PATENT DOCUMENT

Publication Number: US-10146116-B2
Application Number: US-201815907314-A
Country: US
Kind Code: B2

Title: Integrated light pipe for optical projection

Abstract:
An optical device includes a first plate having a first transparent region defining an exit face of the device, and a second plate having a second transparent region defining an entrance face of the device. At least one lens is formed over at least one of the first and second transparent regions. First and second planar reflectors are spaced apart and fixed between the first and second plates in mutually-parallel orientations diagonal to the first and second plates, thereby defining an optical path through the device from the entrance face, reflecting from the first and second reflectors, through the exit face and passing through the at least one refractive surface.

Claims:
The invention claimed is: 
     
       1. An optical device, comprising:
 a light pipe, comprising an entrance face and an exit face and first and second reflectors spaced apart and fixed so as to define an optical path through the light pipe from the entrance face, reflecting from the first and second reflectors, through the exit face; 
 a light source, fixed in proximity to the entrance face so that light emitted by the light source propagates along the optical path; and 
 at least one diffractive optical element (DOE), fixed in proximity to the exit face so that the light passing through the exit face transilluminates the at least one DOE, thereby generating patterned light. 
 
     
     
       2. The device according to  claim 1 , and comprising a first spacer fixed between the exit face and the at least one DOE and a second spacer fixed between the light source and the entrance face. 
     
     
       3. The device according to  claim 1 , wherein the at least one DOE comprises first and second DOEs, which are spaced apart long the optical path in proximity to the exit face so that the light transilluminates both of the first and second DOEs. 
     
     
       4. The device according to  claim 3 , and comprising a spacer layer having an opening therethrough, wherein the first and second DOEs are formed on respective surfaces of first and second transparent substrates, and the first and second substrates are mounted on respective, opposing sides of the spacer layer with the first and second DOEs aligned with the opening. 
     
     
       5. The device according to  claim 4 , wherein the first and second transparent substrates are bonded to the spacer layer such that the first and second DOEs are contained within the opening. 
     
     
       6. The device according to  claim 1 , and comprising at least one lens fixed to at least one of the entrance and exit faces. 
     
     
       7. The device according to  claim 6 , wherein the at least one lens comprises at least a first lens formed over the entrance face and at least a second lens formed over the exit face. 
     
     
       8. The device according to  claim 6 , wherein the at least one lens comprises a pair of refractive surfaces formed on opposing sides of at least one of the entrance and exit faces. 
     
     
       9. The device according to  claim 1 , and comprising first and second plates, having respective first and second transparent regions that define the entrance face and the exit face, while the optical path between the entrance and exit faces passes between the first and second plates. 
     
     
       10. The device according to  claim 9 , wherein the first and second reflectors are spaced apart and fixed between the first and second plates in mutually-parallel orientations diagonal to the first and second plates. 
     
