screen100.

To facilitate the description and inter-relation between figures, a coordinate system with three axes orthogonal to one another is provided as shown inFIGS. 1-7and9-12. The axes intersect mutually at the origin of the coordinate system which is intended to be the center of the via LGS100. The axes in all figures are offset from their actual locations for clarity of illustration. Moreover,FIG. 1is are understood to be a plan view of the LGS100according to the XZ-plane, and method of fabrication depicted inFIGS. 2-6and9is rendered according to the YX-plane, with the stacking of fabricated ribbon sections inFIGS. 10 and 11rendered according to the ZY-plane.FIG. 12is again rendered according to the YX-plane with the indicated enlarged areas rendered generally in accordance with the ZY-plane.

InFIG. 1there is shown a portion of a light guide screen (LGS)100. In at least one embodiment wherein the light guides are optical fibers, LGS100may also be referred to as a fiber optic rear projection display. In at least one embodiment LGS100has a plurality of aligned magnifying layers102providing a viewing surface104. Specifically, the magnifying layers102each provide an input location106, a magnifying output location108, and a flexible midsection110.

To effectively establish the viewing surface104it is important that the magnifying layers102be properly aligned. More specifically, and as further discussed below, the input locations106should be properly aligned and the magnifying output locations108should be properly aligned. If either or both are misaligned with respect to each other, it is likely that the resulting image upon the viewing surface104will be distorted and/or even unacceptable to viewers. In addition, in at least one embodiment, it is desirable for the magnifying layers102to be substantially similar.

With respect to an overview of the method of making as illustrated inFIGS. 2 through 9, in at least one embodiment the method of making a self-aligned LGS100includes providing a first ribbon section of light guides with at least one alignment feature and providing a second ribbon section of light guides with at least one alignment feature configured to mate with at least one alignment feature of the first ribbon section. The ribbon sections are stacked, the alignment features aligning the first and second ribbon sections.

More specifically, and with respect to the flowchart ofFIG. 14, in at least one embodiment, the method of making a self-aligned LGS100includes providing a first ribbon section with an input end and an output end, and at least one physical alignment feature disposed adjacent to each end, block1400. A second ribbon section with an input end and an output end, and at least one physical alignment feature disposed adjacent to each end is also provided, block1402.

The at least one physical alignment feature adjacent to the output end of the second ribbon section is configured to mate with the at least one physical alignment feature adjacent to the output end of the first ribbon section. The ribbon sections are stacked, block1404. The alignment features align the first and second ribbon sections, block1406,1408. The alignment process has been illustrated as a parallel operation. Indeed, the process of providing each ribbon section may also be performed in parallel. So as to provide an LGS100having more than two ribbon sections, the process is repeated, decision1410until an appropriate number of ribbon sections have been provided and stacked.

It will be understood and appreciated that a variety of different fabrication methods may be employed. For example, a sufficient number of ribbon sections may be fabricated before stacking commences, or ribbon sections may be fabricated and stacked in an alternating process. Multiple ribbon sections may be fabricated and then stacked before another multiple set of sections is provided.

As shown inFIG. 2, in at least one embodiment the fabrication process may be commenced by providing a ribbon200of individual light guides202. The ribbon may be pre-fabricated, or assembled by drawing multiple light guides202together from one or more light guide storage devices, such as spools206. If drawn from a continuous source such as spool206. It is understood and appreciated that the light guides202are cut to some operator determined length. The light guides may also be provided by a light guide provider such as, for example, a polymer extrusion apparatus. Preferably, the ribbon is one light guide202thick. The number of light guides202placed side by side to establish ribbon200is a matter of desired screen resolution. Although, spool206is illustrated as supplying a single light guide202. It is understood and appreciated that in at least one embodiment, spool206provides multiple light guides202as a ribbon, and that in at least one embodiment, this spool provided ribbon, when cut is ribbon200.

With respect to the summary overviews provided above, in one embodiment, the ribbon sections are fabricated in pairs from sections of ribbon200. In at least one alternative embodiment, the ribbon sections are fabricated in sequence directly from the ribbon200. Each of these embodiments will now be discussed.

