Patent Description:
AR-HMD devices can be embodied in a wearable headset that is arranged to display an image within a short distance from a human eye. Some AR-HMD devices are provided with a frame which has a central portion fitting over a user's (wearer's) nose bridge and left and right support extensions which fit over a user's ears. Optical components are arranged in the frame so as to display an image within a few centimeters of the user's eyes. The image can be a computer-generated image on a display, such as a micro display. The optical components are arranged to transport light of the desired image which is generated on the display to the user's eye to make the image visible to the user. The display on which the image is generated can form part of a light engine, such that the image itself generates collimated light beams which can be guided by the optical component to provide an image visible to the user.

Different kinds of optical components have been used to convey the image from the display to the human eye. These can include lenses, mirrors, optical waveguides, holograms and diffraction gratings, for example. In some display systems, the optical components are fabricated using optics that allow the user to see the image, but not the "real world". Other types of display systems provide view-through optics, so that the generated image which is displayed to the user is overlaid onto a real-world view (i.e., AR).

Waveguide-based display systems typically transport light from a light engine to the eye via a TIR (Total Internal Reflection) mechanism in a waveguide (light guide). Such systems can incorporate diffraction gratings, which cause effective beam expansion so as to output expanded versions of the beams provided by the light engine. This means the image is visible over a wider area when looking at the waveguide's output than when looking at the light engine directly. Provided the eye is within an area such that it can receive some light from substantially all of the expanded beams, the whole image will be visible to the user. Such an area is referred to as an eye box.

Components of AR-HMD devices may require very precise positioning and alignment within the devices in order to function properly. Even minor mechanical or thermal stresses applied to these components (e.g., waveguides) can potentially affect the positioning or alignment of such components and thereby adversely affect functionality of the devices. Additionally, these components may be vulnerable to damage due to being dropped or other impacts, normal handling, or environmental factors.

It is with respect to these considerations and others that the disclosure made herein is presented.

<CIT> discloses auxiliary eyeglasses for attachment to primary eyeglasses. The auxiliary eyeglasses has a bridge including a rigid connecting tube that is disposed between two lens units. Two movable rods are connected respectively to the lens units, extend respectively through two open ends of the connecting tube, are movable within the connecting tube, and engage respectively and fittingly non-circular holes so as to prevent rotation of the movable rods relative to the connecting tube.

<CIT> discloses a support for a optical waveguide, the support having one (or two) V-shaped displacement amplifiers for controlling the strain in the waveguide when subject to different temperatures.

<CIT> discloses an image display device that comprises an image forming unit and a light guide unit.

<CIT> discloses an optical arrangement for deflecting a laser beam which includes an optics holder and a reflective optic fixed to the optics holder.

<CIT> discloses an optical element mounting apparatus having a base structure, a first mounting pad located on a first flexure formed in the base structure, a second mounting pad located on a second flexure formed in the base structure, and a third mounting pad located on the base structure.

The invention relates to the augmented reality head-mounted display device defined in the appended claims.

Techniques described herein relate to optical mounts. In some implementations, an optical mount is provided that is to receive an optical element. The optical element may be an optical waveguide. The optical mount that has the optical waveguide mounted thereto is part of the augmented reality (AR) head-mounted display (HMD) device ("AR-HMD device") according to the claimed invention.

AR-HMD devices may comprise many components that create thermal stresses. Furthermore, AR-HMD devices may experience mechanical stresses, such as jarring forces that are created when AR-HMD devices are inadvertently dropped. The various stresses experienced by AR-HMD devices may damage the one or more optical elements implemented by such devices. For example, stresses experienced by the AR-HMD devices may damage (e.g., bow, warp, etc.) the one or more optical elements incorporated in the AR-HMD devices.

The optical mounts disclosed herein are designed to be resistant to the various stresses that may be experienced by AR-HMD devices. Specifically, in some implementations, an optical mount is provided with mechanical compliance and resiliency. Such mechanical compliance and resiliency associated with the various optical mounts disclosed herein are intended to absorb thermal and/or mechanical stresses that may be experienced by AR-HMD devices, while protecting and preserving the operational functionality of optical waveguides coupled to the disclosed optical mounts.

