Optical waveguide and display device

0001This invention relates to an optical waveguide and a display device. In particular it is relevant to display devices in which image bearing light is injected into a waveguide, is expanded therein e.g. by diffraction gratings, in two orthogonal dimensions to form a visible image and is released from the waveguide.

0002Such devices which use a single waveguide, for example as shown in <patcit id="pcit0001" dnum="US6580529B"><text>US6580529</text></patcit>, can be optimised only for one part of the visible spectrum. Usually the middle part of the spectrum is chosen, with the result that the display has a strong greenish hue.

0003To obtain a full colour display from this type of device it has been necessary to either limit the field of view, or employ three waveguides. Each waveguide is optimised for a different one of the three primary colours red, green and blue. The outputs of the three waveguides are then additionally combined to form an approximately full-colour display. Such a device has the disadvantages of complexity and cost, since three waveguides are required, and the further disadvantage of weight and bulk, which is in particularly undesirable in head-mounted or helmet-mounted displays.

0004Alternatively, a full-colour solution is obtainable using a three-layer stacked volume grating in a single waveguide (<patcit id="pcit0002" dnum="US7418170B"><text>US7418170</text></patcit>) but such gratings are difficult to manufacture in quantity, and are consequently expensive.

0005The present invention at least in its preferred embodiments seeks to reduce some or all of the disadvantages of the prior art. Document D1 = <patcit id="pcit0003" dnum="US2006221448A1"><text>US 2006/221448 A1</text></patcit> discloses an optical waveguide for a colour display device, comprising two waveguides. Document D2 = <patcit id="pcit0004" dnum="US2005001975A1"><text>US 2005/001975 A1</text></patcit> discloses a diffraction grating with at least one coating layer. Document D3 = <patcit id="pcit0005" dnum="WO2007141587A1"><text>WO 2007/141587 A1</text></patcit> discloses an optical waveguide for a colour display device, comprising two waveguides.

0006In one aspect the invention provides an optical method of displaying an expanded colour image comprising extracting from input light bearing said coloured image a first spectral portion and a second spectral portion such that together the two portions contain sufficient information for the image to be displayed in substantially its original colours, separately expanding the two spectral portions each in two dimensions and recombining the expanded spectral portions to display the expanded colour image.

0007The invention provides an optical structure for receiving light over a field of view, as defined in claim 1.

0008The first input diffraction region comprises a periodic diffraction grating structure having a layered coating configured to increase diffraction efficiency of the first input diffraction region in respect of light bearing each said primary colour component image, received over the respective first portion of the field of view, to diffract the received light into the first waveguide and to transmit substantially all of the received light that is not diffracted into the first waveguide.

0009Furthermore, the second input diffraction region comprises a periodic diffraction grating structure having a layered coating including a reflective layer, configured to increase diffraction efficiency of the second input diffraction region in respect of light bearing each said primary colour component image, received over the respective second portion of the field of view, to diffract the received light into the second waveguide.

0010In an example embodiment, the second waveguide is arranged in parallel with the first waveguide such that light output from the first waveguide passes through the second waveguide and through the second image expansion arrangement and wherein the second image expansion arrangement is arranged to transmit substantially all of the light output from the first waveguide that passes through the second image expansion arrangement.

0011In an example implementation, the layered coating of the first input diffraction region comprises at least one layer of a material selected from one or both of silicon dioxide and titanium dioxide and the layered coating of the second input diffraction region comprises at least one layer of titanium dioxide overlain by the reflective layer comprising a layer of silver.

0012The first and the second image expansion arrangements each comprise a respective output diffraction region arranged to expand light propagating through the respective waveguide in a first dimension and to diffract at least a portion of the expanded light out of the respective waveguide.

0013The first and the second image expansion arrangements each comprise a respective intermediate diffraction region arranged to expand light propagating through the respective waveguide in a second dimension, different to the first dimension.

0014In a particular implementation, the first primary colour component image is a red component image, the second primary colour component image is a green component image and the third primary colour component image is a blue component image.

