US 7,542,209 B2Grant

Compact head mounted display devices with tilted/decentered lens element

Issue Date:2009-06-02

•108 Claims

•30 Drawing Sheets

Abstract

One embodiment of the invention comprises a simplified light-weight head mounted displays comprising an off-axis combiner and imaging optics defining an optical path. The imaging optics comprises a lens group comprising a plurality of lenses in the optical path. The lens group has a first optical axis. Each of said plurality of lenses have optical axes collinear with the first optical axis. The imaging optics further comprises a single lens element in the optical path having a second optical axis that is different from the first optical axis. The single lens element has positive optical power and is the only lens element in the optical path between the lens group and the combiner that has an optical axis collinear with the second optical axis.

Metadata

Assignee

Optical Research Associates

Inventor

James P. McGuire, Jr.

Application Information

Application Number:US 11/218,325

Filing Date:2005-09-01

Priority Date:2004-09-01

Art Unit:2873

Classifications

IPC:

G02B27/14

Patent Drawings (30 sheets)

Description

Related Applications

[0001] This application claims is a continuation-in-part of U.S. patent application Ser. No. 11/134,841, filed May 20, 2005 and entitled “Head Mount Display Devices”, which claims priority to U.S. Patent Application No. 60/677,666, filed May 3, 2005 and entitled “Simple Helmet Mounted Display With Plastic Element”, both of which are incorporated herein by reference in its entirety, and this application also claims priority to U.S. Provisional Application No. 60/606,210, filed Sep. 1, 2004 and entitled “Compact Head and Helmet Mounted Display”, which is also incorporated herein by reference in its entirety.

[0002] In addition, this application also incorporates by reference U.S. patent application Ser. No. 10/852,728, filed on May 24, 2004 and entitled “Beamsplitting structures and methods in optical systems”, U.S. patent application Ser. No. 10/852,679, filed on May 24, 2004 and entitled “Apparatus and methods for illuminating optical systems”, U.S. patent application Ser. No. 10/852,669, filed on May 24, 2004 and entitled “Light distribution apparatus and methods for illuminating optical systems”, and U.S. patent application Ser. No. 10/852,727, filed on May 24, 2004 and entitled “Optical combiner designs and head mounted displays”, each in their entirety.

Background

[0003] 1. Field of the Invention

[0004] This invention relates to displays and methods that may be used, for example, in displays and projection systems, such as head mounted displays, helmet mounted displays and heads-up display, etc.

[0005] 2. Description of the Related Art

[0006] Optical devices for presenting information and displaying images are ubiquitous. Some examples of such optical devices include computer screens, projectors, televisions, and the like. Front projectors are commonly used for presentations. Flat panel displays are employed for computers, television, and portable DVD players, and even to display photographs and artwork. Rear projection TVs are also increasingly popular in the home. Cell phones, digital cameras, personal assistants, and electronic games are other examples of hand-held devices that include displays. Heads-up displays where data is projected on, for example, a windshield of an automobile or in a cockpit of an aircraft, will be increasingly more common. Helmet mounted displays are also employed by the military to display critical information superimposed on a visor or other eyewear in front of the wearer's face. With this particular arrangement, the user has ready access to the displayed information without his or her attention being drawn away from the surrounding environment, which may be a battlefield in the sky or on the ground. In other applications, head mounted displays provide virtual reality by displaying graphics on a display device situated in front of the user's face. Such virtual reality equipment may find use in entertainment, education, and elsewhere. In addition to sophisticated gaming, virtual reality may assist in training pilots, surgeons, athletes, teen drivers and more.

[0007] Preferably, these different display and projection devices are compact, lightweight, and reasonably priced. As many components are included in the optical systems, the products become larger, heavier, and more expensive than desired for many applications. Yet such optical devices are expected to be sufficiently bright and preferably provide high quality imaging over a wide field-of-view so as to present clear text or graphical images to the user. In the case of the helmet or more broadly head mounted displays, for example, the display preferably accommodates a variety of head positions and varying lines-of-sights. For projection TVs, increased field-of-view is desired to enable viewers to see a bright clear image from a wide range of locations with respect to the screen. Such optical performance depends in part on the illumination and imaging optics of the display.

[0008] What is needed, therefore, are illumination and imaging optics for producing lightweight, compact, high quality optical systems at a reasonable cost.

Summary

[0009] Various embodiments are described herein. One embodiment of the invention comprises an apparatus for a head mounted display, said apparatus comprising: imaging optics defining an optical path, said imaging optics comprising: a lens group comprising a plurality of lens elements in said optical path, said lens group having a first optical axis, each of said plurality of lenses having optical axes collinear with said first optical axis; and a single lens element in said optical path having a second optical axis that is different from the first optical axis; and an off-axis combiner in said optical path, wherein said single lens element has positive optical power and is the only lens element in said optical path between said lens group and said combiner that has an optical axis collinear with the second optical axis.

[0010] Another embodiment of the invention comprises a head mounted display device for displaying images comprising: an image formation device comprising a plurality of pixels selectively adjustable for producing spatial patterns; imaging optics disposed with respect to the image formation device to receive light from said plurality of pixels for forming an image thereof, said image formation device and said imaging optics defining an optical path, said imaging optics comprising: a lens group comprising a plurality of lens elements in said optical path, said lens group having a first optical axis, each of said plurality of lenses having optical axes collinear with said first optical axis; and a single lens element in said optical path having a second optical axis that is different from the first optical axis, said single lens element having positive optical power; an off-axis combiner in said optical path, said combiner configured to reflect light from said imaging optics such that said image may be displayed; and head gear that supports said image formation, imaging optics, and combiner, wherein said single lens element in said imaging optics is the only lens element in said optical path between said image formation device and said combiner that has an optical axis collinear with the second optical axis.

[0011] Another embodiment of the invention comprises an apparatus for a head mounted display, said apparatus comprising: imaging optics defining an optical path, said imaging optics comprising: a single first lens element in said optical path having a first optical axis; and a single second lens element in said optical path having a second optical axis that is different from the first optical axis; and an off-axis combiner in said optical path, wherein said single second lens element has positive optical power and is the only lens element in said optical path between said single first lens element and said combiner.

[0012] Another embodiment of the invention comprises a head mounted display device for displaying images comprising: an image formation device comprising a plurality of pixels selectively adjustable for producing spatial patterns; imaging optics disposed with respect to the image formation device to receive light from said plurality of pixels for forming an image thereof, said image formation device and said imaging optics defining an optical path, said imaging optics comprising: a first single lens element in said optical path having a first optical axis; and a single lens element in said optical path having a second optical axis that is different from the first optical axis, said single lens element having positive optical power; an off-axis combiner in said optical path, said combiner configured to reflect light from said imaging optics such that said image may be displayed; and head gear for supporting said image formation, imaging optics, and combiner, wherein said single lens element in said imaging optics is the only lens in said optical path between said image formation device and said combiner that has an optical axis collinear with the second optical axis.

[0013] Another embodiment of the invention comprises a head mounted display for displaying images comprising: an image formation device comprising a plurality of pixels selectively adjustable for producing spatial patterns; imaging optics disposed with respect to the image formation device to receive light from said plurality of pixels for forming an image thereof, said image formation device and said imaging optics forming an optical path, said imaging optics comprising at least a lens or other type of optical element; an off-axis reflector in said optical path, said off-axis reflector configured to reflect light from said imaging optics such that said image may be displayed; and head gear that supports said image formation, imaging optics, and combiner, wherein no more than two lenses are included in said path between said image formation device and said off-axis reflector.

[0014] Another embodiment of the invention comprises an apparatus for a head mounted display, said apparatus comprising: imaging optics comprising at least a lens or other type of optical element, said lenses defining an optical path; an off-axis reflective combiner in said optical path; and a support, said imaging optics and said combiner secured to said support, wherein no more than two lenses and no reflectors having optical power are included in said optical path.

[0015] Another embodiment of the invention comprises an apparatus for a head mounted display, said apparatus comprising: imaging optics comprising at least a lens or other type of optical element, said imaging optics defining an optical path; a reflective combiner in said optical path, said reflective combiner comprising an aspheric combiner; and a support structure, said imaging optics and said combiner secured to said support structure, wherein only lenses having two aspheric refractive optical surfaces are included in said optical path.

[0016] Another embodiment of the invention comprises a head mounted display for displaying images comprising: an image formation device comprising a plurality of pixels selectively adjustable for producing spatial patterns; optics disposed with respect to the image formation device to receive light from said plurality of pixels for forming an image thereof, said optics comprising at least one non-rotationally symmetric lens comprising first and second surfaces having first and second shapes that are rotationally symmetric about first and second axes that are tilted and decentered with respect to each other; a combiner configured to reflect light from said imaging optics such that said image may be displayed; and head gear for supporting said image formation device, imaging optics, and combiner.

[0017] Another embodiment of the invention comprises optics for a head mounted display comprising an image formation device, said optics comprising: imaging optics configured to be disposed with respect to the image formation device to receive light from said image formation device, said imaging optics comprising at least one non-rotationally symmetric lens comprising front and rear surfaces having first and second shapes that are rotationally symmetric about first and second axes, said first and second axes being tilted with respect to each other; and an off-axis combiner.

[0018] Another embodiment of the invention comprises a method of forming an image in a person's eye, said method comprising: forming an image using an image formation device have a plurality of pixels; collecting light from said plurality of pixels with refracting optics comprising a non-rotationally symmetric lens comprising first and second surfaces having shapes that are rotationally symmetric about different first and second axis; and reflecting said light from an off-axis reflector into the eye to form an image in the eye.

[0019] Another embodiment of the invention comprises an optical system for displaying images, said optical system comprising: an image formation device comprising a plurality of pixels selectively adjustable for producing spatial patterns; imaging optics disposed with respect to the image formation device to receive light from said plurality of pixels for forming an image thereof, said image formation device and said imaging optics defining an optical path, said imaging optics comprising at least a lens or other type of optical element; and an off-axis reflector in said path, said off-axis reflector configured to reflect light from said imaging optics such that said image may be displayed, wherein said no more than two lenses are included in said optical path between said image formation device and said off-axis reflector.

[0020] Another embodiment of the invention comprises an apparatus for displaying an image, said apparatus comprising: imaging optics comprising at least a lens or other type of optical element, said imaging optics defining an optical path; an off-axis reflective combiner in said optical path; and a support structure, said imaging optics and said off-axis reflective combiner secured to said support structure, wherein no more than two lens and no reflectors having optical power are in said optical path.

[0021] Another embodiment of the invention comprises an apparatus for forming an image, said apparatus comprising: imaging optics comprising at least a lens or other type of optical element, said imaging optics defining an optical path; a reflective combiner in said optical path, said reflective combiner comprising an aspheric combiner; and a support structure, said imaging optics and said combiner secured to said support structure, wherein only lenses having two aspheric refractive optical surfaces are in said optical path.

[0022] Another embodiment of the invention comprises a method of forming an image, said method comprising: producing an image in an object field; and forming an image of the object field with optics comprising exactly two lenses and an off-axis reflective combiner.

[0023] Another embodiment of the invention comprises an optical system for displaying images comprising: an image formation device comprising a plurality of pixels selectively adjustable for producing spatial patterns; optics disposed with respect to the image formation device to receive light from said plurality of pixels for forming an image thereof, said optics comprising at least one non-rotationally symmetric lens comprising first and second surfaces having first and second shapes that are rotationally symmetric about first and second axes that are tilted and decentered with respect to each other; and a combiner configured to reflect light from said imaging optics such that said image may be displayed.

[0024] Another embodiment of the invention comprises optics for imaging an image formation device, said optics comprising: imaging optics configured to be disposed with respect to the image formation device to receive light from said image formation device, said imaging optics comprising at least one non-rotationally symmetric lens comprising front and rear surfaces having first and second shapes that are rotationally symmetric about first and second axes, said first and second axes being tilted with respect to each other; and an off-axis combiner.

[0025] Another embodiment of the invention comprises a method of forming an image, said method comprising: forming an image using an image formation device have a plurality of pixels; collecting light from said plurality of pixels with refracting optics comprising a non-rotationally symmetric lens comprising first and second surfaces having shapes that are rotationally symmetric about different first and second axis; and reflecting said light from an off-axis reflector to form an image.

[0026] One embodiment comprises a head mounted display for displaying images comprising an image formation device comprising a plurality of pixels selectively adjustable for producing spatial patterns; imaging optics disposed with respect to the image formation device to receive light from said plurality of pixels for forming an image thereof, said imaging optics comprising no more than two lenses; an off-axis combiner configured to reflect light from said imaging optics such that said image may be displayed; and head gear for supporting said image formation, imaging optics, and combiner.

[0027] Another embodiment of the invention comprises optics for a head mounted display comprising an image formation device, said optics comprising: imaging optics disposed with respect to said image formation device to receive light from said image formation device, wherein imaging optics comprises no more than two lens and no reflectors having optical power; and an off-axis reflective combiner.

[0028] Another embodiment of the invention comprises optics for a head mounted display comprising an image formation device, said optics comprising: imaging optics disposed with respect to the image formation device to receive light from said image formation device, said imaging optics comprising only lens having two aspheric refractive optical surfaces; and a reflective combiner comprising an aspheric combiner.

[0029] Another embodiment of the invention comprises a method of forming an image in the eye of a wearer of a head mounted display, said method comprising: forming an image in an object field; and forming an image of the object field with optics comprising exactly two lenses and an off-axis reflective combiner, said image formed in the eye of the wearer.

[0030] Another embodiment of the invention comprises a head mounted display for displaying images comprising: a image formation device comprising a plurality of pixels selectively adjustable for producing spatial patterns; optics disposed with respect to the image formation device to receive light from said plurality of pixels for forming an image thereof, said optics comprising at least one non-rotationally symmetric lens comprising first and second surfaces having first and second shapes that are rotationally symmetric about first and second axes that are tilted and decentered with respect to each other; a combiner configured to reflect light from said imaging optics such that said image may be displayed; and head gear for supporting said image formation device, imaging optics, and combiner.

[0031] Another embodiment of the invention comprises optics for a head mounted display comprising an image formation device, said optics comprising: imaging optics configured to be disposed with respect to the image formation device to receive light from said image formation device, said imaging optics comprising at least one non-rotationally symmetric lens comprising front and rear surfaces having first and second shapes that are rotationally symmetric about first and second axes, said first and second axes being tilted with respect to each other; and an off-axis combiner.

[0032] Another embodiment of the invention comprises a method of forming an image in a person's eye, said method comprising: forming an image using an image formation device have a plurality of pixels; collecting light from said plurality of pixels with refracting optics comprising a non-rotationally symmetric lens comprising first and second surfaces having shapes that are rotationally symmetric about different first and second axis; and reflecting said light from an off-axis reflector into the eye to form an image in the eye.

[0033] Another embodiment of the invention comprises an optical system for displaying images comprising: an image formation device comprising a plurality of pixels selectively adjustable for producing spatial patterns; imaging optics disposed with respect to the image formation device to receive light from said plurality of pixels for forming an image thereof, said imaging optics comprising no more than two lenses; and an off-axis combiner configured to reflect light from said imaging optics such that said image may be displayed.

[0034] Another embodiment of the invention comprises optics for displaying an image formed on an image formation device, said optics comprising: imaging optics configured to be disposed with respect to said image formation device to receive light from said image formation device, wherein imaging optics comprises no more than two lens and no reflectors having optical power; and an off-axis reflective combiner.

[0035] Another embodiment of the invention comprises optics for imaging an image formation device, said optics comprising: imaging optics disposed with respect to the image formation device to receive light from said spatial light modulator, said imaging optics comprising only lens having two aspheric refractive optical surfaces; and a reflective combiner comprising an aspheric combiner.

[0036] Another embodiment of the invention comprises a method of forming an image, said method comprising: producing an image in an object field; and forming an image of the object field with optics comprising exactly two lenses and an off-axis reflective combiner.

[0037] Another embodiment of the invention comprises an optical system for displaying images comprising: an image formation device comprising a plurality of pixels selectively adjustable for producing spatial patterns; optics disposed with respect to the image formation device to receive light from said plurality of pixels for forming an image thereof, said optics comprising at least one non-rotationally symmetric lens comprising first and second surfaces having first and second shapes that are rotationally symmetric about first and second axes that are tilted and decentered with respect to each other; and a combiner configured to reflect light from said imaging optics such that said image may be displayed.

[0038] Another embodiment of the invention comprises optics for imaging an image formation device, said optics comprising: imaging optics configured to be disposed with respect to the image formation device to receive light from said image formation device, said imaging optics comprising at least one non-rotationally symmetric lens comprising front and rear surfaces having first and second shapes that are rotationally symmetric about first and second axes, said first and second axes being tilted with respect to each other; and an off-axis combiner.

[0039] Another embodiment of the invention comprises a method of forming an image, said method comprising: forming an image using an image formation device have a plurality of pixels; collecting light from said plurality of pixels with refracting optics comprising a non-rotationally symmetric lens comprising first and second surfaces having shapes that are rotationally symmetric about different first and second axis; and reflecting said light from an off-axis reflector to form an image.

Brief Description of the Drawings

[0040] FIG. 1 is a schematic representation of a display apparatus comprising a beamsplitter disposed in front of a spatial light modulator that directs a beam of light to the spatial light modulator to provide illumination thereof;

[0041] FIG. 2 is a perspective view of a projection system comprising an optical apparatus similar to that depicted schematically in FIG. 1;

[0042] FIG. 3 is a schematic representation of a preferred display apparatus comprising a “V” prism for illuminating a spatial light modulator;

[0043] FIG. 4 is a perspective view of an optical system for a rear projection TV comprising a “V” prism such as shown in FIG. 3 disposed between a pair of light sources for illuminating a spatial light modulator;

[0044] FIG. 5 is a perspective view of a prism device having a pair of reflective surfaces for providing illumination of a display, wherein light is coupled into the prism via light propagating conveyances;

[0045] FIG. 6 is a perspective view of a prism element having four input ports for receiving light from four integrating rods and four reflective surfaces for reflecting the light input through the four input ports;

[0046] FIG. 7 is a perspective view of another prism structure having four input ports for receiving light and four reflecting faces comprising wire grid polarizers for reflecting polarized light input into the input ports;

[0047] FIG. 8A is a cross-sectional view of the prism structure shown in FIG. 7 along the line 8A-8A;

[0048] FIG. 8B is a top view of the prism structure depicted in FIGS. 7 and 8A showing the four triangular faces and wire grid polarizers for reflecting polarized light input into the four ports of the prism structure;

[0049] FIGS. 9A and 9C are perspective views of other prism structures having multiple input ports for receiving light and a reflecting surface for reflecting polarized light input into the input ports;

[0050] FIGS. 9B and 9D are a cross-sectional views of the prism structures shown in FIGS. 9A and 9D along the lines 9B-9B, and 9D-9D respectively;

[0051] FIG. 10 is a schematic representation of an illuminating system comprising a “V” prism further comprising a plurality of light sources, as well as beamshaping optics and a diffuser for each of two input ports;

[0052] FIG. 11 is a schematic representation of an optical fiber bundle split to provide light to a pair of input ports of an illumination device such as the prism shown in FIG. 10;

[0053] FIGS. 12 and 13 are schematic representations of the illuminance incident on two respective portions the spatial light modulator wherein the illuminance has a Gaussian distribution;

[0054] FIG. 14 is plot on axes of position (Y) and illuminance depicting a Gaussian distribution;

[0055] FIG. 15 is a schematic representation of the illuminance distribution across the two portions of the spatial light modulator which is illuminated by light reflected from the respective reflecting surfaces of the “V” prism;

[0056] FIGS. 16 and 17 are schematic representations of the illuminance incident on the two portions of the spatial light modulator of the “V” prism wherein the central peak is shifted with respect to the respective portions of the spatial light modulator;

[0057] FIG. 18 is a schematic representation of the illuminance having a “flat top” distribution incident on one portion of the spatial light modulator;

[0058] FIG. 19 is a plot on axes of position (Y) and illuminance depicting a “top hat” distribution;

[0059] FIG. 20 is a cross-sectional schematic representation of a diffuser scattering light into a cone of angles;

[0060] FIG. 21 is a plot on axes of angle, θ, and intensity illustrating different angular intensity distributions that may be provided by different types of diffusers;

[0061] FIG. 22 is a schematic illustration of a field-of-view for a display showing a non-uniformity in the form of a stripe at the center of the field caused by the V-prism;

[0062] FIG. 23 is a cross-sectional view of the V-prism schematically illustrating the finite thickness of the reflective surfaces of the V prism that produce the striped field non-uniformity depicted in FIG. 22;

[0063] FIG. 24 is a cross-sectional view of wire grid polarizer comprising a plurality of strips spaced apart by air gaps;

[0064] FIG. 25 is a cross-sectional view of wire grid polarizer comprising a plurality of strips with glue filled between the strips;

[0065] FIG. 26 is a cross-sectional view of wire grid polarizer comprising a plurality of strips and a MgF overcoat formed thereon;

[0066] FIGS. 27A-27G are cross-sectional views schematically illustrating one embodiment of a process for forming a V-prism comprising a pair of wire grid polarization beamsplitting surfaces;

[0067] FIG. 28 is a cross-sectional view of a wedge shaped optical element for providing correction of astigmatism and coma that is disposed between the “V” prism and the spatial light modulator;

[0068] FIG. 29 is a cross-sectional view of a “V” prism having a wedge shape that includes correction of astigmatism and coma;

[0069] FIG. 30 is a plot on axes of position (Y) versus illuminance on the spatial light modulator for a wedge-shaped prism used in combination with different type diffusers;

[0070] FIG. 31 is a plot of the illuminance distribution across the spatial light modulator provided by a wedge-shaped “V” prism;

[0071] FIG. 32 is a histogram of luminous flux per area (in lux) that illustrates that the luminous flux per area received over the spatial light modulator is within a narrow range of values;

[0072] FIG. 33 is a plot of the illuminance distribution across the spatial light modulator provided by a “V” prism in combination with a wedge separated from the “V” prism by an air gap such as shown in FIG. 28;

[0073] FIG. 34 is a histogram of luminous flux per area (in lux) that illustrates that the luminous flux per area received over the spatial light modulator is within a narrow range of values;

[0074] FIG. 35 is a schematic representation of a V-prism together with an X-cube;

[0075] FIG. 36 is a schematic representation of a V-prism together with an Philips prism;

[0076] FIG. 37 is a schematic representation of a configuration having reduced dimensions that facilitates compact packaging;

[0077] FIG. 38 is a schematic representation of a configuration for providing non-constant illuminance at the spatial light modulator;

[0078] FIG. 39 shows graded illuminance across the spatial light modulator;

[0079] FIG. 40 is a plot on axis of illuminance versus position (Y) showing that the illuminance across the spatial light modulator increases from one side to another;

[0080] FIG. 41 is a cross-sectional view of a diffuser that scatters light different amounts at different locations on the diffuser;

[0081] FIG. 42 shows three locations on a diffuser that receive different levels of luminous flux corresponding to different illuminance values (I₁, I₂, and I₃) and that scatter light into different size cone angles (Ω₁, Ω₂, and Ω₃) such that the luminance at the three locations (L₁, L₂, and L₃) is substantially constant;

[0082] FIG. 43 is a plot of luminance across the spatial light modulator, which is substantially constant from one side to another;

[0083] FIG. 44 is a histogram of luminous flux per area per solid angle (in Nits) that illustrates that the luminous flux per area per solid angle values received over the spatial light modulator are largely similar;

[0084] FIG. 45 is a cross-sectional view schematically showing a light box and a plurality of compound parabolic collectors optically connected thereto to couple light out from the light box; and

[0085] FIGS. 46-56 are schematic representations of displays such as head mounted displays.

