PATENT DOCUMENT

Publication Number: US-11364697-B1
Application Number: US-202016803161-A
Country: US
Kind Code: B1

Title: Methods of manufacturing fiber optic plates for electronic devices

Abstract:
An electronic device may have a housing with a display. A protective display cover layer for the display may have an image transport layer such as a fiber optic plate. The fiber optic plate may be formed from a bundle of fibers. The fibers may be formed using fiber extruding equipment. Each fiber may have a core covered with a cladding, a stray light absorbing layer, and binder material. The fibers may be deformed in a heated chamber by pressing inwardly with a die that has a recess, causing the fibers to bulge into the recess. A cutter can be used to cut off a layer of the deformed fibers. This layer may be machined and polished to form the fiber optic plate.

Claims:
What is claimed is: 
     
       1. A method of forming a fiber optic plate for an electronic device display cover layer, comprising:
 with computer-controlled fiber bundle positioning equipment, moving a fiber bundle formed from fibers in a heated chamber; 
 deforming the fiber bundle by pressing against the fiber bundle in the heated chamber with a die that has a recess so that a portion of the fiber bundle bulges into the recess; 
 cutting a layer of deformed fibers from the deformed fiber bundle using a cutter; and 
 forming the fiber optic plate from the layer of deformed fibers. 
 
     
     
       2. The method defined in  claim 1  wherein the heated chamber has a guide plate, the method further comprising:
 receiving fibers from the computer-controlled fiber bundle positioning equipment at a first side of the guide plate and providing the fiber bundle to an interior region of the heated chamber at an opposing second side of the guide plate. 
 
     
     
       3. The method defined in  claim 2  further comprising:
 closing a gate over an opening in the heated chamber while the fiber bundle is being deformed. 
 
     
     
       4. The method defined in  claim 3  further comprising:
 after cutting the layer of deformed fibers from the deformed fiber bundle, removing the layer of deformed fibers from the chamber through the opening while the gate is open. 
 
     
     
       5. The method defined in  claim 4 , further comprising:
 before moving the fiber bundle formed from the fibers in the heated chamber, extruding the fibers from an extruder. 
 
     
     
       6. The method defined in  claim 5  wherein extruding the fibers from the extruder comprises extruding fibers having a core of a first refractive index, a cladding on the core having a second refractive index that is lower than the first refractive index, and a stray light absorbing layer on the cladding. 
     
     
       7. The method defined in  claim 6  wherein extruding the fibers from the extruder further comprises extruding fibers having binder on the stray light absorbing layer. 
     
     
       8. The method defined in  claim 7  wherein forming the fiber optic plate from the layer of deformed fibers comprises polishing the layer of deformed fibers using polishing equipment. 
     
     
       9. The method defined in  claim 5  wherein extruding the fibers comprises extruding polymer fibers. 
     
     
       10. A method of forming a layer of deformed fibers, comprising:
 extruding fibers from an extruder that each include a transparent core, a transparent cladding, and a binder layer; 
 with a guide plate, forming a fiber bundle from the extruded fibers; 
 deforming fibers in the fiber bundle within a heated chamber by pressing against the fiber bundle with a die; and 
 cutting off the layer of the deformed fibers with a cutter. 
 
     
     
       11. The method defined in  claim 10  wherein the die has a recess and wherein deforming the fibers comprises pressing against the fiber bundle with the die to cause the fibers of the fiber bundle to bulge into the recess. 
     
     
       12. The method defined in  claim 11  wherein extruding the fibers comprises extruding a stray light absorbing layer between the transparent cladding and the binder layer. 
     
     
       13. The method defined in  claim 11  wherein the guide plate is coupled to the heated chamber and separates an interior region in the chamber from an exterior region and wherein extruding the fibers comprises extruding polymer. 
     
     
       14. The method defined in  claim 13  wherein the chamber has an opening and a gate, the method further comprising:
 closing the gate to cover the opening while deforming the fibers with the die in the interior region. 
 
     
     
       15. The method defined in  claim 14  further comprising:
 opening the gate to uncover the opening; and 
 removing the cut off layer of the deformed fibers from the heated chamber through the opening. 
 