FIGS. 3˜6illustrate the processing steps in one embodiment where the ribbon sections are fabricated in pairs from section of ribbon200. WhereasFIG. 2shows the ribbon200being formed from light guides202drawn from one or more spools206, ribbon200may also be provided as a continuous ribbon from a continuous source. In at least one embodiment, the continuous source is a one or more supply spools208, seeFIG. 2. Other continuous sources, such as, but not limited to, an extrusion system or embossing system may also be used. As shown inFIG. 3, ribbon200has a first end204. If ribbon200is being provided as a continuous ribbon from one or more supply spools, a second end300, opposite from the first end204is established at a predetermined distance from the first end204.

An appropriate bonding agent such as, for example, glue302, is applied to the first end204to create bonded first end306. Specifically, the glue302is applied in a sufficient quantity to bind the light guides202together with a final thickness about the same as an individual light guide202. In at least one embodiment, glue302is not run continuously over the ribbon200from first end204to second end300; rather, it is applied over an area proximate to the first end204sufficient to establish at least one self alignment feature.

In a similar process, a bonding agent such as, for example, glue304, is applied to the second end300to create bonded second end308. Specifically, the glue304is applied in a sufficient quantity to bind the light guides202together to form a bonded total thickness about the same as an individual light guide. Substantially matching the first end204, glue302is applied over an area proximate to the second end300sufficient to establish at least one alignment feature. In at least one embodiment, in addition to glues302and304, a thin layer of material (not shown) may be bonded over the first and second ends204,300. As is appreciated with respect to the figures, the ribbon200lies in a plane, e.g. the YX-plane as shown. The light guides of the ribbon define a perimeter310. This perimeter310extends perpendicularly from the plane of the ribbon200.

As shown inFIG. 4, ribbon200has a longitudinal centerline400. To establish a device for vertical alignment and curtail the chance for rotation about longitudinal centerline400, in at least one embodiment, the alignment features may be referred to as alignment guides402,404provided in both first end204and second end300, respectively. More specifically, as shown inFIG. 4, two alignment holes402A,402B are established on opposing sides of centerline400in bonded first end306.

A matching set of alignment holes404A,404B are established in bonded second end308. As shown and described in further detail below, in at least one embodiment, alignment holes402A,402B,404A,404B are rectangular. Although illustrated as holes, alignment guides may be holes, mating bumps and dimples, and combinations thereof. In addition, alignment holes402A,402B need not be the same size and shape. It is also appreciated that alignment holes402A,402B,404A and404B are within the perimeter310of the ribbon200.

Between first end204and second end300is ribbon midsection500, as shown inFIG. 5. Although the plurality of light guides202need not be bonded together continuously from first end204to second end300, at least a section of the light guides202between first end204and second end300are bonded together with an appropriate bonding agent such as, for example, glue, to establish a bonded area, identified as bonded midsection502.

The bonded midsection502provides at least one self alignment feature. More specifically, the bonded midsection502provides at least one physical alignment feature506. Further, in at least one embodiment, physical alignment features506are provided on the top and bottom of bonded midsection502. It is understood and appreciated that bonded midsection502may exist equally disposed between first end204and second end300, or it may be disposed closer to one end or the other.

In at least one embodiment, at least one spacer is also bonded across the same area of bonded midsection502. AsFIG. 5provides a top view, a first bonded spacer504is shown. First spacer504may be bonded at an angle other than perpendicular to longitudinal centerline400. To limit waste, reduce excess material and reduce weight, in at least one embodiment, first spacer504is an appropriately sized and shaped parallelogram across bonded midsection502.

In at least one preferred embodiment, a second spacer (not shown inFIG. 5; seeFIG. 11for second spacer1100) of substantially the same shape as first spacer504is bonded to the ribbon midsection502opposite from and in alignment with first spacer504. In other words, first spacer504may be considered a top spacer and second spacer1100may be considered a bottom spacer. Together, first spacer504, second spacer1100and ribbon200provide a bonded stack. In an alternative embodiment, the bottom spacer may be omitted.