     
       11. The device according to  claim 10 , wherein the first and second plates and the first and second reflectors define a cavity that contains the optical path, and
 wherein the device comprises third and fourth plates, which are fixed to the first and second plates and the first and second planar reflectors on opposing sides of the device in an orientation perpendicular to the first and second plates and the planar reflectors so as to enclose the cavity.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 15/691,762, filed Aug. 31, 2017, which is a continuation of U.S. patent application Ser. No. 14/852,563, filed Sep. 13, 2015 (now abandoned). 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to optical devices and methods for their manufacture, and particularly to miniaturized integrated optical devices. 
     BACKGROUND 
     Miniature optical projectors are used in a variety of applications. For example, such projectors may be used to cast a pattern of coded or structured light onto an object for purposes of 3D mapping (also known as depth mapping). In this regard, U.S. Patent Application Publication 2008/0240502 describes an illumination assembly in which a light source, such as a laser diode or LED, transilluminates a transparency with optical radiation so as to project a pattern onto the object. (The terms “optical” and “light” as used herein refer generally to any of visible, infrared, and ultraviolet radiation.) An image capture assembly captures an image of the pattern that is projected onto the object, and a processor processes the image so as to reconstruct a three-dimensional (3D) map of the object. 
     PCT International Publication WO 2008/120217 describes further aspects of the sorts of illumination assemblies that are shown in the above-mentioned US 2008/0240502. In one embodiment, the transparency comprises an array of micro-lenses arranged in a non-uniform pattern. The micro-lenses generate a corresponding pattern of focal spots, which is projected onto the object. 
     Optical projectors may, in some applications, project light through one or more diffractive optical elements (DOEs). For example, U.S. Patent Application Publication 2009/0185274 describes apparatus for projecting a pattern that includes two DOEs that are together configured to diffract an input beam so as to at least partially cover a surface. The combination of DOEs reduces the energy in the zero-order (undiffracted) beam. In one embodiment, the first DOE generates a pattern of multiple beams, and the second DOE serves as a pattern generator to form a diffraction pattern on each of the beams. 
     As another example, U.S. Pat. No. 9,091,413 describes photonics modules that include optoelectronic components and optical elements (refractive and/or patterned) in a single integrated package. According to the inventors, these modules can be produced in large quantities at low cost, while offering good optical quality and high reliability. They are useful as projectors of patterned light, for example in 3D mapping applications as described above, but they may also be used in various other applications that use optical projection and sensing, including free-space optical communications. 
     SUMMARY 
     Embodiments of the present invention that are described hereinbelow provide integrated optical devices with enhanced reliability and manufacturability. 
     There is therefore provided, in accordance with an embodiment of the present invention, an optical device, which includes a first plate having a first transparent region defining an exit face of the device and a second plate having a second transparent region defining an entrance face of the device. At least one lens is formed over at least one of the first and second transparent regions. First and second planar reflectors are spaced apart and fixed between the first and second plates in mutually-parallel orientations diagonal to the first and second plates, thereby defining an optical path through the device from the entrance face, reflecting from the first and second reflectors, through the exit face and passing through the at least one refractive surface. 
     In a disclosed embodiment, the at least one lens includes at least a first lens formed over the first transparent region and at least a second lens formed over the second transparent region. Additionally or alternatively, the at least one lens includes at least first and second lenses formed on opposing sides of at least one of the first and second plates. Further additionally or alternatively, the first and second plates and the first and second planar reflectors define a cavity that contains the optical path, and the device includes third and fourth plates, which are fixed to the first and second plates and the first and second planar reflectors on opposing sides of the device in an orientation perpendicular to the first and second plates and the planar reflectors so as to enclose the cavity. 