     
     
       16. The method defined in  claim 15  further comprising:
 machining the cut off layer of the deformed fibers to form a surface with a curved edge profile; and 
 polishing the surface to form a polished fiber optic plate. 
 
     
     
       17. A method of forming a fiber optic plate, comprising:
 forming fibers that each include a core, a cladding, a stray light absorbing layer, and binder; 
 forming a fiber bundle by passing the fibers through a guide plate into an interior region of a heated chamber; 
 deforming the fibers by applying pressure to the fiber bundle with a mold; 
 opening a gate over an opening in the heated chamber; 
 removing the deformed fibers through the opening; and 
 using the deformed fibers to form the fiber optic plate. 
 
     
     
       18. The method defined in  claim 17  further comprising:
 using a cutter to cut off a layer of the deformed fibers within the interior region, wherein removing the deformed fibers comprises removing the cut off layer of the deformed fibers. 
 
     
     
       19. The method defined in  claim 17  wherein forming the fibers comprises forming the fibers from polymer materials. 
     
     
       20. The method defined in  claim 17  wherein the mold comprises a computer-controlled mold with a recess and wherein deforming the fibers comprises pressing inwardly against the fiber bundle with the computer-controlled mold to cause the fibers to bulge into the recess. 
     
     
       21. The method defined in  claim 17  wherein forming the fibers comprises extruding the fibers using an extruder and passing the extruded fibers through corresponding holes in multiple parallel guide plates.

Description:
This application claims the benefit of provisional patent application No. 62/847,823, filed May 14, 2019, which is hereby incorporated by reference herein in its entirety. 
    