[0086] FIG. 57 is a schematic representation of a simplified light-weight head mounted display comprising a combiner and a pair of plastic lenses.

[0087] FIGS. 58 and 59 are schematic representations of compact head mounted displays comprising a combiner and imaging optics wherein the imaging optics comprises a plurality of lenses combined with a single tilted and/or decentered positive lens.

Detailed Description of the Preferred Embodiment

[0088] To present graphics or other visual information to a viewer, images and/or symbols, e.g., text or numbers, can be projected onto a screen or directed into the viewer's eye. FIG. 1 schematically illustrates a display 10 disposed in front of a viewer 12 (represented by an eye). In a preferred embodiment, this display 10 includes a spatial light modulator 14 that is illuminated with light 16 and imaged with imaging or projection optics 18. The spatial light modulator 14 may comprise, for example, a reflective polarization modulator such as a reflective liquid crystal display. This liquid crystal spatial light modulator preferably comprises an array of liquid crystal cells each which can be individually activated by signals, e.g., analog or digital, to produce a high resolution pattern including characters and/or images. More generally, the spatial light modulator may comprise an array of modulators or pixels that can be selectively adjusted to modulate light. The projection optics 18 may, for example, project the image to infinity (or a relatively large distance) or may form a virtual image that may be imaged onto the retina by the eye. Such a display may be employed, for example, in a television or head mounted display.

[0089] To illuminate the LCD spatial light modulator 14, a beamsplitter 20 is disposed in front of the LCD. The beamsplitter 20 has a reflective surface 22 that reflects the beam of light 16 introduced through a side 24 of the beamsplitter toward the LCD 14. Reflections from the LCD 14 pass through the reflective surface 22 on another pass and exit a front face 26 of the beamsplitter 20. The imaging optics 18 receives the light from the beamsplitter 20 and preferably images the pattern produced by the LCD display 14 onto the retina of the viewer's eye 12.

[0090] Preferably, the light entering the side 24 of the beamsplitter 20 is polarized light and the beamsplitter comprises a polarization beamsplitter. In such a case, the reflective surface 22 may preferably comprise a polarization dependent reflective surface that reflects light having one polarization and transmits light having another polarization state. The cells within the LCD spatial light modulator 14 also may for example selectively rotate the polarization of light incident on the cell. Thus, the state of the LCD cell can determine whether the light incident on that cell is transmitted through the reflective surface 22 on the second pass through the beamsplitter 20 based on whether the polarization is rotated by the cell. Other types of liquid crystal spatial light modulators may also be used as well.

[0091] A perspective view of a similar type of optical apparatus 30 is shown in FIG. 2. This device 30 may also include a projection lens 18 and may be employed as a projector to project a real image of the spatial light modulator 14 onto a screen 31. The beamsplitter 20 may comprise a prism such as a polarization beamsplitting prism, and in certain preferred embodiments, the beamsplitter may comprise a multi-layer coated beamsplitting prism comprising a stack of coating layers that provide polarization discrimination as is well known in the art. MacNeille type polarizing cubes comprising a cube such as shown in FIG. 1 with a multilayer coating on a surface tilted at an angle of about 45° may be used, however, the field-of-view may be limited by dependence of the efficiency of the multilayer on the angle of incidence. If instead of the conventional multilayer coating employed on a MacNeille beamsplitting cube, the coating layers comprise birefringent layers that separate polarization based on the material axis rather than the angle of incidence, effective performance for beams faster than f/1 can be obtained. Such birefringent multilayers may be available from 3M, St. Paul, Minn.

[0092] Alternative beamsplitters 20 may be employed as well. Examples of some alternative polarization beamsplitters that separate light into two polarization states include crystal polarizers and plate polarizers. Advantageously, crystal polarizers have a relatively high extinction ratio, however, crystal polarizers tend to be heavy, relatively expensive, and work substantially better for relatively slow beams with larger F-numbers (F/#). Image quality is predominantly better for one polarization compared to another. Plate polarizers can comprise multi-layer coatings that are applied on only one side of a plate instead of in a cube. Plate polarizers are light and relatively inexpensive. However, image quality is also primarily higher for one polarization state, and with plate polarizers, the image quality is degraded substantially for speeds approaching f/1. Other types of polarizers such as photonic crystal polarizers, and wire-grid polarizers may be employed as well. Photonic crystal polarizers comprise a stack of layers that forms a photonic crystal that can be used to discriminate polarizations. Photonic crystal polarizers are available from Photonic Lattice Inc., Japan. Photonic crystal polarizers have theoretically excellent field-of-views and wavelength acceptance, however, photonic crystal polarizers are fabricated using expensive lithographic processes. Wire grid polarizers comprise a plurality of wires aligned substantially parallel across a planar surface. These wire grids may also discriminate polarization. Wire grid polarizers may be available, e.g., from NanoOpto Corporation, Summerset, N.J., as well as Moxtek, Inc., Orem, Utah. Wire grid polarizers have good extinction in transmission, however, these polarizers are somewhat leaky in reflection. Aluminum used to form the wire grid also tends to have higher absorption than dielectric materials. Nevertheless, wire grid polarizers are preferred for various embodiments of the invention.

[0093] As discussed above, multi-layer coatings comprising a plurality of birefringent layers in cube polarizers work well for beams faster than f/1 and provide high image quality for both polarizations. Wire grid polarizers and photonic crystal polarizers, may replace the birefingent multilayers in the beamsplitter cube in preferred embodiments. The cube configuration, however, depending on the size, can be heavy. The beamsplitter 20 shown in FIGS. 1 and 2 comprises a beamsplitter cube having sides of approximately equal length. Similarly, the beamsplitter 20 has a size (e.g. thickness, t) greater than the width, w, of the spatial light modulator 14.

[0094] As shown in FIG. 2, a light source 32 is disposed with respect to the polarization beamsplitter 20 to introduce light into the beamsplitter to illuminate the spatial light modulator 14. The beamsplitter 20 includes one port for receiving light. The light is introduced into the beamsplitter 20 through the side 24. The reflective surface 22 is sloped to face both this side 24 and the LCD display 14 such that light input through the side 24 of the beamsplitter is reflected toward the LCD display. This reflective surface 22 may comprise a planar surface tilted at an angle of between about 40 and 50 degrees with respect to the side 24 of the beamsplitter but may be inclined at other angles outside this range as well. The illuminated LCD display can be imaged with the imaging optics 18. The imaging optics 18 may comprise a projection lens that is relatively large and heavy to accommodate a sufficiently large back focal distance and a sufficiently large aperture through the beamsplitter cube 20 to the spatial light modulator 14.

[0095] Beamsplitters with other dimensions or having other geometries and configurations may also be employed as well. A variety of novel beamsplitters and optical systems using beamsplitters are described herein. In one exemplary embodiment of the invention, for example, by including two or more ports, the thickness of the beamsplitter may be reduced. Such a design is illustrated in FIG. 3. FIG. 3 shows a display 40 comprising a beamsplitter device 42 having two ports 44, 46 for receiving two beams of light 48, 50. The display 40 further comprises a spatial light modulator 52 and imaging optics 54 for imaging the spatial light modulator. As discussed above, the spatial light modulator 52 may comprise a liquid crystal spatial light modulator comprising an array of liquid crystal cells. These liquid crystal cells may be selectively controlled accordingly to data or video signals received by the spatial light modulator.

[0096] The beamsplitter device 42 may comprise a prism element comprising glass or plastic or other materials substantially transparent to the incident light 48, 50. The prism element 42 shown has two input faces 56, 58 for receiving the two beams of light 48, 50, respectively. In the embodiment illustrated in FIG. 3, these two input surfaces 56, 58, are parallel and counter-opposing, disposed on opposite sides of the prism. Similarly, the two input ports 44, 46 are oppositely directed, the optical path of the corresponding light beam being directed along substantially opposite directions. Although the input ports 44, 46 are oriented 180° with respect to each other, other configurations where, for example, the ports are directed at different angles such as 30°, 40°, 60°, 72°, 120° etc, and angles between and outside these ranges are possible. The two input faces 56, 58 are preferably substantially optically transmissive to the light 48, 50 such that the light can be propagated through the prism 42.

[0097] The prism element 42 also has two reflecting surfaces 60, 62 that reflect light received by the two ports 44, 46 toward a first (intermediate) output face 64 and onto the spatial light modulator 52. The two reflecting surfaces 60, 62 are sloping with respect to the input and output faces 56, 58, 64 such that light input through the input faces is reflected to the output face. In one preferred example, the reflecting surfaces 60, 62 are inclined at an angle of between about 40 to 50 degrees with respect to the input faces 56, 58 and at an angle of between about 40 to 50 degrees with respect to the first output face 64. The angle or inclination or declination, however, should not be limited to these angles.

[0098] The two reflective surfaces 60, 62 are also oppositely inclined. In the example shown in FIG. 3, the reflective surfaces 60, 62 slope from a central region of the output face 64 to the respective opposite input faces 56, 58. The reflecting surfaces 60, 62 meet along a line or edge 66 in the central region of the output face 64, and may be coincident with the output face 64. This configuration, however, should not be construed as limiting as other designs are possible. The prism 42 may be referred to herein as a “V” prism in reference to the “V” shape formed by the reflective surfaces 60, 62 that are oppositely inclined or sloping and that preferably converge toward the vertex (or apex) 66 located in the central region of the output face 64.

[0099] Preferably, each of the reflective surfaces 60, 62 comprises a polarization dependent reflective surface that reflects light having one polarization and transmits light having another polarization state. For example, the reflective surfaces 60, 62 may each reflect the s-polarization state and transmit the p-polarization state or vice versa. Alternative configurations are possible and the reflective surfaces 60, 62 may be designed to reflect and transmit other states as well. In various preferred embodiments, the reflective surfaces 60, 62 are formed using multi-layered birefringent coatings or wire grids as described above.

[0100] The “V” prism 42 can therefore be said to be a polarization beamsplitter, as this prism device splits beams having different polarizations. Preferably, however, light entering the sides of the beamsplitter 42 is polarized light. In such a case, the reflective surfaces 60, 62 are preferably selected to reflect the light beams 48, 50 introduced through the respective sides 56, 58 of the beamsplitter 42. The input beams 48, 50 propagating along paths oppositely directed and parallel to the Y-axis (as shown in FIG. 3) are redirected along similarly directed optical paths parallel to the Z-axis towards the LCD 52. The spatial light modulator 52 is also preferably a reflective device. Accordingly, light from both input beams 48, 50 traveling toward the liquid crystal array 52 is preferably reflected in an opposite direction along a path parallel to the Z-axis back to the reflective surfaces 60, 62.

[0101] The cells within the LCD spatial light modulator 52 also preferably selectively rotate the polarization of light incident on the cell. Thus, reflections from the LCD 52 will pass through the reflective surfaces 60, 62 on another pass and exit a front face 68 of the beamsplitter 42. In this manner, the state of the LCD cell can determine whether the light incident on that cell is transmitted through the reflective surface 60, 62 on the second pass through the beamsplitter 42 based on whether the polarization is rotated by the respective cell. High resolution patterns such as text or images can thereby be produced by individually activating the liquid crystal cells using, for example, electrical signals. Other types of spatial light modulators may be used. These spatial light modulators may be controlled by other types of signals. These spatial light modulators may or may not comprise liquid crystal, may or may not be polarization dependent, and may or may not be reflective. For example, transmissive spatial light modulators may be employed in alternative embodiments. The type of spatial light modulator, however, should not be restricted to those recited herein.

[0102] The imaging optics 54 images the spatial light modulator 52. The imaging optics 54 enables patterns created by the modulated liquid crystal array 52 to be formed on the retina of the viewer or in other embodiments, for example, on a screen or elsewhere.

[0103] The addition of an input port 46 and a corresponding reflective surface 62 permits the beamsplitting element 42 to have a smaller thickness, t. As shown in FIGS. 1 and 3, the respective prism elements 20, 42 have widths, w. The ratio of the thickness to the width (t/w) is less for the “V” prism 42 as a smaller thickness is required to accommodate a given prism width, w. Similarly, a smaller thickness, t, is needed to illuminate a spatial light modulator 14, 52 having a given width, w.

[0104] The width of the spatial light modulator 14, 52 may be, for example, ½ to 1 inch (13 to 25 millimeters) on a diagonal. The thickness of the prism 42 may be between about ¼ to ½ inch (6 to 14 millimeters). Accordingly, the input faces 56, 58 and reflective surfaces 60, 62, may be between about ⅓×½ inch (9×12 millimeters) to about ⅔×1 inch (18×24 millimeters), respectively. A beam 1 inch (25 millimeters) diagonal may be used to illuminate the spatial light modulator 14, 52. Other dimensions outside these ranges may be used and should not be limited to those specifically recited herein. Also, although the shape of the spatial light modulator 42 as well as the shape of the input ports 56, 58 and the reflective surfaces 60, 62 may be square or rectangular in many embodiments, other shapes are possible.

[0105] As discussed above, adding additional ports 46 such as provided by the “V” prism 42 may advantageously yield a smaller, lighter, more compact illumination system. For example, the thickness and mass of the “V” prism polarization beamsplitting element 42 may be about ½ that of a polarization beamsplitting cube 20 for illuminating a same size area of the spatial light modulator 14, 52 specified by the width, w. Similarly, the back focal distance of the projection lens or imaging optics 54 may be shortened. As a result, the imaging optics 54 used in combination with the “V”-prism can be reduced in size (e.g., in diameter) in comparison with the imaging optics 18 used in combination with a prism cube 20 in a display having a similar F-number or numerical aperture. Reduced size, lower cost, and possibly improved performance of the imaging optics 54 may thus be achieved.

[0106] In one preferred embodiment, the “V”-prism 42 comprises a square prism element comprising three smaller triangular prisms having triangular shape when viewed from the side as shown in FIG. 3. A method of fabricating such a “V” prism 42 is discussed below with reference to FIGS. 27A-27G. The prisms 42 may have polarization beamsplitting coatings such as multiple birefringent layers to create selectively reflective surfaces 60, 62 that separate polarization states. Such a “V”-prism 42 preferably performs well for f-numbers down to about F/1 and lower. In other embodiments, the polarization beamsplitting surfaces 60, 62 may comprise wire grid polarizers or photonic crystal polarization layers, for example.

[0107] FIG. 4, shows an illumination engine 53 for a rear projection television (which may be, e.g., an HDTV) comprising a “V” prism 42. The “V” prism 42 comprises a pair of polarization beamsplitting cubes 70, 72 arranged such that the reflective surfaces 60, 62 are oppositely inclined and thus face different directions. Accordingly, as described above, light input from the two oppositely directed input ports 44, 46 can be reflected through the output face 64 on each of the beamsplitters 70, 72 for example, to a liquid crystal spatial light modulator 52. FIG. 4 depicts two sources of illumination 74, 76 coupling light in the two oppositely facing ports 44, 46 located on opposite sides of the prism element 42. This light 48, 50 following oppositely directed paths parallel to the Y-axis, is reflected from the sloping reflective surfaces 60, 62 along a path parallel to the Z-axis toward the spatial light modulator 52. The two polarization beamsplitters 70, 72 in the device 42 may be secured in place using optical contact, cement, adhesive, clamps, fasteners or by employing other methods to position the two cubes appropriately. Preferably, these two polarization cubes 70, 72 are adjoining such that the reflective surfaces 60, 62 are in sufficiently close proximity to illuminate the spatial light modulator 52 without creating a dark region between the two polarization cubes. The “V”-prism 42 may be formed in other ways as well.

[0108] The illumination engine 53 shown in FIG. 4 further includes a support assembly 55 for supporting the “V” prism and the sources of illumination 74, 76. Although this support assembly 55 is shown as substantially planar, the support assembly need not comprise a board or planar substrate. Other approaches for supporting the various components may be used and the specific components that are affixed or mounted to the support structure may vary. The support structure 55 may for example comprise a frame for holding and aligning the optics. Walls or a base of the rear projection TV may be employed as the support structure 55. The examples describe herein, however, should not be construed as limiting the type of support used to support the respective system.

[0109] Each of these illumination sources 74, 76 comprises an LED array 57 and first and second fly's eye lenses 59, 61 mounted on the support assembly 55. The fly's eye lenses 59, 61 each comprise a plurality of lenslets. In various preferred embodiments, the first and second fly's eye lenses 59, 61 are disposed along an optical axis from the LED array 57 to the spatial light modulator 52 through the reflective surfaces 60, 62 with suitable longitudinal separation. For example, the LED array 57 is imaged by the first fly's eye lens 59 onto the second fly's eye lens 61, and the first fly's eye lens is imaged by the second fly's eye lens onto the spatial light modulator 52. In such embodiments, the first fly's eye lens 59 may form an image of the LED array 57 in each of the lenslets of the second fly's eye lens 61. The second fly's eye lens 61 forms overlapping images of the lenslets in the first fly's eye lens 59 onto the spatial light modulator 52. In various preferred embodiments, the first fly's eye 59 comprises a plurality of elongated or rectangular lenselets that are matched to the portion of the spatial light modulator 52 to be illuminated by the LED array 57.

[0110] The illumination engine 53 further comprises imaging or projection optics 54 for example for projecting an image of the LCD 52 onto a screen or display or directly into an eye. The illumination engine 53 depicted in FIG. 4 is shown as part of a rear projection TV having a flat projection screen 63 and a tilted reflector 65 for forming the image on the screen for the viewer to see. One or more additional reflectors may be employed to reorient the image or to accommodate illumination engines 53 having output in different directions. As the “V” prism 42 may have reduced thickness in comparison to a polarization cube for illuminating a similarly dimensioned region of the spatial light modulator 52, the imaging or projection optics 54 in the illumination engine 53 may be scaled down in size in comparison with a system having an identical f-number or numerical aperture.

[0111] Other configurations and designs for providing illumination are possible. FIG. 5, for example, depicts a prism device 80 comprising a pair of reflective surfaces 82, 84 oriented differently than the reflective surfaces in the “V” prism 42. The prism element 80 shown comprises a pair of polarization beamsplitting cubes 86, 88 with the reflective surfaces 82, 84 formed using wire grid polarizers, although MacNeille-type prisms could be employed in other embodiments. The wire grid polarizers comprise an array of elongated strips or wires arranged substantially parallel. In various preferred embodiments, these elongated strips comprise metal such as aluminum. The wire grid polarizers reflect one linear polarization and transmit another orthogonal linear polarization. Alternative embodiments may employ other types of polarizers such as polarizers formed from a multiple birefringent layer coating as well as photonic crystal polarizers.

[0112] The prism element 80 has two ports 90, 92 on different sides of the prism element. Light piping 95 is shown in FIG. 5 as directing illumination from a light source (not shown) through two respective input faces 98, 100, one on each of the polarization beamsplitting cubes 86, 88. The light piping 95 may comprise sidewalls 97 that form conduits or conveyances with hollow channels 99 therein through which light propagates. Preferably, the inner portions 101 of the conduits are reflecting, and may be diffusely reflecting in certain preferred embodiments, such that light propagates through the inner channel of the light piping 95 from the light source to the input faces 98, 100 of the prism element 80. The light piping 95 shown in FIG. 5 branches into two arms 103a, 103b that continue toward the two input faces 98, 100. Preferably, the two arms 103a, 103b have suitable dimensions and reflectivity of the respective sidewalls 97 to provide substantially equal illumination at the two input faces 98, 100. In various preferred embodiments, the light piping 95 may be shaped (e.g., molded) to accommodate or conform to the other components or to fit into a particular space in a device, such as a helmet-mounted display or, more broadly, a head-mounted display. (As used herein helmet-mounted displays, which accompany a helmet, are one type of head-mounted display, which may or may not be mounted on helmet.)

[0113] Each of the reflective surfaces 82, 84 in the prism device 80 is oriented at an angle with respect to the input face 98, 100 and an output face 102. The angle with respect to the output face 102 may be, for example, between about 40 to 50 degrees or outside these ranges. The reflective surfaces 82, 84 in this prism element 80, however, face different directions on different sides of the prism element than the reflective surfaces 60, 62 in the “V” prisms 42. For example, one of the reflective surfaces 84 is oriented to receive light propagating along an optical path parallel to the X-axis and to reflect the light along an optical path parallel to the Z-axis. The other reflective surface 82 is oriented to receive light propagating along an optical path parallel to the Y-axis and to reflect the light along an optical path parallel to the Z-axis. Accordingly, the two reflective surfaces 82, 84 face different directions, here 90° apart. Ports directed along other directions also may be employed.

[0114] A range of other configurations are possible wherein a pair of reflective surfaces are provided. Preferably, these reflective surfaces are inclined to reflect light input into the prism element 80 from one of the side surfaces along a common direction. Different input sides can be used as the input surfaces in different embodiments. For example, the side surfaces can be oppositely facing or can be oriented 90 degrees with respect to each other or at different angles with respect to each other. The reflective surfaces can be planar and square or rectangular as shown in FIG. 5 or may have different shapes. The reflective surfaces can be tilted substantially the same amount or can be inclined or decline or be angled different amounts. The reflective surfaces can also be inclined in different directions. Still other configurations are considered possible and should not be limited to those specifically described herein as variations can be suitably employed consistent with the teaching disclosed herein.

[0115] FIG. 6 shows a square prism element 110 with four input ports 112 on four separate sides of the square prism. Four light sources 114 coupled to rectangular integrating rods 116 are also depicted. The rectangular integrating rods 116 may comprise hollow conduits with inner sidewalls that are reflecting, possibly diffusely reflecting. In alternative embodiments, the rectangular integrating rods 116 are not hollow but instead comprise material such as glass, crystal, polymer, that is substantially optically transmissive and that is shaped to provide reflecting sidewalls. Light propagates through this material or through the hollow conduit reflecting multiple times from the sidewalls of the integrating rod 116. The multiple reflections preferably provide mixing that homogenizes the output preferably removing bright spots or other non-uniformities. In some embodiments, the integration rods 116 have a square or rectangular cross-section orthogonal to respective optical axes extending lengthwise therethrough. Such cross-sections are desirable for illuminating a square or rectangular region on the spatial light modulator. Other shapes are also possible. In various preferred embodiments, the cross-section is elongated in one direction, as is a rectangle. Also, although rectilinear shaped integrating rods 116 are shown, curvilinear structures may be employed as well. Lightpipes that follow a curve path including, for example, fiber bundles, large core fibers, and other substantially flexible lines that may be bent may be employed. Alternatively, rigid but curved lightpipes may be employed as well in alternative embodiments.

[0116] The four input ports 112 include input surfaces 118 each forming an optical path to one of four respective reflecting surfaces 120. The four ports 112 and input surfaces 118 face four different directions outward from the four sides of the square prism 110. The reflective surfaces 120 also face four different directions. These reflective surfaces 120 are tilted toward an output face 124, which is depicted in FIG. 6 as under or behind the prism element 110. Accordingly, light received by the four input surfaces 118 is deflected downward in FIG. 6 toward the output face 124 where a reflective LCD module (not shown) may be located. Preferably, these reflective surfaces 120 are polarization splitting surfaces, and the light input is polarized such that the light reflects toward the output face 124. The prism element 110 may be formed from four adjoining beamsplitting cubes appropriately oriented.

