# US 12,007,565 B2 · Optical waveguide, manufacturing method of optical waveguide, and head-mounted display device > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,007,565 B2 - Document ID: US12007565B2 - Status: Granted - Kind: B2 - Application number: 17/233,521 - Filed: 2021-04-18 - Published: 2022-03-03 - Granted: 2024-06-11 - Earliest claimed: 2020-08-28 - Assignees: Coretronic Corporation - Applicants: Coretronic Corporation - Inventors: Hung-Ta Chien - Web page: https://patentgrep.com/patent/US12007565B2 ## CPC - G02B 27/0172: {characterised by optical features} - G02B 27/10: Beam splitting or combining systems (polarising systems G02B27/28; mixing and splitting light signals using optical waveguides G02B6/28; {beam shaping, e.g. changing the cross-sectional area, by dividing or superposing multiple light beams G02B27/0905}) - G02B 6/12004: {Combinations of two or more optical elements} - G02B 6/34: utilising prism or grating {(G02B6/293 takes precedence)} - G02B 2006/12035: {Materials} - G02B 2006/12166: {Manufacturing methods} - G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS ## Abstract The disclosure provides an optical waveguide, a manufacturing method of an optical waveguide, and a head-mounted display device. The optical waveguide has a first optical region and a second optical region for transmitting an image beam. The optical waveguide includes a plate body, multiple first light-guiding optical elements, and multiple optical microstructures. The first light-guiding optical elements are disposed in parallel lines on a light-guiding plane inside the plate body. The light-guiding plane is located in the first optical region, and there is a spacing between the adjacent first light-guiding optical elements. The image beam transmitted to the light-guiding plane is separated into multiple sub image beams, and the transmission paths of the sub image beams are at least partially different. The optical coupling-out structure is disposed in the plate body and is located in the second optical region. ## Claims ### Claim 1 An optical waveguide, comprising: a first optical region and a second optical region for transmitting an 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 plate body, 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, wherein the second light-guiding optical elements are 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. ### Claim 2 (depends on 1) The optical waveguide according to claim 1, wherein the first light-guiding optical elements are a partially reflective layer, when the image beam transmits to each of the first light-guiding optical elements, part of the image beam penetrates each of the first light-guiding optical elements to form a first sub image beam, and another part of the image beam is reflected by each of the first light-guiding optical elements to form a second sub image beam, and the first sub image beam and the second sub image beam are adapted to form the sub image beams. ### Claim 3 (depends on 1) The optical waveguide according to claim 1, wherein the first light-guiding optical elements are a mirror reflection layer, when the image beam transmits to each of the first light-guiding optical elements, the image beam reflected by the first light-guiding optical elements forms a first partial image beam, the image beam passing through the spacing between the two adjacent first light-guiding optical elements forms a second partial image beam, and the first partial image beam and the second partial image beam are adapted to form the sub image beams. ### Claim 4 (depends on 1) The optical waveguide according to claim 1, wherein a size of each of the first light-guiding optical elements is smaller than 2 mm. ### Claim 5 (depends on 1) The optical waveguide according to claim 1, wherein a distance between the two adjacent second light-guiding optical elements is less than or equal to 4 mm. ### Claim 6 (depends on 1) The optical waveguide according to claim 1, wherein the plate body comprises: a first structure layer, comprising 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; and a second structure layer, comprising 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, the second inclined surfaces correspond to the first inclined surfaces, the second connecting surfaces correspond to the first connecting surfaces, such that the first zigzag structure matches with the second zigzag structure to form the optical microstructures, and the second inclined surfaces are in contact with the first inclined surfaces to form the optical surfaces of the optical microstructures. ### Claim 7 (depends on 6) The optical waveguide according to claim 6, wherein the first structure layer further comprises a first plane, the second structure layer further comprises a second plane, and the second plane and the first plane are in contact with each other to form the light-guiding plane. ### Claim 8 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. ### Claim 9 (depends on 8) The manufacturing method of the optical waveguide according to claim 8, wherein the optical waveguide comprises the first optical region and a second optical region, a 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 plane and the second plane are located in the first optical region, and the optical microstructures are located in the second optical region. ### Claim 10 (depends on 8) The manufacturing method of the optical waveguide according to claim 8, further comprising: providing a bonding layer, adapted to connect the first structure layer with the second structure layer, wherein a difference between a refractive index of the bonding layer and a refractive index of the first structure layer is less than 0.01, and a difference between a refractive index of the bonding layer and a refractive index of the second structure layer is less than 0.01. ### Claim 11 (depends on 8) The manufacturing method of the optical waveguide according to claim 8, wherein a size of each of the first light-guiding optical elements is smaller than 2 mm. ### Claim 12 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. ### Claim 13 (depends on 12) The head-mounted display device according to claim 12, wherein the first light-guiding optical elements are a partially reflective layer, when the image beam transmits to each of the first light-guiding optical elements, part of the image beam penetrates each of the first light-guiding optical elements to form a first sub image beam, and another part of the image beam is reflected by each of the first light-guiding optical elements to form a second sub image beam, and the first sub image beam and the second sub image beam are adapted to form the sub image beams. ### Claim 14 (depends on 12) The head-mounted display device according to claim 12, wherein the first light-guiding optical elements are a mirror reflection layer, when the image beam transmits to each of the first light-guiding optical elements, the image beam reflected by the first light-guiding optical elements forms a first partial image beam, the image beam passing through the spacing between the two adjacent first light-guiding optical elements forms a second partial image beam, and the first partial image beam and the second partial image beam are adapted to form the sub image beams. ### Claim 15 (depends on 12) The head-mounted display device according to claim 12, wherein a size of each of the first light-guiding optical elements is smaller than 2 mm. ### Claim 16 (depends on 12) The head-mounted display device according to claim 12, wherein a distance between the two adjacent second light-guiding optical elements is less than or equal to 4 mm. ### Claim 17 (depends on 12) The head-mounted display device according to claim 12, wherein the plate body comprises: a first structure layer, comprising 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; and a second structure layer, comprising 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, the second inclined surfaces correspond to the first inclined surfaces, the second connecting surfaces correspond to the first connecting surfaces, such that the first zigzag structures match with the second zigzag structures to form the optical microstructures, and the second inclined surfaces are in contact with the first inclined surfaces to form the optical surfaces of the optical microstructures. ### Claim 18 (depends on 17) The head-mounted display device according to claim 17, wherein the first structure layer further comprises a first plane, the second structure layer further comprises a second plane, and the second plane and the first plane are in contact with each other to form the light-guiding plane.