0015In a particular implementation, each of the first and second input diffraction regions comprise a periodic diffraction grating having a different respective pitch, selected from 343nm and 460nm.

0016The invention also provides a display system comprising the optical structure according to embodiments of the invention recited above. Furthermore, the display system may be configured for head-mounting, mounting on a helmet or for use as a head-up display.

0017The invention now will be described merely by way of example with reference to the accompanying drawings; wherein: <ul id="ul0001" list-style="none"><li><figref idref="f0001">Figure 1</figref> illustrates a problem of a prior art device;</li><li><figref idref="f0001">Figure 2</figref> illustrates the principle of the present invention,</li><li><figref idref="f0002">Figure 3</figref> shows part of a structure according to the invention,</li><li><figref idref="f0002">Figures 4a and 4b</figref> show side views of a structure according to the invention, <figref idref="f0002">Figure 4b</figref> being an enlarged view of part of <figref idref="f0002">Figure 4a</figref>,</li><li><figref idref="f0003">Figure 5</figref> is a further enlarged view of a grating of <figref idref="f0002">Figure 4b</figref>,</li><li><figref idref="f0003">Figure 6</figref> shows the effect of a coating layer in <figref idref="f0002">Figure 4b</figref>,</li><li><figref idref="f0004">Figures 7</figref>, <figref idref="f0005">8 and 9</figref> illustrate the operation of the grating of <figref idref="f0003">Figure 5</figref>,</li><li><figref idref="f0006">Figure 10</figref> is a further enlarged view of another grating of <figref idref="f0002">Figure 4b</figref>,</li><li><figref idref="f0006">Figure 11</figref> illustrates the operation of the grating of <figref idref="f0006">Figure 10</figref>, and</li><li><figref idref="f0007">Figure 12</figref> shows the overall transmission efficiency of sub-structure according to the invention, consisting of the elements shown in <figref idref="f0003">Figures 5</figref> and <figref idref="f0006">10</figref>.</li></ul>

0018Current single-waveguide displays designs can only be optimised for one part of the full colour spectrum. For example <figref idref="f0001">Figure 1</figref> shows the angular output of a waveguide made of a glass having a refractive index of 1.62, and using diffraction gratings having a pitch of 410nm, for an input image having a 30° field of view. It can be seen that for the three primary colours (red, green and blue) the full 30° field of view is obtained only for the green part of the spectrum (<figref idref="f0001">Figure 1a</figref>). Only a portion of the red image can be displayed by the waveguide (<figref idref="f0001">Figure 1b</figref>); the remainder of the red rays fail to diffract because they are evanescent. Further, only a portion of the blue image can be displayed (<figref idref="f0001">Figure 1c</figref>); when the remainder of the blue rays are injected into the waveguide, they are diffracted at too low an angle for total internal reflection within the waveguide, and thus fail to propagate along it.

0019Thus, conventionally three waveguides are required for a full colour display unless a stacked volume grating is used.

0020In the preferred embodiment of the invention a three-colour solution is implemented using only single surface gratings in two waveguides, the outputs of which are shown in <figref idref="f0001">Figure 2</figref>. One waveguide has gratings of 343nm pitch, and displays the majority (and preferably all) of the blue image, at least (and preferably more than) half of the green image and a small part of the red image. The other waveguide has gratings of 460nm pitch, and displays the majority (and preferably all) of the red image, at least (and preferably more than) half of the green image and a small part of the red image. The outputs of the two waveguides are shown respectively in <figref idref="f0001">Figures 2a and 2b</figref>. The proportion of each colour image displayed by the second waveguide is such that when taken with the proportion of the corresponding colour image displayed by the first waveguide, and properly aligned with it, all of that colour image is displayed; <figref idref="f0001">Figure 2</figref> shows the display for a 34° field of view.