[0117] Four polarizers may be inserted between the light sources 114 or the integrating rods 116, and the input faces 118. These polarizers may be referred to herein as pre-polarizers. The polarizers preferably ensure that substantially all the light reaching the input faces 118 has suitable polarization such that this light is reflected by the polarization splitting reflective surfaces 120.

[0118] Another embodiment of a square prism element 150 having four input ports 152 is illustrated in FIG. 7. This prism element 150 includes four faces 160 where light can be input and four triangular reflective surfaces 170 that are similarly inclined toward an apex region 175 such that light input through the input face 160 is reflected upward and out an output surface 178 as shown in FIGS. 7, 8A, and 8B. A spatial light modulator (not shown) such as a reflective liquid crystal array device or other reflective modulator assembly may be located adjacent the output surface 178 to reflect light back into the prism 150 via the output face 178. A side sectional view as well as a top view are depicted in FIGS. 8A and 8B. The adjacent triangular reflective surfaces 170 are preferably adjoined to each other along edges 180 that are inclined toward the apex region 175. In the orientation shown in FIGS. 7, 8A, and 8B, the four reflective surfaces 170 appear to form a pyramid-shaped surface. The four input ports 152 face four different directions outward from the square prism 150. The four triangular reflective surfaces 170 also face four different directions. Preferably, the four reflective surfaces 170 comprise polarization splitting surfaces that reflect one polarization state and transmit another polarization state. These four surfaces may reflect similar or different polarizations. Preferably, polarized light is coupled into the input ports 152 such that the light is reflected from the polarization splitting reflective surfaces 170. These polarization splitting interfaces 170 may be formed using multilayered coatings, grid polarizers, and photonic crystals, as described above as well as other types of polarizers both known and yet to be devised. Grid polarizers 190 comprising arrays of parallel metal strips are shown in FIGS. 7, 8A, and 8B. The size of these grid polarizers 190 and the metal strips forming the polarizers are exaggerated in the schematic drawings presented.

[0119] Another embodiment of a prism element 150 having multiple input ports 152 is illustrated in FIG. 9A. This prism element 150 comprises a circularly symmetric prism. The prism element 150 includes input faces 160 where light can be input and reflective surfaces 170 that are similarly inclined toward an apex region 175 such that light input through the input faces 160 is reflected upward and out an output surface 178 as shown in FIGS. 9A and 9B. A spatial light modulator (not shown) such as a reflective liquid crystal modulator assembly may be located adjacent the output surface 178 to reflect light back into the prism 150 via the output face 178. A side sectional view is depicted in FIG. 9B. The reflective surfaces 170 are preferably inclined toward the apex region 175. In the orientation shown in FIGS. 9A-9B, the reflective surfaces 170 appear to form a conical-shaped surface. The surface 170 is circularly symmetric about an axis 179 through the apex 175. The input ports 152 face different directions outward from the circular prism 150. The reflective surfaces 170 also face different directions. As shown in the cross-section in FIG. 9B, the surface is curved along a direction parallel to the axis 179. The curvature, slope, concavity may vary. Other variations in the curvature may be included. Other types of surfaces of revolution providing inclined reflective surfaces may also be employed. FIGS. 9C and 9D depict a prism 150 having a reflective surface 170 shaped like a cone. Instead of having a curvature that varies along the axis of rotation, the slope is substantially constant. The linear incline of this reflective surface 170 is depicted in the cross-section shown in FIG. 9D. The surfaces shown in FIGS. 9A and 9C have shapes conforming to the shape of surfaces of revolution about the axis 179. Polarization beamsplitting surfaces having shapes that conform to portions of such surfaces of revolution are also possible. Also, the curve that is rotated to form the surface of revolution for the corresponding shape may be irregular yielding differently shaped surfaces. Other shapes are possible for the reflective surfaces 170.

[0120] Preferably, the reflective surfaces 170 comprise polarization splitting surfaces that reflect one polarization state and transmit another polarization state. Preferably, polarized light is coupled into the input ports 152 such that the light is reflected from the polarization splitting reflective surfaces 170. These polarization splitting interfaces 170 may be formed using multilayered coatings, grid polarizers, and photonic crystals, as described above as well as other types of polarizers both known and yet to be devised.

[0121] The prism elements preferably comprise glass or other material substantially transmissive to the light input into the input ports. Examples of optically transmissive materials that may be employed include BK7 and SFL57 glass. Other materials may be employed as well and the prism should not be limited to those transmissive materials specifically recited herein. These prism elements need not be limited to square configurations. Other shapes and sizes such as for example rectangular, hexagonal, etc. can be employed. Other techniques for reflecting one polarization state and transmitting another polarization state can be used as well. These reflective surfaces, for example, may comprise polarization plates in various embodiments.

[0122] As discussed above, the resultant illumination device is thinner and thus provides for lighter, more compact designs. Lower cost and higher performance may also be achieved. Smaller projection optics with shorter back focal length may also be employed.

[0123] An optical apparatus 200 is depicted in FIG. 10 comprising a “V” prism 202 that is optically coupled to an array of light emitting diodes (LEDs) 204 via optical fiber lines 206 to first and second input ports 208, 210. Such an optical apparatus 200 may be included in a head-mounted display such as a helmet-mounted display and may be enclosed in a housing and supported on a support structure (both not shown). The fiber lines 206 are considered to be a particular type of light pipe which include incoherent fiber bundles, coherent fiber bundles, large core optical fibers, hollow conduits, or other types of light pipes. Optical fibers lines 206 advantageously offer flexibility, for example, for small compact devices and designs where packaging requirements restrict size and placement of components. The LED array 204 comprises three LEDs 212, which may comprise for example red, green, and blue LEDs. The three LEDs 212 are depicted coupled to the three optical fibers lines 206. Each of the three optical fibers lines 206 is split into a pair of separate first and second fiber lines 206a, 206b. The first fiber line 206a associated with each of the three LEDs is optically coupled to the first input port 208 of the “V” prism 202. The second fiber line 206b associated with each of the three LEDs 212 is optically coupled to the second input port 210 of the “V” prism 202. Light from each of the LEDs 212 can therefore be distributed to both ports 208, 210 of the “V” prism 202.

[0124] In various preferred embodiments, the three optical fiber lines 206 comprise fiber bundles such as incoherent fiber bundles. FIG. 11 schematically illustrates one optical bundle 222 abutted to one light source 224 or light emitter so as to receive light from the light source. The optical fiber bundle 222 is split into two sections 226, 228 that follow paths to two opposite ends of an optical device 230 such as a “V” prism. These two sections 226, 228 correspond to the first and second fiber lines 206a, 206b depicted in FIG. 10.

[0125] The fiber bundles 222 preferably comprise a plurality of optical fibers. The fiber bundles 222 may be split, for example, by separating the optical fibers in the bundle into two groups, one group for the first fiber line 206a to the first input port 208 and one group for the second fiber line 206b to the second input port 210. In various preferred embodiments, a first random selection of fibers is used as the first fiber line 206a and a second random selection of fibers is used as the second fiber line 206b. To provide an approximately equal distribution of light into the separate first and second lines 206a, 206b directed to the first and second input ports 208, 210, the number of fibers is preferably substantially the same in both the separate first and second lines 206a, 206b. This distribution can be adjusted by removing fibers from either the first or second of the fiber lines 206a, 206b. Scaling, introducing correction with the spatial light modulator 236, can also be employed to accommodate for differences in the illumination directed onto different portions of the display.

[0126] In one preferred embodiment, light emitted by the red, green, and blue light sources 212 is introduced into the optical fiber bundle 222. As described above, this fiber bundle 222 is split such that the red light, the green light, and the blue light is input into opposite sides of the “V” prism 202. As is well known, light that appears white can be produced by the combination of red, green, and blue. In addition, a wide range of colors can be produced by varying the levels of the red, green, and blue hues. Although three light sources 212 are shown comprising red, green, and blue LEDs, more or less number of different color light sources may be provided. For example, four colored emitters may be employed that include near blue and deep blue emitters for obtaining high color temperature. Still more colors can be employed. In some embodiments eight or more colors may be included. Light sources other than LEDs may also be employed, and color combinations other than red, green and blue may be used. Fluorescent and incandescent lamps (light bulbs) and laser diodes are examples of alternative types of light sources. Other types of sources are possible as well. Other color combinations include cyan, magenta, and yellow although the specific colors employed should not be limited to those described herein. Various preferred embodiments include a plurality different color emitters that provide color temperatures between about 3000K and 8500K (white), although this range should not be construed as limiting.

[0127] Although the fiber bundle 222 is shown in FIG. 10 as being split into two portions 226, 228 corresponding to the two input ports 208, 210 of the “V” prism 202, the fiber bundle may be split further, for example, when the number of input ports is larger. In various embodiments, separate fiber bundles may be brought together at the source. Alternatively, a plurality of fiber bundles, one for each input port, may be positioned to couple light into the respective input port. These fiber bundles may be split into a plurality of ends that are optically coupled to the plurality of light emitters. Accordingly, light from the different color emitters is brought together and input into the two sides of the prism 202. Various other combinations are possible.

[0128] In certain other embodiments, more than one set of emitters may be employed, e.g. one set for each port 208, 210. Separate sources with separate fiber bundles can be employed for separate ports 208, 210. Utilizing a common light source such as a common red, green, or blue LED or LED array for the plurality of input ports, however, has the advantage of providing uniformity in optical characteristics such as for example in the wavelength of the light. Both sides of the “V” prism will thus preferably possess the same color.

[0129] A homogenizer such as an integrating rod, another form of light pipe, may also be employed to mix the red, green, and blue light. Light boxes such as cavities formed by diffusely reflecting sidewalls may be used as well for mixing and/or for conveying light. A fiber bundle can be optically connected to a light pipe such as a conduit or a single large (or smaller) core fiber. In other embodiments, the fiber bundle can be altogether replaced with optical fiber or flexible or rigid light pipes, or optical couplers, which may have large core or small core. Various combinations, e.g., of light sources, light piping, optical fiber and optical fiber bundles, and/or mixing components, etc., may also be utilized.

[0130] In certain preferred embodiments, individual red, blue, and green conveyances from respective red, blue, and green emitters may be coupled to a mixing component such as a mixing rod or light box or other light pipe where the different colors are combined. In other embodiments, light piping such as molded walls that form optical conduits may include a LED receiver cup for coupling from different color emitters, e.g., red, green, and blue LEDs, through the light piping to a mixing area such as a light box that may be output to a lens or other optical element. Alternative configurations and combinations are possible and the particular design should not be limited to those examples specifically recited herein.

[0131] To produce color images using the spatial light modulator, the different color emitters can be time division multiplexed with each color emitter separately activated for a given time thereby repetitively cycling through the different colors. The spatial light modulator is preferably synchronized with the cycling of the color emitters and can be driven to produce particular spatial patterns for each of the colors. At sufficiently high frequencies, the viewer will perceive a single composite colored image. In other embodiments more fully described below, the three colors can be separated out by color selective filters and directed to three separate modulators dedicated to each of the three colors. After passing through the respective spatial light modulators, the three colors can be combined to produce the composite color image. Exemplary devices for accomplishing color multiplexing include the “X-cube” or the “Philips prism”. In other embodiments, more colors can be accommodated, e.g., with time division multiplexing and/or with additional spatial light modulators.

[0132] As shown in FIG. 10, beam shaping optics 232 are disposed in an optical path between the optical fiber lines 206a and the first input face 234 of the “V” prism. These beam shaping optics 232 may comprise, for example, a refractive lens element or a plurality of refractive lens elements. Alternatively, diffractive optical elements, mirrors or reflectors, graded index lenses, or other optical elements may also be employed. In various preferred embodiments, the beam shaping optics 232 has different optical power for different, e.g., orthogonal directions. The beam shaping optics, 232, may for example, be anamorphic. The beam shaping optics 232 preferably has different optical power for orthogonal meridianal planes that contain the optical axis through the beam shaping optics 232. For example, the beam shaping optics 232 may comprise an anamorphic lens or anamorphic optical surface. A cylindrical lens may be suitably employed in certain preferred embodiments. In one preferred embodiment, the beam shaping optics 232 comprises a lens having an aspheric surface on one side and a cylindrical surface on another side. The cylindrical surface has larger curvature in one plane through the optical axis and smaller or negligible curvature in another plane through the optical axis. Preferably, the beam shaping optics 232 is configured to produce a beam or illumination pattern that is asymmetric. The beam may, for example, be elliptical or otherwise elongated, possibly being substantially rectangular, so as to illuminate a rectangular field. The rays of light corresponding to the beam exiting the beam shaping optics 232 may be bent (e.g. refracted) more in one direction than in another orthogonal direction. Accordingly, the corresponding rays of light may diverge at wider angles, for example, in the X-Y plane than in the Y-Z plane. In some embodiments, integrating rods having rectangular cross-section or a fly's eye lens with rectangular lenslets may illuminate a rectangular field. Other cross-sections and shapes may be used to illuminate areas other than rectangular. Although the beamshaping optics 232 is described as preferably being anamorphic or have different optical power in different directions, in some embodiments, the beam shaping optics need not be so configured.

[0133] The beam shaping optics 232 also may be configured to provide a substantially uniform distribution of light over the desired field. This field may correspond, for example, to the reflective surface of the “V” prism 202 or the corresponding portion of a LCD array 236 disposed with respect to an output of the “V” prism to receive light therefrom. The luminance may be substantially constant across the portion on the LCD 236 to be illuminated. In certain embodiments, preferably substantially uniform luminance is provided across the pupil of the optical system. This pupil may be produced by imaging optics, e.g., in the head-mounted display or other projection or display device. Control over the light distribution at the desired portion of the spatial light modulator 236 may be provided by the beamshaping optics 232.

[0134] The optical system 200 further comprises a collimating element 238 which preferably collimates the beam as shown in FIG. 10. The collimating element 238 depicted in FIG. 10 comprises a Fresnel lens, which advantageously has reduced thickness and is light and compact. Other types of collimating elements 238 may also be employed, such as other diffractive optical elements, mirrors, as well as refractive lenses. For example, the Fresnel lens could be replaced with an asphere, however, the Fresnel lens is likely to weigh less. In the embodiment illustrated in FIG. 10, the Fresnel lens is proximal the input face 234 of the “V” prism 202. As described above, in the case where the beamshaping optics 232 is configured to produce a uniform light distribution, the illuminance at the collimating element 238 preferably is substantially constant. The collimating lens 238 may also be anamorphic to collimate an elliptical or elongated beam.

[0135] An optical diffuser 240 is also disposed in the optical path of the beam to scatter and diffuse the light. In various preferred embodiments, the diffuser 240 spreads the light over a desired pupil such as an exit pupil of the imaging or projection optics 54 (see FIGS. 3 and 4). The diffuser 240 is also preferably configured to assist in filling the pupil. The pupil shape is the convolution of the diffuser scatter distribution and the angular distribution exiting the Fresnel collimating element 238.

[0136] In some embodiments, the diffuser 240 also preferably assists in providing a uniform light distribution across the pupil. For example, the diffuser may reduce underfilling of the pupil, which may cause the display to appear splotchy or cause other affects. As described more fully below, when the viewer moves his/her eye around, the viewer would see different amounts of light at each eye position. In various embodiments, for example, the F-number of the cone of rays collected by the projection optics or imaging optics varies with position (e.g., position on the spatial light modulator). Underfilling for some positions in the spatial light modulator causes different levels of filling of the imaging optics pupil for different field positions, which produces variations observed by the viewer when the eye pupil moves. Uniformity is thereby reduced. Preferably the imaging system pupil is not underfilled. Conversely, if the pupil is overfilled, light is wasted. The Fresnel lens also preferably avoids overfilling and inefficient loss of light. Accordingly, diffuser designs may be provided for tailoring the fill, such that the pupil is not overfilled. The collimating lens used in combination with the diffuser aids in countering underfilling.

[0137] A variety of types of diffusers such as for example holographic diffusers may be employed although the diffuser should not be limited to any particular kind or type. The diffuser 238 may have surface features that scatter light incident thereon. In other embodiments, the diffusers may have refractive index features that scatter light. Different designs may be used as well. A lens array such as one or more fly's eye lenses comprising a plurality of lenslets can also be used. In such a case, the lenslets preferably have an aspheric surface (e.g., a conic profile or a curve defined by a non-zero conic constant) suitable for fast optical systems such as about f/1.3 or faster.

[0138] The diffuser 238 may also be combined with a polarizer or the Fresnel lens or the polarizer and/or the Fresnel lens may be separate from the diffuser. Preferably, however, the polarizer is included in the optical path of the beam before the reflective beamsplitting surface of the beamsplitter 202. Accordingly, this polarizer is referred to herein as the pre-polarizer. Different types of polarizers that provide polarization selection may be employed including polarizers that separate polarization by transmitting, reflecting, or attenuating certain polarizations depending on the polarization. For example, polarizers that transmit a first polarization state and attenuate a second polarizations state, polarizers that transmit a first polarization state and reflect a second polarization state, and polarizers that reflect a first polarization state and attenuate a second polarizations state may be employed. Other types of polarizers and polarization selective devices may be employed as well.

[0139] The pre-polarizer is preferably oriented and configured such that light propagating therethrough has a polarization that is reflected by the polarization beamsplitting surface in the prism 202. Preferably, substantially all of the light entering the input port 208, 210 is polarized so as to be reflected by the polarization beamsplitting surface and to thereby avoid transmission of light through the polarization beamsplitting surface. If such light leaks through, e.g., the first polarization beamsplitting surface and reaches the second reflective surface, this light may be reflected by the second surface and may continue onto the output. Such leakage may potentially wash out the pattern produced by the LCD and/or create imbalance between two sides of the output. A post-polarizer 241 disposed at the output of the V-prism may reduce this effect by removing the polarization that leaks through the first polarization beamsplitting surface and is reflected by the second polarization beamsplitting surface in the V-prism 202. Accordingly, this post-polarizer 241 preferably removes light having a polarization that is selected to be reflected by the first and second polarization beamsplitting surfaces within the V prism 202. Both the pre-polarizers and the post polarizer 241 may comprise polarizers currently known as well as polarizers yet to be devised. Examples of polarizers include birefringent polarizers, wire grid polarizers, as well as photonic crystal polarizers.

[0140] The optical apparatus 200 depicted in FIG. 10 includes beamshaping optics 232, collimating elements 238, diffusers 240, and polarizers for each port. Accordingly, for the “V” prism 202 having two ports 208, 210, a pair of each of these components is shown. In other embodiments comprising more ports, the additional input ports may be similarly outfitted with beamshaping optics, collimating elements, diffusers, and polarizers. Other elements such as filters etc. can also be included and any of the elements shown may be excluded as well depending potentially on the application or design. Various other combinations and arrangements of such elements are also possible.

[0141] As discussed above, light from the array of light sources 204 is coupled into the optical fiber line 206 and distributed to the input ports 208, 210 of the prism 202. The light output from the optical fiber 206 is received by the beamshaping optics 232, which preferably tailors the beam substantially to the size and shape of the portion of the spatial light modulator 236 to be illuminated. Similarly, the size and shape of the beam substantially may match that of an aperture or pupil associated with the optical system 200 in various preferred embodiments. The beam may be for example between about 5 and 19 millimeters wide along one direction and between about 10 and 25 millimeters along another direction. In various embodiments, the beamshaping optics 232 converts a circular shaped beam emanating from the optical fiber 206a, 206b into an elliptical beam. The cross-section of the beam exiting the optical fiber 206 taken perpendicular to the direction of propagation of the beam is generally circular. The beam shaping optics 232 preferably bends the beam accordingly to produce a perpendicular cross-section that is generally elliptical or elongated. This shape may be substantially rectangular in some embodiments.

[0142] Preferably, the beamshaping optics 232 also provides for more uniform distribution across the spatial light modulator 200. The beam exiting the optical fiber 206 may possess a substantially Gaussian intensity distribution with falloff in a radial direction conforming approximately to a Gaussian function. Such a Gaussian intensity distribution may result in a noticeable fall off in light at the LCD 236. Accordingly, the beamshaping optics 232 preferably produces a different distribution at the LCD 236. In certain preferred embodiments discussed more fully below, the beamshaping optics 232 is configured such that the light at the LCD 236 has a “top hat” or “flat top” illuminance distribution which is substantially constant over a large central region.

[0143] FIGS. 12 and 13 show the illuminance distribution at the spatial light modulator 234 for the respective first and second input ports 208, 210 of the “V” prism 202. This illuminance distribution is substantially Gaussian. A cross-section of a Gaussian illuminance distribution such as across the line 14-14 in FIG. 12 is presented in FIG. 14. The Gaussian has a peak with an apex and sloping sides. As shown, this Gaussian is circularly symmetric about the Z-axis. FIGS. 12 and 13 also show a portion of the perimeter 242 of the output face. One edge 244 of the perimeter corresponds to the vertex of the prism. For each side, a peak is centrally located within the rectangular field of the reflective surface of the prism and/or the rectangular portion of the LCD 236.

[0144] FIG. 15 schematically illustrates flux from the two sides of the “V” prism 202 combined together for example at the spatial modulator 236. FIG. 15 also shows a perimeter 242 corresponding to the two portions of the output face associated with the two sides of the “V” prism 202, respectively. This perimeter may likewise correspond to the two portions of the spatial light modulator 236. Two peaks in the illuminance distribution are centrally located within each of the rectangular portions of the LCD 236.

[0145] The light beam may be offset such that the peak is shifted from center in one direction as illustrated in FIGS. 16 and 17, which show the illuminance incident on the two portions of the spatial light modulator corresponding to the two sides of the “V” prism. FIGS. 16 and 17 show a perimeter 242 delineating the two portions of the spatial light modulator 236 coinciding with the reflective surfaces in the prism 202, and/or the output faces. Line 244 on the perimeter 242 corresponds to the vertex of the prism. The illuminance is represented as a Gaussian distribution with a peak shifted in the Y direction from the center of the spatial light modulator 236. The light beam may be shifted or altered in other ways to preferably provide more uniform illumination.

[0146] In various exemplary embodiments that employ Koehler illumination, the falloff in the source angular distribution maps to the corners of the two output portions of the “V” prism 202 as well as, for example, to the corresponding portions of the spatial light modulator 236. (In Koehler illumination, the light source is imaged in the pupil of the projection optics, e.g., at infinity.) If the falloff is sufficiently slow and not too large, the observable variation in light level may not be significant. If however, the falloff is sharp and sizeable, the variation across the output of the “V” prism 202 may result for example in noticeable fluctuations in light reaching the eye in specific circumstances.

[0147] In various embodiments, the illumination output by the prism 202, however, is preferably substantially constant and uniform. As discussed above, therefore, a “top hat” or “flat top” illuminance distribution may be preferred over the Gaussian distribution. A substantially “top hat” illuminance distribution incident on the output face 234 of the prism 202 is shown in FIG. 18. A cross-section of the “top hat” illuminance distribution across the line 19-19 is presented in FIG. 19. The “top hat” distribution is substantially constant over a central portion 246 and falls off rapidly beyond the substantially constant central portion. The width of the substantially constant central portion 246 is preferably sufficiently large so as to fill the appropriate area, such as for example the eye pupil in certain display embodiments such as for head mounted and helmet mounted displays. In the case where the “top hat” distribution is substantially constant within the central portion 246, substantially constant illuminance across the pupil may be provided. This “top hat” distribution is shown as circularly symmetric about the Z-axis although asymmetric such as elliptical shapes may be preferred. FIG. 18 also shows the perimeter 242 of the portion of the spatial light modulator 234 illuminated by one side of the V-prism, or the corresponding reflective surface and/or output face of the prism 202. One edge 244 of the perimeter 242 corresponds to the vertex of the prism 202. Although a “top hat” distribution is shown, other distributions wherein the light level, e.g., illuminance, is substantially constant may be employed. Preferably, the illuminance is substantially constant at least across a portion of the “V” prism 202 output corresponding to the relevant pupil such as the pupil of the eye for certain embodiments.

