Facebook Patent | Apparatus and method for manufacturing optically anisotropic polymer thin films

Patent: Apparatus and method for manufacturing optically anisotropic polymer thin films

Drawings: Click to check drawins

Publication Number: 20220105672

Publication Date: 20220407

Applicant: Facebook

Abstract

A method includes attaching a clip array to opposing edges of a polymer thin film, the clip array having a plurality of first clips slidably disposed on a first track located proximate to a first edge of the polymer thin film and a plurality of second clips slidably disposed on a second track located proximate to a second edge of the polymer thin film, applying a positive in-plane strain to the polymer thin film along a transverse direction by increasing a distance between the first clips and the second clips, and decreasing an inter-clip spacing amongst the first clips and amongst the second clips along a machine direction while applying the in-plane strain to form an optically anisotropic polymer thin film.

Claims

1. A method comprising: attaching a clip array to opposing edges of a polymer thin film, the clip array comprising a plurality of first clips slidably disposed on a first track located proximate to a first edge of the polymer thin film and a plurality of second clips slidably disposed on a second track located proximate to a second edge of the polymer thin film; applying a positive in-plane strain to the polymer thin film along a transverse direction by increasing a distance between the first clips and the second clips; and decreasing an inter-clip spacing amongst the first clips and amongst the second clips along a machine direction while applying the in-plane strain to form an optically anisotropic polymer thin film.

2. The method of claim 1, wherein the polymer thin film comprises two or more polymer layers.

3. The method of claim 1, wherein the polymer thin film comprises a polymer selected from the group consisting of polyethylene naphthalate, polyethylene terephthalate, polybutylene naphthalate, and polybutylene terephthalate.

4. The method of claim 1, further comprising heating the polymer thin film to a temperature greater than a glass transition temperature of at least one component of the polymer thin film while applying the in-plane strain.

5. The method of claim 1, wherein a crystalline content of the polymer thin film increases while applying the positive in-plane strain.

6. The method of claim 1, wherein a translation rate of the first and second clips along the machine direction decreases while applying the in-plane strain.

7. The method of claim 1, wherein the decrease in the inter-clip spacing is proportional to the spacing increase between the first clips and the second clips.

8. The method of claim 1, wherein the optically anisotropic polymer thin film comprises at least approximately 1 volume percent of a crystalline phase.

9. The method of claim 1, wherein the optically anisotropic polymer thin film is characterized by: a first in-plane refractive index (n.sub.x) along the transverse direction; a second in-plane refractive index (n.sub.y) along the machine direction; and a third refractive index (n.sub.z) along a thickness direction substantially orthogonal to both the first direction and the second direction, wherein the first refractive index is greater than the second refractive index, and the second refractive index is substantially equal to the third refractive index.

10. The method of claim 9, wherein n.sub.x is greater than approximately 1.85.

11. The method of claim 9, wherein (n.sub.x-n.sub.y) is greater than approximately 0.2.

12. The method of claim 1, wherein the inter-clip spacing decreases by an amount within approximately 10% of the square root of a transverse stretch ratio of the polymer thin film.

13. A film stretching apparatus comprising: a clip array including a plurality of first clips slidably disposed on a first track and a plurality of second clips slidably disposed on a second track spaced away from the first track, the plurality of first clips and the plurality of second clips configured to reversibly attach to opposing edges of a deformable thin film; and a drive system configured to drive movement of the plurality of first and second clips respectively along the first and second tracks, wherein a distance between the first track and the second track increases within a deformation zone of the apparatus, and an inter-clip spacing between the plurality of first clips along the first track and between the plurality of second clips along the second track decreases within the deformation zone.

14. The film stretching apparatus of claim 13, wherein the drive system comprises a plurality of linear stepper motors configured to independently drive each of the plurality of first and second clips.

15. The film stretching apparatus of claim 13, wherein the distance between the first track and the second track increases along a machine direction within the deformation zone.

16. The film stretching apparatus of claim 13, wherein the distance between the first track and the second track is proportional to the inter-clip spacing.

17. A film stretching apparatus comprising: a clip array including a plurality of first clips slidably disposed on a first track and a plurality of second clips slidably disposed on a second track spaced away from the first track, the plurality of first clips and the plurality of second clips configured to reversibly attach to opposing edges of a deformable thin film; and a drive system configured to drive movement of the plurality of first and second clips respectively along the first and second tracks, wherein a distance between the first track and the second track decreases within a deformation zone of the apparatus, and an inter-clip spacing between the plurality of first clips along the first track and between the plurality of second clips along the second track increases within the deformation zone.

18. The film stretching apparatus of claim 17, wherein the drive system comprises a plurality of linear stepper motors configured to independently drive each of the plurality of first and second clips.

19. The film stretching apparatus of claim 17, wherein the distance between the first track and the second track increases along a machine direction within the deformation zone.

20. The film stretching apparatus of claim 17, wherein the distance between the first track and the second track is proportional to the inter-clip spacing.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority under 35 U.S.C. .sctn. 119(e) of U.S. Provisional Application No. 63/087,535, filed Oct. 5, 2020, the contents of which are incorporated herein by reference in their entirety.