    
     FIELD 
     This relates generally to electronic devices, and, more particularly, to display cover layers for electronic devices. 
     BACKGROUND 
     Electronic devices may have displays. Displays have arrays of pixels for displaying images for a user. To prevent damage to the pixels, the pixels can be covered with a transparent display cover layer. If care is not taken, however, the inclusion of a display cover layer into an electronic device may cause the device to have larger inactive border regions than desired or may introduce undesired image distortion. 
     SUMMARY 
     An electronic device may have a housing. A display may be mounted in the housing. A protective display cover layer may be formed over the display. During operation, images on the display may be viewed through the protective display cover layer. 
     The protective display cover layer may have an image transport layer such as a fiber optic plate. The fiber optic plate may guide and expand image light from the display and thereby expand the effective size of images on the display. The expanded image size helps cover peripheral housing structures and minimizes the size of display borders. 
     The fiber optic plate may be formed from a bundle of fibers. The fibers may be formed using an extruder. Each fiber may have a core covered with a cladding, a stray light absorbing layer, and binder material. A loose bundle of the fibers may be processed in a heated chamber. 
     The fibers may be deformed in the heated chamber by pressing inwardly with a die that has a recess. This causes the fibers to bulge into the recess. The binder holds the fibers together. A cutter can be used to cut off a layer of the deformed fibers. This layer may be machined into a desired shape such as a shape with rounded edge profiles. A polishing tool may polish the fibers to form a fiber optic plate for the protective display cover layer. The protective display cover layer, a display, and other components may be assembled into a housing to form an electronic device. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of an illustrative electronic device with a fiber optic plate in accordance with an embodiment. 
         FIG. 2  is a cross-sectional view of a portion of a fiber-optic plate in accordance with an embodiment. 
         FIG. 3  is a cross-sectional side view of illustrative equipment for deforming fibers into a desired shape in accordance with an embodiment. 
         FIG. 4  is a diagram showing illustrative equipment that may be used for forming a fiber optic plate in accordance with an embodiment. 
         FIG. 5A  is a side view illustrative extruder in accordance with an embodiment. 
         FIG. 5B  is a perspective view of illustrative guide plates for the extruder of  FIG. 5A  in accordance with an embodiment. 
         FIG. 6  is a side view of an illustrative heated process chamber in accordance with an embodiment. 
         FIG. 7  is a flow chart of illustrative operations involved in forming a fiber optic plate in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     An electronic device may have a display. The display may have an array of pixels for creating an image. The image may pass through a protective display cover layer that overlaps the array of pixels. To minimize display borders, the display cover layer may include an image transport layer formed from a coherent fiber bundle or Anderson localization material. The image transport layer helps expand the effective size of the image without imparting undesired distortion to the image. In an illustrative configuration, which may sometimes be described herein as an example, a display cover layer for the display in an electronic device is formed from a fiber optic plate that contains a deformed coherent fiber bundle. 
     A cross-sectional side view of a portion of an illustrative electronic device with a display cover layer that includes a fiber optic plate is shown in  FIG. 1 . In the example of  FIG. 1 , device  10  is a portable device such as a cellular telephone, wristwatch, or tablet computer. Other types of devices may have display cover layers with fiber optic plates, if desired. 
     Device  10  includes a housing such as housing  12 . Housing  12  may be formed from polymer, metal, glass, crystalline material such as sapphire, ceramic, fabric, fibers, fiber composite material, natural materials such as wood and cotton, other materials, and/or combinations of such materials. Housing  12  may be configured to form housing walls. The housing walls may enclose one or more interior regions such as interior region  24  and may separate interior region  24  from exterior region  22 . 
     Electrical components  18  may be mounted in interior region  24 . Electrical components  18  may include integrated circuits, discrete components, light-emitting components, sensors, and/or other circuits and may, if desired, be interconnected using signal paths in one or more printed circuits such as printed circuit  20 . If desired, one or more portions of the housing walls may be transparent (e.g., so that light associated with an image on a display or other light-emitting or light-detecting component can pass between interior region  24  and exterior region  22 ). 