[0148] The intensity exiting the optical fiber 206a, 206b may be more Gaussian than “top hat” or “flat top” resulting in more falloff. As discussed above, clipping the rotationally symmetric angular distribution with a rectangular field can produce more significant falloff near the center of the spatial light modulator 236 and consequently at the center of the display or projection screen since the vertex of the “V” prism 202 corresponds to the center of the output of the “V” prism. In certain embodiments, therefore, the beamshaping optics 232 preferably provides a substantially “top hat” illuminance distribution at the spatial light modulator 236. A lens 232 that is aspheric at least on one of the optical surfaces may yield such a distribution. An integrating rod may also output a substantially constant illumination distribution like a flat top distribution that falls of rapidly. When using an integrating rod or light pipe that provides substantially constant illumination, beam shaping optics may or may not be used to further flatten the illumination distribution. (In various embodiments, preferably the diffusers as well as the collimator may be employed with the integrating rod or light pipe, e.g., to increase uniformity. The diffuser may, for example, be used instead of longer integrating rods or light pipes thereby increasing compactness.)

[0149] Asymmetric beamshaping optics 232 are also preferably used to produce an asymmetric beam. For example, a cylindrical lens having a cylindrical surface may advantageously convert the circular peaked distribution into a distribution having a central oval portion, more suitable for the rectangular field. As described above, the beamshaping optics 232 may comprise one or more refractive elements having an aspheric surface and an anamorphic (e.g., cylindrical) surface. As stated above, an integrating rod having an asymmetric (e.g., rectangular) cross-section or a fly's eye lens comprising a plurality of asymmetrically shaped (e.g., rectangular) lenslets may be used to provide such asymmetric beam patterns. Other approaches to providing asymmetric distributions are possible.

[0150] As will be discussed more fully below, the diffuser 240 is also preferably configured to provide substantially uniform light levels. The diffuser may include a plurality of scatter features that scatter incident light into a cone of angles such as illustrated in FIG. 20. The diffuser may be designed to substantially limit this cone of angles, θ. In addition, the diffuser may be configured to provide a specific angular distribution wherein the intensity varies with angle according to a distribution, I(θ). In certain preferred embodiments, for example, this angular distribution also substantially conforms to a “top hat” distribution. Top hat and Gaussian angular distributions 248, 250 are plotted in FIG. 21. (Such distributions are similar to corresponding Bidirectional Scatter Distribution Functions, BSDFs). For the Gaussian distribution 250, the intensity peaks for a central angle, θ_o, but falls off gradually for angles larger and smaller than the central angle. In contrast, for the “top hat” distribution 248, a portion 252 of the angles have a substantially similar intensity level. For angles outside that region 252, however, the intensity rapidly drops off. Such a distribution 248 may be useful for efficiently distributing the light to the desired areas without unnecessary and wasteful overfill.

[0151] The size of the spatial light modulator 236 may be between about 6 to 40 millimeters or between about 12 to 25 millimeters on a diagonal. In certain embodiments, the spatial light modulator 236 may have shapes other than square, and may for example be rectangular. In one exemplary embodiment, the aspect ratio of the spatial light modulator that is illuminated is about 3:4. Dividing the illuminated region in two may yield an aspect ratio of about 3:8 for the section of the spatial light modulator illuminated by one side of the V-prism. More broadly, the portion illuminated by one half of the output port may be between about 2×4 millimeters to 14×28 millimeters although sizes outside these ranges are possible. Still other shapes, e.g., triangular, are possible. Accordingly, the beam used to illuminate the spatial light modulator 236 may have a length and width between about 2×4 millimeters to 14×28 millimeters, respectively. The collimator aperture, diffuser aperture, polarizer aperture as well as the input faces 234 and reflective surfaces of the prism 202 may have aperture sizes in one direction between about 2 and 14 millimeters and in another direction between about 4 and 28 millimeters. The dimensions, however, should not be limited to those recited here.

[0152] FIG. 22 depicts a field-of-view 265 for a display such as a head mounted display produced by a V-prism. A dark stripe 266 is visible at the center of the field 265. This stripe 266 results from the finite thickness of the beamsplitting reflective surfaces 268 of the V prism, which is shown in FIG. 23. In the case where polarization beam splitting is provided by a plurality of birefringent layers, the stack of birefringent layers introduces this thickness. In the case where the polarization beam splitting layer comprises a wire grid, the height of the wires contributes to this thickness. Other structures such as photonic crystal polarizers have finite thickness, which may cause this stripe to be visible. A portion 270 of the output of the V-prism, is affected by the reduced performance of the beamsplitting surfaces. This region 270, as well as the thickness of the beamsplitting layers 268, has been exaggerated in this schematic drawing and, accordingly, is not to scale. The stripe 266 shown in FIG. 22 is likewise exaggerated as well and is preferably not visible to the viewer.

[0153] To decrease the size of the stripe 266, the thickness of the polarization beamsplitting layer 268 is preferably reduced. Preferably, the thickness is not larger than a few percent of the beam at the pupil of the system. In various preferred embodiments, for example, the thickness of the polarization beamsplitting structure 268, e.g., the thickness of the multiple birefringent layer stack or the photonic crystal polarizers is less than about 5 to 100 micrometers. Thicknesses outside this range, however, are possible. A post-polarizer 272 may also be included to potentially reduce this effect.

[0154] FIGS. 24-26 depict cross-sectional views of wire grid polarizers 275. The wire grid polarizer 275 comprises a plurality of elongated strips 276 preferably comprising metal such as aluminum. The elongated strips 276 are arranged parallel to each other. The height of the wires 276 is between about 20 to 60 nanometers although larger or smaller strips may be employed in different embodiments. The strips 276 may have a width of between about 10 and 90 nanometers and a periodicity of between about 50 and 150 nanometers. The strips 276 may be separated by a distance to provide a duty cycle of between about 0.25 and 0.75. The periodicity is preferably sufficiently small for the wavelengths of use such that the plurality of strips 276 does not diffract light into different orders. Light will therefore be substantially limited to the central or zero order. Values outside these ranges, however, are possible.

[0155] In FIG. 24, the strips 276, formed on a substrate 278, are separated by open spaces such as air gaps 280. A layer of glue 282 or other adhesive material is employed to affix a superstrate 284 to the wire grid polarizer. In such an embodiment, preferably the glue 282 is viscous and does not fill in the open regions 280 separating the strips 276. In FIG. 25, glue 282 fills these open regions 280. In various preferred embodiments, the glue 282 has an index of refraction similar to that of the substrate 278 and/or superstrate 284. Accordingly, if the substrate 278 and superstrate 284 comprise BK7 glass, preferably the glue 282 has an index of refraction of about 1.57. FIG. 25 shows a layer of oxide 286 such as aluminum oxide (Al₂O₃) that may be formed on metal strips 276 comprising for example aluminum. FIG. 26 shows a layer of MgF 288 formed over the array of strips. This layer of MgF may range between about 0.5 and 20 microns thick although other thicknesses outside this range are possible. The MgF is shown in the regions separating the strips 276 as well in this exemplary embodiment. Other materials beside MgF, such as for example, silica may be employed in other embodiments of the invention.

[0156] One exemplary process for forming the wire grid polarizers 275 in the V-prism is illustrated in FIGS. 27A-27G. Preferably, substantially smooth surfaces 502 are formed on a first triangular prism 504, for example, by polishing as shown in FIG. 27A. This prism 504 may comprise glass such as BK7 or SF57 or other glass or substantially optically transmissive material. In certain preferred embodiments, this prism 504 has a cross-section in the shape of a right triangle having a hypotenuse 506. The surfaces 502 of this prism are preferably substantially planar, at least those corresponding to the hypotenuse 506 and one of the sides opposite the hypotenuse shown in the cross-section.

[0157] A first wire grid polarizer 508 is formed on a side of the prism 504 as illustrated in FIG. 27B. Metal deposition and patterning may be employed to create an array of parallel metal strips comprising the wire grid polarizer 508. These strips are shown as being formed on the surface 502 corresponding to the hypotenuse 506 in the cross-section shown in FIG. 27B. In certain preferred embodiments, the metal strips may be formed on a glass wafer 510 using lithographic processes. The wafer 510 may be diced into pieces that are bonded or adhered to the prism 504. Open spaces may separate the strips. An overcoat layer comprising, e.g., MgF or silica or other material, may be formed over the plurality of strips.

[0158] A second triangular prism 514 similar to the first triangular prism 504 is attached to the first triangular prism sandwiching the first wire grid polarizer 508 between the two prisms as depicted in FIG. 27C. This second prism 514 may also comprise glass such as BK7 or SF57 or other glass or substantially optically transmissive material. Similarly, this second prism 514 may have a cross-section in the shape of a right triangle having a hypotenuse 516. At least the surface corresponding of the hypotenuse 516 shown in the cross-section is preferably substantially planar. A substantially cylindrical structure having a substantially square cross-section is formed by attaching the second triangular prism 514 to the first triangular prism 504.

[0159] The first and second triangular prisms 504, 514 together with the first wire grid polarizer 508 sandwiched therebetween are cut and/or polished along a diagonal of the square cross-section formed by attaching the first triangular prism to the second triangular prism as shown in FIG. 27D. A substantially cylindrical structure 524 having a substantially triangular cross-section is thereby created. This triangular cross-section 524 is a right triangle with a hypotenuse 526 that is preferably substantially orthogonal to the first wire grid polarizer 508.

[0160] A second wire grid polarizer 538 is added to the substantially triangular cylindrical structure 524 as shown in FIG. 27E. The second wire grid polarizer 538 may be created by depositing and patterning metal to form a plurality of parallel metal strips. As described above, in certain preferred embodiments, the metal strips may be formed on a glass wafer 540 using lithographic processes. The wafer 540 may be diced into pieces that are bonded or adhered to the prism 504. An overcoat layer comprising, e.g., MgF or silica or silica or other material, may be formed on the second wire grid 538. As illustrated in FIG. 27E, the second wire grid polarizer 538 is disposed on a surface of the substantially cylindrical structure 524 corresponding to the hypotenuse 526 of the triangular cross-section. Accordingly, the second wire grid polarizer 538 is preferably approximately orthogonal to the first wire grid polarizer 508.

[0161] A third triangular prism 534 similar to the first and second triangular prisms 504, 514 is attached to the first and second triangular prisms sandwiching the second wire grid polarizer 538 therebetween (see FIG. 27F). This third prism 534 may also comprise glass such as BK7 or SF57 or other glass or substantially optically transmissive material. Similarly, this third prism 534 may have a cross-section substantially in the shape of a right triangle having a hypotenuse 536, and at least the surface of this third triangular prism 534 corresponding to the hypotenuse is preferably substantially planar. The surface corresponding to the hypotenuse 536 of the third triangular prism is preferably adjacent to the second wire grid 538 or the overcoat layer formed thereon. A substantially cylindrical structure 544 having a substantially square cross-section is thereby formed by attaching the third triangular prism 534 to the first and second triangular prisms 504, 514. This square cross-section has four sides, two sides are provided by the first and second triangular prisms 504, 514 respectively, and two sides are provided by the third triangular prism 534. The first wire grid 508 partly extends along a portion of a first diagonal of this square cross-section while the second wire grid 538 extends along a second diagonal of the square cross-section that is orthogonal to the first diagonal.

[0162] The first, second, and third triangular prisms 504, 514, 534 together with the second wire grid polarizer 538 are cut and/or polished thereby removing portions of the third triangular prism and portions of either the first or second triangular prisms along one side of the generally square cross-section. In FIG. 27G, portions of the first triangular prism 504 are removed together with portions of the third triangular prism 534. In certain preferred embodiments, a substantially planar surface 542 is formed by cutting and/or polishing. Preferably, the portions of the first and second wire grid 508, 538 that remain extend toward this substantially planar surface 542 at an angle of about 40° to 50° to this substantially planar surface, and about 80-100° with respect to each other. Additionally, sufficient material is removed by cutting and/or polishing such that the portions of the first and second wire grid 508, 538 also preferably extend to this substantially planar surface 542. The result is a V-prism 550. In the case where MgF coatings are employed, a slight asymmetry may be introduced depending on whether material is removed by polishing the first or second triangular prism 504, 514 together with the third triangular prism 534.

[0163] Variations in the process of forming the V-prism are possible. For example, substantially planar surfaces need not be formed in certain embodiments. Curved surfaces on the V-prism that have power may be formed. Different methods of fabricating the wire grid polarizers 510, 538 are also possible and one or both of the MgF layers 510, 540 may or may not be included. Additional processing steps may be added or certain steps may be removed, altered, or implemented in a different order. In certain embodiments, for example, a flat with a wire grid formed thereon may be cemented to the triangular prism instead of depositing and patterning the plurality of metal strips directly on the prism. Other techniques for forming the V-prism including those yet devised may be employed as well.

[0164] In various preferred embodiments, the optical system 200 may further comprise an optical wedge 254 with the V-prism. This optical wedge 254 may for example be disposed between the (intermediate) output face of the “V” prism and the spatial light modulator 236 as shown in FIG. 28. The wedge 254 may comprise, for instance, a plate of material such as glass that is substantially optically transmissive to the light. The plate, however, has one surface tilted with respect to the other. The thickness of the wedge 254, therefore, varies across the field. The optical wedge 254 introduces astigmatism and coma when the beam is focused through the wedge. This astigmatism and coma can be employed to offset astigmatism and coma introduced by other optical elements such as the imaging optics 54. Optical wedges are described, for example, in U.S. Pat. No. 5,499,139 issued to Chen which is hereby incorporated herein by reference in its entirety.

[0165] The optical wedge 254 shown in FIG. 28 is separated from the prism 202 by a gap, which may be an air gap. In contrast, FIG. 29 shows a wedge-shaped prism 256 wherein the wedge is incorporated in the prism. The wedge-shaped prism 256 may for example have one output surface, the intermediate output, tilted with respect to the other output surface. This prism 256 also introduces astigmatism and coma and can be used to counter these effects introduced by components elsewhere in the system 200. In certain circumstances, however, the wedge 254 separated from the prism 202 by a gap yields improved optical performance.

[0166] In certain embodiments wherein the wedge-shaped prism 256 is employed, the diffuser preferably has a “top hat” angular distribution 248 such as shown in FIG. 21, which provides increased uniformity. Otherwise, the illuminance distribution may exhibit additional non-uniformities. FIG. 30 shows a plot of illuminance across the liquid crystal spatial light modulator 236 for embodiments that include a wedge-shaped prism 256. A diffuser 240 having a Gaussian angular distribution 250 such as shown in FIG. 21 yields an illuminance distribution shown by a first plot 258 that has a dip in the illuminance. A diffuser 240 having a “top hat” angular distribution 248 such as shown in FIG. 21 yields an illuminance distribution shown by a second plot 260 having a substantially constant illuminance across the field. The wedge-shaped prism 256 can be replaced with a prism 202 and wedge 254 combination such as shown in FIG. 28 wherein a gap separates the prism and the spatial light modulator 236. A substantially constant illuminance results. Such a configuration will also reduce angular uniformity requirements of the diffuser 240. For example, both diffusers 240 with Gaussian distributions and diffusers with “flat top” distributions can perform suitably well.

[0167] A mapping of the illuminance across the spatial light modulator 236 for a wedge-shaped prism 256 having a 1.3° wedge is shown in FIG. 31. Substantial uniformity is demonstrated. FIG. 32 is a histogram of the luminous flux per area (in lux). This plot shows that the luminous flux per area received over the spatial light modulator 236 is within a narrow range of values.

[0168] The uniformity is greater for the example wherein the wedge 254 is separate from the prism 202 with an air gap therebetween. FIG. 33 shows a mapping of the illuminance for such a case. The variation is within ±12%. FIG. 34 shows the smaller range of variation in illuminance level. The illuminance level may depend on the particular system design or application. Values outside these ranges are possible as well.

[0169] The wedge-shaped prism 356 may also demonstrate improved performance if the “V” is rotated with respect to the tilted surface forming the wedge. In such a configuration, the thickness of the wedge increases (or decreases) with position along a direction parallel to the edge that forms the apex of the “V” shaped component.

[0170] A color splitting prism may also be included together with the V-prism in certain embodiments to provide color images, graphics, text, etc. FIG. 35 illustrates an optical system 600 for a projector comprising a V-prism 602 and an X-cube 604. The V-prism 602 is disposed between a projection lens 606 and the X-cube 604. X-cubes are available from 3M, St. Paul, Minn.

[0171] The V-prism 602 comprises first and second input ports 608 for receiving illumination that is preferably polarized. The V-prism 602 further comprises first and second polarization beamsplitting surfaces 610 for reflecting the illumination received through the first and second input ports 608. The first and second polarization beamsplitting surfaces 610 are oriented to reflect light received through said first and second input ports 608 to a central input/output port 612 of the X-cube 604.

[0172] The X-cube 604 additionally comprises first and second reflective color filters 614 that reflect certain wavelengths and transmit other wavelengths. The first and second reflective color filters 614 preferably have respective wavelength characteristics and are disposed accordingly to reflect light of certain color to first and second color ports 616 where first and second spatial light modulators 618 are respectively disposed. The X-cube 604 further comprises a third color port 620 located beyond the first and second reflective color filters 614 to receive light not reflected by the first and second reflective color filters. A third spatial light modulator 622 is disposed to receive light from this third color port 620. In various preferred embodiments, reflective spatial light modulators that selectively reflect light may be employed to create two-dimensional spatial patterns. Light reflected from the first and second spatial light modulator 618 through the respective port 616 will be reflected from the first and second reflective color filters 614 respectively. Light reflected from the third spatial light modulator 622 through the third color port 620 will be transmitted through the first and second reflective color filters 614. The light returned by the spatial light modulators 618, 622 will therefore pass through the X-cube 604 and the central input/output port 612 of the X-cube. This light will continue through the V-prism 602 onto and through the projection optics 606 to a screen 624 where a composite color image is formed for viewing.

[0173] Other components, such as e.g., polarizers, diffusers, beamshaping optics etc., may also be included. Optical wedges may be included as well between the X-cube 604 and the spatial light modulators 618, 622 in certain embodiments. Other designs, configurations, and modes of operation are possible.

[0174] Other types of color devices may also be employed. FIG. 36 illustrates an optical system 650 for a rear projection television comprising a V-prism 652 and a Philips prism 654. The V-prism 652 is disposed between a projection lens 656 and the Philips prism 654. Philips prisms are available from Richter Enterprises, Wayland, Mass.

[0175] The V-prism 652 comprises first and second input ports 658 for receiving illumination that is preferably polarized. The V-prism 652 further comprises first and second polarization beamsplitting surfaces 660 for reflecting the illumination received through the first and second input ports 658. The first and second polarization beamsplitting 660 surfaces are oriented to reflect light received through said first and second input ports 658 to a central input/output port 662 of the Philips prism.

[0176] The Philips prism 654 additionally comprises first and second reflective color filters 664, 665 that reflect certain wavelengths and transmit other wavelengths. The first and second reflective color filters 664, 665 preferably have respective wavelength characteristics and are disposed accordingly to reflect light of certain color to first and second color ports 666, 667 where first and second spatial light modulators 668, 669 are respectively disposed. The Philips prism 654 further comprises a third color port 670 located beyond the first and second reflective color filters 664, 665 to receive light not reflected by the first and second reflective color filters. A third spatial light modulator 672 is disposed to receive light from this third color port 670.

[0177] In various preferred embodiments, reflective spatial light modulators that selectively reflect light may be employed to create two-dimensional spatial patterns. Light reflected from the first and second spatial light modulator 668, 669 through the respective port 666, 667 will be reflected from the first and second reflective color filters 664, 665 respectively. Light reflected from the third spatial light modulator 672 through the third color port 670 will be transmitted through the first and second reflective color filters 664, 665. The light returned by the spatial light modulators 667, 668, 672 will therefore pass through the Philips prism 654 and the central input/output port 662 of the Philips prism. This light will continue through the V-prism 652 onto and through the projection optics 656 to a pair of mirrors (not shown) that for forming a composite color image on a screen for viewing. As described above, other components, such as e.g., polarizers, diffusers, beamshaping optics, etc., may also be included. Additionally, optical wedges may be included between the Philips prism 654 and the spatial light modulators 668, 669, 672 in certain embodiments.

[0178] FIGS. 35 and 36 do not show the optical components used to couple light to the V-prisms 602, 652. As discussed above, however, illumination may be provided using light pipes and light boxes including conformal walls that define cavities for light to flow as well as mirrors and other refractive, reflective, and diffractive optical components. Illumination may also be provided by optical fibers, fiber bundles, rigid or flexible waveguides, etc. In certain cases where compactness is a consideration, such configurations may be designed to reduce overall size.

[0179] FIG. 37 shows one example where a mirror 270 for folding the input beam may be included in the optical system 200 to reduce the width of the system. The folding mirror 270 may comprise a planar specularly reflective surface such as shown or may comprise other reflective optical elements as well. As depicted in FIG. 37, this beam folding mirror 270 may be easily integrated into the illuminator optical path. The fold mirror 270 bends the optical path of the beam reducing the width of the system, and thereby facilitating compact packaging. In various preferred embodiments, this optical path is bent by about 90°, however, different angles are possible as well. A dimension, d, corresponding to the width of the system is shown in FIG. 37. In various preferred embodiments, this dimension, d, may be 1-3 inches, and preferably about 2 inches. Sizes outside this range are also possible. The folding mirror may, however, increase stray light effects.

[0180] In various embodiments, non-uniform controlled illumination at the spatial light modulator 236 is desired. For example, in some cases, uniform illuminance at the spatial light modulator 236 (with an intensity distribution that falls off only slightly towards higher angles) produces a non-uniform distribution at the output of the optical system. As discussed above, in many optical systems imaging systems, for instance, the F-number or cone of rays collected by the optical system varies across the field due to distortion. Uniformly illuminating the object field of such an imaging system results in the collection of different amounts of light from different locations in the object field and corresponding illuminance variation at the image plane. Non-uniform illumination at the spatial light modulator, may compensate for this effect and provide uniformity at the image field.

[0181] Accordingly, if a uniform spatial illuminance distribution across the display results in a gradation in the uniformity seen by the observer, a non-uniform illuminance can be used to compensate for the gradation. One method for achieving a compensating linear variation in the illuminance is to use an off-axis illumination such as shown in FIG. 38. In this embodiment, the optical axis of the fiber output and the beamshaper optics 236 is oriented at an oblique angle with respect to the optical axis through the Fresnel collimating lens 238, diffuser 240, polarizer, and the “V” prism input 234. The light source and beamshaping optics 236 are appropriately rotated with respect to the Fresnel lens 238 and the “V” prism 202, and the Fresnel lens, diffuser 240, and “V” prism are decentered with respect to the fiber output and the beam shaping optics 232. Similarly, the optical path of the beam of light propagating from the fiber optic 206a, 206b and the beamshaping optics 232 to the Fresnel collimating lens 238 is angled with respect to the optical path of the beam through the Fresnel lens, diffuser 240, polarizer and input 234 of the “V” prism 202. FIG. 38 depicts the rotation of the beamshaping optics about an axis parallel to the Z axis and the decentering in the X direction. This tilt of the light source with respect to the V-prism may, for example, range between about 5° to 45°, e.g., about 26°. The decenter of the light source with respect to the central axis through the V-prism may be between about 11 and 25 millimeter in some cases. Values outside these ranges, however, are possible.