BRIEF DESCRIPTION OF THE DRAWINGS

[0002] The accompanying drawings illustrate a number of exemplary embodiments and are a part of the specification. Together with the following description, these drawings demonstrate and explain various principles of the present disclosure.

[0003] FIG. 1 is a top down plan view representation of an example apparatus for manufacturing an optically anisotropic polymer thin film according to some embodiments.

[0004] FIG. 2 is a schematic view of a further example apparatus for manufacturing an optically anisotropic polymer thin film according to some embodiments.

[0005] FIG. 3 illustrates a roll-to-roll manufacturing configuration for conveying and orienting a polymer thin film according to certain embodiments.

[0006] FIG. 4 illustrates a roll-to-roll manufacturing configuration for conveying and orienting a polymer thin film according to further embodiments.

[0007] FIG. 5 is an illustration of exemplary augmented-reality glasses that may be used in connection with embodiments of this disclosure.

[0008] FIG. 6 is an illustration of an exemplary virtual-reality headset that may be used in connection with embodiments of this disclosure.

[0009] Throughout the drawings, identical reference characters and descriptions indicate similar, but not necessarily identical, elements. While the exemplary embodiments described herein are susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, the exemplary embodiments described herein are not intended to be limited to the particular forms disclosed. Rather, the present disclosure covers all modifications, equivalents, and alternatives falling within the scope of the appended claims.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0010] Polymer thin films exhibiting optical anisotropy may be incorporated into a variety of systems and devices, including birefringent gratings, reflective polarizers, optical compensators and optical retarders for systems using polarized light such as liquid crystal displays (LCDs). Birefringent gratings may be used as optical combiners in augmented reality displays, for example, and as input and output couplers for waveguides and fiber optic systems. Reflective polarizers may be used in many display-related applications, particularly in pancake optical systems and for brightness enhancement within display systems that use polarized light. For orthogonally polarized light, pancake lenses may use reflective polarizers with extremely high contrast ratios for transmitted light, reflected light, or both transmitted and reflected light.

[0011] The degree of optical anisotropy achievable through conventional thin film manufacturing processes is typically limited, however, and is often exchanged for competing thin film properties such as flatness, toughness and/or film strength. For example, highly anisotropic polymer thin films often exhibit low strength in one or more in-plane direction, which may challenge manufacturability and limit throughput. Notwithstanding recent developments, it would be advantageous to provide mechanically robust, optically anisotropic polymer thin films that may be incorporated into various optical systems including display systems for artificial reality applications. The instant disclosure is thus directed generally to optically anisotropic polymer thin films and their methods of manufacture, and more specifically to systems for applying a tensile stress to a polymer thin film along a first direction while allowing the polymer thin film to relax along a direction substantially orthogonal to the first direction, i.e., a second direction, to induce a desired in-plane optical anisotropy.

[0012] As used herein, the term “substantially” in reference to a given parameter, property, or condition may mean and include to a degree that one of ordinary skill in the art would understand that the given parameter, property, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances. By way of example, depending on the particular parameter, property, or condition that is substantially met, the parameter, property, or condition may be at least approximately 90% met, at least approximately 95% met, or even at least approximately 99% met.

[0013] Many applications utilize light that propagates along or substantially along a direction normal to the major surface of a polymer thin film, i.e., along the z-axis. Insomuch as the optical efficiency of the polymer thin film may be determined principally by the in-plane birefringence, it may be beneficial to configure the polymer thin film such that n.sub.x>>n.sub.y, where n.sub.x and n.sub.y are mutually orthogonal in-plane refractive indices. In this regard, it will be appreciated that comparative, uniaxially-oriented polymer thin films may be characterized by n.sub.x>n.sub.y.gtoreq.n.sub.z, where the in-plane birefringence (i.e., n.sub.x-n.sub.y) is typically limited to values less than approximately 0.2, e.g., approximately 0.01, approximately 0.05, or approximately 0.1.

[0014] The refractive index of a crystalline polymer thin film may be determined by its chemical composition, the chemical structure of the polymer repeat unit, its density and extent of crystallinity, as well as the alignment of the crystals. Among these factors, the crystal alignment may dominate. In crystalline or semi-crystalline optical polymer thin films, the optical anisotropy may be correlated to the degree or extent of crystal orientation, whereas the degree or extent of chain entanglement may create comparable optical anisotropy in amorphous polymer thin films.

[0015] As disclosed further herein, during processing where a polymer thin film is stretched to induce a preferred alignment of crystals and an attendant modification of the refractive index, Applicants have shown that one approach to forming an optically uniaxial material is to eliminate or substantially eliminate in-plane stretching along the machine direction while applying a tensile force along a transverse direction. In accordance with particular embodiments, Applicants have developed a polymer thin film manufacturing method for forming an optically uniaxial polymer thin film characterized by in-plane refractive indices (n.sub.x and n.sub.y) and a through-thickness refractive index (n.sub.z), where n.sub.x>n.sub.y=n.sub.z. In particular embodiments, the difference in in-plane refractive indices (i.e., n.sub.x-n.sub.y) may be greater than 0.2, and the high in-plane refractive index (i.e., n.sub.x) may be greater than approximately 1.85.