According to the invention, an AR-HMD device having an optical mount is provided. The optical mount includes a first body segment to receive and engage an optical element; a first surface and a second surface disposed on the first body segment, the first surface and the second surface to receive and engage the optical element; and at least one compliance joint disposed in the first body segment, the at least one compliance joint disposed between the first surface and the second surface, the at least one compliance joint allowing the first body segment to have an elasticity or compliance.

A method includes providing an optical mount comprising at least a first surface and a second surface and at least one compliance joint disposed between the first surface and the second surface. The method may further include coupling an optical element to the first surface and the second surface. The at least one compliance joint allows the optical mount to have an elasticity or compliance in a first direction of the optical mount, the elasticity or compliance designed to mitigate bowing and/or warping of the optical element in the first direction of the optical mount due to stress experienced by the optical mount and/or the optical element.

<FIG> schematically shows an example of an environment in which AR-HMD devices may be used. In the illustrated example, an AR-HMD device <NUM> is configured to communicate data to and from an external processing system <NUM> through a connection <NUM>, which can be a wired connection, a wireless connection, or a combination thereof. In other use cases, however, the AR-HMD device <NUM> may operate as a standalone device. The connection <NUM> can be configured to carry any kind of data, such as image data (e.g., still images and/or full-motion video, including 2D and 3D images), audio, multimedia, voice, and/or any other type(s) of data. The processing system <NUM> may be, for example, a game console, personal computer, tablet computer, smartphone, or other type of processing device. The connection <NUM> can be, for example, a universal serial bus (USB) connection, Wi-Fi connection, Bluetooth or Bluetooth Low Energy (BLE) connection, Ethernet connection, cable connection, DSL connection, cellular connection (e.g., <NUM>, LTE/<NUM> or <NUM>), or the like, or a combination thereof. Additionally, the processing system <NUM> may communicate with one or more other processing systems <NUM> via a network <NUM>, which may be or include, for example, a local area network (LAN), a wide area network (WAN), an intranet, a metropolitan area network (MAN), the Internet, or a combination thereof.

The AR-HMD device <NUM> also includes one or more optical mounts <NUM>. The one or more optical mounts <NUM> may also be referred to herein as an optical waveguide mount <NUM>. Specific details of the optical waveguide mount <NUM> are provided hereinafter.

The AR-HMD device <NUM> may enclose various sensors and other components (not shown), such as one or more microphones, visible-spectrum head-tracking cameras, infrared (IR) spectrum depth cameras, IR illumination sources, and visible-spectrum video cameras. The AR-HMD device <NUM> may also enclose electronics (not shown) to control the functionality of the AR-HMD device <NUM>. For example, the AR-HMD device <NUM> may include display related components, including light sources (e.g., light emitting diodes), imagers (e.g., liquid crystal on silicon devices), lenses, beam splitters and/or additional waveguides, the details of which are not germane to this disclosure.

In some implementations, the AR-HMD device <NUM> includes a single optical waveguide mount <NUM> or a plurality of optical waveguide mounts <NUM>. The optical waveguide mount <NUM> may be adapted to carry an optical waveguide (not shown). Specifically, an optical waveguide may be adhesively or otherwise attached to the optical waveguide mount <NUM>. In some implementations, the optical waveguide mount <NUM> is made from molded plastic or the like. Specifically, the molded plastic may be a polycarbonate material. However, the optical waveguide mount <NUM> may be made from other materials, such as an opaque material made from plastic or metal, acrylic, and the like. Furthermore, the optical waveguide mount <NUM> may be adapted to carry an optical element other than an optical waveguide. For example, the optical waveguide mount <NUM> may carry a lens, or the like.

The optical waveguide mount <NUM> may be considered a mounting structure for an optical waveguide. In some implementations, the optical waveguide received by the optical waveguide mount <NUM> may comprise optical grade glass. However, other materials for the optical waveguide may be used. In some implementations, the optical waveguide comprises a plurality of waveguides stacked on top of each other. For example, an optical waveguide may comprise a plurality of optical grade layers such that there is one waveguide layer for each of the red, green and blue components of an RGB display. However, other color formats and corresponding waveguide configurations may be used instead.