     In one embodiment, the device includes a patterning element and a first spacer, fixed between the patterning element and the first plate so as to hold the patterning element in proximity to the exit face, as well as a light source mounted on a substrate and a second spacer, fixed between the substrate and the second plate so as to hold the light source in proximity to the entrance face, so that light emitted from the light source passes through the device along the optical path and transilluminates the patterning element, thereby generating patterned light. 
     There is also provided, in accordance with an embodiment of the present invention, a method for producing an optical device. The method includes fixing together first and second planar reflectors in mutually-parallel orientations with a predefined spacing between the first and second planar reflectors. First and second plates are provided, having respective first and second transparent regions that respectively define exit and entrance faces of the device, with at least one lens formed over at least one of the first and second transparent regions. The first and second plates are fixed to the fixed-together planar reflectors in an orientation diagonal to the planar reflectors, so as to define an optical path through the device from the entrance face, reflecting from the first and second reflectors, through the exit face and passing through the at least one refractive surface. 
     In some embodiments, providing the first and second plates includes forming an array of lenses on a transparent substrate, and dicing the transparent substrate to produce at least one of the first and second plates with the at least one lens formed thereon. Typically, the array of lenses is formed by molding or replication on the transparent substrate. Additionally or alternatively, fixing together the first and second planar reflectors includes fixing together multiple pairs of the planar reflectors so as to define multiple optical devices having respective optical cavities, wherein fixing the first and second plates includes attaching the transparent plate to the multiple pairs of the planar reflectors so that the lenses in the array are respectively aligned with the optical cavities before dicing the transparent substrate. 
     In a disclosed embodiment, the method includes, before fixing together the first and second planar reflectors, polishing and applying a reflective coating to respective inner surfaces of the planar reflectors from which the optical path is to reflect within the device. 
     In some embodiments, the first and second plates and the first and second planar reflectors define a cavity that contains the optical path, and the method includes fixing third and fourth plates to the first and second plates and the first and second planar reflectors on opposing sides of the device in an orientation perpendicular to the first and second plates and the planar reflectors so as to enclose the cavity. 
     In a disclosed embodiment, fixing together the first and second planar reflectors includes bonding a pair of reflective sheets to opposing sides of spacers having a thickness equal to the predefined spacing, dicing the bonded reflective sheets and spacers along a first direction perpendicular to the spacers to produce a set of strips, arranging the set of strips side-by-side, bonding the third and fourth plates to opposing sides of the arranged set of the strips, dicing the set of the strips and the third and fourth plates that are bonded thereto along a second direction diagonal to the strips so as to produce multiple rows of diagonal cavities, and dicing apart the cavities in each of the multiple rows to produce the fixed-together planar reflectors. Typically, fixing the first and second plates to the fixed-together planar reflectors includes, before dicing apart the cavities, arranging the multiple rows of the diagonal cavities side by side, and bonding the first and second plates to opposing sides of the arranged multiple rows, with an array of lenses on at least one of the first and second plates aligned with the cavities, wherein dicing apart the cavities includes dicing apart the first and second plates and the aligned lenses together with the cavities to which they are fixed. 
     In some embodiments, the method includes fixing a patterning element in proximity to the exit face, and fixing a light source in proximity to the entrance face, so that light emitted from the light source passes through the device along the optical path and transilluminates the patterning element, thereby generating patterned light. Typically, fixing the patterning element includes fixing a first spacer between the first plate and the patterning element, and fixing the light source includes fixing a second spacer between the second plate and a substrate on which the light source is mounted. 
     The present invention will be more fully understood from the following detailed description of the embodiments thereof, taken together with the drawings in which: 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A and 1B  are schematic sectional views of an integrated light pipe, in accordance with an embodiment of the invention; 
         FIG. 2A  is a schematic top view of a reflector assembly used in producing an integrated light pipe, in accordance with an embodiment of the invention; 
         FIG. 2B  is a schematic side view of a reflector strip cut from the assembly of  FIG. 2A , in accordance with an embodiment of the invention; 