[0016] The formation of optically anisotropic polymer thin films may accompany a high Poisson’s ratio in such thin films. As used herein, a polymer thin film having a “high Poisson’s ratio” may, in certain examples, refer to a polymer thin film having a Poisson’s ratio of greater than approximately 0.5, e.g., approximately 0.6, approximately 0.65, approximately 0.7, approximately 0.75, approximately 0.8, approximately 0.85, or approximately 0.9, including ranges between any of the foregoing values. The Poisson’s ratio may describe the anisotropic properties of a material, including optical properties such as birefringence. The Poisson’s ratio (v) may be defined as the ratio of the change in the width per unit width of a material to the change in its length per unit length as a result of an applied stress. With tensile deformations considered positive and compressive deformations considered negative, the Poisson’s ratio may be expressed as v=-.epsilon..sub.t/.epsilon..sub.n, where .epsilon..sub.t is transverse strain and .epsilon..sub.n is longitudinal strain.

[0017] The Poisson’s ratio of a polymer thin film is largely dictated by the film-forming process. For isotropic, elastic materials, the Poisson’s ratio is thermodynamically constrained to the range -1.ltoreq.v.ltoreq.0.5. Moreover, most polymers exhibit a Poisson’s ratio within a range of approximately 0.2 to approximately 0.3. As disclosed herein, optically anisotropic polymer thin films may be characterized by a Poisson’s ratio greater than 0.5, which may enable improved performance for gratings, retarders, compensators, reflective polarizers, etc. that incorporate such thin films.

[0018] The presently disclosed optically anisotropic polymer thin films may be characterized as optical quality polymer thin films and may form, or be incorporated into, an optical element such as a birefringent grating, optical retarder, optical compensator, reflective polarizer, etc. Such optical elements may be used in various display devices, such as virtual reality (VR) and augmented reality (AR) glasses and headsets. The efficiency of these and other optical elements may depend on the degree of in-plane birefringence.

[0019] According to various embodiments, an “optical quality polymer thin film” or an “optical thin film” may, in some examples, be characterized by a transmissivity within the visible light spectrum of at least approximately 20%, e.g., 20, 30, 40, 50, 60, 70, 80, 90 or 95%, including ranges between any of the foregoing values, and less than approximately 10% bulk haze, e.g., 0, 1, 2, 4, 6, or 8% haze, including ranges between any of the foregoing values.

[0020] In accordance with various embodiments, a reflective polarizer may include a multilayer architecture of alternating (i.e., primary and secondary) polymer layers. In certain aspects, the primary and secondary polymer layers may be configured to have (a) refractive indices along a first in-plane direction (e.g., along the x-axis) that differ sufficiently to substantially reflect light of a first polarization state, and (b) refractive indices along a second in-plane direction (e.g., along the y-axis) orthogonal to the first in-plane direction that are matched sufficiently to substantially transmit light of a second polarization state. That is, a reflective polarizer may reflect light of a first polarization state and transmit light of a second polarization state orthogonal to the first polarization state. As used herein, “orthogonal” states may, in some examples, refer to complementary states that may or may not be related by a 90.degree. geometry. For instance, “orthogonal” directions used to describe the length, width, and thickness dimensions of a polymer thin film may or may not be precisely orthogonal as a result of non-uniformities in the thin film.

[0021] In a multilayer structure, one or more of the polymer layers, i.e., one or more primary polymer layers and/or one or more secondary polymer layers, may be characterized by a directionally-dependent refractive index. By way of example, a primary polymer layer (or a secondary polymer layer) may have a first in-plane refractive index (n.sub.x), a second in-plane refractive index (n.sub.y) orthogonal to and less than the first in-plane refractive index, and a third refractive index (n.sub.z) along a direction orthogonal to a major surface of the primary (or secondary) polymer layer (i.e., orthogonal to both the first in-plane refractive index and the second in-plane refractive index), where the second refractive index is substantially equal to the third refractive index, i.e., n.sub.x>n.sub.y=n.sub.z. One or more of the polymer layers, i.e., one or more primary polymer layers and/or one or more secondary polymer layers, may be characterized as an optical quality polymer thin film.

[0022] In a multilayer architecture of alternating polymer layers, each primary polymer layer and each secondary polymer layer may independently have a thickness ranging from approximately 10 nm to approximately 200 nm, e.g., 10, 20, 50, 100, 150, or 200 nm, including ranges between any of the foregoing values. A total multilayer stack thickness may range from approximately 1 micrometer to approximately 200 micrometers, e.g., 1, 2, 5, 10, 20, 50, 100, or 200 micrometers, including ranges between any of the foregoing values.

[0023] According to some embodiments, the areal dimensions (i.e., length and width) of an optically anisotropic polymer thin film may independently range from approximately 5 cm to approximately 50 cm or more, e.g., 5, 10, 20, 30, 40, or 50 cm, including ranges between any of the foregoing values. Example optically anisotropic polymer thin films may have areal dimensions of approximately 5 cm.times.5 cm, 10 cm.times.10 cm, 20 cm.times.20 cm, 50 cm.times.50 cm, 5 cm.times.10 cm, 10 cm.times.20 cm, 10 cm.times.50 cm, etc.