[0182] In this embodiment, the beamshaping optics 232 comprises a lens having a cylindrical surface. As described above, this cylindrical surface improves collection efficiency of the rectangular input face of the “V” prism 202. The resultant efficiency is substantially similar to the efficiency achieved in the uniform luminance configurations. Other elements within the optical system 200 may be tilted, decentered and/or off-axis as well. In addition, not all of the components need to be tilted, decentered, and off-axis in every embodiment. Other variations are possible.

[0183] The result of the tilt and decenter is that the illuminance across the Fresnel collimating lens 238, diffuser 240, polarizer, input 234 of the prism 202, and liquid crystal spatial light modulator 236 is non-uniform. In particular, in this embodiment, the illuminance across the intermediate output of the “V” prism 202 and at the spatial light modulator 236 is graded as shown by the plots in FIGS. 39 and 40. In this embodiment, this gradation from high to low illuminance extends along the X direction parallel to the vertex of the “V” prism. As shown, the optical path distance from the beam shaping optics 232 to the Fresnel collimating lens 238 varies across the field introducing a corresponding variation in the illuminance.

[0184] Preferably, the configuration is selected to provide the desired illumination, which may be a specific illumination of the object field to counter non-uniformity in the optics, e.g., imaging optics 54, and to ultimately yield uniformity in the image plane. One exemplary configuration is the off-axis illumination depicted in FIG. 38, which can be suitably adjusted to offset non-uniformities in off-axis imaging systems 54 and provide uniformity in the image field. Other configurations, however, adjusted in a variety of ways may be utilized to provide the desired effect. For example, an absorption plate having graded transmission properties or transmittance that varies with location along the width of the plate may be employed. Alternative designs are also possible. Also, although the illuminance is depicted as a generally decreasing value with position, X, along the width of the spatial light modulator 236, the variation in illumination can take other forms. Preferably the system 200 is configured to provide the desired illumination across the spatial light modulator 236. In some cases, the desired profile is a generally decreasing, e.g., substantially monotonically decreasing illuminance across a substantial portion of the light spatial light modulator 236. For example, the ratio of illuminance from one end to another may range from about 2:1 to 6:1 over a lateral distance of between about 15 to 45 millimeters. This distance may be, for example, about 26 millimeters when the spatial light modulator may be for example about 17×19 millimeters. Values outside these ranges, however, are possible.

[0185] In various embodiments, the diffuser 240 is graded in the lateral direction. The diffuser 240 includes a plurality of scattering (e.g., diffractive features) laterally disposed at locations across the diffuser to scatter light passing through the diffuser. As shown in FIGS. 41 and 42, light incident on the diffuser is scattered by these diffractive features into a plurality of directions filling a projected solid angle having a size determined by the diffractive features in the diffuser. As shown, the projected solid angle into which light is scattered may be different for different locations on the diffuser. Preferably, the scattering features in the diffuser are arranged such that the projected solid angle into which light is scattered increases with lateral position on the diffuser. Accordingly, light incident on a first location 260 is scattered into a first projected solid angle Ω₁, light incident on a second location 262 is scattered into a second projected solid angle Ω₂, and light incident on a third location 264 is scattered into a third projected solid angle Ω₃. These locations are shown in FIG. 42 as being arranged sequentially along the X-direction. Similarly, the projected solid angle Ω₁, Ω₂, Ω₃associated with the three locations 260, 262, 264, progressively increases such that light is dispersed into smaller angles for locations on one side of the diffuser and larger angles for locations on the other side of the diffuser.

[0186] Gradation in the scattering characteristics across the diffuser can be useful in various applications. For example, as described above, the imaging optics may possess an F-number or numerical aperture and corresponding collection angle that varies with field. If the illumination is reflected from the liquid crystal spatial light modulator 236 into a constant projected solid angle, the projected solid angle of the illumination may not match the respective collection angle of the imaging optics. The light from some field points on the liquid crystal modulator 236 may fill the aperture of the imaging optics; however, the light from other field points may fail to fill the corresponding aperture of the imaging optics.

[0187] For displays such as head-mounted including helmet-mounted displays, the aperture of the imaging optics preferably maps to the pupil of the eye 12. If the aperture of the imaging optics is under-filled, slight movement of the eye pupil may cause dramatic drop off in light received by the retina. Increased tolerance is therefore desirable as the eye and head of the viewer may move laterally shifting the location of the eye pupil.

[0188] Overfilling is a possible solution. The projected solid angle into which the spatial light modulator emits light may fill the aperture of the imaging optics in each case, overfilling the aperture for some field points. This latter approach, however, is less efficient as light outside the aperture is discarded. Moreover, light that is outside the aperture of the imaging optics may not be absorbed and can scatter back into the field-of-view, reducing the image contrast.

[0189] Accordingly, in various preferred embodiments, the projected solid angle into which light propagates from the spatial light modulator 236 is substantially matched to the corresponding collection angle of the imaging optics. For example, in cases where the f-number of the imaging optics varies with field position, the projected solid angle associated with the output of the liquid crystal modulator 236 is preferably field dependent as well. A graded diffuser such as described above can provide this effect. The diffuser 240 preferably scatters light into projected solid angles that increase in size across the diffuser. This light illuminates the reflective spatial light modulator 236. The light is reflected from the liquid crystal modulator 236 into projected solid angles that increase across the spatial light modulator. Preferably, these increasing projected solid angles substantially match the collection angles of the imaging optics, which also increase with field position. If the projected solid angles for the various points on the spatial light modulator 236 are substantially equivalent to the respective collection angles of the imaging optics, the aperture of the imaging optics will be efficiently filled for each particular field location.

[0190] In various preferred embodiments, non-uniform, and more specifically graded illumination such as provided by the off-axis illumination configuration shown in FIG. 38 is combined with a graded diffuser having scatter properties that progressively vary with transverse location across the diffuser. Graded illuminance is illustrated in FIGS. 39 and 40. Such an illuminance distribution across the diffuser can be paired with an increasingly large projected solid angle into which the diffuser 240 scatters light. Preferably, this combination provides substantially constant luminance as higher illuminance and wider projected solid angles can be selected to yield substantially the same luminance as lower illuminance and corresponding narrower projected solid angles.

[0191] In the example shown in FIG. 42, light incident on the first location 260 has an illuminance I₁and is scattered into the first projected solid angle Ω₁to produce a resultant luminance L₁. Light incident on the second location 262 has an illuminance I₂and is scattered into the second projected solid angle Ω₂to yield luminance L₂. Light incident on the third location 264 has an illuminance I₃and is scattered into the third projected solid angle shown Ω₃thereby providing a resultant luminance L₃. In this case, the illuminance increases progressively with lateral position across the diffuser 240 such that I₁<I₂<I₃. Similarly, the projected solid angle Ω₁, Ω₂, Ω₃associated with the three locations 260, 262, 264, is progressively wider. Accordingly, less light is distributed over a smaller range of angles while more light is distributed over a wider range of angles. In certain embodiments, for example, the projected solid angle may range from 0 to π radians across the diffuser. The ratio of projected solid angles from one end of the diffuser to another end of the diffuser used to illuminate the spatial light modulator may range, for example, from 2:1 to 6:1. Values outside these ranges, however, are possible. Substantially constant luminance across the diffuser 240 can thereby be achieved if the illuminance (e.g., I₁, I₂, I₃) and projected solid angles (e.g. Ω₁, Ω₂, Ω₃) are appropriately matched. L₁, L₂, and L₃are therefore preferably substantially equal.

[0192] A plot of the substantially constant luminance at the spatial light modulator 236 is shown in FIG. 43. The luminance of the spatial light modulator 236 may, for example, be about 10 nits to 150 nits, depending possibly on the application and/or system design. These values correspond to the luminance at the eye. Luminance at the LCD are preferably higher to compensate for losses in the imaging optics. FIG. 44 is a histogram of luminance (in nits) that illustrates that the luminous flux per area per steradian values received over the spatial light modulator 236 are largely similar. The variation in luminance, for example, may be less than 10% across small regions of the display or 50% between any two points in the display. Different specifications of the variation may be employed for different applications. For example, in some embodiments, the luminance at the LCD preferably does not vary by a factor greater than about 1.5. The spatial light modulator 236 therefore preferably appears to have a constant luminance at the different positions thereon (assuming the liquid crystal is not modulated to produce an image or pattern). Absent this combination, the display, projector, or other optical system may appear to the viewer to be non-uniformly lit.

[0193] Other configurations for providing non-uniform illumination and uniform luminance may be employed. In FIG. 45, for example, a light pipe 680 feeds into a light box 682 optically coupled to a plurality of angle area converters such as compound parabolic collectors (CPCs) 684 disposed across the light box. This light box 682 typically comprises a chamber defined, for example, by diffusely reflecting sidewalls or textured surfaces. Such lightboxes are similar to those used as LCD backlights for direct view applications. The angle area converters, are disposed on one of the sidewalls. Nine exemplary angle area converters 684, here compound parabolic collectors 684, are shown. In the embodiment shown, each of these collectors 684 comprises a pair of parabolic reflectors 686 oppositely situated along an optical axis 688 through the respective angle area converters 684. The pair of spaced apart parabolic reflectors 686 define input and output apertures 690, 692 and numerical apertures. In the embodiment shown in FIG. 45, the input apertures 690 and numerical apertures for the plurality of angle area converters 684 increases with longitudinal position (in the X direction) across the light box 682. The numerical aperture also increases although the output aperture is substantially the same for the plurality of angle area converters 684.

[0194] FIG. 45 is a cross-sectional view, and thus the sidewalls of the light box 682 as well as the angle area converters 686 extend into the Z direction as well. Accordingly, the angle area converters 684 are symmetrical about a plane that corresponds to the optical axis 688 shown in the cross-section of FIG. 45. The light box 682 and plurality of angle area converters 688 are disposed in front of one of the input faces of the V prism.

[0195] As illustrated by arrows, the light pipe 680 couples light into the light box 682. This light exits the light box 682 through the plurality of angle area converters 684. The different numerical apertures and different apertures 690 control the illumination in the lateral (X) direction as well as the projected solid angle into which the light is output.

[0196] Accordingly, the angle area converters convert increased area at the input into increased numerical aperture at the output. The increased numerical aperture at the output is useful for matching to increasing F-number with position across the field. To provide constant luminance, more light is collected with increased input aperture to accommodate increased numerical aperture at the output.

[0197] The compound parabolic collectors work well as angle area converters 684 with the light box 682. The luminance into the compound parabolic collectors equals the luminance out of the compound parabolic reflector. The f-number is controlled by using a different compound parabolic reflector input size. As the input sizes vary across the light box 682, gaps between the CPC prevent light from immediately exiting the light box 682, however, this light is reflected back into the light box and recycled for subsequent egress through the compound parabolic collectors. Gaps between the output apertures of the CPCs may, however, introduce variation in the “average” spatial luminance across the field.

[0198] Accordingly, the plurality of angle area converters 684 can control the illumination that reaches the input face of the V-prism. In certain preferred embodiments, the illuminance and projected solid angle vary to provide substantially constant luminance. Although the plurality of angle area converters 684 may be selected to provide non-uniform illuminance and uniform luminance, other designs are possible where uniform illuminance and/or non-uniform luminance is provided. Other types of configurations may also be employed. Components other than light boxes and angle area converters may also be employed in other embodiments. Other types of angle area converters different from compound parabolic collectors may also be employed. A lens array comprising a plurality of lenses having increasing numerical aperture may be employed in certain embodiments.

[0199] Implementations for illuminating displays, projectors, and other optical systems should not be limited to those embodiments specifically shown herein. For example, the various components specifically described may be included or excluded and their interrelationship may be altered. For instance, configurations for providing non-uniform illumination at the diffuser 240 other than the off-axis scheme depicted in FIG. 38 may be employed. The diffuser 240 may comprise devices well-known in the art such as diffractive optical elements, holographic optical elements, holographic diffusers as well as structures yet to be devised. Also, although embodiments are depicted that include a “V” prism 202 having two ports 208, 210, other beamsplitting elements may be employed and the number of input ports need not be limited to two. The system may include one or more input ports. Other techniques for directing the illumination onto the spatial light modulator 236 may also be employed as well although polarization beamsplitters 202 such as the “V” prism offer some advantages. Various configurations and approaches for providing composite colored images are possible.

[0200] Moreover, controlling the illumination incident on a diffuser 240 having variable scattering properties at different locations may be a powerful tool in improving optical properties of displays, projectors, and other optical systems. Although described here in connection with providing constant luminance, the scattering may be adjusted otherwise to provide the desired non-constant luminance profile. Other variations are possible as well. Accordingly, the illumination and the scattering or light dispersing features of the diffuser 240 may be different.

[0201] An example of a display device 300 such as a helmet mounted display or, more broadly, a head mounted display that includes a polarization beamsplitter such as a “V” prism 302 is shown in FIG. 46. The display comprises a liquid crystal spatial light modulator 304 proximal the “V” prism 302. An optical path extends from the spatial light modulator 304 through the “V” prism 302 and imaging or projection optics 306 and reflects off a combiner 308 to a viewer's eye 310, which includes a pupil 312. The combiner 308 folds the image projected by the imaging optics 306 into the eye 310. The combiner 308 may be at least partially transparent such that the viewer can see both the surrounding environment 313 as well as the images and patterns created by the spatial light modulator 304. The combiner 308 may comprise, for example, a visor mounted on a helmet. The combiner 308 can be used for head mounted displays that are not transparent such as may be used in immersive virtual reality. The combiner 308 shown in FIG. 46 is substantially planar.

[0202] A display 300 having a concave combiner 308 is shown in FIG. 47. This combiner 308 has convergent optical power to image the exit pupil of the projection optics 306 onto the eye pupil 312 of the wearer. Such a combiner 308 may reduce the aperture size and thus the size and weight of the imaging optics 306 as shown. A wide field-of-view may also be provided with the powered optical combiner 308 as part of an optical relay.

[0203] A display 300 that projects the image produced by the spatial light modulator 304 at (or near) infinity is shown in FIG. 48. An intermediate projected image 307 is shown located between the projection optics 306 and the combiner 308. A virtual image of the projected image 307 is produced by the combiner 308 at (or near) infinity, e.g., at a large distance which is comfortable for viewing by the eye 310. Accordingly, the rays (indicated by dashed lines) are depicted as being substantially collimated. This combiner 308 may be partially or totally reflective.

[0204] A display 300 having a powered on-axis combiner 308 that forms an image of the exit pupil of the imaging optics 306 at the eye pupil 112 is shown in FIG. 49. A beamsplitter 309 directs the beam from the projector optics 306 to the combiner 308. The combiner 308 shown is circularly or rotationally symmetric about the optical axis passing through the combiner 308. Similarly, a central ray bundle strikes the on-axis optical combiner 308 at an angle of zero. Another type of on-axis combiner is flat. The combiners 308 in FIGS. 47 and 48 are off-axis combiners and are not circularly symmetric about the respective optical axes passing therethrough.

[0205] On-axis combiners have the advantage of being rotationally symmetric about the central ray bundle; as a consequence, aberrations introduced by the combiner may be corrected in the projection optics using surfaces that are also rotationally symmetric about the central ray bundle. The drawback of an on-axis combiner is that a beamsplitter is also employed, and thus the configuration is heavier and bulkier.

[0206] Off-axis combiners are lightweight, however, because the light reflects obliquely from a powered reflecting surface, larger amounts of aberration (chiefly, astigmatism) may be generated in both the image of the pupil (see FIG. 47) and in the intended display image (see FIG. 48). To reduce these aberrations, the combiner surface can be made aspheric, for example, as a toroidal surface, anamorphic surface, or other type of surface.

[0207] Preferably control is provided for both the aberrations of the image as well as the aberrations of the pupil. If the pupil image is substantially uncorrected, for example, the caustic (region where the rays cross) near the pupil may be large such that large diameter optics are preferably used to intercept the rays. In addition, the aberrations of the pupil are not entirely separable from those of the image. If, for example, the ray bundles for some of the image field locations have crossed before reaching the imaging optics, and others have not, then the imaging optics are presented with the field positions in a “scrambled” order, and performing image correction may be difficult.

[0208] In one preferred embodiment, a combiner having a conic surface and more specifically an ellipsoid of revolution may be employed. Preferably, this ellipsoid has one of two conic foci located at or near the eye of the wearer, and the other conic focus located at or near the pupil of the projection optics.

[0209] Such a design provides several advantages. Since the conic surface is a surface of revolution, this surface may be fabricated through single-axis diamond turning. If the part is to be made in mass-production using an injection molding, compression molding, or casting, then the mold inserts may be made by injection molding. Also, if one conic focus is at the eye and the other conic focus is at the pupil of the projection optics, then spherical aberration of the pupil may be substantially reduced or eliminated. In addition, the central rays for all the points in the field preferably cross at the center of the pupil, and the “scrambling” described above is thereby substantially reduced or eliminated. Also astigmatism in the image is reduced, since a conic surface does not introduce astigmatism when one of the foci is placed at the pupil.

[0210] FIG. 50 shows an exemplary display device 400 comprising a spatial light modulator 402, a beamsplitter 404 such as a “V” prism for illuminating the spatial light modulator, imaging optics 406, and a combiner 408. The display device 400 may comprise a head-mounted display such as a helmet-mounted display. Accordingly, the combiner 408 combines images formed using the spatial light modulator 402 with the forward field-of-view of the wearer's eye. The “V” prism 404 may comprise high index flint to reduce the size and weight of the system 400. The display device 400 further includes a wedge 409 between the “V” prism 404 and the spatial light modulator 402 as described above. The wedge 409 may comprise a high index crown to effectively control the aberrations, while minimizing the size and weight of the system 400. The combiner 408 is an “elliptical” combiner conforming to the shape of an ellipsoid (shown in cross-section as an ellipse 414). One of the foci of the ellipse is at the stop, which preferably corresponds to the pupil of the eye.

[0211] A prescription for one preferred embodiment of the display device 400 is presented in TABLES I and II wherein the optical parameters for optical elements A1 to A13 are listed. These optical parameters include radius of curvature, thickness, material, as well as terms where appropriate defining aspheric curvature, tilt, and decenter. The radius of curvature, thickness, and decenter data are in millimeters. As is well known, aspheric surfaces may be defined by the following expression:
Aρ⁴+Bρ⁶+Cρ⁸+Dρ¹⁰+Eρ¹²+Fρ¹⁴
where ρ is the radial dimension. Non-zero values for one or more of these constants A, B, C, D, etc. are listed when the surface is aspheric. Additionally, the conic constant, k, may be provided when the surface is a conic surface. Tilt about the X axis as well as decenter in the Y and Z directions are also included for some of the surfaces in TABLE II.

[0212] The imaging optics 406 comprises ten refractive lenses A2-A11, each of which comprises glass. The imaging optics 406 comprises two groups. The first group comprises the single lens A2. The second group comprises the remaining lens, A3-A11. The field aberrations from the elliptical combiner A1 are partially cancelled by the lens A2 in the first group, which is a low index meniscus lens and which does not share the axis of the group of lenses A3-A10 in the second group or of the combiner. In particular, the meniscus lens A2 is tilted and/or decentered with respect to the remainder of the lenses A3-A11 in the optical system and the V-prism A12. Accordingly, this tilted lens A2 has a first optical axis about which the lens is circularly symmetric. Similarly, the plurality of lenses A3-A11 in the second group has a corresponding second optical axis about which the lenses are circularly symmetric. The two optical axes, however, are different and non-parallel. Preferably, only one lens (in the first group) is tilted with respect to the other lenses (in the second group) although in other embodiments the first group comprises more than one lens aligned along the first optical axis.

[0213] One of these lenses A4 comprising the imaging optics 406 has an aspheric shaped surface. This aspheric surface is near an intermediate pupil to provide for spherical aberration correction. Color correction is provided by the cemented doublets A5/A6, A8/A9, and A10/A11.

[0214] The entrance pupil diameter for this system is 15.0 millimeters. The field-of-view is evaluated between 50 to −15 degrees along the horizontal axis and 25 to −25 degrees along the vertical axis. The imaging optics 406 has an exit pupil that is imaged by the combiner 408 to form a conjugate pupil 412 where the eye pupil (not shown) may be placed.

[0215] FIG. 51 shows another embodiment of the display device 400. A prescription for one preferred embodiment of this display device 400 is presented in TABLES III and IV. The optical parameters for nine optical elements B1 to B9 are listed. One of the optical elements B1 corresponds to the reflective combiner 408. One of the optical elements B8 corresponds to the V-prism 408, and one of the optical elements B9 corresponds to the wedge 410. The imaging optics 406 comprises the remaining six optical elements B2-B7, each refractive lenses. The imaging optics 406 is split into a first group comprising the first lens B2 and a second group comprising the remaining five lenses B3-B7.

[0216] Like the system 400 in FIG. 50, the combiner 408 is an “elliptical” combiner conforming to the shape of an ellipsoid (shown in cross-section as an ellipse 414). In this embodiment, however, two of the lenses B3 and B6 are plastic. These elements comprise Zeonex 1600R (Z-1600R) available from Zeon Chemicals L.P., Louisville, Ky. Plastic lenses can be fabricated in high volumes at lower cost than glass lenses. Plastic lenses are also lighter. The remaining refractive optical components B2, B4, B5, B7, B8, B9, comprise optical glass. The “V” prism 404 (B8) comprises high index flint to reduce the size and weight of the system 400. The wedge 409 between the “V” prism 404 and the spatial light modulator 402 comprises high index crown to effectively control the aberrations, while minimizing the size and weight of the system 400. Both of the plastic lenses B3, B6 have aspheric surfaces. One of the lenses B2 is also tilted and decentered with respect to the other lenses B3-B9. Like the system 400 in FIG. 51, the lens in the first group B2, a meniscus lens, is symmetrical about a first optical axis. The remaining lenses B3-B9, which are in the second group, are symmetrical about a second optical axis. These two optical axes, however, are different. Advantageously, this optical system also has only nine optical elements B1-B9, six of which are lenses. The imaging system 406 comprises a cemented doublet B4/B5 for color correction. The aspheric surface on B6 is near the “V” prism to correct for astigmatism and coma. The aspheric surface on B3 is near an intermediate pupil to provide for spherical aberration correction. The field aberrations from the elliptical combiner B1 are partially cancelled by the low index meniscus lens B2 which, as discussed above, does not share the axis of the first group of lenses B3-B7 nor the combiner. Some of the edges of a number of the lenses B3, B4, B6, B7, are cut off to reduce the weight of the system 400. The entrance pupil diameter for this system is 15.0 millimeters. The field-of-view is evaluated between 50 to −15 degrees along the horizontal axis and 25 to −25 degrees along the vertical axis.