     Electrical components  18  may include control circuitry. The control circuitry may include storage and processing circuitry for supporting the operation of device  10 . The storage and processing circuitry may include storage such as hard disk drive storage, nonvolatile memory (e.g., flash memory or other electrically-programmable-read-only memory configured to form a solid state drive), volatile memory (e.g., static or dynamic random-access-memory), etc. Processing circuitry in the control circuitry may be used to control the operation of device  10 . For example, the processing circuitry may use sensors and other input-output circuitry to gather input and to provide output and/or to transmit signals to external equipment. The processing circuitry may be based on one or more microprocessors, microcontrollers, digital signal processors, baseband processors, power management units, audio chips, application specific integrated circuits, etc. The control circuitry may include wired and/or wireless communications circuitry (e.g., antennas and associated radio-frequency transceiver circuitry such as cellular telephone communications circuitry, wireless local area network communications circuitry, etc.). The communications circuitry of the control circuitry may allow device  10  to communicate with other electronic devices. For example, the control circuitry (e.g., communications circuitry in the control circuitry) may be used to allow wired and/or wireless control commands and other communications to be conveyed between devices such as cellular telephones, tablet computers, laptop computers, desktop computers, head-mounted devices, handheld controllers, wristwatch devices, other wearable devices, keyboards, computer mice, remote controls, speakers, accessory displays, accessory cameras, and/or other electronic devices. Wireless communications circuitry may, for example, wirelessly transmit control signals and other information to external equipment in response to receiving user input or other input from sensors or other devices in components  18 . 
     Input-output circuitry in components  18  of device  10  may be used to allow data to be supplied to device  10  and to allow data to be provided from device  10  to external devices. The input-output circuitry may include input devices that gather user input and other input and may include output devices that supply visual output, audible output, or other output. 
     Output may be provided using light-emitting diodes (e.g., crystalline semiconductor light-emitting diodes for status indicators and/or displays, organic light-emitting diodes in displays and other components), lasers, and other light-emitting devices, audio output devices (e.g., tone generators and/or speakers), haptic output devices (e.g., vibrators, electromagnetic actuators, piezoelectric actuators, and/or other equipment that supplies a user with haptic output), and other output devices. 
     The input-output circuitry of device  10  (e.g., the input-output circuitry of components  18 ) may include sensors. Sensors for device  10  may include force sensors (e.g., strain gauges, capacitive force sensors, resistive force sensors, etc.), audio sensors such as microphones, touch and/or proximity sensors such as capacitive sensors (e.g., a two-dimensional capacitive touch sensor integrated into a display, a two-dimensional capacitive touch sensor and/or a two-dimensional force sensor overlapping a display, and/or a touch sensor or force sensor that forms a button, trackpad, or other input device not associated with a display), and other sensors. Touch sensors for a display or for other touch components may be based on an array of capacitive touch sensor electrodes, acoustic touch sensor structures, resistive touch components, force-based touch sensor structures, a light-based touch sensor, or other suitable touch sensor arrangements. If desired, a display may have a force sensor for gathering force input (e.g., a two-dimensional force sensor may be used in gathering force input on a display). 
     If desired, the sensors may include optical sensors such as optical sensors that emit and detect light, ultrasonic sensors, optical touch sensors, optical proximity sensors, and/or other touch sensors and/or proximity sensors, monochromatic and color ambient light sensors, image sensors, fingerprint sensors, temperature sensors, sensors for measuring three-dimensional non-contact gestures (“air gestures”), pressure sensors, sensors for detecting position, orientation, and/or motion (e.g., accelerometers, magnetic sensors such as compass sensors, gyroscopes, and/or inertial measurement units that contain some or all of these sensors), health sensors, radio-frequency sensors (e.g., sensors that gather position information, three-dimensional radio-frequency images, and/or other information using radar principals or other radio-frequency sensing), depth sensors (e.g., structured light sensors and/or depth sensors based on stereo imaging devices), optical sensors such as self-mixing sensors and light detection and ranging (lidar) sensors that gather time-of-flight measurements, humidity sensors, moisture sensors, gaze tracking sensors, three-dimensional sensors (e.g., time-of-flight image sensors, pairs of two-dimensional image sensors that gather three-dimensional images using binocular vision, three-dimensional structured light sensors that emit an array of infrared light beams or other structured light using arrays of lasers or other light emitters and associated optical components and that capture images of the spots created as the beams illuminate target objects, and/or other three-dimensional image sensors), facial recognition sensors based on three-dimensional image sensors, and/or other sensors. 