[0024] In some embodiments, a multilayer structure may be characterized by a progressive change in the thickness of each primary and secondary polymer layer pair. That is, a multilayer architecture may be characterized by an internal thickness gradient where the thickness of individual primary and secondary polymer layers within each successive pair changes continuously throughout the stack.

[0025] In various aspects, by way of example, a multilayer stack may include a first pair of primary and secondary polymer layers each having a first thickness, a second pair of primary and secondary polymer layers adjacent to the first pair each having a second thickness that is less than the first thickness, a third pair of primary and secondary polymer layers adjacent to the second pair each having a third thickness that is less than the second thickness, etc. According to certain embodiments, a thickness step for such a multilayer stack suitable for forming a reflective polarizer may be approximately 2 nm to approximately 20 nm, e.g., 2, 5, 10, or 20 nm, including ranges between any of the foregoing values. By way of example, a multilayer stack having a thickness gradient with a 10 nm thickness step may include a first pair of primary and secondary polymer layers each having a thickness of approximately 85 nm, a second pair of primary and secondary polymer layers adjacent to the first pair each having a thickness of approximately 75 nm, a third pair of primary and secondary polymer layers adjacent to the second pair each having a thickness of approximately 65 nm, a fourth pair of primary and secondary polymer layers adjacent to the third pair each having a thickness of approximately 55 nm, and so on.

[0026] According to further embodiments, a multilayer stack may include alternating primary and secondary polymer layers where the thickness of each individual layer changes continuously throughout the stack. For instance, a multilayer stack may include a first pair of primary and secondary polymer layers, a second pair of primary and secondary polymer layers adjacent to the first pair, a third pair of primary and secondary polymer layers adjacent to the second pair, etc., where the thickness of the first primary layer is greater than the thickness of the first secondary layer, the thickness of the first secondary layer is greater than the thickness of the second primary layer, the thickness of the second primary layer is greater than the thickness of the second secondary layer, the thickness of the second secondary layer is greater than the thickness of the third primary layer, the thickness of the third primary layer is greater than the thickness of the third secondary layer, and so on.

[0027] In certain embodiments, a multilayer structure may include a stack of alternating primary polymer layers and secondary polymer layers where the primary polymer layers may exhibit a higher degree of in-plane optical anisotropy than the secondary polymer layers. For instance, the primary polymer layers may have in-plane refractive indices that differ by at least 0.2 whereas the secondary polymer layers may have in-plane refractive indices that differ by less than 0.2. In such embodiments, by way of example, the primary (more optically anisotropic) polymer layers may include polyethylene naphthalate (PEN), polyethylene terephthalate (PET), or polyethylene isophthalate, and the secondary (less optically anisotropic) polymer layers may include a co-polymer of any two of the foregoing, e.g., a PEN-PET co-polymer, although further compositions are contemplated for the primary polymer layers and the secondary polymer layers.

[0028] By way of example, a pancake optical system, such as a pancake lens, may include an optical element having a reflective surface and a reflective polarizer. A pancake lens may be either transmissive or reflective. According to some embodiments, a transmissive system may include a partially transparent mirrored surface and a reflective polarizer configured to reflect one handedness of circularly polarized light and transmit the other handedness of the circularly polarized light. A reflective system, on the other hand, may include a reflective polarizer configured to transmit one polarization of light, a reflector, and a quarter wave plate for converting linearly polarized light to circularly polarized light. Thus, the reflective polarizer may be a circularly polarized element such as, for example, a cholesteric reflective polarizer, or a linearly polarized element that is adapted for use with a quarter wave plate.

[0029] In accordance with various embodiments, an optically anisotropic polymer thin film may be formed by applying a desired stress state to a crystallizable polymer thin film. A polymer composition capable of crystallizing may be formed into a single layer using appropriate extrusion and casting operations well known to those skilled in the art. For example, PEN may be extruded and oriented as a single layer to form an optically and mechanically anisotropic film. According to further embodiments, a crystallizable polymer may be coextruded with other polymer materials that are either crystallizable, or those that remain amorphous after orientation to form a multilayer structure. In a further example, PEN may be coextruded with copolymers of terephthalic and isophthalic acid mixtures polymerized with ethylene glycol.

[0030] In single layer and multilayer examples, the thickness of each respective layer may independently range from approximately 5 nm to approximately 1 mm or more for a range of mechanical and optical applications, e.g., 5, 10, 20, 50, 100, 200, 500, or 1000 nm, including ranges between any of the foregoing values. As used herein, the terms “polymer thin film” and “polymer layer” may be used interchangeably. Furthermore, reference to a “polymer thin film” or a “polymer layer” may include reference to a “multilayer polymer thin film” and the like, unless the context clearly indicates otherwise.