[0217] FIG. 52 shows another embodiment of the display device 400. A prescription for one preferred embodiment of this display device 400 is presented in TABLES V and VI. This optical system has a reduced number of optical elements. The optical parameters for nine optical elements C1 to C9 are listed. One of the optical elements C1 corresponds to the reflective combiner 408. One of the optical elements C6 corresponds to the V-prism 408, and one of the optical elements C7 corresponds to the wedge 410. The imaging optics 406 comprises the remaining four optical elements C2-C5, each refractive lenses. This decreased number of lens C2-C5 advantageously reduces the weight and cost of the optical system 400. The lenses C2-C5 are grouped into a first group and a second group. The first group comprises the first lens C2 and the second group comprises the three remaining lenses C3-C5. In other embodiments, the first group may comprise more than one lens although a single lens element is preferred.

[0218] Like the systems 400 in FIGS. 50 and 51, the combiner 408 is an “elliptical” combiner conforming to the shape of an ellipsoid (shown in cross-section as an ellipse 414). In this embodiment, however, each of the four powered elements C2-C5 are plastic. These elements C2-C5 comprise acrylic (PMMAO), Zeonex 480R (Z-480R), and Zeonex 1600R (Z-1600R). Z-480R and Z-1600R are available from Zeon Chemicals L.P., Louisville, Ky. Other plastic and non-plastic materials may be used as well. Plastic lenses, however, can advantageously be fabricated in high volumes at lower cost than glass lenses. Plastic lenses are also lighter. The “V” prism comprises a high index flint to reduce the size and weight of the system. The wedge between the “V” prism 404 and the spatial light modulator 402 comprises a high index crown to effectively control the aberrations, while minimizing the size and weight of the system.

[0219] Each of the lenses C2-C5 in the imaging system is aspheric to correct for monochromatic aberrations. One of the lenses C2 is also tilted and decentered with respect to the other three lenses C3-C5. Like the system 400 in FIGS. 50 and 51, the lens C2 in the first group, a meniscus lens, is symmetrical about a first optical axis. The remaining lenses C3-C5, which are in the second group, are also symmetrical about a second optical axis. The first and second optical axes are oriented differently. The optical elements C3-C5 in the second group each comprises a plastic flint. One lens C4 in the second group comprises a diffractive element for color correction. This diffractive element, a hologram, is characterized by the following expression:
φ=c_1ρ²+c_2ρ⁴
where φis the phase shift imparted on the wavefront passing through the diffractive features on this optical element C4, ρis the radial dimension, and c₁and c₂are constants. The values of c₁and c₂are −7.285×10⁻⁴and −1.677×10⁻⁷, respectively. The diffractive optical element is designed to use the first order (m=³⁰1) at a wavelength of about 515 nanometers. The field aberrations from the elliptical combiner are partially cancelled by the low index lens in the first group, which does not share the same optical axis as either of the second group of lenses in the imaging optics 406 or of the combiner 408. The entrance pupil diameter for this system is 15.0 millimeters. The field-of-view is evaluated between 50 to −15 degrees along the horizontal axis and 25 to −25 degrees along the vertical axis.

[0220] Other designs may be used as well. For example, variations in the number, shape, thickness, material, position, and orientation, are possible. Holographic or diffractive optical elements, refractive and/or reflective optical elements can be employed in a variety of arrangements. Many other variations are possible and the particular design should not be limited to the exact prescriptions included herein.

[0221] Various preferred embodiments, however, employ combiners having a shape in the form of a conic surface. Conic surfaces are formed by generating a conic section, a particular type of curve, and rotating the curve about an axis to sweep out a three-dimensional surface. The shape of a conic surface is determined by its conic constant, k. The conic constant, k, is equal to the negative of the square of the eccentricity, e, of the conic curve in two dimensions that is rotated to form the three-dimensional surface. Conic surfaces are well know and are described, for example, in “Aspheric Surfaces”, Chapter 3 of Applied Optics and Optical Engineering, Vol. VIII, R. Shannon and J. Wyant, ed., Academic Press, New York N.Y. 1980.

[0222] An ellipsoid (also known as a prolate spheroid) is formed by rotating an ellipse about an axis referred to as a major axis, which joins two conic foci. The conic constant for an ellipsoid has a value between zero and −1. A sphere is a special case of an ellipsoid, with a conic constant of zero. A hyperboloid is formed in a similar manner, however, the value of the conic constant is more negative than −1. A paraboloid has a conic constant of exactly −1, and is formed by rotating a parabola about an axis that is perpendicular to a line referred to as a directrix of the parabola and a point on the axis, the focus of the parabola. An oblate spheroid has a positive conic constant. In various preferred embodiments, the conic constant is between about −0.25 and 0, or 0 and +0.60, and may be between about −0.36 and 0, or 0 and +0.44.

[0223] In various preferred embodiments for eliminating spherical aberration of the pupil, one conic focus 418 is located exactly at the eye 412 and the other conic focus 420 is located exactly at the pupil 416 of the projection optics 406. The conic constant for this combiner 408 has a conic constant between 0 and −1 and the surface is therefore ellipsoidal. (Since the eye pupil and the projection optics pupil are physically separated, the surface is not spherical.)

[0224] FIG. 53 is a schematic cross-sectional representation of the ellipsoid (shown as an ellipse 414) and the combiner 408 substantially conforming to the shape of the ellipsoid. The ellipsoid includes two foci 418, 420 and a major axis 422 through the two foci. A pupil 412 in the viewer's eye and an exit pupil 416 for the imaging optics 406 are depicted at the two foci 418, 420 of the ellipsoid. In various embodiments, the shape of the combiner 408 substantially conforms to a portion of the ellipsoid 414. In addition, the ellipsoid 414 is positioned with respect to the pupil 412 of the eye and the exit pupil 416 of the imaging optics 406 such that the pupils 412, 416 substantially coincide with the locations of the foci 418, 420 of the corresponding ellipsoid defining the shape of the combiner 408. In such a configuration, the ellipsoidal combiner 408 preferably images the projector pupil 416 generally onto the eye pupil 412.

[0225] FIG. 54 illustrates another example wherein the combiner 408 conforms to the shape of an ellipsoid and the pupil 412 of the viewer's eye and the exit pupil 416 of the imaging optics 406 substantially correspond to the locations of the foci 418, 420 of the ellipsoidal. FIG. 54 also depicts a plurality of lenses comprising the imaging or projection optics 406. The shape of the combiner 408 may deviate from conforming to a portion of an ellipse 414 and the pupils 412, 416 may be shifted with respect to the foci 418, 420. The major axis 422 of the ellipsoid 414 intersects the two foci 418, 420. As shown by the location of beam path reflected from the combiner 408 with respect to the major axis 422 through the ellipsoid, the combiner is an off-axis combiner.

[0226] In one preferred embodiment, to eliminate spherical aberration at the center of the field-of-view, a reflective surface having a shape of a paraboloid (formed by rotating a parabola about its axis of symmetry) may be used. Preferably, this rotation axis of the paraboloid defining the reflective surface is substantially parallel to the line-of-sight of the eye at the center of the field. Moreover, the conic focus to the paraboloid is preferably disposed at the image point for that field.

[0227] FIG. 55, for example, illustrates another display system 450 comprising an object plane 454, imaging optics 456, and a combiner 458. An optical path extends from the object plane 454, through the imaging optics 456, off the combiner 458 and into an eye 460 with a pupil 462. FIG. 55 depicts a schematic cross-sectional representation of a paraboloid (shown as a parabola 464) and the combiner 458 substantially conforming to the shape of the paraboloid. The paraboloid 464 is defined by a focus 466 and a directrix 468. An intermediate image 467 is at the focus 466 of the parabola 464. In various embodiments, the shape of the combiner 458 substantially conforms to a portion of a paraboloid 464. Additionally, the parabola 464 is positioned such that the focus 466 of the paraboloid 464 defining the shape of the combiner 458 substantially overlaps the intermediate image 467. With such a configuration, the intermediate image 467 is reproduced at or near infinity, e.g., a distance sufficiently far for comfortable viewing of the viewer, as close as several meters to several kilometer as well as outside this range. As discussed above, spherical aberration at the pupil 462 may be reduced with this configuration.

[0228] In some embodiments, the goals of simultaneously reducing the aberrations at pupil and the aberration of the image lead to a conic constant between 0 and −1, which yields an ellipsoid. The conic foci of this ellipsoid are preferably located near although not coincident with the eye and the projection optics pupil respectively. The proximity in relationship with the foci may be selected so as to reduce pupil and image aberration, e.g., as reflected in a merit function used to evaluate different designs. In various preferred embodiments, the exit pupil is at a distance from the one of the foci that is less than about ¼ the distance along the major axis of the ellipsoid that separates the foci.

[0229] FIG. 56, for example, shows an embodiment wherein the combiner 408 comprises an ellipsoidal surface 414 and the viewer's eye and the exit pupil 416 of the imaging optics 406 are shifted away from the foci 418, 420 of the ellipse defining the shape of the combiner. More specifically, one of the foci 420 is between the exit pupil 416 of the imaging optics 406 and an intermediate image 407 formed by the imaging optics. The combiner 408 is positioned with respect to the imaging optics 406 and the object 404 as well as the resultant intermediate image 407 to project the intermediate image to or near infinity (e.g., a distance sufficiently far for comfortable viewing of the viewer, as close as several meters to kilometers). Accordingly, the rays (indicated by dashed lines) are depicted as being substantially collimated In addition, both the aberration at the pupil and the aberration at the image are reduced. The distance of the eye and pupil of the projection optics is preferably such that reduced value of the image and pupil aberrations is obtained.

[0230] Another design comprises a simplified and light-weight head mounted display comprising a combiner and a pair of plastic lenses. One of the lenses is a rotationally symmetric optical element and one of the lenses is a non-rotationally symmetric optical element. This non-rotationally symmetric optical element comprises first and second lens surfaces that are tilted and decentered with respect to each other. One of the lens surfaces may also comprise a diffractive or holographic optical element for color correction. Advantageously having projection optics comprising only two lenses, both of which comprise plastic, reduces the cost and weight of the system.

[0231] FIG. 57 shows an exemplary embodiment of such a display device 500. A prescription for one preferred embodiment of this display device 500 is presented in TABLES VII and VIII. This optical system 500 has a reduced number of optical elements. The optical parameters for three optical elements D1, D2, D3 are listed.

[0232] One of the optical elements D1 corresponds to the reflective combiner 508. This combiner 508 could be a partially reflective off-axis combiner as discussed above. Like the systems 500 in FIGS. 50 and 51 the combiner 508 is an “elliptical” combiner conforming to the shape of an ellipsoid (shown in cross-section as an ellipse 514).

[0233] In addition to the combiner 508, the device 500 comprises imaging optics 506. The imaging optics 506 comprises the remaining two powered optical elements D2 and D3, each of which are refractive lenses. (Although, not shown, the display device 500 may include a V-prism and a wedge such as described above in embodiments, for example, where a spatial light modulator is used that is illuminated with light from a light source.) The decreased number of lenses advantageously reduces the weight and cost of the optical system 500.

[0234] Moreover, in this embodiment, the only two lenses D2, D3 are each plastic. These elements D2 and D3 comprise Zeonex 480R (Z-480R), which is available from Zeon Chemicals L.P., Louisville, Ky. Other plastic and non-plastic materials may be used as well. Plastic lenses, however, can advantageously be fabricated in high volumes at lower cost than glass lenses. Plastic lenses are also lighter.

[0235] Each of the optical surfaces 520, 522, 524, 526, 528 on each of the optical elements Dl-D3 are aspheric. The reflective surface 520 on the combiner 508 is ellipsoidal and thus aspheric. The surfaces 522, 524 (surfaces 4 and 5 in Tables VII and VIII) on lens D2 are also each aspheric. Similarly, the surfaces 526, 528 (surfaces 6 and 7 in Tables VII and VIII) on lens D3 are each aspheric. Each of the aspheric surfaces 520, 522, 524, 526, 528 are different.

[0236] Moreover, the surfaces 522, 524 (surfaces 4 and 5 in Tables VII and VIII) on the lens D2 are tilted and decentered with respect to each other. Both refractive optical surfaces 522, 524 have shapes (aspheric) that are rotationally symmetric about respective optical axes. However, these optical axes are tilted and decentered with respect to each other. The result is a non-rotationally symmetric optical element, an optical element that itself is not rotationally symmetric about an optical axis.

[0237] In various preferred embodiments, by definition lens D2 is a lens and not a prism, combiner, or catadioptric optical element. Light propagates through D2 without substantial reflection. Similarly, lens D3 is a lens and light propagates through D3 without substantial reflection. In various preferred embodiments, the reflection in reduced to below 10%.

[0238] Lens D3, however, is rotationally symmetric about an optical axis. Both refractive optical surfaces 526, 528 on lens D3 have shapes (aspheric shapes) that are also rotational symmetric about substantially the same optical axis. The optical axis through lens D3, however, is different than both optic axes for the two surfaces 522, 524 on lens D2. Moreover, all of these optical axes are different from the optical axis for the elliptical combiner D1.

[0239] These varying degrees of freedom, the different tilts and decenters, as well as the different aspheric shapes, enable a high performance optical device 500 to be designed with relatively few optical elements. Correction of monochromatic aberrations is thus possible with only the five optical surfaces (one reflective 520, and four refractive 522, 524, 526, 528) on three optical elements, lenses D1 and D2 and reflective combiner D3.

[0240] Since both lenses comprise the same material, chromatic aberration is substantially corrected by a diffractive element on the lens D3. In particular, one of the surfaces 526 (surface 6 in Tables VII and VIII) includes diffractive features that form a diffractive element. This diffractive element, a hologram, is characterized by the following expression:
φ=c₁ρ²+c₂ρ⁴+c₃ρ⁶
where φ is the phase shift imparted on the wavefront passing through the diffractive features on this optical element D3, ρ is the radial dimension, and c₁, c₂, and C₃are constants. The values of c₁, c₂, and c₃are −1.748×10⁻³, 1.283×10⁻⁶, and 6.569×10⁻⁹, respectively. The diffractive optical element is designed to use the first order (m=⁺1) at a wavelength of about 515 nanometers.

[0241] In other embodiments, chromatic correction may be provided by using different lens materials for D2 and D3. For example, different plastic or polymeric materials having different dispersion properties may be used. In certain embodiments, non-plastic materials may also be used, however, plastic offer the advantage of reduced manufacturing costs even for aspherics, and plastic is light weight. In another embodiment, one of the lenses may be plastic and the other lens may be glass. Still other designs are possible.

[0242] In the prescription shown in Tables VII and VIII, the entrance pupil diameter for this system is 10.0 millimeters. The field-of-view is evaluated between +8 to −8 degrees along the horizontal axis and +6 to −6 degrees along the vertical axis.

[0243] FIG. 58 shows another light-weight head mounted display device 800 comprising a combiner 808 and imaging optics 806 having at least two optical axes. The device 800 includes an image formation device 802 comprising, e.g., an emissive display or a spatial light modulator, which is imaged by the imaging optics 406 and a combiner 808. A prescription for one embodiment of this display device 800 is presented in TABLES IX and X. This optical system 800 includes a plurality of optical elements E1-E6, the details of which are listed in TABLES IX and X.

[0244] One of the optical elements E1 is the reflective combiner 808. This combiner 808 is a partially reflective combiner. Like the systems 600 in FIGS. 50 and 51, the combiner 808 is an “elliptical” combiner conforming to the shape of an ellipsoid (shown in cross-section as an ellipse 814). In the embodiment shown in FIG. 58, the ellipsoid has an axis that passed through the image pupil or stop 812 where the eye pupil is to be located. More particularly, in this embodiment, the image pupil or stop 812 is at one of the foci of the ellipsoid. The combiner 808 is an off-axis combiner as the field-of-view, e.g., seen from the eye is not aligned with the axis of symmetry of the combiner. Accordingly, the bundle of rays that is shown distributed across the field is not disposed substantially symmetrically about the optical axis. In this particular, the prescription in Table IX and X shows the off-axis combiner tilted −68.03° about the stop.

[0245] In addition to the combiner 808, the device 800 comprises imaging optics 806. The imaging optics 806 comprises a plurality of powered optical elements: a first lenses element, E2, a second lens element, E3, a third lens element, E4, and a fourth lens element, E5. In the embodiment shown in FIG. 58, the first and fourth lens elements E2, E5 are plastic. The fourth lens element E5 includes an aspheric surface formed in the plastic. The second and third lens elements E3, E4 comprises different glasses and form a doublet.

[0246] The first lens element, E2, has first and second surfaces 822, 824 (surfaces 4 and 5 in Tables IX and X). These surfaces 822 and 824 share a common optical axis. In the embodiment shown in FIG. 58, both the refractive optical surfaces 822, 824 have shapes that are rotationally symmetric about this common optical axis. This first lens element, E2, has positive optical power. In this embodiment, this first lens element E2 comprises plastic as discussed above.

[0247] The first lens element E2 is tilted and decentered with respect to the combiner E1 as shown by the prescription listed in Tables IX and XI. In general, tilt and decenter as listed in Tables IX and XI is measured with respect to the previous surface. For the surface after the combiner 808 (surface 3), however, the tilt and decenter is measured with respect to the stop 812, as is the case for each of the prescriptions in Tables herein. The tilt and decenter of surface 3, the first surface after the combiner 808, defines the tilt and decenter of the first surface 822 of the first lens element E2, as is also the case for each of the prescriptions in the Tables herein. Thus, the tilt and decenter listed in Tables IX and X for both the combiner 808 (E1) and the first surface 822 of the first lens E2 are with respect to the stop 812. The relative tilt and decenter between these the first lens E2 and the combiner 808 (E1) is therefore obtained by computing the difference between the tilts and decenters for the combiner and surface 3. As a result, in the embodiment shown in FIG. 58, the first surface 822 is tilted about 68.08°−62.38° or 5.65°, as measured with respect to the combiner 808. Thus, the first lens element E2 has a different optical axis than the combiner E1.

[0248] The second lens element E3 is rotationally symmetric about yet another optical axis. Both refractive optical surfaces on the second lens element E3 have shapes that are also rotational symmetric about substantially the same optical axis. The optical axes through the second lens element E3, however, is different than the optic axis for the two surfaces 822, 824 on the first lens element E2 and is also different than the optical axis for the combiner 808 (E1).

[0249] Additionally, the third lens element E4, is rotationally symmetric about the same optical axis as the third lens element E3. Both refractive optical surfaces on third lens element E4 have shapes that are also rotational symmetric about substantially this same optical axis. The optical axes through the third lens element E4, however, is different than the optic axis for the two surfaces 822, 824 on first lens element E2. As discussed above, the second lens element E3 and third lens element E4 form a doublet. The second lens element E3 comprises a different glass than the third lens element E4, selected so that the doublet reduces chromatic aberration.

[0250] The fourth lens element E5 is also rotationally symmetric about the same optical axis as the second and third lens elements E3 and E4. Both refractive optical surfaces on the fourth lens element E5 have shapes (one of which is aspheric) that are also rotational symmetric about substantially the same optical axis. The optical axes through the fourth lens element E5, however, is different than both optic axes for the two surfaces 822, 824 on the first lens element, E2. As stated above, this fourth optical element E5 comprises plastic.

[0251] In various preferred embodiments, by definition lens E2 is a lens and not a prism, combiner, or catadioptric optical element. Light propagates through E2 without substantial reflection. Similarly, lens elements E3, E4, and E5 are a lenses and light propagates through E3, E4, and E5 without substantial reflection. In various preferred embodiments, the reflection in reduced to below 10% for each lens element.

[0252] As shown in FIG. 58, the device 800 further comprises another non-lens element, a wedge, E6. This wedge E6 may be used to reduce aberrations such as astigmatism and coma. The wedge E6 is between the imaging optics 806 and the object, which may be the image formation device 802. As discussed above, images of this image formation device 802 are formed by the imaging optics 806 and combiner 808 at the eye. This image formation device 802 may comprise an emissive light source such as an array of organic light emitting diodes (OLED). An exemplary array comprising 852×600 organic light emitting diodes is available from Emagin located in Bellevue, Wash. Other image formation devices are used. Illumination may also be provided, for example, in the case where the image formation device is not emissive.

[0253] As discussed above, in this system 800, the lens elements E2, E3, E4, and E5 include more than one axis. In particular, a group of the lens elements comprising the second, E3, third, E4, and fourth E5, share a common optical axis which is different than the axis for a single one of the lenses, the first lens element, E2. In the embodiment in FIG. 58, the first lens element E2 has a single optical axis that is tilted and decentered with respect the single optical axis for the other lens elements E3, E4, and E5. Additionally, all of these optical axes are different from the optical axis for the elliptical combiner E1.

[0254] The tilt and decenter of the optical axis and the corresponding lenses permit additional degrees of freedom with which to control aberration and improve performance. These varying degrees of freedom, the different tilts and decenters, as well as the different aspheric shapes (e.g., of the combiner 808 and of the fourth lens element E5) enable a high performance optical device 800 to be designed with relatively few optical elements. Correction of aberrations is thus possible with only the eight optical surfaces (one reflective, and seven refractive) on five powered optical elements, the combiner E1 and lenses E2 to E5. The small number of lens elements advantageously reduces the weight and cost of the optical system 800.

[0255] Moreover, in this embodiment, the two of the lenses E2, E5 are plastic. These elements E2 and E5 comprise Zeonex 480R (Z-480R), which is available from Zeon Chemicals L.P., Louisville, Ky. Other plastic and non-plastic materials may be used as well. Plastic lenses, however, can advantageously be fabricated in high volumes at lower cost than glass lenses. Plastic lenses are also lighter.

[0256] As a result, the refractive portion for the head mounted display, including the imaging optics 806 and the prism 808, comprise less than about 30 grams for each eye. Advantageously, the center of gravity is near the center of the head because most of the weight of the optics is located rearward. Such a system is safer to wear.

[0257] In this system, the first lens E2 of the imaging optics 806 is also positive which advantageously provides for a more compact device 800. By comparison, if the first lens E2 were negative, the imaging optics 806 would form a reverse telephoto system as the remaining lens elements E3, E4, E5, together have positive power. Reverse telephoto systems have a length greater than the effective focal length of the reverse telephoto system. Conversely, a positive first lens E2 combined with the positive power provided by the remaining lenses elements E3, E4, E5 provides imaging optics that is shorter than a reverse telephoto relay. This reduced length contributes to the compactness of the system.

[0258] The system 800 also provides good optical performance. The field of view provided is about 30×22 degrees with full overlap between the two eyes. The exit pupil is 10 millimeters in diameter in this embodiment. The modulation transfer function is greater than 0.4 at 33 line pairs per millimeter for a 10 millimeter pupil.

[0259] A wide range of variations are possible. More or less lenses may be used. In various embodiment, however, the imaging optics 808 comprises a plurality of lens elements which have a first optical axis and another single lens element which has second optical axis different from the first optical axis. The group of lenses having the common optical axis may comprise two, three, four, five or more lenses. Reduced number of lenses offers the advantage of reduce weight, cost, and complexity. Similarly, only one other lens is included in the imaging optics and this lens has a different optical axis. This lens may be positive to provide for a compact system.

[0260] As discussed with regard to FIG. 57, however, this single lens may be a non-rotationally symmetric lens having two surfaces (e.g. aspheres), each with different optical axes from each other. The single lens may have a pair of surfaces that are each rotationally symmetric, one of which shares a common optical axis as the other lenses in the imaging optics and one which is different. In such embodiments, at least one of the surfaces and optical axes of the first lens element is tilted and/or decentered with respect to a plurality of other lenses in the imaging optics, which may also include other types of optical elements besides lenses. The single lens may have one surface that is non-rotationally symmetric and one surface that is rotationally symmetric as well.