         FIG. 3  is a schematic top view of a stack of reflector strips, in accordance with an embodiment of the invention; 
         FIG. 4  is a schematic top view of an array of light pipe strips, which are cut from the stack of reflector strips shown in  FIG. 3 , in accordance with an embodiment of the invention; 
         FIGS. 5A and 5B  are schematic side and top views, respectively, of an array of lenses, in accordance with an embodiment of the invention; 
         FIGS. 6A and 6B  are schematic side and top views, respectively, of an array of integrated telescopes, in accordance with an embodiment of the invention; 
         FIG. 7  is a schematic side view of an array of integrated telescopes, in accordance with another embodiment of the invention; 
         FIG. 8  is a schematic side view of an array of diffractive stacks, in accordance with an embodiment of the invention; and 
         FIG. 9  is a schematic side view of an integrated optical projector, in accordance with an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     Overview 
     Mass production of miniaturized optical devices calls for product designs that meet the often-conflicting objectives of high precision and reliability and low manufacturing cost. Such designs typically require tight, well-controlled assembly tolerances, structural strength, and manufacturability with high yield, all within strict size and cost constraints. 
     Embodiments of the present invention that are described hereinbelow address these demands in the context of a device having a folded optical design. The design is “folded” in the sense that the optical path through the device reflects from two internal reflectors in the course of passing from the entrance face to the exit face. This sort of design can be useful, inter alia, in extending the optical length of the device while maintaining a low overall dimensional profile. The extended length can be advantageous, for example, in telescopic and microscopic optical designs, in which lenses are positioned at or near one or both of the entrance and exit faces. 
     In the disclosed embodiments, an optical device comprises a pair of plates having transparent regions defining the entrance and exit faces of the device. (The plates, which are referred to herein as the entrance and exit plates, may be entirely transparent, so that the “transparent regions” encompass the entire areas of the plates.) To define the folded optical path, a pair of planar reflectors are fixed between the pair of plates, in mutually-parallel orientations diagonal to the entrance and exit plates and spaced apart by a predefined distance. At least one lens is formed over one or both of the transparent regions. For greater optical power, lenses are formed over both transparent regions and may, alternatively or additionally, be formed on both sides of one or both of the plates in at least one of the transparent regions. 
     The entrance and exit plates and the two planar reflectors define a cavity between them, typically with a parallelogram profile, which contains the optical path. In the embodiments described below, additional side plates are fixed to the entrance and exit plates and to the planar reflectors on opposing sides of the device in an orientation perpendicular to the entrance and exit plates and the planar reflectors so as to enclose the cavity. These side plates may be bonded to the other optical components so as to seal the cavity, or they may contain vent holes. This sort of device is referred to herein as an integrated light pipe. 
     In a disclosed embodiment, the light pipe is integrated into a miniature optical projector. In this embodiment, a patterning element, such as a diffractive optical element (DOE) or other transparency, is held in proximity to the exit face of the light pipe by a first spacer, fixed between the patterning element and the exit plate. A light source, mounted on a substrate, is held in proximity to the entrance face by a second spacer, fixed between the substrate and the entrance plate. Thus, light emitted from the light source passes through the light pipe along the optical path and transilluminates the patterning element, thereby generating patterned light. The patterned light may be used, for example, in 3D mapping systems, as described in the Background section, as well as in other applications of optical projection that are known in the art. 
     Although the disclosed embodiments relate specifically to projection systems of this sort, light pipes in accordance with the principles of the present invention may alternatively be used in other sorts of integrated optical designs for both projection and imaging applications. The methods of manufacture that are described hereinbelow may likewise be adapted for use in the production of other sorts of integrated optical devices, particularly devices containing folded optical paths. 
     Light Pipe Design 