[0031] Example polymers may include one or more of polyethylene naphthalate, polyethylene terephthalate, polyethylene isophthalate, polybutylene terephthalate, polyoxymethylene, aliphatic or semi-aromatic polyamides, ethylene vinyl alcohol, polyvinylidene fluoride, isotactic polypropylene, polyethylene, and the like, as well as combinations, including isomers and co-polymers thereof. Further example polymers may be derived from phthalic acid, azelaic acid, norbornene dicarboxylic acid and other dicarboxylic acids. Suitable carboxylates may be polymerized with glycols including ethylene glycol, propylene glycol, and other glycols and di-hydrogenated organic compounds.

[0032] In some embodiments, the crystalline content may include polyethylene naphthalate or polyethylene terephthalate, for example, although further crystalline polymer materials are contemplated, where a crystalline phase in a “crystalline” or “semi-crystalline” polymer thin film may, in some examples, constitute at least approximately 1 vol. % of the polymer thin film. In some embodiments, the crystalline content of the crystallizable polymer thin film may increase during the act of stretching. In some embodiments, stretching may alter the orientation of crystals within a crystallizable polymer thin film without substantially changing the crystalline content.

[0033] An optically anisotropic polymer thin film may be formed using a thin film orientation system configured to heat and stretch a polymer thin film in at least one in-plane direction in one or more distinct regions thereof. In some embodiments, a thin film orientation system may be configured to stretch a polymer thin film, i.e., a crystallizable polymer thin film, along only one in-plane direction. For instance, a thin film orientation system may be configured to apply an in-plane stress to a polymer thin film along the x-direction while allowing the thin film to relax along an orthogonal in-plane direction (e.g., along the y-direction). As used herein, the relaxation of a polymer thin film may, in certain examples, accompany the absence of an applied stress along a relaxation direction.

[0034] According to some embodiments, within an example system, a polymer thin film may be heated and stretched transversely to a direction of film travel through the system. In such embodiments, a polymer thin film may be held along opposing edges by plural movable clips slidably disposed along a diverging track system such that the polymer thin film is stretched in a transverse direction (TD) as it moves along a machine direction (MD) through heating and deformation zones of the thin film orientation system. In some embodiments, the stretching rate in the transverse direction and the relaxation rate in the machine direction may be independently and locally controlled. In certain embodiments, large scale production may be enabled, for example, using a roll-to-roll manufacturing platform.

[0035] In some embodiments, as will be described in further detail herein, an inter-clip spacing along either or both tracks may vary as a function of location within the thin film orientation system. For instance, an inter-clip spacing along either track may independently increase or decrease as the clips move and guide the polymer thin film from an input zone of the system to an output zone of the system. Such a configuration may effectively increase (or decrease) the translation rate of the polymer thin film along the machine direction during application of the transverse tensile stress.

[0036] In certain aspects, the tensile stress may be applied uniformly or non-uniformly along a lengthwise or widthwise dimension of the polymer thin film. Heating of the polymer thin film may accompany the application of the tensile stress. For instance, a semi-crystalline polymer thin film may be heated to a temperature greater than its glass transition temperature (T.sub.g), e.g., T.sub.g+10.degree. C., T.sub.g+15.degree. C., T.sub.g+20.degree. C., T.sub.g+30.degree. C., T.sub.g+40.degree. C., and T.sub.g+50.degree. C., including ranges between any of the foregoing values, to facilitate deformation of the thin film and the formation and realignment of crystals therein.

[0037] The temperature of the polymer thin film may be maintained at a desired value or within a desired range before, during and/or after the act of stretching, i.e., within a pre-heating zone or a deformation zone downstream of the pre-heating zone, in order to improve the deformability of the polymer thin film relative to an un-heated polymer thin film. The temperature of the polymer thin film within a deformation zone may be less than, equal to, or greater than the temperature of the polymer thin film within a pre-heating zone.

[0038] In some embodiments, the polymer thin film may be heated to a constant temperature throughout the act of stretching. In some embodiments, a region of the polymer thin film may be heated to different temperatures, i.e., during and/or subsequent to the application of the tensile stress. In some embodiments, different regions of the polymer thin film may be heated to different temperatures. In certain embodiments, the strain realized in response to the applied tensile stress may be at least approximately 20%, e.g., approximately 20%, approximately 50%, approximately 100%, approximately 200%, approximately 300%, approximately 400%, approximately 500%, or approximately 700% or more, including ranges between any of the foregoing values.

[0039] The degree of relaxation as determined by the clip spacing along the machine direction may by high during a first portion of the stretching operation, which may induce wrinkling of the polymer thin film. The degree of relaxation may then be lower during a second, subsequent portion of the stretching operation in order to produce a uniformly flat film.

[0040] Following deformation of the polymer thin film, the heating may be maintained for a predetermined amount of time, followed by cooling of the polymer thin film. The act of cooling may include allowing the polymer thin film to cool naturally, at a set cooling rate, or by quenching, such as by purging with a low temperature gas, which may thermally stabilize the polymer thin film.

