Patent ID: 6921452

Claim:
A method of producing a stacked waveguide optical panel having a controlled light cone emitting therefrom, comprising: laying a first sheet in a trough sized slightly larger than the first sheet; filling the trough with a thermally curing epoxy; stacking a plurality of sheets, each having light transmissive properties approximately equivalent to the first sheet, atop the first sheet in the trough, thereby forming a layer of epoxy between each sheet; applying uniform pressure to the stack formed by said stacking, thereby causing the epoxy to flow to a generally uniform level between two adjacent sheets; baking the stack to cure; cooling the stack slowly to prevent cracking of the sheets; placing the stack against a saw and cutting the stack, using the saw, at two opposite ends at an angle to form a wedge-shaped panel having an inlet face and an outlet face; and forming at the outlet face a plurality of light redirective elements which direct light incident on the outlet face into a controlled light cone.