As shown inFIG. 5, first spacer504provides at least one physical alignment feature506. In at least one embodiment, first spacer504provides four physical alignment features506A,506B,506C,506D, symmetrically located. Paralleling first spacer504, second spacer1100provides at least one physical alignment feature1102, as well. As shown inFIG. 11, the alignment features1102of second spacer1100are configured to mate with alignment features506. More specifically, alignment features1102are appropriately sized to mate with physical alignment features506. Further, in at least one embodiment, the physical mating alignment features506,1102are self locking.

As shown inFIG. 5, physical alignment features506are disposed upon ribbon200and spacer504is sized to lie flush to the edges of ribbon200. In at least one embodiment, spacer504may extend beyond the edges of ribbon200. Further still, alignment features506may be disposed upon the extended ends of spacer504such that alignment features506are not directly above light guides202.

As shown inFIG. 6, ribbon200is severed through the bonded midsection502, and at least one spacer (top spacer504shown) relative to longitudinal centerline400. So as to provide a magnification property, further discussed below, in at least one embodiment, ribbon200is severed at an angle acute to the longitudinal centerline400. In an alternative embodiment ribbon200is severed at an angle substantially transverse to longitudinal centerline400. Moreover, ribbon200is cut at an angle of between about zero (0) and ninety (90) degrees relative to the longitudinal centerline.

A cut at other than 90 degrees establishes an output end for each light guide202that is angled. The output ends for each light guide202may not require further cleaning or polishing.

Further, this cutting establishes two ribbon sections602A,602B. In addition, this cut divides first spacer504in two, with one half remaining on each ribbon section602A,602B. For ribbon section602A, this is identified as top spacer620A, and for ribbon section602B this is identified as top spacer620B. Likewise bottom spacer (not shown) is also divided in two with one half remaining on each ribbon section602A and602B respectively. As shown, it is understood and appreciated that physical alignment features506remaining are within the perimeter defined by the light guides of each ribbon section, e.g. alignment features506A and506B are within the perimeter310A of light guide ribbon section602A and alignment features506C and506D are within the perimeter310B of the light guide ribbon section602B.

In an embodiment where a single physical alignment feature is provided, cutting ribbon200will divide the at least one physical alignment feature as well. As is illustrated in the accompanying figures, it may be preferred to provide a plurality of physical alignment features symmetrically disposed to the intended cut line through the bonded midsection502. The provided self alignment features are configured such that when the bonded area is cut and the alignment features thus divided, the at least one alignment feature remaining on one side of the cut (i.e. ribbon section602A) will mate with the at least one alignment feature remaining on the other side of the cut (i.e., ribbon section602B).

Ribbon section602A has alignment holes402A,402B proximate to input end604A, and physical alignment features506A,506B proximate to output end606A. The input end604A may be considered the first end and the output end606A may be considered the second end. Ribbon section602B has alignment holes404A,404B proximate to input end604B, and physical alignment features506C,506D proximate to output end606B.

In at least one embodiment, flexible midsections110A,110B exist between respective input ends604A,604B and output ends606A,606B of ribbon sections606A,606B. Moreover, in at least one embodiment ribbon section602B is a substantially identical twin of ribbon section602A, rotated one-hundred-eighty degrees. In at least one alternative embodiment, while the input ends604A,604B and output ends606A,606B are substantially identical, the length of each ribbon's midsection110A,110B may be different. As the ribbon sections602A,602B are to be stacked, varying the lengths of the midsection110A,110B may be preferred so as to eliminate the bunching of excess material and/or facilitate the ease of the stacking process.

With respect to the above described activities, it is a matter of fabrication preference whether the activities are combined. More specifically, the light guides of the ribbon may be bonded and cut in substantially contemporaneous operations. Providing the alignment holes404A,404B and severing the ribbon through the bonded midsection502may also occur as substantially contemporaneous operations.

In at least one embodiment, the light guides202are cladded optical fibers, each substantially identical and having a round cross-section. It is understood and appreciated that the clad is made of a material with a lower index of refraction than the core.FIG. 7is an enlarged cross-section of a single optical fiber700as used in ribbon sections602A,602B.