[0041] Following deformation and crystal realignment, the crystals may be at least partially aligned with the direction of the applied tensile stress. As such, an optically uniaxial polymer thin film may exhibit a high degree of birefringence, e.g., in-plane birefringence, where n.sub.x>n.sub.y=n.sub.z. In some embodiments, the difference (n.sub.x-n.sub.y) may be greater than approximately 0.2, where n.sub.x may be greater than approximately 1.85, e.g., approximately 1.87 or approximately 1.89.

[0042] In accordance with various embodiments, optically anisotropic polymer thin films may include fibrous, amorphous, partially crystalline, or wholly crystalline materials. Such materials may also be mechanically anisotropic, where one or more characteristics including but not limited to compressive strength, tensile strength, shear strength, yield strength, stiffness, hardness, toughness, ductility, machinability, thermal expansion, and creep behavior may be directionally dependent.

[0043] The optically anisotropic polymer thin films disclosed herein may be used to form multilayer reflective polarizers that may be implemented in a variety of applications. For instance, a multilayer reflective polarizer may be used to increase the polarized light output by an LED- or OLED-based display grid that includes an emitting array of monochromatic, colored, or IR pixels. In some embodiments, a reflective polarizer thin film may be applied to an emissive pixel array to provide light recycling and increased output for one or more polarization states. Moreover, highly optically anisotropic polymer thin films may decrease pixel blur in such applications.

[0044] An example reflective polarizer may be characterized as a multilayer structure having between approximately 2 and approximately 1000 layers of alternating first and second polymers, e.g., 2, 10, 20, 50, 100, 250, 500, 1000 layers, or more, including ranges between any of the foregoing values. The first polymer may form an optically birefringent polymer thin film. Layers of the first polymer may exhibit a difference between a high in-plane refractive index and a low in-plane refractive index each measured at 550 nm of at least approximately 0.2, and a difference between an out of plane refractive index and the low in-plane refractive index each measured at 550 nm of less than approximately 0.1, e.g., less than approximately 0.05, or even less than approximately 0.025.

[0045] A reflective polarizer including an optically anisotropic polymer thin film may be thermally stable and have a reflectivity of less than approximately 10%, e.g., less than approximately 5%, less than approximately 2%, or less than approximately 1%, for linearly p-polarized light incident at a 45.degree. angle and oriented along the pass axis of the reflective polarizer. The reflective polarizer may exhibit less than approximately 5% strain (e.g., less than approximately 5% shrinkage, less than approximately 2% shrinkage, less than approximately 1% shrinkage, or less than approximately 0.5% shrinkage) when heated at approximately 95.degree. C. for at least 40 minutes.

[0046] Aspects of the present disclosure thus relate to the formation of a multilayer reflective polarizer having improved mechanical and optical properties and including one or more optically anisotropic polymer thin films. The improved mechanical properties may include improved dimensional stability and improved compliance in conforming to a compound curved surface. The improved optical properties may include a higher contrast ratio and reduced polarization angle variance when conformed to a compound curved surface.

[0047] Features from any of the embodiments described herein may be used in combination with one another in accordance with the general principles described herein. These and other embodiments, features, and advantages will be more fully understood upon reading the following detailed description in conjunction with the accompanying drawings and claims.

[0048] The following will provide, with reference to FIGS. 1-6, detailed descriptions of methods and systems for manufacturing optically anisotropic polymer thin films. The discussion associated with FIGS. 1-4 relates to example thin film processing systems. The discussion associated with FIGS. 5 and 6 relates to exemplary virtual reality and augmented reality devices that may include one or more optically anisotropic polymer thin films as disclosed herein.

[0049] In conjunction with various embodiments, a polymer thin film may be described with reference to three mutually orthogonal axes that are aligned with the machine direction (MD), the transverse direction (TD), and the normal direction (ND) of a thin film orientation system, and which may correspond respectively to the length, width, and thickness dimensions of the polymer thin film. Throughout various embodiments and examples of the instant disclosure, the machine direction may correspond to the y-direction of a polymer thin film, the transverse direction may correspond to the x-direction of the polymer thin film, and the normal direction may correspond to the z-direction of the polymer thin film.

[0050] An example thin film orientation system for forming a uniaxially-oriented polymer thin film is shown schematically in FIG. 1. System 100 may include a thin film input zone 130 for receiving and pre-heating a crystallizable portion 110 of a polymer thin film 105, a thin film output zone 147 for outputting a crystallized and oriented portion 115 of the polymer thin film 105, and a clip array 120 extending between the input zone 130 and the output zone 147 that is configured to grip and guide the polymer thin film 105 through the system 100, i.e., from the input zone 130 to the output zone 147. Clip array 120 may include a plurality of movable first clips 124 that are slidably disposed on a first track 125 and a plurality of movable second clips 126 that are slidably disposed on a second track 127.

[0051] During operation, proximate to input zone 130, clips 124, 126 may be affixed to respective edge portions of polymer thin film 105, where adjacent clips located on a given track 125, 127 may be disposed at an inter-clip spacing 150. For simplicity, in the illustrated view, the inter-clip spacing 150 along the first track 125 within input zone 130 may be equivalent or substantially equivalent to the inter-clip spacing 150 along the second track 127 within input zone 130. As will be appreciated, in alternate embodiments, within input zone 130, the inter-clip spacing 150 along the first track 125 may be different than the inter-clip spacing 150 along the second track 127.