0021The three colour images do not have to be separated; in fact as shown in <figref idref="f0001">Figure 2</figref> each waveguide will display some of each primary colour image. The two regions of each primary colour image from the two waveguides do however have to complement each other so that a full image is formed in each colour. To ensure that this is achieved, there may be some overlap between the two parts of the image from the respective waveguides. This overlap can improve the efficiency of the display system, without materially affecting the colour balance.

0022Factors which must be taken into account to achieve a full image in each primary colour include: <ul id="ul0002" list-style="bullet" compact="compact"><li>The correct choice of (unequal) pitches for the input diffraction gratings of the waveguides. The expansion gratings within each waveguide will generally have a pitch equal to the input grating for that particular waveguide.</li><li>The grating profiles, which controls the amount of light diffracted into the required order. Generally, a sawtooth type profile is preferred for input gratings.</li><li>The application of suitable coating layers on the input gratings.</li></ul>

0023<figref idref="f0002">Figure 3</figref> shows part of a structure according to the invention. It is based on the structure shown in <figref idref="f0002">Figure 4</figref> of our earlier co-pending applications <patcit id="pcit0006" dnum="GB0906266A"><text>GB0906266.2</text></patcit> and <patcit id="pcit0007" dnum="EP09275024" dnum-type="L"><text>EP09275024.9</text></patcit>.

0024The structure comprises a slab waveguide 10, i.e. one which has parallel principal faces 12, 14 (<figref idref="f0002">Figure 4</figref>) and parallel opposite edge surfaces 16, 18 and 20, 22. The waveguide has a grating area 24 in which is provided an input transmission grating 26. Image bearing light is inputted to the input grating 26 generally in the Z-direction (into the plane of the Figure) and, depending on its wavelength either is diffracted to a mirrored region 27 of edge surface 18 and thence to a first pupil expansion grating 28, or is not diffracted. In the latter case it passes through the waveguide and out of the rear surface 16.

0025A second slab waveguide 10' (<figref idref="f0002">Figure 4a</figref>) is disposed immediately behind the waveguide 10. Features corresponding to those of the waveguide 10 have the same reference numerals with the addition of a prime ('). As noted with reference to <figref idref="f0001">Figure 2</figref>, the input grating 26 of the first waveguide 10 is of 343nm pitch, and the input grating 26' of the second waveguide 10' is of 460nm pitch. In the example given here, all the gratings within a given waveguide will have the same pitch.

0026Referring to <figref idref="f0002">Figure 4b</figref>, incoming light rays 34 bearing a full colour image enter the waveguide 10 though its front principal surface 12 and are incident on the input grating 26. Some of the rays (those forming the image components shown in <figref idref="f0001">Figure 2a</figref>) as determined by their wavelengths, the pitch of the grating, and the angle of incidence, are diffracted into the minus one reflected order (labelled -1R_a in <figref idref="f0002">Figure 4b</figref>) and propagate within the waveguide via the mirrored surface 27 to the first expansion grating 28 and thence to the second expansion grating 30. The output of the first waveguide thus is the expanded spectral portion of the full image shown in <figref idref="f0001">Figure 2a</figref>. Other rays incident on the grating 26 are not diffracted and pass straight though it as the zero transmission order labelled '0Ta' in <figref idref="f0002">Figure 4b</figref>.

0027Some rays may be diffracted into other unwanted orders, and are wasted. In order to minimise this, the grating 26 ideally should be such that any ray not diffracted into the '-1R_a' order should stay in the undiffracted '0T_a' order. Coatings applied to the profiled surface of the grating 26 assist towards achievement of this objective as described hereafter.

0028The transmitted '0Ta' light, which contains the three spectral image portions shown in <figref idref="f0001">Figure 2b</figref> is incident on the front surface 12' of the second waveguide 10', and thence upon the input grating 26'. This grating has a mirrored (reflective) coating as described hereafter and thus operates wholly as a reflection grating.