Each optical fiber700has a longitudinal light guide core702and an external circumferential cladding704. In at least one alternative embodiment, optical fibers202may have cross-sections relating to a square, triangle, octagon or other polygon. In such instances where alternatively shaped optical fibers202are employed, the term diameter may be inapplicable, and terms such as, for example, vertical cross distance and horizontal cross distance may be used.

It is of course realized that optical fiber700may bend, coil or otherwise contour such that longitudinal centerline706is not always a straight line. Optical fiber700is shown with core702symmetric about longitudinal centerline706for ease of discussion and illustration.

In at least one embodiment, output end708is angled relative to longitudinal core702, at angle710. In at least one embodiment, the input end718of optical fiber700will be perpendicular to the longitudinal core702. As such, the horizontal width of input end718is not as great as the horizontal width of output end708. In the embodiment shown, input end718is substantially circular, illustrated by cross-section712, while the output end708is substantially elliptical, illustrated by cross-section714.

In at least one embodiment, the magnification quality of magnifying output end708is about a factor of ten over the input end718. More specifically, the acute angle for cutting is pre-determined to provide a known magnification property to the output end of each ribbon section.

In at least one embodiment, the core702is formed of a generally optically clear plastic or plastic-type material, including but not limited to a plastic such as acrylic, Plexiglas, polycarbonate material and combinations thereof. The material used to construct the core702may or may not be polarized, as the presence or absence of polarization may benefit particular embodiments.

In at least one embodiment, each optical fiber700is preferably substantially totally internally reflecting such that the light, illustrated as lines716, received at the input end718within a maximum divergence angle is substantially delivered to the magnifying output end708with minimal loss. Cladding704is a material having a refraction index lower then that of the core702. Total internal reflection, or TIR, is the reflection of all incident light off the interface of the core and the clad. This interface may also be referred to as the boundary. TIR only occurs when a light ray impinges upon the boundary from the medium and the angle of incidence for the light ray is greater than the “critical angle.” The angle is measured with respect to the normal of the boundary surface between the core and the clad.

The critical angle is defined as a the angle of incidence which provides an exit angle of refraction of 90 degrees when the light impinges on the boundary from the side of the denser medium (side with the higher index of refraction). For any angle of incidence greater than the critical angle, the light traveling through the denser medium (medium with a higher index of refraction) will undergo total internal refraction. The value of the critical angle depends upon the combination of materials present on each side of the boundary.

As the input/output ends of ribbon section602B are substantially identical to those of ribbon section602A, the ribbon sections may be similarly oriented and stacked. As the ribbon sections may be cut at various locations, ribbon sections of different lengths may be selected to fit different sections of the screen.

FIG. 8is a conceptual representation of alignment issues. For simplicity of illustration and discussion, with respect toFIG. 8, the four sets800A,800B,800C,800D of ribbon sections do not show spacers, cladding, bonding materials or the self alignment features discussed above. In addition, whereas the above figures illustrate the ribbon sections as flat and unbent, in the perspective views ofFIG. 8, the ribbon sections are shown bent so as to show the relative effect of alignment issues between input ends808and magnifying output ends810.

Set800A includes stacked ribbon sections802A,804A,806A. Set800B includes stacked ribbon sections802B,804B,806B. Set800C includes stacked ribbon sections802C,804C,806C. Set800D includes stacked ribbon sections802D,804D,806D. Each set800A˜D has an input end808A˜D, and a magnifying output end810A˜D, respectively. Image source820provides the same image to the input end808A˜D of each set800A˜D.

As shown for set800A, proper alignment at input end808A yields proper alignment of the image at output end810A. Set800B illustrates misalignment of input end808B and the corresponding misalignment of the image at output end810B. Set800C illustrates image misalignment at output810C despite proper alignment at input end808C. Set800D illustrates image alignment as input ends800D and output ends810D have matching misalignment. Moreover, if either or both the input ends808and output ends810are misaligned with respect to each other, it is likely that the resulting image will be distorted.

As shown inFIG. 9, in at least one embodiment, input ends604A,604B are aligned with the use of alignment pins900A,900B,900C. More specifically, ribbon section602A is positioned such that alignment pins900A,900B pass through alignment hole402A and alignment pin900C passes through alignment hole402B.

