Optical waveguide, manufacturing method of optical waveguide, and head-mounted display device

A manufacturing method of an optical waveguide adapted to transmit an image beam, the manufacturing method of the optical waveguide comprising:

• providing a first structure layer, wherein the first structure layer comprises a first plane;
• providing a second structure layer, wherein the second structure layer comprises a second plane;
• forming a plurality of first light-guiding optical elements on the first plane or the second plane, wherein a spacing exists between the adjacent first light-guiding optical elements;
• and
• connecting the first structure layer with the second structure layer, such that the first plane and the second plane are in contact with each other to form a light-guiding plane, wherein the image beam transmitting to the light-guiding plane is separated into a plurality of sub image beams, transmission paths of the sub image beams are at least partially different, and the sub image beams are transmitted in a first optical region via total reflection,
• wherein the first structure layer comprises a plurality of first inclined surfaces and a plurality of first connecting surfaces, wherein each of the first connecting surfaces is connected to different ends of the adjacent first inclined surfaces to form a first zigzag structure, the second structure layer comprises a plurality of second inclined surfaces and a plurality of second connecting surfaces, wherein each of the second connecting surfaces is connected to different ends of the adjacent second inclined surfaces to form a second zigzag structure, and the manufacturing method of the optical waveguide further comprises:
• forming a plurality of second light-guiding optical elements on the first inclined surfaces of the first structure layer or the second inclined surfaces of the second structure layer, wherein the second light-guiding optical elements are adapted to allow part of the image beam to pass therethrough and reflect another part of the image beam;
• and
• corresponding the second inclined surface to the first inclined surface, corresponding the second connecting surface to the first connecting surface, such that the first zigzag structure matches with the second zigzag structure to form a plurality of optical microstructures, and the second inclined surfaces are in contact with the first inclined surfaces to form a plurality of optical surfaces of the optical microstructures after connecting the first structure layer with the second structure layer.

A head-mounted display device, configured to be disposed in front of at least one eye of an user, comprising a display unit and an optical waveguide, wherein

• the display unit is adapted to provide an image beam;
• and
• the optical waveguide comprises a first optical region and a second optical region for transmitting the image beam, a plate body, a plurality of first light-guiding optical elements, and a plurality of optical coupling-out structures, wherein:
• the plate body comprises a light-entering side, wherein the first optical region is located between the light-entering side and the second optical region;
• the first light-guiding optical elements are disposed in parallel lines on a light-guiding plane in the optical waveguide, wherein the light-guiding plane is located in the first optical region, a spacing exists between the adjacent first light-guiding optical elements, the image beam transmitting to the light-guiding plane is separated into a plurality of sub image beams, transmission paths of the sub image beams are at least partially different, and the sub image beams in the first optical region are transmitted via total reflection to the second optical region;
• and
• the optical coupling-out structures are disposed in the plate body and are located in the second optical region,
• wherein the plate body comprises a first surface and a second surface opposite to each other, and the light-guiding plane is located between and parallel to the first surface and the second surface,
• wherein the optical coupling-out structures are a plurality of optical microstructures, each of the optical microstructures respectively comprises an optical surface, the optical surfaces of the optical microstructures are respectively inclined with respect to the light-guiding plane, and the optical waveguide further comprises:
• a plurality of second light-guiding optical elements, located on the optical surfaces of the optical microstructures, and adapted to reflect at least part of at least one of the sub image beams, wherein another part of the at least one of the sub image beams continues to be transmitted in the plate body, and the at least part of the at least one of the sub image beams leaves the plate body from the second surface after being reflected by the second light-guiding optical elements.