     In some configurations, components  18  may include mechanical devices for gathering input (e.g., buttons, joysticks, scrolling wheels, key pads with movable keys, keyboards with movable keys, and other devices for gathering user input). During operation, device  10  may use sensors and/or other input-output devices in components  18  to gather user input (e.g., buttons may be used to gather button press input, touch and/or force sensors overlapping displays can be used for gathering user touch screen input and/or force input, touch pads and/or force sensors may be used in gathering touch and/or force input, microphones may be used for gathering audio input, etc.). The control circuitry of device  10  can then take action based on this gathered information (e.g., by transmitting the information over a wired or wireless path to external equipment, by supplying a user with output using a haptic output device, visual output device, an audio component, or other input-output device in housing  12 , etc.). 
     If desired, electronic device  10  may include a battery or other energy storage device, connector ports for supporting wired communications with ancillary equipment and for receiving wired power, and other circuitry. In some configurations, device  10  may serve as an accessory and/or may include a wired and/or wireless accessory (e.g., a keyboard, computer mouse, remote control, trackpad, etc.). 
     Device  10  may include one or more displays. The displays may, for example, include an organic light-emitting diode display, a liquid crystal display, a display having an array of pixels formed from respective light-emitting diodes (e.g., a pixel array having pixels with crystalline light-emitting diodes formed from respective light-emitting diode dies such as micro-light-emitting diode dies), and/or other displays. The displays may include rigid display structures and/or may be flexible displays. For example, a light-emitting diode display may be sufficiently flexible to be bent. Displays for device  10  may have pixel arrays for displaying images for a user. Each pixel array (which may sometimes be referred to as a display panel, display substrate, or display) may be mounted under a transparent display cover layer that helps to protect the pixel array. In the example of  FIG. 1 , pixel array (display)  14  is mounted under an image transport layer such as fiber optic plate  16 , which serves as a protective display cover layer (and which may sometimes be referred to as forming a transparent portion of the housing for device  10 ). Additional protective layers (e.g., transparent layers of glass, crystalline material such as sapphire, etc.) may be stacked above and/or below fiber optic plate  16 . The configuration of  FIG. 1  in which the display cover layer for device  10  is formed from fiber optic plate  16  is illustrative. 
     During operation, the pixels of display  14  produce image light that passes through optical fibers  16 F in fiber optic plate  16  for viewing by a user such as viewer  28  who is viewing device  10  in direction  26 . The fibers or other optical structures of image transport layer structures such as fiber optic plate  16  (which may sometimes be referred to as a coherent fiber bundle) transport light (e.g., image light and/or other light) from one surface (e.g., the surface of plate  16  facing display  14 ) to another (e.g., the surface of plate  16  facing viewer  28 ) while preserving the integrity of the image light or other light. This allows an image produced by an array of pixels in a flat or curved display to be transferred from an input surface of a first shape at a first location to an output surface with a curved cross-sectional profile, compound curvature, or other desired second shape at a second location. The fiber optic plate may therefore move the location of an image and may optionally change the shape of the surface on which the image is presented. 
     Device  10  may have four peripheral edges and a rectangular footprint when viewed in direction  26  or may have other suitable shapes. To help minimize the size of inactive display borders as a user is viewing front face F of device  10  as shown in  FIG. 1 , the shapes of fibers  16 F along the rectangular periphery of plate  16  may be deformed outwardly as shown in  FIG. 1 . The deformed shapes of fibers  16 F help distribute image light laterally outwards in the X-Y plane so that the effective size of display  14  is enlarged and the image produced by display  14  covers some or all of the sidewalls of housing  12  when the image on front face F is being viewed by viewer  28 . For example, the bent shapes of fibers  16 F may help shift portion of the displayed image laterally outward in the X-Y plane along the edges and corners of device  10  to block the sidewall portions of housing  12  from view. In some arrangements, the portions of fibers  16 F at the outermost surface of layer  16  are oriented parallel or nearly parallel with viewing direction  26  and the Z axis of  FIG. 1 , which helps ensure that some or all of the light that has passed through plate  16  will travel in the Z direction and be viewable by viewer  28 . 