[0261] Similarly, any of the other lenses may be a non-rotationally symmetric lens having two surfaces (e.g. aspheres), each with different optical axes from each other. Such a lens may have a pair of surfaces that are each rotationally symmetric, one of which shares a common optical axis as the other lens or lenses in the group and one which is different. In such embodiments, at least one of the surfaces of the lens element has an optical axes coincident with the shared common optical axis. For example, in one embodiment, only one surface on each of E3, E4, and E5 shares a common optical axis, the other surfaces having other optical axes. In some embodiments, any of these lenses may have one surface that is non-rotationally symmetric and one surface that is rotationally symmetric as well.

[0262] Other variations are possible. For example, one or more of the lenses surfaces or elements may be replaced with a transmissive diffractive optical element having power referred to herein as a diffractive lens or diffractive lens element. For instance, the color correction provided by the doublet comprising the second and third lens elements E3, E4, may be provided instead by a diffractive optical lens. The diffractive optical lens may comprises diffractive features disposed on a surface of a lens or a plane parallel plate or sheet. The diffractive features may be arranged to provide power to the transmissive diffractive optical element. Such transmissive diffractive optical elements having power have optical axes and thus can be used in a system with multiple optical axes that provide added degrees of design freedom. For example, one or more (even each) of the second, third, or fourth optical elements E3, E4, E5 sharing the common optical axis could be replaced with diffractive optical lenses. Similarly, the single optical element E2 having a different optical axis than the rest of the optical elements may comprise a diffractive optical lens.

[0263] The shape and materials used for the lens elements E2, E3, E4, and E5 may vary. A fold mirror comprising a substantially flat reflective surface may be inserted in the device, for example, between the first lens element E2 and the combiner 808. Such a flat fold mirror has no power but can enable the imaging optics 806 to be angled and positioned differently with respect to the combiner 808, for example, such that the imaging optics 806 are closer to the head and the head mounted display is more form fitting to the head. Other fold mirrors may be included elsewhere as well. Other types of reflective components may also be included in the device. For example, reflectors may be included in addition to lenses in the imaging optics.

[0264] The order of the lens elements may vary. For example, the first lens element need not be located first, but may be between the other lenses. In this case, for instance, E2 might be between E3 and E4, or E4 and E5 or between E5 and the image formation device. The order of E3, E4, and E5 may also vary. In one embodiment, the imaging optics 806 are between the combiner 808 and the image formation device 802 with the single positive lens (e.g., E2) closest to the image formation device and the remaining lenses (e.g., E3, E4, E5) closest to the combiner. Thus, the lens closest to the combiner may be tilted and/or decentered. Alternatively, the tilted and/or decentered element could be inserted somewhere in the middle of the other elements in the imaging optics. This tilted and/or decentered element can have positive or negative power.

[0265] Other optical elements (e.g., reflectors, fold mirrors, wedges, filter, etc.) can be inserted anywhere in the optical system. Other types of optical elements may be included anywhere in the optical path between the combiner 808 and the image formation device 802.

[0266] The combiner 808 may also be different. An anamorphic asphere or toroid can be used. The combiner may, for example, be substantially totally reflecting. Additionally, the combiner 808 may comprise an on-axis combiner. The combiner 808 need not have an optical axis that passes through the eye pupil. The combiner 808 also need not be rotationally symmetrical about an axis. The surface of the combiner 808 may be defined by a generally bi-laterally symmetric XY-polynomial, for example. Other shapes and configurations are also possible.

[0267] Also, although the imaging optics 800 shown in FIG. 58 comprises a single lens element E2 having at least one surface with an optical axis that is different than the optical axis shared by the remaining elements E3, E4, and E5, the remaining lens elements need not each share that same optical axis. For example one or more these lens elements E3, E4, E5 could be tilted and/or decentered as well. Thus, the single lens element E2 may have an optical axis that is different than common optical axis shared by two or more lens elements, even though additional lens elements may be included in the imaging optics 808 that do not share a common axis.

[0268] In certain embodiments, the single lens element E2 has an optical axis that is different than the optical axis of one other lens element in imaging optics 808 comprising only two lenses such as shown in FIG. 57. The imaging optics 808, may include other non-lens type elements such as a reflector or fold mirror.

[0269] Moreover, as described above, any of the remaining lenses E3, E4, E5 may have at least one surface that has a different optical axis from the others. This optical axis may be different than the optical axis or optical axes for the first lens E2.

[0270] FIG. 59 shows another light-weight head mounted display device 900 comprising a combiner 908 and imaging optics 906 having at least two optical axes. The device 900 includes an image formation device such as a spatial light modulator 902, which is imaged by the imaging optics 906 and a combiner 908. A prescription for one embodiment of this display device 900 is presented in TABLES XI and XII. This optical system 900 includes a plurality of optical elements F1-F5, the details of which are listed in TABLES XI and XII.

[0271] One of the optical elements F1 comprises the reflective combiner 908. This combiner 908 is a partially reflective combiner and is an “elliptical” combiner conforming to the shape of an ellipsoid (shown in cross-section as an ellipse 914). In the embodiment shown in FIG. 59, the ellipsoid has an axis that passes through the image pupil or stop 912 where the eye pupil is to be located. Also, in this embodiment, the image pupil or stop 912 is at one of the foci of the ellipsoid. The combiner 908 is an off-axis combiner as the field-of-view, e.g., seen from the eye, is not aligned with the axis of symmetry of the combiner. Accordingly, the bundle of rays distributed across the field is not disposed substantially symmetrically about the optical axis of the combiner 908. In particular, the prescription in Table XI and XII shows the off-axis combiner tilted −68.96° about the stop 912.

[0272] In addition to the combiner 908, the device 900 comprises imaging optics 906. The imaging optics 906 comprises a plurality of powered optical elements: a first lenses element, F2, a second lens element, F3, and a third lens element, F4. Each of the lens elements F2, F3, and F4 have at least one aspheric surface and comprise plastic. The first lens element F2, has two aspheric surfaces while the other two lens each have one aspheric surface.

[0273] The first lens element, F2, has a first surfaces 922 and a second surface 924 (surfaces 2 and 3 in Tables XI and XII) that share a common optical axis. In the embodiment shown in FIG. 59, both the refractive optical surfaces 922, 924 have shapes that are rotationally symmetric about this common optical axis. As stated above, both surface 922, 924 are aspheric. This first lens element, F2, also has positive optical power.

[0274] In contrast with the design depicted in FIG. 57, the first lens element F2 is not tilted and decentered with respect to the combiner F1 as shown by the prescription listed in Tables XI and XII and depicted in FIG. 59. Tilt and decenter as listed in Tables IX and XI is generally measured with respect to the previous surface. For the surface after the combiner (surface 3), however, the tilt and decenter is measured with respect to the stop 912, as is the case for each of the prescriptions in Tables presented herein. The tilt and decenter of surface 3, the first surface after the combiner 908, defines the tilt and decenter of the first surface 922 of the first lens element F2, as is also the case for each of the prescriptions in the Tables herein. Thus, the tilt and decenter listed in Tables XI and XII for both the combiner 908 and the first surface 922 of the first lens F2 are with respect to the stop 912. The relative tilt and decenter between these the first lens F2 and the combiner F1 is therefore obtained by computing the difference between the tilts and decenters for the combiner 908 and surface 3. As a result, in the embodiment shown in FIG. 59, the first surface 922 is tilted about −68.98°+68.98° or 0° and is decentered by 0−68.055 or −68.055 millimeters (in the Z direction) as measured with respect to the focus of the combiner 908. Thus, the first lens element F2 has the same optical axis as the combiner F1.

[0275] The second lens element F3 is rotationally symmetric about another optical axis. Both refractive optical surfaces on the second lens element F3 have shapes that are also rotational symmetric about substantially the same optical axis. The optical axes through the second lens element F3, however, is different than the optic axis for the two surfaces 922, 924 on the first lens element F2. The optical axes through the second lens element F3, are also different than the optic axis for the combiner F1.

[0276] The second lens element F3 comprises a diffractive optical lens for reducing chromatic aberration. This diffractive optical lens comprise a transmissive diffractive optical surface having power that is disposed on a glass lens. The diffractive surface, a hologram, is characterized by the following expression:
φ=c₁σ²+c₂σ⁴+c₃σ⁶. . .
where φ is the phase shift imparted on the wavefront passing through the diffractive features on this optical element F3, σ is the radial dimension, and c₁, c₂, and c₃are constants. The values of c₁and c₂are −7.580×10⁻⁴, 1.044×10⁻⁶, and −4.08×10⁻⁹, respectively. The diffractive optical element is designed to use the first order (m=⁺1) at a wavelength of about 555 nanometers.

[0277] The third lens element F4, is rotationally symmetric about same optical axis as the third lens element F3. Both refractive optical surfaces on third lens element F4 have shapes that are also rotational symmetric about substantially this same optical axis. The optical axes through third lens element F4, however, is different than the optic axis for the two surfaces 922, 924 on first lens element F2.

[0278] In various preferred embodiments, by definition lens F2 is a lens and not a prism, combiner, or catadioptric optical element. Light propagates through F2 without substantial reflection. Similarly, lens elements F3, and F4 are lenses and light propagates through F3 and F4 without substantial reflection. In various preferred embodiments, the reflection in reduced to below 10%.

[0279] As shown in FIG. 59, the device 900 further comprises another non-lens element, an optional wedge, F5. This wedge F5 may be used to reduce aberrations such as astigmatism and coma. The wedge F5 is in the optical path between the imaging optics 906 and the object, e.g., the spatial light modulator 902. As discussed above, images of this spatial light modulator 902 are formed by the imaging optics 906 and combiner 908 at the eye. This spatial light modulator 902 may comprise liquid crystal on silicon (LCOS), for example. A v-prism and/or other illumination components may also be included as discussed above but are not depicted in FIG. 59. Other types of spatial light modulaters may be used and other types display elements such as emissive displays may be used instead of a spatial light modulator.

[0280] In this system 900, the lens elements F2, F3, and F4 includes more than one axis. In particular, a group of the lens elements, the second, F3 and the third, F4, share a common optical axis that is different than a single one of the lenses, the first lens element, F2. In the embodiment shown in FIG. 59, the first lens element F2 has a single optical axis that is tilted and decentered with respect the single optical axis for the other two lens elements F3 and F4. In this embodiment, however, the first lens F2 shares a common optical axis with the combiner 908, although the third and four lens elements F3 and F4 do not.

[0281] The tilt and decenter of the first lens F2 with respect to the other lenses, F3, F4 permit additional degrees of freedom with which to control aberration and improve performance. These varying degrees of freedom, the different tilts and decenters, as well as the different aspheric shapes (e.g., of the each of the powered optical elements, the combiner 908 and the first, second, and third lenses F2, F3, F4) enable a high performance optical device 900 to be designed with relatively few optical elements. Correction of aberrations is thus possible with only the seven optical surfaces (one reflective, one diffractive and refractive, and five other refractive surfaces) on four powered optical elements, the combiner F1 and lenses F2 to F4. The small number of lens elements F2, F3, F4 advantageously reduces the weight, cost, and complexity of the optical system 900.

[0282] Moreover, in this embodiment, each of the lenses elements F2, F3, and F4 are plastic. These lenses F2, F3, F4 comprise Zeonex 480R (Z-480R), which is available from Zeon Chemicals L.P., Louisville, Ky. Other plastic and non-plastic materials may be used as well. Plastic lenses, however, can advantageously be fabricated in high volumes at lower cost than glass lenses. Plastic lenses are also lighter.

[0283] As a result, the eyepiece for the head mounted display which includes the image formation device 902, the imaging optics 906 and the combiner 908, is low cost and lightweight. Advantageously, the center of gravity is beind the nose because most of the weight of the optics is located rearward. Such a system 900 is safer and more comfortable to wear.

[0284] In this system, the first lens F2 of the imaging optics 906 is also positive which advantageously provides for a more compact system. By comparison, if the first lens F2 were negative, the imaging optics 906 would form a reverse telephoto system as the remaining lens elements F3, F4 together have positive power. Reverse telephoto systems are longer than the effective focal length of the reverse telephoto. Conversely, a positive first lens F2 combined with the positive power provided by the remaining lenses F3, E4 provides a system more like a telephoto lens that has a length that is shorter than the effective focal length of the imaging optics 906. This reduced length contributes to the compactness of the system.

[0285] The system 900 also provides good optical performance. The field of view provided is about 30×22 degrees with full overlap between the two eyes. The exit pupil is 10 millimeters in diameter in this embodiment. The modulation transfer function is greater than 0.3 at 33 line pairs per millimeter for a 10 millimeter pupil. This system is also telecentric.

[0286] A wide range of variations are possible. More or less lenses may be used. In various embodiment, however, the imaging optics 808 comprises a plurality of lens elements which have a first optical axis and another single lens element which has second optical axis different from the first optical axis. The group of lenses having the common optical axis may comprise two, three, four, five or more lenses. Reduced number of lenses offers the advantage of reduce weight, cost, and complexity. Similarly, only one other lens is includes in the imaging optics and this lens has a different optical axis. This lens may be positive to provide for a compact system.

[0287] As discussed with regard to FIG. 57, however, this single lens may be a non-rotationally symmetric lens having two surfaces (e.g., aspheric), each with different optical axes from each other. The single lens may have a pair of surfaces that are each rotationally symmetric, one of which shares a common optical axis as the other lenses in the imaging optics and one which is different. In such embodiments, at least one of the surfaces and optical axes of the first lens element is tilted and/or decentered with respect to a plurality of other lenses in the imaging optics, which may also include other types of optical element besides lens. The single lens may have one surface that is non-rotationally symmetric and one surface that is rotationally symmetric as well.

[0288] Similarly, any of the other lenses may be a non-rotationally symmetric lens having two surfaces (e.g. aspheres), each with different optical axes from each other. Such a lens may have a pair of surfaces that are each rotationally symmetric, one of which shares a common optical axis as the other lens or lenses in the group and one which is different. In such embodiments, at least one of the surfaces of the lens element has an optical axes coincident with the shared common optical axis. For example, in one embodiment, only one surface on each of F3 and F4 shares a common optical axis, the other surfaces having other optical axes. In some embodiments, any of these lenses may have one surface that is non-rotationally symmetric and one surface that is rotationally symmetric as well.

[0289] Other variations are possible. For example, one or more of the lenses or surfaces may be replaced with a transmissive diffractive optical element having power referred to herein as a diffractive lens or diffractive optical lens element. As discussed above, the diffractive optical lens may comprises diffractive features disposed on a surface of a lens or a plane parallel plate or sheet. The diffractive features may be arranged to provide power to the transmissive diffractive optical element. For instance, a transmissvie diffractive surface having optical power may be disposed on a surface of a lens as in the case of the second lens F3 or on a plane parallel plate or sheet. Such transmissive diffractive optical elements having power have optical axes and thus can be used in a system with multiple optical axes that provide added degrees of design freedom for added aberration control. For example, one or more (even each) of the second and third optical elements F3, F4 sharing the common optical axis could be replaced with diffractive optical lenses. Similarly, the single positive optical element having a different optical axis than the rest of the optical elements may comprise a diffractive optical lens.

[0290] The shape and materials used for the lens elements F2, F3, and F4 may vary. A fold mirror comprising a substantially flat reflective surface may be inserted in the device, for example, between the first lens element F2 and the combiner 908. Such a flat fold mirror has no power but can enable the imaging optics 906 to be angled and positioned differently with respect to the combiner 908, for example, such that the imaging optics 906 are closer to the head and the head mounted display is more form fitting to the head. Other fold mirrors may be included elsewhere as well. Other types of reflective components may also be included in the device. For example, reflectors may be included in addition to lenses in the imaging optics.

[0291] The order of the lens elements may vary. For example, the first lens element need not be located first, but may be between the other lenses. In this case, for instance, F2 might be between F3 and F4, or F4 and F5 or between F5 and the image formation device. The order of F3 and F4 may also vary. In one embodiment, the imaging optics 906 are between the combiner 908 and the image formation device 902 with the single positive lens (e.g., F2) closest to the image formation device and the remaining lenses (e.g., F3, F4) closest to the combiner. Thus, the lens closest to the combiner 908 may be tilted and/or decentered. Alternatively, the tilted and/or decentered element could be inserted somewhere in the middle of the other elements in the imaging optics 908. This tilted and/or decentered element can have positive or negative power.

[0292] Other optical elements (e.g., reflectors, fold mirrors, wedges, filter, etc.) can be inserted anywhere in the optical system and in the path between the combiner 908 and the image formation device 902.

[0293] The combiner 908 may also be different. An anamorphic asphere or toroid can be used. The combiner may, for example, be substantially totally reflecting. Additionally, the combiner 908 may also comprise an on-axis combiner. The combiner 908 need not have an optical axis that passes through the eye pupil. The combiner 908 also need not be rotationally symmetrical about an axis. The surface of the combiner 908 may be defined by a generally bi-laterally symmetric XY-polynomial, for example. Other shapes and configurations are also possible.

[0294] Also, in certain embodiments, the single lens element F2 has an optical axis that is different than the optical axis of one other lens element in imaging optics 908 comprising only two lenses such as shown in FIG. 57. The imaging optics 908, may include other non-lens type elements such as one or more reflectors or fold mirrors.

[0295] Moreover, as described above, any of the remaining lenses F3, F4 may have at least one surface that has a different optical axis from the others. This optical axis may be different than the optical axis or optical axes for the first lens F2.

[0296] Although, not shown, the display device 900 may include a V-prism such as described above in embodiments, for example, where a spatial light modulator is used that is illuminated with light from a light source. Other illumination and display apparatus and method such as, for example, those describe above as well as those not recited herein or not yet devised may be used.

[0297] In general, a wide range of other designs may be used as well. The lens prescriptions provided are merely exemplary and are not limiting. For example, variations in the number, shape, thickness, material, position, and orientation of the optical elements, are possible. Holographic or diffractive optical elements, refractive and/or reflective optical elements can be employed in a variety of arrangements. Many other variations are possible and the particular design should not be limited to the exact prescriptions included herein.

[0298] Different image formation devices may be used to produce the image. For example, an array of organic light emitting diodes (OLEDS) may be used in some cases. This type of image formation device is emissive as the OLEDS produce light. Spatial light modulators may also be employed in some embodiments. The spatial light modulators may be illuminated by a separate light source. Approaches such as described above may be used to deliver light from the light source to the spatial light modulators.

[0299] In various preferred embodiments, the image formation device comprises a plurality of pixels that can be separately activated to produce an image or symbol (e.g., text, numbers, characters, etc). The plurality of pixels may comprise a two-dimensional array. This image formation device may be in an object field that is imaged by the imaging optics. An image of the image formation device, for example, may be formed at a finite or infinite distance away in some embodiments and may be a virtual image in other embodiments. Other configurations are also possible.

[0300] Although various structures and methods for illumination and imaging are depicted in connection with displays such as head mounted displays and helmet mounted displays, other displays such as heads-up displays as well as non-display applications can benefit from the use of such technology. Examples of devices that may incorporate this technology include projectors, flat panel displays, back projection TV's, computer screens, cell phones, GPS systems, electronic games, palm top, personal assistants and more. This technology may be particularly useful for aerospace, automotive, and nautical instruments and components, scientific apparatus and equipment, and military and manufacturing equipment and machinery. The potential applications range from home electronics and appliances to interfaces for business and industrial tools, and medical devices and instruments as well as other electronic and optical displays and systems both well known as well as those yet to be devised. Other applications for example in industry such as, for manufacturing, e.g., parts inspection and quality control are possible. The applications should not be limited to those recited herein. Other uses are possible.

[0301] Similarly, configurations other than those described herein are possible. The structures, devices, systems, and methods may include additional components, features, and steps and any of these components, features, and steps may be excluded and may or may not be replaced with others. The arrangements may be different.

[0302] Moreover, various embodiments of the invention have been described above. Although this invention has been described with reference to these specific embodiments, the descriptions are intended to be illustrative of the invention and are not intended to be limiting. Various modifications and applications may occur to those skilled in the art without departing from the true spirit and scope of the invention as defined in the appended claims.