[0052] In addition to input zone 130 and output zone 147, system 100 may include one or more additional zones 135, 140, 145, etc., where each of: (i) the translation rate of the polymer thin film 105, (ii) the shape of first and second tracks 125, 127, (iii) the spacing between first and second tracks 125, 127, (iv) the inter-clip spacing 150, 152, 155, 157, 159, and (v) the local temperature of the polymer thin film, etc. may be independently controlled.

[0053] In an example process, as it is guided through system 100 by clips 124, 126, polymer thin film 105 may be heated to a selected temperature within each of zones 130, 135, 140, 145, 147. Fewer or a greater number of thermally controlled zones may be used. As illustrated, within zone 135, first and second tracks 125, 127 may diverge along a transverse direction such that polymer thin film 105 may be stretched in the transverse direction while being heated, for example, to a temperature greater than its glass transition temperature.

[0054] Referring still to FIG. 1, within zone 135 the spacing 152 between adjacent first clips 124 on first track 125 and the spacing 157 between adjacent second clips 126 on second track 127 may decrease relative to the inter-clip spacing 150 within input zone 130. In certain embodiments, the decrease in clip spacing 152, 157 from the initial spacing 150 may scale approximately as the square root of the transverse stretch ratio. The actual ratio may depend on the Poisson’s ratio of the polymer thin film as well as the requirements for the stretched thin film, including flatness, thickness, etc. In some embodiments, the ratio may change with the degree of orientation of a polymer thin film. For example, the ratio may be greater than a square root of the stretch ratio at the beginning of the stretching operation, and less than a square root of the stretch ratio toward the end of the stretching operation, such that, in certain embodiments, the ratio may change from a maximum value at the beginning of the stretching operation to a minimum value at the end of the stretching operation. A total ratio change may be greater than approximately 5%, greater than approximately 10%, or greater than approximately 20%. In particular embodiments, an inter-clip spacing may decrease by an amount equal to .+-.10% of the square root of a transverse stretch ratio of the polymer thin film.

[0055] In some embodiments, the temperature of the polymer thin film 105 may be decreased as the stretched polymer thin film 105 enters zone 140. Rapidly decreasing the temperature following the act of stretching may enhance the conformability of the polymer thin film 105. In some embodiments, the polymer thin film 105 may be thermally stabilized, where the temperature of the polymer thin film 105 may be controlled within each of the post-stretch zones 140, 145, 147. A temperature of the polymer thin film may be controlled by forced thermal convection or by radiation, for example, IR radiation, or a combination thereof.

[0056] Downstream of stretching zone 135, according to some embodiments, a transverse distance between first track 125 and second track 127 may remain constant or, as illustrated, initially decrease (e.g., within zone 140 and zone 145) prior to assuming a constant separation distance (e.g., within zone 147). In a related vein, the inter-clip spacing downstream of stretching zone 135 may increase or decrease relative to inter-clip spacing 152 along first track 125 and inter-clip spacing 157 along second track 127. For example, inter-clip spacing 155 along first track 125 within output zone 147 may be less than inter-clip spacing 152 within stretching zone 135, and inter-clip spacing 159 along second track 127 within output zone 147 may be less than inter-clip spacing 157 within stretching zone 135. According to some embodiments, the spacing between the clips may be controlled by modifying the local velocity of the clips on a linear stepper motor line, or by using an attachment and variable clip-spacing mechanism connecting the clips to the corresponding track.

[0057] According to various embodiments, as a tensile stress is applied to the polymer thin film along the transverse direction, a dynamic inter-clip spacing within the stretching zone will allow the polymer film to relax along the machine direction. By avoiding an induced strain along the machine direction, crystals within the polymer thin film may have a preferred orientation along the transverse direction but may remain randomly distributed in each of the machine direction and the normal direction such that the crystals exhibit a uniaxial orientation and n.sub.x>n.sub.y=n.sub.z.

[0058] In some embodiments, thermal stabilization downstream of deformation zone 135 may include additional crystallization of the polymer thin film. By continuing to decrease the inter-clip spacing along the tracks downstream of deformation zone 135, e.g., within zone 140, relaxation of the polymer thin film along the machine direction during additional crystal growth may inhibit the realization of stresses along the machine direction of the polymer thin film and an attendant realization of preferred orientation, i.e., along the machine direction, of the newly-formed crystals.

[0059] The strain impact of the thin film orientation system 100 is shown schematically by unit segments 160, 165, which respectively illustrate pre-stretch dimensions and corresponding post-stretch dimensions for a selected area of polymer thin film 105. In the illustrated embodiment, polymer thin film 105 has a pre-stretch width (e.g., along the transverse direction) and a pre-stretch length (e.g., along the machine direction). As will be appreciated, a post-stretch width may be greater than the pre-stretch width and a post-stretch length may be less than the pre-stretch length.