     Fibers  16 F for fiber optic plate  16  may have any suitable configuration. A cross-sectional view of fiber optic plate  16  in an illustrative arrangement in which fibers  16 F have multiple layers of material is shown in  FIG. 2 . As shown in  FIG. 2 , fibers  16 F may each have a core such as core  16 F- 1 . Cores  16 F- 1  and the other structures of fiber optic plate  16  may be formed from transparent materials such as polymer, glass, crystalline material such as sapphire, and/or other transparent materials. In an illustrative configuration, which may sometimes be described herein as an example, fiber optical plate  16  includes polymer fibers. 
     Fiber cores  16 F- 1  may be formed from polymer of a first refractive index and may be surrounded by cladding  16 F- 2  (e.g., polymer) of a second, lower refractive index. This arrangement allows fibers  16 F to guide light in accordance with the principal of total internal reflection. In some configurations, a stray light absorbing layer such as layer  16 F- 3  may be applied as a coating on cladding  16 F- 2  to help absorb stray light. Core  16 F- 1  and cladding  16 F- 2  may be formed from clear polymers. Stray light absorbing layer  16 F- 3  may contain black pigment or other light absorbing material that renders layers  16 F- 3  opaque (e.g., layer  16 F- 3  may be formed from a material that absorbs and blocks light). Binder material  16 FB (e.g., clear polymer) may hold fibers  16 F together to form plate  16 . The fractional cross-sectional areas occupied by core  16 F- 1 , cladding  16 F- 2 , stray light absorbing layer  16 F- 3 , and binder  16 FB may respectively be 65%-85%, 2-10%, 1-5%, and 5-15%, and/or other suitable values. 
     The diameter of core  16 F- 1  may be 5-15 microns or other suitable size (e.g., at least 3 microns, at least 7 microns, 10 microns, at least 15 microns, less than 20 microns, less than 14 microns, etc.). The thickness of cladding  16 F- 2  may be 0.5 microns, at least 0.1 microns, at least 0.4 microns, less than 2 microns, less than 0.9 microns, or other suitable thickness. The thickness of stray light absorbing layer  16 F- 3  may be 0.1 microns, at least 0.01 microns, at least 0.05 microns, less than 2.5 microns, less than 0.4 microns, less than 0.15 microns, or other suitable thickness. If desired, fibers  16 F may contain more layers, fewer layers, layers arranged in different orders, and/or may have other configurations. 
       FIG. 3  shows how a collection of fibers  16 F may be deformed under heat and pressure using heated molding structures (a heated mold) such as die  30 . Die  30  may have multiple portions that are joined inwardly to press against fibers  16 F. Die  30  may have a recessed portion (see, e.g., recess  30 R) located between protruding portions  30 P. Recess  30 R may have a rectangular cross-sectional profile or other suitable shape. When die  30  presses inwardly on fibers  16 F, protruding portions  30 P push against fibers  16 F and cause fibers  16 F to bow outwardly and bulge into recess  30 R. During deformation operations, fibers  16 F may be heated to a temperature sufficient to soften fibers  16 F without melting fibers  16 F (e.g., a temperature of 150° C. or other suitable temperature sufficient to soften fibers  16 F). After the deformed fibers are cooled, the deformed fibers will solidify and become rigid. Plates  16  may then be formed that have desired shapes such as the illustrative plate shapes shown by dashed lines  16 ′ of  FIG. 3 . 
       FIG. 4  is a diagram of illustrative fabrication equipment that may be used in forming fiber optic plate  16 . As shown in  FIG. 4 , the fabrication equipment may include equipment for forming fibers  16 F (e.g., fiber forming equipment) such as extruder  32 . Extruder  32  may produce spools of fibers. The fibers on the spools may include single-strand fibers and/or bundles that contain hundreds of fibers (as an example). 
     Spooled fiber may be supplied to process chamber  36  using spool feeder  34 . Process chamber  36  may have a guide plate with hundreds or thousands of holes for fibers  16 F (single fibers and/or bundles of fibers  16 F) from spool feeder  34 . The guide plate may, as an example, have a first side that receives about 10 million fibers  16 F and may guide these fibers into a loose fiber bundle that exits an opposing second side for further processing using die  30  ( FIG. 3 ). The loose fiber bundle that exits the second may laterally cover an area approximately equal to the desired area of the fiber optic plate being formed. Fibers  16 F may be deformed by a mold in process chamber  36 . 
     Following formation of fiber optic plate structures in process chamber  36 , post processing tools  38  may be used to form finished fiber optic plates  16 . Tools  38  may include, for example, equipment to create desired surface shapes for the surfaces of each fiber optic plate  16  (e.g., machining equipment such as a grinding tool for forming curved edge profiles in the plate, saws or other cutting tools, polishing equipment for polishing the surfaces of each fiber optic plate  16 , etc.). 