       FIGS. 1A and 1B  are schematic sectional views of an optical device configured as an integrated light pipe  20 , in accordance with an embodiment of the invention. The views in the two figures are rotated by 90° relative to one another, as indicated by the Cartesian axes in the figures, with the section in  FIG. 1B  taken along the line marked IB-IB in  FIG. 1A . The optical path through light pipe  20  is shown as a dashed line through the light pipe, extending from an entrance face in an entrance plate  22  to an exit face in an exit plate  24 . For the sake of convenience, the Z-axis is taken to be along the direction of the optical axis at the entrance and exit faces, and this direction is referred to alternatively as the vertical direction (although light pipe  20  can typically operate in any orientation). 
     Plates  22  and  24  typically comprise a transparent substrate, such as a glass plate or wafer, oriented in the X-Y plane in the present example. A pair of planar reflectors  26  and  28 , mutually parallel and spaced apart by a precisely-defined distance, are fixed diagonally between plates  22  and  24 . Reflectors  26  and  28  may comprise any suitable material, such as glass, ceramic or silicon, with surface coatings  34  and  36  of a type suitable to give high reflectance in the wavelength range in which pipe  20  is to operate (for example, gold or dielectric coatings). The angles of plates  26  and  28  are tightly controlled by the manufacturing process of light pipe  20 , as described further hereinbelow. Plates  22  and  24  and reflectors  26  and  28  thus define an internal cavity  29  of light pipe  20  having a parallelogram shape. 
     Lenses  30 ,  32 ,  38  and  40  are formed on opposing sides of plates  22  and  24 , respectively, at the entrance and exit faces of light pipe  20 . Alternatively, a smaller number of lenses may be formed, depending on application requirements. Typically, lenses  30 ,  32 ,  38  and  40  are formed as arrays of lens elements by molding or replication on transparent substrates that are then diced to produce plates  22  and  24 , as illustrated hereinbelow. Although lenses  30 ,  32 ,  38  and  40  are shown in the figures as refractive elements, the lenses may, alternatively or additionally, comprise diffractive elements. Further additionally or alternatively, the lenses may have anti-reflective and/or other thin-film coatings, and some or all of the lenses may have surrounding apertures, as are known in the art. As further options, one or more of the lenses may have an associated diffuser or may be configured as an array of two or more lenses (for example, when light pipe  20  is to receive light from two or more light sources). 
     As shown in  FIG. 1B , the sides of light pipe  20  are closed by plates  42  and  44 , which are oriented in the X-Z plane in the illustrated embodiment, perpendicular to plates  22 ,  24  and to reflectors  26 ,  28 . Plates  42  and  44 , which may likewise comprise glass or silicon, are fixed to plates  22  and  24  and to reflectors  26  and  28  on opposing sides of light pipe  20 , so as to enclose cavity  29  within the light pipe. Depending on application requirements, the cavity may be hermetically sealed, or may have air vents (not shown). 
     As a result of the manufacturing process that is described below, triangular voids  46  may remain at the corners of light pipe  20 , as shown in  FIG. 1A . For enhanced mechanical integrity and ease of mounting, it may be advantageous either to fill voids  46 , for example with an epoxy or polymer filling, or to dice plates  22  and  24  in such a way as to remove the overhanging parts above these voids. Alternatively, reflectors  26  and  28  may be made from thicker substrates, so that voids  46  do not remain after dicing. 
     Manufacturing Process 
     The figures that follow show successive steps in a process of manufacturing that can be used to produce integrated light pipe  20 , in accordance with an embodiment of the invention. Alternatively, this process may be adapted to produce other types of integrated optical devices. 
       FIGS. 2A and 2B  schematically illustrate a reflector assembly  48  that is used in a first stage of this process, in accordance with an embodiment of the invention.  FIG. 2A  is a top view of reflector assembly  48 , while  FIG. 2B  is a side view of a reflector strip  58  that is cut from assembly  48 . 
     Assembly  48  comprises an upper reflective sheet  50  and a lower reflective sheet  52 , separated by spacers  54 . Sheets  50  and  52  will ultimately be diced to define reflectors  26  and  28 , with cavity  29  between them, as described hereinbelow. Therefore, before producing assembly  48 , sheets  50  and  52  are ground and polished to the desired thickness and surface quality. The polished surfaces, which are to become the inner surfaces of planar reflectors  26  and  28 , facing into cavity  29 , are then coated with reflective surface coatings  34  and  36 . These coatings may be applied using any suitable process that is known in the art, such as sputtering (for metal coatings) or vacuum evaporation (for dielectrics). 