As disclosed in the foregoing, even minor mechanical or thermal stresses applied to the display-related components of the AR-HMD device <NUM> may affect the positioning, shape and/or alignment of the waveguide(s) and thereby adversely affect the quality of the images generated and/or other functionality of the AR-HMD device <NUM>. For example, a slight curvature, bow, or other deformation of the waveguide(s) can cause the generated images to become distorted, adversely affecting their degree of realism and potentially causing physical discomfort to the user of the AR-HMD device <NUM>. Therefore, in some implementations, the optical waveguide mount <NUM> implements at least one compliance joint to accommodate mechanical and/or thermal stresses that may be applied to the AR-HMD device <NUM> and/or the waveguide(s) housed within the AR-HMD device <NUM>. Specifically, the optical waveguide mount <NUM> may implement at least one compliance joint to mitigate against bowing or warping in a waveguide, which may occur due to stresses (e.g., thermal stresses) caused by components of the AR-HMD device <NUM>. The at least one compliance joint may also mitigate against mechanical stresses, such as jarring forces that may occur if the AR-HMD device <NUM> is inadvertently dropped.

<FIG> illustrates an exemplary perspective view of the optical waveguide mount <NUM>. In particular, the exemplary perspective view of the optical waveguide mount <NUM> in <FIG> illustrates a perspective top or frontside view of the optical waveguide mount <NUM>.

In general, the optical waveguide mount <NUM> receives and carries an optical waveguide <NUM>. Alternatively, in an example not according to the claimed invention, the optical waveguide mount <NUM> may receive and carry an optical element other than a waveguide. The shape of the optical waveguide <NUM> is exemplary, as the optical waveguide <NUM> may be manufactured in various shapes and sizes. In some implementations, the optical waveguide <NUM> comprises a solid structure of optical material. In other implementations, the optical waveguide <NUM> comprises a plurality of optical layers manufactured from optical material. The optical waveguide <NUM> may be manufactured using optical grade glass, optical grade plastic, or other transparent or semitransparent material.

As indicated above, in some implementations, the optical waveguide mount <NUM> is made from molded plastic, or the like. Specifically, the molded plastic may be a polycarbonate material. In some implementations, a body segment <NUM> of the optical waveguide mount <NUM> may function as a lens.

In some implementations, the optical waveguide mount <NUM> has a size and shape that accommodates an overall size and shape of the optical waveguide <NUM>. In other implementations, the optical waveguide mount <NUM> does not particularly match the overall size and shape of the optical waveguide <NUM>. For example, in some implementations, the optical waveguide mount <NUM> is manufactured to comprise a body segment <NUM>. Specifically, the optical waveguide mount <NUM> may be manufactured to omit the body segment <NUM>. The body segments <NUM> and <NUM> may be manufactured as a single unit, such as by injection molding or extrusion. In some implementations, the body segments <NUM> and <NUM> are separate units that may be coupled together, such as by one or more fasteners and/or adhesives.

The optical waveguide <NUM> may be mounted to the optical waveguide mount <NUM> by way of one or more adhesive bearing surfaces <NUM>. Specifically, the adhesive bearing surfaces <NUM> may receive an adhesive. The optical waveguide <NUM> may be caused to engage the adhesive disposed on the adhesive bearing surfaces <NUM>, by pressing or the like, to couple the optical waveguide <NUM> to the optical waveguide mount <NUM>. The illustrated number of adhesive bearing surfaces <NUM> is merely exemplary, as the optical waveguide mount <NUM> may employ any number of adhesive bearing surfaces <NUM>. Furthermore, the illustrated location of the adhesive bearing surfaces <NUM> is exemplary, as the adhesive bearing surfaces <NUM> may be located at other positions on the optical wave mount <NUM>.

In some implementations, an alternative attaching mechanism may be used to couple the optical waveguide <NUM> to the optical waveguide mount <NUM>. For example, one or more mechanical fasteners may be used to couple the optical waveguide <NUM> to the optical waveguide mount <NUM>. In particular, a mechanical fastener may be used at one or more of the surfaces <NUM> to enable coupling the optical waveguide <NUM> to the optical waveguide mount <NUM>. Suitable mechanical fasteners include screws, rivets, and the like.