       FIG. 5A  is a diagram of an illustrative extruder. As shown in  FIG. 5A , extruder  32  may have hoppers  40  that contain material (e.g., polymers) for the different portions of plate  16 . A first of hoppers  40  may, for example, include a clear polymer of a first refractive index for forming core  16 F- 1 . A second of hoppers  40  may include a clear polymer of a second refractive index that is lower than the first refractive index. The polymer in the second hopper may be used in forming cladding  16 F- 2 . A third of hoppers  40  may include a polymer (e.g., a black light-absorbing polymer) for forming stray light absorbing layer  16 F- 3 . A fourth of hoppers  40  may include a polymer for forming binder  16 FB. The different polymers in hoppers  40  may be heated to soften and/or liquefy these polymers so that these different polymers may be extruded through extrusion head  42  (e.g., a spin-pack die) to form fibers  16 F. One or more spools such as spool  44  may collect the extruded fibers  16 F. 
     As shown in  FIG. 5A , extruder  32  may have a series of parallel plates such as guide plates  43  to help prevent extruded fibers  16 F from becoming misaligned. Each of plates  43  may have a respective hole for each fiber  16 F being produced by the extruder, as shown by holes  45  in plates  43  of  FIG. 5B . Holes  45  may have any suitable shapes and sizes. As an example, holes  45  may be circular and each plate  43  may contain holes  45  of a common diameter. Appropriate hole size and appropriate separations between plates  43  may be determined by measuring the amount of travel fibers  16 F would experience in the absence of plates  43 . With an illustrative configuration, plate-to-plate separation DS and the separation between the uppermost of plates  43  and the bottom of head  42  may be about 1 cm, at least 0.1 cm, less than 10 cm, less than 1 cm, or other suitable distance and the diameter of holes  45  may decrease from plate to plate as a function of increasing distance from head  42 . There may be any suitable number of plates  43  (e.g., at least two, at least three, fewer than five, fewer than three, 2-4, 2-3, etc.). In an illustrative arrangement with two of plates  43 , the uppermost of plates  43  adjacent to head  42  may have holes  45  of a first diameter (e.g., 25 mm, at least 5 mm, less than 125 mm, etc.) and the lowermost of plates  43  may have holes of a second diameter that is smaller than the first diameter (e.g., 15 mm, at least 3 mm, less than 75 mm, etc.). Using fiber guide structures between head  42  and spool  44  may help maintain fiber order and alignment and may therefore help ensure fiber parallelism and coherence in plate  16 , ensuring that the image produced at the exit surface of plate  16  will be satisfactory for viewing by the user. 
       FIG. 6  is a diagram of an illustrative process chamber for deforming fibers  16 F into a desired shape for fiber optic plates  16 . As shown in  FIG. 6 , computer-controlled spool feeder  34  may supply fibers  16 F at a desired feed rate to guide plate  46 . Guide plate  46  may be mounted in an opening in walls  48  of process chamber  36 . Guide plate  46  may have openings that receive fibers  16 F. In an illustrative configuration, guide plate  46  may have at least 100, at least 500, at least 2000, at least 5000, fewer than 100,000, fewer than 25,000, fewer than 10,000, or other suitable number of holes and may be configured to receive at least 1 million, at least 10 million, fewer than 100 million, or other suitable number of fibers. Fibers  16 F may be received from spools in spool feeder  34  at the upper side of guide plate  46  and may exit at the lower side of guide plate  46  as loose fiber bundle  16 F′. 
     Gases (e.g., nitrogen, oxygen, etc.) may be selectively introduced into interior  62  of chamber  36  from one or more computer-controlled gas sources  52 . Process chamber walls  48  and other portions of chamber  36  may be heated (e.g., using computer-controlled heaters  50 ). For example, walls  48  and the gasses, fiber structures, and other structures in interior region  62  may be heated to about 150° C. or other suitable temperature sufficient to soften the fibers  16 F of fiber bundle  16 F′ without melting these fibers. Die  30  has computer-controlled positioners that position different die sections. A computer-controlled die arrangement allows die  30  to expand laterally outward to receive fiber bundle  16 F′ and to be moved laterally inward (towards fiber bundle  16 ′) when it is desired to deform fiber bundle  16 F. 
     During deformation operations, the softened fibers of bundle  16 F pass into the area within die  30 . When it is desired to deform fibers  16 F of bundle  16 F′ to a desired shape, computer-controlled die gates  54  may be closed and the movable pieces of die  30  may be pushed inwardly against the sides of bundle  16 F′ by computer-controlled positioners. This indents fiber bundle  16 F′ where pressed by protruding portions  30 P and causes fiber bundle  16 F to bulge outwardly where aligned with recess  30 R. As a result, an outwardly protruding fiber bundle portion with deformed fibers is created (e.g., a bulge is created that runs around the periphery of the fiber bundle  16 F′). Gates  54  may then be opened. 
     Cutter  56  may have one or more parts with one or more sharp edges  56 T for cutting through fiber bundle  16 F′ within chamber interior  62  (e.g., while fibers  16 F are soft). The position of cutter  56  may be adjusted using a computer-controlled positioner. After the fiber bundle has been deformed by die  30 , cutter  56  may be moved laterally through the fiber bundle to cut off a layer of the fiber bundle that contains the deformed fibers. This cut off layer forms a rough plate of deformed fibers (e.g., a blank) that can later be machined, polished, and/or otherwise processed by tools  38  into a pair of finished fiber optic plates  16  (see, e.g., dashed lines  16 ′ of  FIG. 3 ). 