     Spacers  54  are fixed between the edges of sheets  50  and  52  to hold the substrates apart by a precise distance, marked “D” in  FIG. 2B . This distance is dictated by the desired optical properties of light pipe  20 . Spacers  54  may comprise the same material (such as glass, ceramic or silicon) as sheets  50  and  52 , or a different material. For example, spacers  54  may be made from an additional sheet of material, possibly from the same material as sheets  50  and  52 , which is diced to produce multiple spacers of the desired width. To ensure that the distance between sheets  50  and  52  is accurately maintained, spacers  54  (or the sheet from which they are cut) are typically ground and polished on both sides to a thickness equal to the specified distance D. Spacers  54  are then bonded between sheets  50  and  52 , for example using a suitable adhesive, with uniform pressure applied along the edges of the substrates during bonding to maintain uniform spacing. 
     After bonding of sheets  50  and  52  to spacers  54 , assembly  48  is diced along lines  56  to produce multiple reflector strips  58 . The width of strips  58  is equal to the width of reflectors  26  and  28  within light pipe  20  in the Y-direction, as shown in  FIG. 1B . 
       FIG. 3  is a schematic top view of a stack of reflector strips  58 , in accordance with an embodiment of the invention. Strips  58  are arranged side by side, with the cavities between reflective surface coatings  34  and  36  parallel to one another and with predefined spaces  62  between adjacent strips  58 . Spaces  62  are chosen to match the pitch of the arrays of lenses that will be used in a subsequent stage of the process (as shown in  FIGS. 5A /B and  6 A/B). 
     Strips  58  may be placed and held in this manner in a suitable jig or on an adhesive tape in the desired spacing and orientation. Spaces  62  may optionally be filled with a solid material, such as a polymer filler. For high yield, it is advantageous that the angle between the line running through the ends of strips  58  and the axes of central cavities  59  of the strips be equal to the diagonal angle of cavity  29  within light pipes  20 . 
     After arranging strips  58  in the manner shown in  FIG. 3 , sheets  60  are bonded to the opposing sides of the array of strips  58 . Sheets  60  typically comprise, like sheets  50  and  52 , a suitable glass, ceramic, or semiconductor material, which will ultimately be diced into plates  42  and  44 , forming the side walls of light pipes  20 . The entire assembly of  FIG. 3  is then diced along lines  66  that are diagonal to strips  58  in order to produce multiple rows  64  of diagonal cavities. The angle between lines  66  and the internal surfaces of cavities  59  is equal to the diagonal angle of cavities  29 , relative to the X-axis, in light pipes  20 . In other words, rows  64  are sliced apart along a direction which is to be the X-Y plane in light pipes  20 , with a distance between lines  66  that is equal to the height of reflectors  26 ,  28  and plates  42 ,  44  in the Z-direction ( FIG. 1B ). Spacers  54  are sliced off at this stage and discarded. The cavities remaining in each of rows  64  will subsequently be diced apart to produce fixed-together planar reflectors  26  and  28  (as shown in  FIGS. 6A /B). 
       FIG. 4  is a schematic top view of an array of rows  64  of light pipe strips, which are cut from the stack of reflector strips  58  shown in  FIG. 3 , in accordance with an embodiment of the invention. Rows  64  are rotated by 90° after slicing, so that the diagonal cavities between the pairs of planar reflectors  26  and  28  are parallel and open outward, relative to the plane of the figure. After rotation, rows  64  are arranged side by side and aligned with one another so that the openings of cavities  29  are located on a grid, with distances between the cavities equal to the pitch of the lens array. Again, a suitable jig or tape may be used to hold rows  64  in the appropriate orientation with the correct spacing. 
       FIGS. 5A and 5B  are schematic side and top views, respectively, of an array of lenses  38 ,  40 , which are formed on opposing sides of a sheet  70 , in accordance with an embodiment of the invention. Sheet  70  will subsequently be diced, together with rows  64 , to produce exit plate  24  of light pipes  20 , while a similar sheet  72  ( FIG. 6A ) is provided and diced to produce entrance plate  22  of the light pipes. Typically, sheets  70  and  72  comprise glass, but any other suitable material may be used, as long as it has at least a transparent region in the area of the lenses. Lenses  38  and  40  may, for example, comprise polymer elements replicated on sheet  70 , or they may be integrally molded with sheet  70 . The pitch of the array of lenses  38 ,  40  is designed to match the pitch of the cavities in rows  64  as shown in  FIG. 4 . 
       FIGS. 6A and 6B  are schematic side and top views, respectively, of an array  74  of integrated light pipes  20 , in accordance with an embodiment of the invention. To form array  74 , sheet  70  is positioned so that lenses  38  and  40  are aligned with the upper openings of cavities  29  of what are to become light pipes  20 , and sheet  70  is then bonded in position. Similarly, sheet  72  is positioned and bonded so that lenses  30  and  32  are aligned with the lower openings of cavities  29 . The entire array  74 , including sheets  70  and  72  and rows  64 , is then diced apart along lines  76  in order to singulate light pipes  20 , including lenses  30 ,  32 , and  40  and cavity  29  therebetween. Optionally, the elements of array  74  may be optically tested before singulation. 