0029The pitch of the grating (460nm) is suitable to diffract the incident light into the '-1R_b' reflected order. The reflected light propagates within the waveguide via the mirrored surface 27' to the expansion grating 28' and 30', where it is expanded into the three spectral image portions of <figref idref="f0001">Figure 2b</figref>.

0030The two waveguides 10, 10' are accurately positioned relative to each other so that expanded light 36 (<figref idref="f0002">Figure 4a</figref>) issuing from grating 30 of waveguide 10 is incident on grating 30' of waveguide 10' so as to pass through it and combine with the expanded light issuing from grating 30' to form a single full-colour image 38 as described with reference to <figref idref="f0001">Figure 2</figref>.

0031The choice of grating pitches determines how the colours are shared between the two waveguides. The first grating pitch is chosen so that it diffracts most of the blue field of view (FOV) and more than half of the green FOV. The pitch of the grating within the second waveguide is chosen so that it diffracts most of the red FOV and the complementary half of the green FOV. The system is then modelled and the grating pitches are fine-tuned to attain the highest FOV for all three colours.

0032The diffraction of light into various orders is determined by the grating profile (see for example <nplcit id="ncit0001" npl-type="s"><text>'Diffraction Analysis of dielectric surface relief gratings' M G Moharam and T K Gaylord, Journ. Optical Soc. America, Vol 72 Issue 10, pp 1385-1392 (1982</text></nplcit>)). Application of coatings to their surfaces can further tune the response of the gratings by controlling the phase of the wavefronts diffracted from the interfaces between the coating layers.

0033<figref idref="f0003">Figure 5</figref> shows one period of the grating 26. It can be seen that the grating has a period (pitch) of 343nm, and is of saw-tooth form with a height of 200nm. This height determines the blaze angle of the grating. The profiled grating surface 40 has a coating layer of silicon dioxide 42 of thickness 100nm, and a further coating layer 44 of titanium dioxide which is 40nm thick.

0034Input light 34 is incident on the front surface 12 of waveguide 10 (not shown in <figref idref="f0003">Figure 5</figref>), which is of a glass having a refractive index of 1.81. The light then passes though a polymer layer 39 (n=1.68) on which the grating profile 40 is formed and is reflected in various proportions from the polymer/SiO₂, the SiO₂/TiO₂ and TiO₂/air interfaces, depending on the angle of incidence and wavelength of each ray. The coating materials and thicknesses are chosen by modelling such that these multiple reflections interfere constructively and therefore the diffraction efficiency into the '-1R' order will be high. Other rays (in this case mainly those towards the red end of the spectrum) at different wavelength and incidence pass through the grating with very little light being diffracted. The grating thus effectively operates as a band pass filter.

0035The grating shown in <figref idref="f0003">Figure 5</figref> is required to have high diffraction efficiency for the '-1R' order, high transmission efficiency for the '0T' order, and low diffraction efficiency for all other (unwanted) orders. <figref idref="f0003">Figure 6</figref> shows the variation of the '+1R' (unwanted) order efficiency with the incident angle of the incoming light 34 on the front face 12 of the waveguide 10. The presence of the intervening parallel-sided glass material of the waveguide through which the light passes before reaching the polymer layer 39 does not affect the effective angle of incidence on the polymer layer which remains the same regardless of the refractive index of the glass. Without the 100nm thick SiO₂ layer, the efficiency of this order (dotted line) peaks to approximately 20% at an angle of incidence of 8 degrees. Addition of the SiO₂ layer suppresses the '+1R' efficiency, as shown by the solid line in the graph, which is desirable.

0036<figref idref="f0004">Figure 7</figref> shows the response of the grating 26 to monochromatic red light of wavelength 632nm; the incident angle again is that of the incoming light 34 in air on to the front face 12 of the waveguide 10. It will be noted that for angles of incidence of less than 3.5 degrees, the grating does not diffract the rays into the '-1R' order. Instead, they are transmitted through the grating in the '0Ta' mode at a transmission efficiency of 90% or more.