In at least one embodiment, alignment holes402A,402B,404A,404B are rectangular and alignment pins900A˜C are substantially cylindrical and substantially identical. As shown, the diameter of each alignment pin900A˜C is about the same as the width of rectangular alignment holes402A,402B.

The length of rectangular alignment holes402A,402B is greater than the combined diameters of alignment pins900A,900B; as such, it is possible for ribbon section602A to slide in the direction along longitudinal centerline400. This accommodates the slight differences in the length of the ribbons602A and602B due to, e.g. manufacturing tolerances. The use of three alignment pins900A˜C substantially prevents the ribbon section602A from rotating about longitudinal centerline400.

Ribbon section602B is then positioned such that alignment pins900A,900B pass through alignment hole404A and alignment pin900C passes through alignment hole404B. Ribbon section602B may move along the centerline400relative to ribbon section602A; however, the light guides comprising each ribbon section will remain aligned in the direction perpendicular to centerline400. In at least one preferred embodiment, the output ends are self-aligned by interlocking alignment features506and1102as shown inFIG. 11and described in more details below.

It is understood and appreciated that in at least one embodiment, a plurality of first and second ribbon sections602A,602B are made prior to stacking the ribbon sections. As stated above, although first and second ribbon sections602A,602B have substantially identical input ends604and output ends606, the length of each ribbon midsection may be different to facilitate stacking, as different sections of the LGS screen accommodate different lengths of ribbons. For fabrication simplification, it may be desirable to provide all of the ribbon sections602before commencing with the stacking procedure, so as to efficiently arrange the varying lengths of first and second ribbon sections602A,602B.

FIG. 10provides an end view of the input ends604A,604B,604C for three ribbon sections602A,602B,602C vertically aligned by alignment pins900A˜C. Alignment pin900B is not shown as it is in line with alignment pin900A. The location of glue302binding light guides202together is also shown. For each light guide, core702and cladding704are illustrated.

FIG. 11is a partial cross-section end view of three stacked ribbon sections (602A,602B,602C) and one additional ribbon section602D being added. The end view of each ribbon section is along dashed line910imposed upon ribbon section602A running parallel to aligned output ends606B in the bottom most illustration ofFIG. 9. As shown, physical alignment feature506C on the top spacer620C of ribbon section602C is pre-positioned and aligned to mate with corresponding alignment feature1102D provided on the bottom spacer1100D of ribbon section602D.

In at least one preferred embodiment, physical alignment feature506is a symmetrically convex bump. Bottom spacer1100A provides a mating concave dimple as physical alignment feature1102. Under appropriate circumstances, alternative physical alignment features may be preferred, such as, for example, a rectangle or asymmetrical polygon. A hole structure may also be provided to receive a protruding mating structure. In addition, the physical alignment features (specifically the protruding structures) may extend beyond a single layer in height. It is of course realized that holes or structures which intrude upon the light guides202of the layers will be removed in a subsequent fabrication step.

As shown, top spacer620B mates with bottom spacer1100C, and top spacer620A mates with bottom spacer1100B. In addition, in at least one embodiment, the output ends606of light guides202are in substantially contiguous parallel contact. It is understood and appreciated that the light guides are cladded light guides. In other words, it is understood and appreciated that the light guide cores are not in contact with one another; rather, it is the cladded outer surfaces that are in contact.

FIG. 11depicts more clearly the bonding agent1116(such as glue, for example) that bonds light guides202, top spacer620and bottom spacer1100of each layer together. For illustrative purposes, light guides202are represented as optical fibers. As shown, optical fiber1104is in intimate contact with optical fiber1106, lying to the left, and optical fiber1108, lying to the right. In other words, in at least one embodiment, the output ends606of individual light guides lie next to one another and are in actual contact, touching along their outer surfaces at a point. Physical alignment features506,1102ensure desired alignment between output ends606of each stacked ribbon section602. Bump and dimple alignment features506,1102may be preferred in certain embodiments as they may be easily fabricated and promote rapid alignment during fabrication.

Moreover, by establishing alignment holes402A,402B,404A,404B and alignment features506A˜C and1102A˜C through automated fabrication processes, significant consistency and tolerance factors may be advantageously maintained. As each light guide202may be verified for integrity before significant fabrication processing commences, the number of defective LGS100components may be significantly reduced.