     When other optical and/or optoelectronic elements are to be integrated with light pipes  20 , some or all of the integration steps may likewise take place before singulation. For example, in a patterned light projector, an array of patterning elements may likewise be produced and bonded to array  74  before singulation. 
       FIG. 7  is a schematic side view of an array  80  of integrated light pipes  20 , in accordance with another embodiment of the invention. Array  80  comprises multiple rows  82  of light pipes  20 , which can be produced by dicing array  74  along lines  76  running in the X-direction, as shown in  FIG. 6B , but not in the Y-direction. Rows  82  are then turned on their sides and stacked with a diagonal offset, as shown in  FIG. 7 . As in previous embodiments, a suitable jig or tape may be used to hold rows  82  in the desired positions. Array  80  is diced along diagonal lines  84  so as to produce singulated light pipes  20  without voids  46  at their corners. 
     Device Integration 
       FIG. 8  is a schematic side view of an array  90  of diffractive stacks  106 , in accordance with an embodiment of the invention. To produce stacks  106 , arrays of diffractive optical elements (DOEs)  92  and  96  are formed on transparent substrates  94  and  98 . The DOEs may be formed, for example, by replication of polymer structures on glass substrates, or by etching the glass substrates or, alternatively, precision molding of polymer substrates. Although the present embodiment relates specifically to production of such diffractive stacks, other sorts of transparencies may alternatively be produced and integrated with light pipes  20 , mutatis mutandis. 
     Substrates  94  and  98  are mounted on opposing sides of a spacer layer  100 . If sealing of DOEs  92  and  96  is desired, spacer layer  100  may comprise an array of openings through a solid layer; after aligning the openings with the DOEs, layer  100  is bonded between substrates  94  and  98 , for example with a suitable adhesive. An additional spacer layer  102  is bonded to the underside of substrate  98 . The resulting assembly is then diced along lines  104  to singulate stacks  106 . Each such stack is then aligned with and mounted over lens  40  on the upper side of a respective light pipe  20 , either before or after singulation of the light pipes. 
       FIG. 9  is a schematic side view of an integrated optical projector  110 , in accordance with an embodiment of the invention. In this embodiment, diffractive stack  106  is mounted over plate  24  on spacers made from layer  102 . On the lower side of projector  110 , a light source  112 , such as a laser diode or LED, is mounted on a substrate  114 , which is connected to plate  22  by spacers  116 . Thus, light emitted from light source  112  passes along the optical path through cavity  29 , reflecting from reflectors  26  and  28 , and transilluminates diffractive stack  106 . Integrated light pipe  20  in this embodiment serves as a beam expanding telescope for light source  112 , while diffractive stack  106  serves as a patterning element, projecting patterned light onto a target. 
     Although  FIG. 9  shows one particular application of integrated light pipe  20 , the principles of the present invention may alternatively be applied in other sorts of integrated optical devices, all of which are considered to be within the scope of the present invention. 
     It will thus be appreciated that the embodiments described above are cited by way of example, and that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and subcombinations of the various features described hereinabove, as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description and which are not disclosed in the prior art.

Metadata:
Filing Date: 20180228
Publication Date: 20181204
Grant Date: 20181204
Priority Date: 20150913
Inventors: KRIMAN, MOSHE
MAGEN, ADAR
Assignee: APPLE INC
CPC Classifications: [{"code": "G02B19/0028", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B3/0068", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B19/0066", "inventive": true, "first": false, "tree": "[]"}, {"code": "G03B21/2033", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B19/0066", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B27/425", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B27/425", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B19/0028", "inventive": true, "first": false, "tree": "[]"}, {"code": "G03B21/2066", "inventive": true, "first": true, "tree": "[]"}, {"code": "G03B21/2066", "inventive": true, "first": true, "tree": "[]"}, {"code": "G03B21/2033", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B3/0068", "inventive": true, "first": false, "tree": "[]"}, {"code": "G03B21/2033", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B27/425", "inventive": true, "first": false, "tree": "[]"}, {"code": "G03B21/2066", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 58236824