The optical waveguide mount <NUM> comprises one or more compliance joints <NUM>. In some implementations, a single compliance joint <NUM> is implemented by the optical waveguide mount <NUM>. The one or more compliance joints <NUM> are disposed in the optical waveguide mount <NUM> to allow the mount <NUM> to expand and/or retract.

The one or more compliance joints <NUM> enable the optical waveguide mount <NUM> to exhibit some elasticity along a first direction (x-axis). The elasticity enabled by the one or more compliance joints <NUM> isolates or substantially isolates the optical waveguide <NUM> from stresses (e.g., thermal stresses) that may cause the optical waveguide <NUM> to bow and/or warp. Such stresses may be associated with the AR-HMD <NUM> and/or the optical waveguide mount <NUM>. In some implementations, such stresses may be caused by components of the AR-HMD <NUM> (e.g., electrical components) and/or jarring forces that may be applied to the AR-HMD <NUM>.

In some implementations, the at least one or more compliance joints <NUM> have a thickness (t) <NUM> in a second direction (z-axis) that is designed to minimize compliance (i.e., expansion and/or retraction) of the optical waveguide mount <NUM> in the second direction (z-axis). In some implementations, the second direction (z-axis) is perpendicular or substantially perpendicular to the first direction (x-axis). In general, the optical waveguide mount <NUM> is to have elasticity or compliance in the first direction (x-axis) and no or minimal elasticity or compliance in the second direction (z-axis). In some implementations, due to the at least one or more compliance joints <NUM>, the optical waveguide mount <NUM> is at least five times more elastic or compliant in the first direction (x-axis) compared to the elasticity or compliance in the second direction (z-axis).

According to the invention, the one or more compliance joints <NUM> are formed as elongated circles or ellipses, and each of the one or more compliance joints <NUM> has an opening <NUM> disposed therein. The opening <NUM> at least partially provides the elasticity or compliance along a first direction (x-axis) of the optical waveguide mount <NUM>. Each of the one or more compliance joints <NUM> may comprise a shape other than an elongated circle or ellipse. For example, the one or more compliance joints <NUM> may be formed as an accordion like honeycomb structure, lattice structure, or the like. Elasticity or compliance associated with the optical waveguide mount <NUM> may be enhanced by locating at least one compliance joint <NUM> between each pair of adhesive bearing surfaces <NUM>.

The one or more compliance joints <NUM> may be springs. Specifically, one or more compliance joints <NUM> embodied as springs may be manufactured integrally as part of the optical waveguide mount <NUM>. In some implementations, one or more compliance joints <NUM> embodied as springs may be mechanically coupled, such as by fastener or the like, to the body segment <NUM> associated with the optical waveguide mount <NUM>. Furthermore, in some implementations, the body segment <NUM> may be made from metal, and the one or more compliance joints <NUM> may be springs. Such a metal body segment <NUM> may be manufactured as one unit to include the one or more compliance joints <NUM> embodied as springs. Alternatively, the metal body segment <NUM> may be manufactured to include distinct units (e.g., (<NUM>) one or more springs and (<NUM>) body portions) that are mechanically coupled together to provide a single unit that is the optical waveguide mount <NUM>. In the foregoing, it is to be understood that the optical waveguide mount <NUM> may be manufactured to include only the body segment <NUM>, or the optical waveguide mount <NUM> may be manufactured to include the body segment <NUM> and the body segment <NUM>.

<FIG> illustrates another exemplary perspective view of the optical waveguide mount <NUM>. In particular, the exemplary perspective view of the optical waveguide mount <NUM> in <FIG> illustrates a bottom or backside view of the optical waveguide mount <NUM>.

As illustrated, the backside of the optical waveguide mount <NUM> comprises reinforcing members <NUM>. In some implementations, some of the reinforcing members <NUM> form a crisscross pattern. The reinforcing members <NUM> aid in preventing or substantially preventing elasticity or compliance of the optical wave mount <NUM> in the second direction (z-axis).

<FIG> illustrates a top or frontside view of the optical waveguide mount <NUM>. <FIG> illustrates a bottom or backside view of the optical waveguide mount <NUM>.