[0303]

TABLE I

Elements	Surface	Radius	Thickness	Glass

Image	0	Infinity	Infinity
Stop	1	Infinity	0.000
A1	2 (aspheric)	−91.077	0.000	Reflective
	3 (tilt/decenter)	Infinity	−10.295
A2	4	29.791	−3.246	NBK10
	5	31.398	0.000
	6 (tilt/decenter)	Infinity	−1.076
A3	7	−51.916	−7.348	SFL57
	8	−84.361	−3.630
A4	9 (aspheric)	−80.585	−10.299	NBK10
	10	136.780	−0.100
A5	11	−63.316	−1.200	SFL57
A6	12	−33.076	−17.828	NBK7
	13	61.314	−0.100
A7	14	72.798	−1.360	SFL57
	15	−3385.379	−0.100
A8	16	−73.456	−12.863	NLAK33
A9	17	58.037	−2.475	NBK10
	18	−111.010	−0.998
A10	19	−89.176	−1.205	NSF5
A11	20	−32.741	−12.929	NLAK33
	21	−159.940	−2.190
A12	22	Infinity	−11.000	SPF57
A13	23	Infinity	−5.000	NLAK33
	24 (tilt)	Infinity	0.000
	25 (tilt)	Infinity	−1.023
Object	26	Infinity	0.000

[0304]

TABLE II

Element	Surface	Aspheric Coefficients	Tilt & Decenter


A1	2	Conic Const.	−0.363	Tilt X	−86.59°
A2	3			Tilt X	−69.56°
				Decenter Y	155.558
				Decenter Z	−5.097
A3	6			Tilt X	−12.65°
				Decenter Y	−4.504
A4	9	A	0.432 × 10⁻⁵
		B	0.700 × 10⁻⁰⁹
A13	24			Tilt X	8.66°
	25			Tilt X	−3.84°
				Decenter Y	−16.260

[0305]

TABLE III

Elements	Surface	Radius	Thickness	Glass

Image	0	Infinity	Infinity
Stop	1	Infinity	0.000
B1	2 (aspheric)	−89.775	0.000	Reflective
	3 (tilt/decenter)	Infinity	0.000
B2	4	60.718	−3.000	NBK10
	5	134.450	0.000
	6 (tilt/decenter)	Infinity	−15.482
B3	7 (aspheric)	−42.156	−18.000	Z-1600R
	8 (aspheric)	112.611	−11.423
B4	9	−38.117	−13.000	SK51
B5	10	77.117	−3.200	SFL57
	11	−57.234	−0.271
B6	12	−39.687	−10.000	Z-1600R
	13 (aspheric)	184.200	−1.110
B7	14	−33.701	−12.291	NSK5
	15	−169.515	−1.808
B8	16	Infinity	−11.000	SKL57
B9	17	Infinity	−4.500	NLAK33
	18 (tilt)	Infinity	0.000
	19 (tilt/decenter)	Infinity	−1.138
Object	20	Infinity	0.000

[0306]

TABLE IV

Element	Surface	Aspheric Coefficients	Tilt & Decenter


B1	2	Conic Const.	−0.354	Tilt X	−74.86°
B2	3			Tilt X	−56.49°
				Decenter Y	142.230
				Decenter Z	−33.024
B3	6			Tilt X	−4.58°
				Decenter Y	−4.261
B3	7	A	0.104 × 10⁻⁵
		B	−0.323 × 10⁻⁰⁹
B3	8	A	−0.243 × 10⁻⁵
		B	−0.186 × 10⁻⁰⁹
B7	13	A	−0.426 × 10⁻⁵
		B	−0.358 × 10⁻⁰⁸
		C	0.313 × 10⁻¹¹
		D	0.820 × 10⁻¹⁵
B9	18			Tilt X	7.34°
	19			Tilt X	−7.67°
				Decenter Y	−11.883

[0307]

TABLE V

Elements	Surface	Radius	Thickness	Glass

Image	0	Infinity	Infinity
Stop	1	Infinity	0.000
C1	2 (aspheric)	−92.177	0.000	Reflective
	3 (tilt/decenter)	Infinity	0.000
C2	4 (aspheric)	234.958	−5.000	PMMAO
	5	−207.944	0.000
	6 (tilt/decenter)	Infinity	−11.044
C3	7 (aspheric)	−40.907	−22.000	Z-480R
	8	126.927	−12.370
	9	77.117	−3.200
C4	10	−39.049	−9.000	Z-480R
	11 (aspheric)	−846.922	−12.954
	(holographic)
C5	12 (aspheric)	−36.352	−17.180	Z-480R
	13	−467.961	−0.100
C6	14	Infinity	−11.000	SKL57
C7	15	Infinity	−4.500	NLAK33
	16 (tilt)	Infinity	0.000
	17 (tilt/decenter)	Infinity	−1.011
Object	18	Infinity	0.000

[0308]

TABLE VI

Element	Surface	Aspheric Coefficients	Tilt & Decenter


C1	2	Conic Const.	−0.325	Tilt X	−61.36°
C2	3			Tilt X	−44.95°
				Decenter Y	118.396
				Decenter Z	−63.306
C2	4	A	0.535 × 10⁻⁶
		B	0.216 × 10⁻⁸
		C	−0.133 × 10⁻¹¹
		D	0.723 × 10⁻¹⁵
C3	6			Tilt X	−4.23°
				Decenter Y	−1.040
C3	7	A	0.198 × 10⁻⁵
		B	−0.397 × 10⁻⁰⁹
		C	0.451 × 10⁻¹²
		D	0.272 × 10⁻¹⁵
C4	11	A	−0.521 × 10⁻⁵
		B	−0.739 × 10⁻⁰⁹
		C	0.256 × 10⁻¹¹
		D	−0.920 × 10⁻¹⁴
		c1	−7.285 × 10⁻⁴
		c2	−1.677 × 10⁻⁷
C5	12	A	−0.934 × 10⁻⁶
		B	−0.944 × 10⁻⁰⁹
		C	0.697 × 10⁻¹²
		D	−0.170 × 10⁻¹⁴
C7	16			Tilt X	7.92°
	17			Tilt X	−8.24°
				Decenter Y	−10.884

[0309]

TABLE VII

Elements	Surface	Radius	Thickness	Glass

Image	0	Infinity	Infinity
Stop	1	Infinity	0.000
D1	2 (aspheric)	−42.993	0.000	Reflective
	(tilt)
	3 (tilt/decenter)	Infinity	0.000
D2	4 (aspheric)	−25.114	−5.769	Z-480R
	5 (tilt/decenter)	75.899	−7.085
	(aspheric)
D3	6 (tilt/decenter)	−20.880	−7.500	Z-480R
	(aspheric)
	(holographic)
	7 (aspheric)	17.851	−11.585
Object	8 (tilt/decent)	INFINITY	−5.430

[0310]

TABLE VIII

Element	Surface	Aspheric Coefficients	Tilt & Decenter


D1	2	Conic Const.	−0.323	Tilt X	−87.58°
D2	3			Tilt X	−73.47°
				Decenter Y	48.899
				Decenter Z	6.581
D2	4	A	0.282 × 10⁻⁴
		B	0.112 × 10⁻⁶
		C	−0.950 × 10⁻⁹
		D	0.532 × 10⁻¹¹
D2	5	A	−0.244 × 10⁻⁴	Tilt X	3.24°
		B	−0.208 × 10⁻⁶	Decenter Y	0.389
		C	0.127 × 10⁻⁸
		D	−0.180 × 10⁻¹⁰
D3	6	A	0.308 × 10⁻⁴	Tilt X	−4.23°
		B	−0.881 × 10⁻⁷	Decenter Y	−1.040
		C	0.499 × 10⁻⁹
		D	−0.465 × 10⁻¹⁰
D3	7	A	−0.563 × 10⁻⁴
		B	0.228 × 10⁻⁶
		C	−0.594 × 10⁻⁸
		D	−0.249 × 10⁻¹³
Object	8			Tilt X	−21.21°
				Decenter	−7.745

[0311]

TABLE IX

Elements	Surface	Radius	Thickness	Glass

Image	0	Infinity	Infinity
Stop	1	Infinity	0.000
E1	2 (aspheric)	−67.773	0.00	Reflective
	(tilt)
	3 (tilt/decenter)	Infinity	0.00
E2	4	−120.806	−8.000	Z-480R
	5	90.939	0.000
	6 (tilt/decenter)	INFINITY	−33.905
E3	7	−30.114	−4.500	NLLF1
E4	8	24.569	−2.000	SFL57
	9	342.282	−6.930
E5	10 (aspheric)	−90.069	−6.000	Z-480R
	11	31.933	−0.100
E6	12	INFINITY	−2.500	NLAK33
	13 (tilt)	INFINITY	0.000
	14 (tilt)	INFINITY	−42.382
Object	15	INFINITY	0.000

[0312]

TABLE X

Element	Surface	Aspheric Coefficients	Tilt & Decenter


E1	2	Conic Const.	−0.425	Tilt X	−68.03°
E2	3			Tilt X	−62.38°
				Decenter Y	59.772
				Decenter Z	−8.799
E3	6			Tilt X	0.24°
				Decenter Y	0.687
E5	10	A	0.117 × 10⁻⁴
		B	−0.270 × 10⁻⁹
		C	0.395 × 10⁻¹¹
		D	0.779 × 10⁻¹³
E6	13			Tilt X	2.06°
Object	14			Tilt X	−18.38°
				Decenter Y	−25.945

[0313]

TABLE XI

Elements	Surface	Radius	Thickness	Glass

Image	0	Infinity	Infinity
Stop	1	Infinity	0.000
F1	2 (aspheric)	−65.938	0.00	Reflective
	(tilt)
F2	3 (aspheric)	−76.211	−14.233	Z-480R
	(tilt/decenter)
	4 (aspheric)	130.422	0.000
	5 (tilt/decenter)	INFINITY	−13.527
F3	6 (aspheric)	−63.914	−5.000	Z-480R
	(holographic)
	7	79.277	−23.318
F4	8 (aspheric)	−75.035	−15.926	Z-480R
	9	46.158	−0.100
F5	10	INFINITY	−5.129	NLAK33
	11 (tilt)	INFINITY	0.000
	12 (tilt)	INFINITY	−2.185
F6	13	INFINITY	−17.000
Object	14	INFINITY	0.000

[0314]

TABLE XII

Element	Surface	Aspheric Coefficients	Tilt & Decenter


F1	2	Conic Const.	−0.430	Tilt X	−68.96°
F2	3	A	0.548 × 10⁻⁶	Tilt X	−68.96°
		B	0.460 × 10⁻⁹	Decenter Z	−68.055
		C	−0.410 × 10⁻¹²
		D	0.165 × 10⁻¹⁵
	4	A	0.182 × 10⁻⁷
		B	0.209 × 10⁻¹⁰
		C	−0.310 × 10⁻¹³
		D	0.304 × 10⁻¹⁶
	5			Tilt X	1.36°
				Decenter Y	12.858
F3	6	A	0.310 × 10⁻⁵
		B	0.123 × 10⁻⁸
		C	0.386 × 10⁻¹⁰
		D	−0.764 × 10⁻¹³
		c1	−7.580 × 10⁻⁴
		c2	1.044 × 10⁻⁶
		c3	−4.081 × 10⁻⁹
F4	8	A	0.237 × 10⁻⁵
		B	−0.165 × 10⁻⁹
		C	0.484 × 10⁻¹²
		D	−0.103 × 10⁻¹⁶
F5	11			Tilt X	7.13°
	12			Tilt X	−8.27°
				Decenter Y	−22.701

Claims

Certificate of Correction present

The claims shown below may not include correction changes. Use the corrected PDF for authoritative text.

What is claimed is:

1. An apparatus comprising:

an image formation device comprising a plurality of pixels selectively adjustable for producing spatial patterns;

imaging optics defining an optical path, said imaging optics comprising:

a lens group comprising a plurality of lens elements in said optical path, said lens group having a first optical axis, each of said plurality of lens elements having optical axes collinear with said first optical axis; and

a single lens element in said optical path having a second optical axis that is different from the first optical axis;

an off-axis combiner in said optical path; and

a support structure configured to be worn on the head of a wearer and to dispose the combiner in front of the eye of the wearer,

wherein said single lens element has positive optical power and is the only lens element in said optical path between said lens group and said combiner that has an optical axis collinear with the second optical axis; and

wherein the apparatus does not include a mirror between the image formation device and the imaging optics.

2. The apparatus of claim 1, wherein said first optical axis is decentered with respect to the second optical axis.

3. The apparatus of claim 1, wherein said first optical axis is tilted with respect to the second optical axis.

4. The apparatus of claim 1, wherein said first optical axis is tilted and decentered with respect to the second optical axis.

5. The apparatus of claim 1, wherein said combiner has a third optical axis that is the same as said first optical axis.

6. The apparatus of claim 1, wherein said combiner has a third optical axis that is the same as said second optical axis.

7. The apparatus of claim 1, wherein said combiner has a third optical axis that is different from said first and second optical axes.

8. The apparatus of claim 1, wherein imaging optics further comprises at least one reflective optical element in said optical path.

9. The apparatus of claim 8, wherein said reflective optical element comprises a fold mirror.

10. The apparatus of claim 1, wherein at least one of said lens elements in said lens group comprises a diffractive lens element, said diffractive lens element being a transmissive optical element that has optical power.

11. The apparatus of claim 10, wherein said diffractive lens element has an optical axis coincident with said first optical axis.

12. The apparatus of claim 1, wherein none of said lens elements in said lens group comprises a diffractive lens element, said diffractive lens element being a transmissive optical element that has optical power.

13. The apparatus of claim 12, wherein none of said lens elements in said optical path comprises a diffractive lens element.

14. The apparatus of claim 12, wherein none of said lens elements in said optical path comprises a diffractive lens element having substantially planar front and rear surfaces.

15. The apparatus of claim 1, wherein at least one of said lens elements in said lens group has an aspheric surface defining an optical axis for said at least one lens.

16. The apparatus of claim 15, wherein said optical axis defined by said aspheric surface is collinear with said first optical axis.

17. The apparatus of claim 16, wherein said at least one of said lens elements in said lens group has front and rear surfaces having aspheric shapes that define axes and said axes are collinear with said first optical axis.

18. The apparatus of claim 15, wherein said optical axis defined by said aspheric surface is not collinear with said first optical axis.

19. The apparatus of claim 18, wherein said at least one of said lens elements in said lens group has front and rear surfaces having aspheric shapes that define axes, one of which is collinear with said first optical axis and one of which is not collinear with said first axis.

20. The apparatus of claim 1, wherein said lens elements in said lens group comprises a plurality of aspheric lens elements each having an aspheric surface defining an optical axis that is collinear with said first optical axis.

21. The apparatus of claim 1, wherein said single lens element has at least one aspheric surface, said aspheric axis defining an optical axis.

22. The apparatus of claim 21, wherein said optical axis defined by said aspheric surface is not collinear with said first optical axis.

23. The apparatus of claim 21, wherein said optical axis defined by said aspheric surface is collinear with said first optical axis.

24. The apparatus of claim 1, wherein said single lens element has front and rear surfaces that have shapes that define different optical axes.

25. The apparatus of claim 1, wherein said single lens element has front and rear surface having shapes that define axes and said axes are coincident.

26. A head mounted display device for displaying images comprising:

an image formation device comprising a plurality of pixels selectively adjustable for producing spatial patterns;

imaging optics disposed with respect to the image formation device to receive light from said plurality of pixels for forming an image thereof, said image formation device and said imaging optics defining an optical path, said imaging optics comprising:

a single lens element in said optical path having a second optical axis that is different from the first optical axis, said single lens element having positive optical power;

an off-axis combiner in said optical path, said combiner configured to reflect light from said imaging optics such that said image may be displayed; and

head gear that supports said image formation device, imaging optics, and combiner,

wherein said single lens element in said imaging optics is the only lens element in said optical path between said image formation device and said combiner that has an optical axis collinear with the second optical axis, and

wherein the device does not include a mirror in the optical path between the image formation device and the imaging optics.

27. The apparatus of claim 1, wherein at least one of said lens elements in said lens group has front and rear surfaces that have shapes that defines different optical axes.

28. The apparatus of claim 1, wherein at least one of said lens elements in said lens group has front and rear surface having shapes that define axes and said axes are coincident.

29. The device of claim 26, wherein said first optical axis is decentered with respect to the second optical axis.

30. The device of claim 26, wherein said first optical axis is tilted with respect to the second optical axis.

31. The device of claim 26, wherein said first optical axis is tilted and decentered with respect to the second optical axis.

32. The device of claim 26, wherein said combiner has a third optical axis that is the same as said first optical axis.

33. The device of claim 26, wherein said combiner has a third optical axis that is the same as said second optical axis.

34. The device of claim 26, wherein said combiner has a third optical axis that is different from said first and second optical axes.

35. The device of claim 26, wherein said imaging optics further comprises at least one reflective optical element in said optical path.

36. The device of claim 35, wherein said reflective optical element comprises a fold mirror.

37. The device of claim 26, wherein at least one of said lens elements in said lens group comprises a diffractive lens element, said diffractive lens element being a transmissive optical element that has optical power.

38. The device of claim 37, wherein said diffractive lens element has an optical axis coincident with said first optical axis.

39. The device of claim 26, wherein none of said lens elements in said lens group comprises a diffractive lens element, said diffractive lens element being a transmissive optical element that has optical power.

40. The device of claim 39, wherein none of said lens elements in said optical path comprises a diffractive lens element.

41. The device of claim 39, wherein none of said lens elements in said optical path comprises a diffractive lens element having substantially planar front and rear surfaces.

42. The device of claim 26, wherein at least one of said lens elements in said lens group has an aspheric surface defining an optical axis for said at least one lens.

43. The device of claim 42, wherein said optical axis defined by said aspheric surface is collinear with said first optical axis.

44. The device of claim 43, wherein said at least one of said lens elements in said lens group has front and rear surfaces having aspheric shapes that define axes and said axes are collinear with said first optical axis.

45. The device of claim 42, wherein said optical axis defined by said aspheric surface is not collinear with said first optical axis.

46. The device of claim 45, wherein said at least one of said lens elements in said lens group has front and rear surfaces having aspheric shapes that define axes, one of which is collinear with said first optical axis and one of which is not collinear with said first axis.

47. The device of claim 26, wherein said lens elements in said lens group comprises a plurality of aspheric lens elements each having an aspheric surface defining an optical axis that is collinear with said first optical axis.

48. The device of claim 26, wherein said single lens element has at least one aspheric surface, said aspheric axis defining an optical axis.

49. The device of claim 48, wherein said optical axis defined by said aspheric surface is not collinear with said first optical axis.

50. The device of claim 48, wherein said optical axis defined by said aspheric surface is collinear with said first optical axis.

51. The device of claim 26, wherein said single lens element has front and rear surfaces that have shapes that defines different optical axes.

52. The device of claim 26, wherein said single lens element has front and rear surface having shapes that define axes and said axes are coincident.

53. An optical system for displaying an image comprising:

an image formation device comprising a plurality of pixels selectively adjustable for producing spatial patterns;

a single lens element in said optical path having a second optical axis that is different from the first optical axis, said single lens element having positive optical power;

an off-axis combiner in said optical path, said combiner configured to reflect light from said imaging optics such that said image may be displayed; and

a support structure configured to be worn on the head of a wearer and attached to said combiner and imaging optics such that said combiner and imaging optics form an image at the eye of a wearer of said support structure,

wherein the optical system does not include a mirror in the optical path between the image formation device and the imaging optics.

54. Apparatus for a displaying images, said apparatus comprising:

an image formation device comprising a plurality of pixels selectively adjustable for producing spatial patterns;

imaging optics defining an optical path, said imaging optics comprising:

a single lens element in said optical path having a second optical axis that is different from the first optical axis;

an off-axis combiner in said optical path; and

support structure configured to be worn on the head of a wearer and attached to said formation device, imaging optics, and said combiner,

wherein the apparatus does not included a mirror between the Image formation device and the imaging optics.

55. The apparatus of claim 1, wherein said imaging optics and said combiner are configured to form said image at an eye of the wearer.

56. The optical system of claim 54, wherein said imagining optics and said combiner are configured to form an image in an eye of said wearer.

57. The optical system of claim 53, wherein said first optical axis is decentered with respect to the second optical axis.

58. The optical system of claim 53, wherein said first optical axis is tilted with respect to the second optical axis.

59. The optical system of claim 53, wherein said first optical axis is tilted and decentered with respect to the second optical axis.

60. The optical system of claim 53, wherein said combiner has a third optical axis that is the same as said first optical axis.

61. The optical system of claim 53, wherein said combiner has a third optical axis that is the same as said second optical axis.

62. The optical system of claim 53, wherein said combiner has a third optical axis that is different from said first and second optical axes.

63. The optical system of claim 53, wherein imaging optics further comprises at least one reflective optical element in said optical path.

64. The optical system of claim 63, wherein said reflective optical element comprises a fold mirror.

65. The optical system of claim 53, wherein at least one of said lens elements in said lens group comprises a diffractive lens element, said diffractive lens element being a transmissive optical element that has optical power.

66. The optical system of claim 65, wherein said diffractive lens element has an optical axis coincident with said first optical axis.

67. The optical system of claim 53, wherein none of said lens elements in said lens group comprises a diffractive lens element, said diffractive lens element being a transmissive optical element that has optical power.

68. The optical system of claim 67, wherein none of said lens elements in said optical path comprises a diffractive lens element.

69. The optical system of claim 67, wherein none of said lens elements in said optical path comprises a diffractive lens element having substantially planar front and rear surfaces.

70. The optical system of claim 53, wherein at least one of said lens elements in said lens group has an aspheric surface defining an optical axis for said at least one lens.

71. The optical system of claim 70, wherein said optical axis defined by said aspheric surface is collinear with said first optical axis.

72. The optical system of claim 71, wherein said at least one of said lens elements in said lens group has front and rear surfaces having aspheric shapes that define axes and said axes are collinear with said first optical axis.

73. The optical system of claim 70, wherein said optical axis defined by said aspheric surface is not collinear with said first optical axis.

74. The optical system of claim 71, wherein said at least one of said lens elements in said lens group has front and rear surfaces having aspheric shapes that define axes, one of which is collinear with said first optical axis and one of which is not collinear with said first axis.

75. The optical system of claim 53, wherein said lens elements in said lens group comprises a plurality of aspheric lens elements each having an aspheric surface defining an optical axis that is collinear with said first optical axis.

76. The optical system of claim 53, wherein said single lens element has at least one aspheric surface, said aspheric axis defining an optical axis.

77. The optical system of claim 76, wherein said optical axis defined by said aspheric surface is not collinear with said first optical axis.

78. The optical system of claim 76, wherein said optical axis defined by said aspheric surface is collinear with said first optical axis.

79. The optical system of claim 53, wherein said single lens element has front and rear surfaces that have shapes that defines different optical axes.

80. The optical system of claim 53, wherein said single lens element has front and rear surface having shapes that define axes and said axes are coincident.

81. The optical system of claim 53, wherein at least one of said lens elements in said lens group has front and rear surfaces that have shapes that defines different optical axes.

82. The optical system of claim 53, wherein at least one of said lens elements in said lens group has front and rear surface having shapes that define axes and said axes are coincident.

83. The apparatus of claim 54, wherein said first optical axis is decentered with respect to the second optical axis.

84. The apparatus of claim 54, wherein said first optical axis is tilted with respect to the second optical axis.

85. The apparatus of claim 54, wherein said first optical axis is tilted and decentered with respect to the second optical axis.

86. The apparatus of claim 54, wherein said combiner has a third optical axis that is the same as said first optical axis.

87. The apparatus of claim 54, wherein said combiner has a third optical axis that is the same as said second optical axis.

88. The apparatus of claim 54, wherein said combiner has a third optical axis that is different from said first and second optical axes.

89. The apparatus of claim 54, wherein imaging optics further comprises at least one reflective optical element in said optical path.

90. The apparatus of claim 89, wherein said reflective optical element comprises a fold mirror.

91. The apparatus of claim 54, wherein at least one of said lens elements in said lens group comprises a diffractive lens element, said diffractive lens element being a transmissive optical element that has optical power.

92. The apparatus of claim 91, wherein said diffractive lens element has an optical axis coincident with said first optical axis.

93. The apparatus of claim 54, wherein none of said lens elements in said lens group comprises a diffractive lens element, said diffractive lens element being a transmissive optical element that has optical power.

94. The apparatus of claim 93, wherein none of said lens elements in said optical path comprises a diffractive lens element.

95. The apparatus of claim 93, wherein none of said lens elements in said optical path comprises a diffractive lens element having substantially planar front and rear surfaces.

96. The apparatus of claim 54, wherein at least one of said lens elements in said lens group has an aspheric surface defining an optical axis for said at least one lens.

97. The apparatus of claim 96, wherein said optical axis defined by said aspheric surface is collinear with said first optical axis.

98. The apparatus of claim 97, wherein said at least one of said lens elements in said lens group has front and rear surfaces having aspheric shapes that define axes and said axes are collinear with said first optical axis.

99. The apparatus of claim 94, wherein said optical axis defined by said aspheric surface is not collinear with said first optical axis.

100. The apparatus of claim 97, wherein said at least one of said lens elements in said lens group has front and rear surfaces having aspheric shapes that define axes, one of which is collinear with said first optical axis and one of which is not collinear with said first axis.

101. The apparatus of claim 54, wherein said lens elements in said lens group comprises a plurality of aspheric lens elements each having an aspheric surface defining an optical axis that is collinear with said first optical axis.

102. The apparatus of claim 54, wherein said single lens element has at least one aspheric surface, said aspheric axis defining an optical axis.

103. The apparatus of claim 102, wherein said optical axis defined by said aspheric surface is not collinear with said first optical axis.

104. The apparatus of claim 102, wherein said optical axis defined by said aspheric surface is collinear with said first optical axis.

105. The apparatus of claim 54, wherein said single lens element has front and rear surfaces that have shapes that define different optical axes.

106. The apparatus of claim 54, wherein said single lens element has front and rear surface having shapes that define axes and said axes are coincident.

107. The apparatus of claim 54, wherein at least one of said lens elements in said lens group has front and rear surfaces that have shapes that define different optical axes.

108. The apparatus of claim 54, wherein at least one of said lens elements in said lens group has front and rear surface having shapes that define axes and said axes are coincident.

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US 7,542,209 B2Grant

Compact head mounted display devices with tilted/decentered lens element

Issue Date:2009-06-02

•108 Claims

•30 Drawing Sheets

Abstract

Metadata

Assignee

Optical Research Associates

Inventor

James P. McGuire, Jr.