US 11,886,008 B2
Methods of fabrication of compound light-guide optical elements having embedded coupling-in reflectors
Ronen Chriki, Lod (IL); Kobi Greenstein, Ness Ziona (IL); Edgar Friedmann, Sdey-Avraham (IL); and Elad Sharlin, Mishmar David (IL)
Assigned to LUMUS LTD., Ness Ziona (IL)
Appl. No. 18/028,803
Filed by Lumus Ltd., Ness Ziona (IL)
PCT Filed Apr. 11, 2022, PCT No. PCT/IL2022/050375
§ 371(c)(1), (2) Date Mar. 28, 2023,
PCT Pub. No. WO2023/026266, PCT Pub. Date Mar. 2, 2023.
Claims priority of provisional application 63/235,837, filed on Aug. 23, 2021.
Prior Publication US 2023/0305230 A1, Sep. 28, 2023
Int. Cl. G02B 6/25 (2006.01); B32B 38/04 (2006.01); B32B 38/00 (2006.01)
CPC G02B 6/25 (2013.01) [B32B 38/0004 (2013.01); B32B 2307/416 (2013.01); B32B 2551/00 (2013.01)] 26 Claims
OG exemplary drawing
 
1. A method of fabricating a compound light-guide optical element (LOE), comprising:
obtaining a stack having a first pair of faces and a plurality of LOEs, each of the LOEs having a pair of major parallel surfaces and a first plurality of mutually parallel partially reflective internal surfaces oblique to the pair of major parallel surfaces;
obtaining a first optical block having a second pair of faces and a second plurality of mutually parallel partially reflective internal surfaces;
bonding together the first optical block and the stack such that one of the faces of the first pair of faces is joined to a first one of the faces of the second pair of faces and such that the first plurality of partially reflective internal surfaces is non-parallel to the second plurality of partially reflective internal surfaces, thereby forming a second optical block;
cutting the second optical block along a cutting plane that passes through a second one of the faces of the second pair of faces, thereby forming a first optical structure having an interfacing surface at the cutting plane;
obtaining a third optical block having a third pair of faces and a plurality of mutually parallel reflective internal surfaces;
bonding together the third optical block and the first optical structure such that a first one of the faces of the third pair of faces is joined to the interfacing surface and such that the plurality of reflective internal surfaces is non-parallel to both the first plurality of partially reflective internal surfaces and the second plurality of partially reflective internal surfaces, thereby forming a second optical structure; and
slicing out at least one compound LOE from the second optical structure by cutting the second optical structure through at least two cutting planes substantially parallel to the major parallel surfaces of consecutive LOEs of the plurality of LOEs.