     To ensure that the interior temperature of chamber  36  is maintained at a desired level, chamber  36  may be provided with a computer-controlled chamber gate such as gate  58  (e.g., one or more sliding doors or other structures for sealing chamber wall opening  64 ). When it is desired to create a sealed chamber (e.g., so that a desired gaseous environment can be maintained in interior  62  and so that the temperature in interior  62  can be maintained as desired), gate  58  may be closed over opening  64 . When it is desired to remove a layer of deformed fibers that has been cut from bundle  16 F′ from interior  62  to the exterior of chamber  36 , gate  58  may be opened. 
     Illustrative steps involved in forming fiber optic plates for device  10  are shown in  FIG. 7 . 
     Following formation of fibers  16 F (e.g., using extruder  32 ) and the loading of fiber sources into spool feeder  34  of  FIG. 6  at step  68 , a loose bundle  16 F′ of fibers  16 F may be formed using guide plate  46  and moved (e.g., lowered) into chamber  36  for processing (e.g., using computer-controlled spools or other computer-controlled fiber bundle positioning equipment associated with spool feeder  34 ). 
     During the operations of block  70 , chamber gate  58  for chamber  32  may be closed while a desired gaseous environment and temperature are created in interior  62  using gas sources  52  and heater  50 . Die gate  54  (which may sometimes be referred to as forming part of die  30 ) may also be closed. 
     During the operations of block  72 , the computer-controlled mold formed from computer-controlled die  30  is pressed against fibers  16 F (e.g., the fibers in loose fiber bundle  16 F′) to deform fiber bundle  16 F′ into a desired shape, as shown in  FIG. 3 . The binder on fibers  16 F binds fibers  16 F together. The shape of die  30  (e.g., the presence of recess  30 R) causes the fiber bundle and its fibers to bulge outwardly into the recess, thereby deforming the fibers as desired. Die gate  54  may be opened after fiber deformation. 
     During the operations of block  74 , chamber gate  58  may be opened. This allows fiber bundle  16 F′ to be lowered by computer-controlled spool feeder  34  and allows computer-controlled cutter  56  to cut off a layer of fiber bundle  16 F′ and fiber bundle  16 F′ for removal from interior  62 . The cut-off piece of fiber bundle  16 F′ forms a plate with deformed fibers suitable for forming one or more (e.g., a pair) of fiber optic plates  16 . If desired, the cutter  56  may be used to cut two individual rough fiber plates from the deformed portion of fibers (e.g., cutter  56  may slice between the upper and lower portions of the deformed fibers aligned with recess  30 R in the example of  FIG. 3  after these deformed fibers exit die  30 ). 
     During the operations of block  78 , tools  38  may be used to form finished fiber optic plates from the layers of deformed fibers exiting processing chamber  36 . Tools  38  may include cutting tools (e.g., saws, etc.) for cutting, machining tools such as grinding tools for grinding the surfaces of a plate of deformed fibers to a desired rough shape (e.g., a shape with rounded peripheral edge profiles as shown in  FIG. 1 ), and polishing tools for polishing the machined surfaces of the fiber optic plates into optically smooth surfaces for use in device  10 . After the finished fiber optic plates are produced in this way, additional structures (e.g., display layers, optional additional cover layers such as protective outer layers of glass or other materials, etc.) may be assembled with housings  12  and components  18  to form devices  10 ). 
     Device  10  may be operated in a system that uses personally identifiable information. It is well understood that the use of personally identifiable information should follow privacy policies and practices that are generally recognized as meeting or exceeding industry or governmental requirements for maintaining the privacy of users. In particular, personally identifiable information data should be managed and handled so as to minimize risks of unintentional or unauthorized access or use, and the nature of authorized use should be clearly indicated to users. 
     The foregoing is merely illustrative and various modifications can be made to the described embodiments. The foregoing embodiments may be implemented individually or in any combination.

Metadata:
Filing Date: 20200227
Publication Date: 20220621
Grant Date: 20220621
Priority Date: 20190514
Inventors: KELLEY, PAUL C.
Assignee: APPLE INC
CPC Classifications: [{"code": "G02B6/08", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29D11/00673", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29D11/00663", "inventive": true, "first": true, "tree": "[]"}, {"code": "G02B6/08", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29D11/00673", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29D11/00663", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29D11/00663", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29D11/00673", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B6/08", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 82060350