0037<figref idref="f0005">Figure 8</figref> shows the response of the grating 26 to monochromatic green light of wavelength 532nm. For angles of incidence of less than 12.5 degrees the grating does not diffract the rays into the -1R order. Zero order transmission (0Ta) in this region is approximately 90%.

0038The response of the grating 26 to monochromatic blue light of wavelength 462nm is shown in <figref idref="f0005">Figure 9</figref>. Across a field of view of 34 degrees (-17 to +17 degrees), the diffraction efficiency into the -1R order is better than 50% and is better than 65% for almost all of the range.

0039<figref idref="f0006">Figure 10</figref> shows the reflective grating 26' of the second waveguide 10'. It is of saw-tooth form, with a period (pitch) of 460nm and a height of 200nm. It is formed on a polymer layer 39' of refractive index 1.68 and has a grating layer 46 of titanium dioxide, 70nm thick, backed by a reflective layer 48 of silver, 150nm thick, from which the incident light is reflected as shown in <figref idref="f0006">Figure 10</figref>. As disclosed in our co-pending applications <patcit id="pcit0008" dnum="GB0906266A"><text>GB0906266.2</text></patcit> and <patcit id="pcit0009" dnum="EP09275024" dnum-type="L"><text>EP09275024.9</text></patcit>, addition of the TiO₂ layer between the polymer and the silver layer yields, through the phenomenon of phase matching, high diffraction efficiency and high angular bandwidth in the '-1R' order.

0040From <figref idref="f0006">Figure 11</figref> it can be seen that <ul id="ul0003" list-style="bullet" compact="compact"><li>For red light (632nm) the grating 26' diffracts light into the -1R order with an efficiency of ~80% over all angles of incidence on face 12' of waveguide 10'.</li><li>For green light (532nm) the grating 26' does not diffract incident rays at angles of higher than 15 degrees. These rays fail to propagate within the waveguide 10'.</li><li>For blue light (462nm) the grating 26' does not diffract incident rays at angles of higher than zero degrees. Hence these rays fail to propagate in the waveguide 10'.</li><li>Outside these incident angle ranges, both blue and green are diffracted into the -1R order with high efficiency.</li></ul>

0041Considering now the efficiency of the input gratings 26, 26' of the two waveguides 10, 10' in diffracting image-bearing light, for any incident ray of a given incident angle and wavelength, the system efficiency (M) as a fraction of the input light intensity is <maths id="math0001" num=""><math display="block"><mi mathvariant="normal">M</mi><mo>=</mo><mo>′</mo><mo>−</mo><mn>1</mn><msub><mi mathvariant="normal">R</mi><mi mathvariant="normal">a</mi></msub><mo>′</mo><mo>+</mo><mfenced separators=""><mo>′</mo><mn>0</mn><msub><mi mathvariant="normal">T</mi><mi mathvariant="normal">a</mi></msub><mo>′</mo><mi mathvariant="normal">x</mi><mo>−</mo><mo>′</mo><mo>−</mo><mn>1</mn><msub><mi mathvariant="normal">R</mi><mi mathvariant="normal">b</mi></msub><mo>′</mo></mfenced><mo>.</mo></math><img file="EP2561396B2_D0001.tif" /></maths>

0042This relationship is shown in <figref idref="f0007">Figure 12</figref>. It can be seen that at 632nm, because grating 26' diffracts across the whole field of view, the overall efficiency is greater than 70%, rising for positive angles of incidence due to the constitution from grating 26. At 532nm, the efficiency of grating 26' is uniformly high except at angles of incidence (<i>i</i>) above 15 degrees. However this is compensated by the 60% efficiency of grating 26' at those angles. Thus, although there is a sharp reduction in system efficiency from 90% at i >15 degrees, nevertheless the overall efficiency remains adequate at 60%.

0043At 462nm, grating 26 has adequate efficiency across the whole field of view (upwards of 60% except for i > 15 degrees), and hence the inability of the grating 26' to diffract at i > 0 degrees can be tolerated.