As ribbon sections602are stacked to provide LGS100, the magnifying output ends606are bonded together with a suitable bonding agent such as, glue. Likewise, input ends604, shown inFIG. 10, are also bonded together with a suitable bonding agent such as glue. When an appropriate number of ribbon sections602have been stacked to provide a desired viewing surface104, shown inFIG. 1, the alignment holes at input end604, shown inFIG. 6, are trimmed off; thereby exposing unobstructed aligned input ends for each light guide202.

With reference now toFIGS. 10 and 11, the properties of magnification provided in at least one fabricated embodiment of an LGS100may be further illustrated. In the embodiment shown, top spacer620and bottom spacer1100provide vertical spacing1110between the center point “x” of each magnifying output end606that is about the same as the center to center spacing1112of each magnifying output ends606in the horizontal direction. In addition, in at least one embodiment, the center to center spacing1112is substantially identical to horizontal dimension1118of each output end606.

In such a configuration, the top and bottom spacers620,1100provide apparent vertical magnification that is substantially the same as the horizontal magnification provided by each magnifying output end606. In at least one embodiment, each magnifying output end606represents a display pixel.

The viewing surface of LGS100is largely composed of display pixels. In at least one embodiment, each display pixel is based upon the magnifying output end606of each light guide202.FIG. 10shows a pixel1014on the input end604(bounded by the dotted lines.) As shown inFIG. 11, a pixel1114on the output end606(bounded by dotted line) includes a portion of top spacer620and bottom spacer1100.

Pixels1014inFIG. 10 and 1114inFIG. 11as drawn conceptually show that the pixel1014is magnified to pixel1114. In alternative embodiments, the top and bottom spacers620,1100may provide more or less spacing, thus providing more or less vertical magnification. In at least one embodiment, the light guides202may each be one-hundred micrometers in diameter. In at least one embodiment, the light guides202are tightly packed such that the perpendicular distance, center to center, between adjacent light guides202, shown as inset210inFIG. 12, is about one-hundred micrometers. In such an embodiment, the thickness for each top and bottom spacer620,1100, shown inFIG. 11, may be four-hundred and fifty micrometers in thickness. The angle of the cut on the output ends606, shown inFIG. 12, is about five degrees (5°). This embodiment provides an isotropic magnification of about ten (10).

FIG. 12illustrates an enlarged top view of LGS100composed of fabricated ribbon section602. More specifically, this top view shows a layer102composed of a plurality of light guides202. Input ends604are aligned and square. Output ends606are angled to provide magnification. Flexible midsection110permits the aligned output ends606to be oriented differently from input ends604.

FIG. 13is an enlarged portion of fabricated LGS100, showing ribbon sections602A˜602G, top spacers620A˜620G and bottom spacers1100A˜1100G providing viewing surface1300. The number labels for top spacers620B˜620F and bottom spacers1100B˜1100F have been omitted, but may be inferred. The flexible midsections110permit aligned input ends604be oriented differently from viewing surface1300.

The ribbon sections602are shown inFIG. 13as vertically continuous across the screen. In at least one vertically aligned embodiment, there are at least 1920 aligned ribbon sections602, each having at least 1080 light guides202, forming a screen with 1920 ×1080 resolution. In an alternative embodiment where the ribbon sections602are horizontally continuous across the screen (not shown), there are at least 1080 aligned ribbon sections602, each having at least 1920 light guides202, again forming a screen with 1920×1080 resolution.

In the figures provided, it is understood and appreciated that the light guides, top spacers, bottom spacers, physical alignment features, bonding glues and other components are drawn in an exaggerated scale for ease of discussion. In addition, the conventions of vertical and horizontal are used with reference to the orientation of the elements within each figure, for ease of discussion.

Changes may be made in the above methods, systems and structures without departing from the scope thereof. It should thus be noted that the matter contained in the above description and/or shown in the accompanying drawings should be interpreted as illustrative and not in a limiting sense. The following claims are intended to cover all generic and specific features described herein, as well as all statements of the scope of the present method, system and structure, which, as a matter of language, might be said to fall therebetween.