<FIG> is a flow diagram of an illustrative process <NUM> associated with the disclosed optical waveguide mount implementations.

In some implementations, a suitable manufacturing system may implement the process or routine <NUM>. For example, a system for manufacturing AR-HMD devices may implement the process <NUM> illustrated in <FIG>. It should be understood that the operations of the methods (e.g., routines and/or processes) disclosed herein are not necessarily presented in any particular order and that performance of some or all of the operations in an alternative order(s) is possible and is contemplated. The operations have been presented in the demonstrated order for ease of description and illustration. Operations may be added, omitted, and/or performed simultaneously, without departing from the scope of the appended claims. Furthermore, it is to be understood that the routine <NUM> may implement and/or comprise one or more of the components and elements illustrated in <FIG> and the related description of those figures.

It also should be understood that the illustrated methods can end at any time and need not be performed in their entireties. Some or all operations of the methods, and/or substantially equivalent operations, can be performed by execution of computer-readable instructions included on a computer-storage media. The term "computer-readable instructions," and variants thereof, as used in the description and claims, is used expansively herein to include routines, applications, application modules, program modules, programs, components, data structures, algorithms, and the like. Computer-readable instructions can be implemented on various system configurations, including single-processor or multiprocessor systems, minicomputers, mainframe computers, personal computers, handheld computing devices, microprocessor-based programmable consumer electronics, combinations thereof, and the like.

The operations of the routine <NUM> may be implemented, at least in part, by an application, component and/or circuit. One or more of the implemented compiled program/application, interpreted program, script or any other executable set of instructions may be executed by at least one processor to cause one or more of the operations of the routine <NUM> to operate.

At block <NUM>, an optical mount, such as the optical waveguide mount <NUM>, is provided. The optical mount may comprise a first surface and a second surface. Specifically, the optical mount may comprise a plurality of adhesive bearing surfaces <NUM>. Furthermore, the optical mount may comprise at least one compliance joint <NUM> disposed between the adhesive bearing surfaces <NUM>.

At block <NUM>, an optical element is coupled to the first surface and the second surface of the optical mount. For example, an optical waveguide <NUM> may be adhesively coupled to the adhesive bearing surfaces <NUM> of the optical waveguide mount <NUM>. In some implementations, the at least one compliance joint <NUM> provides an elasticity or compliance in the optical mount to mitigate bowing and/or warping of the optical waveguide <NUM> due to the stress experienced by the optical waveguide mount <NUM>. Such stress may include thermal stress and/or mechanical stress, or the like.

Claim 1:
An augmented reality head-mounted display device for displaying an image for viewing by a user when wearing the augmented reality head-mounted display device, the augmented reality head-mounted display device comprising:
an optical waveguide mount (<NUM>) to which an optical waveguide (<NUM>) of the augmented reality head-mounted display device is mounted, the optical waveguide mount (<NUM>) comprising:
a body segment (<NUM>) arranged to receive and engage the optical waveguide (<NUM>);
a first surface (<NUM>) and a second surface (<NUM>) disposed on the body segment (<NUM>), the first surface (<NUM>) and the second surface (<NUM>) being arranged to receive and engage the optical waveguide (<NUM>); and
at least one compliance joint (<NUM>) disposed in the body segment (<NUM>), the at least one compliance joint (<NUM>) being formed as an elongated circle or ellipse, the elongated circle or ellipse having an opening (<NUM>) disposed therein, the at least one compliance joint (<NUM>) being disposed between the first surface (<NUM>) and the second surface (<NUM>) such that the first surface (<NUM>) and the second surface (<NUM>) are respectively disposed on opposite sides of the opening (<NUM>), the at least one compliance joint (<NUM>) and opening (<NUM>) allowing the body segment (<NUM>) to have an elasticity or compliance in a first direction of the body segment (<NUM>) between the first surface (<NUM>) and the second surface (<NUM>), the elasticity or compliance being arranged to mitigate bowing and/or warping of the optical waveguide (<NUM>) due to stress experienced by the optical waveguide mount (<NUM>) and/or the optical waveguide (<NUM>).