[0060] Referring to FIG. 2, shown is a further example system for forming an optically anisotropic polymer thin film. System 200 may include a thin film input zone 230 for receiving and pre-heating a crystallizable portion 210 of a polymer thin film 205, a thin film output zone 245 for outputting an at least partially crystallized and oriented portion 215 of the polymer thin film 205, and a clip array 220 extending between the input zone 230 and the output zone 245 that is configured to grip and guide the polymer thin film 205 through the system 200. As in the previous embodiment, clip array 220 may include a plurality of first clips 224 that are slidably disposed on a first track 225 and a plurality of second clips 226 that are slidably disposed on a second track 227.

[0061] In an example process, proximate to input zone 230, first and second clips 224, 226 may be affixed to edge portions of polymer thin film 205, where adjacent clips located on a given track 225, 227 may be disposed at an initial inter-clip spacing 250, which may be substantially constant or variable along both tracks within input zone 230. Within input zone 230 a distance along the transverse direction between first track 225 and second track 227 may be constant or substantially constant.

[0062] System 200 may additionally include one or more zones 235, 240, etc. The dynamics of system 200 allow independent control over: (i) the translation rate of the polymer thin film 205, (ii) the shape of first and second tracks 225, 227, (iii) the spacing between first and second tracks 225, 227 along the transverse direction, (iv) the inter-clip spacing 250 within input zone 230 as well as downstream of the input zone (e.g., inter-clip spacings 252, 255, 257, 259), and (v) the local temperature of the polymer thin film, etc.

[0063] In an example process, as it is guided through system 200 by clips 224, 226, polymer thin film 205 may be heated to a selected temperature within each of zones 230, 235, 240, 245. A temperature greater than the glass transition temperature of a component of the polymer thin film 205 may be used during deformation (i.e., within zone 235), whereas a lesser temperature, an equivalent temperature, or a greater temperature may be used within each of one or more downstream zones.

[0064] Referring still to FIG. 2, within zone 235 the spacing 252 between adjacent first clips 224 on first track 225 and the spacing 257 between adjacent second clips 226 on second track 227 may increase relative to the inter-clip spacing 250 within input zone 230, which may apply an in-plane tensile stress to the polymer thin film 205 and stretch the polymer thin film along the machine direction. Moreover, the extent of inter-clip spacing on one or both tracks 225, 227 within deformation zone 235 may be constant or variable and, for example, increase as a function of position along the machine direction.

[0065] In response to the tensile stress applied along the machine direction, system 200 is configured to inhibit the generation of stresses and an attendant realignment of crystals along the transverse direction. As illustrated, within zone 235, first and second tracks 225, 227 may converge along a transverse direction such that polymer thin film 205 may relax in the transverse direction while being stretched in the machine direction.

[0066] In some embodiments, the temperature of the polymer thin film 205 may be decreased as the stretched polymer thin film 205 exits zone 235. In some embodiments, the polymer thin film 205 may be thermally stabilized, where the temperature of the polymer thin film 205 may be controlled within each of the post-deformation zones 240, 245. A temperature of the polymer thin film may be controlled by forced thermal convection or by radiation, for example, IR radiation, or a combination thereof.

[0067] Downstream of deformation zone 235, the inter-clip spacing may increase, decrease, or remain substantially constant relative to inter-clip spacing 252 along first track 225 and inter-clip spacing 257 along second track 227. For example, inter-clip spacing 255 along first track 225 within output zone 245 may be substantially equal to the inter-clip spacing 252 as the clips exit zone 235, and inter-clip spacing 259 along second track 227 within output zone 245 may be substantially equal to the inter-clip spacing 257 as the clips exit zone 235.

[0068] The strain impact of the thin film orientation system 200 is shown schematically by unit segments 260, 265, which respectively illustrate pre- and post-deformation dimensions for a selected area of polymer thin film 205. In the illustrated embodiment, polymer thin film 205 has a pre-stretch width (e.g., along the transverse direction) and a pre-stretch length (e.g., along the machine direction). As will be appreciated, a post-stretch width may be less than the pre-stretch width and a post-stretch length may be greater than the pre-stretch length.

[0069] In some embodiments, a roll-to-roll system may be integrated with a thin film orientation system, such as thin film orientation system 100 or thin film orientation system 200, to manipulate a polymer thin film. In further embodiments, as illustrated herein with reference to FIG. 3 and FIG. 4, a roll-to-roll system may itself be configured as a thin film orientation system.

[0070] An example roll-to-roll polymer thin film orientation system is depicted in FIG. 3. In conjunction with system 300, a method for stretching a polymer thin film 310 may include mounting the polymer thin film between linear rollers 340, 360 and heating a portion 380 of the polymer thin film located between the rollers 340, 360 to a temperature greater than its glass transition temperature. A heat source 350, such as an IR source optionally equipped with an IR reflector 355, may be used to heat the polymer thin film 380 within the deformation region between the rollers 340, 360.

[0071] While maintaining the temperature of the polymer thin film, rollers 340, 360 may be engaged and the polymer thin film may be stretched. For instance, first roller 340 may rotate at a first rate and second roller 360 may rotate at a second rate greater than the first rate to stretch the polymer thin film along a machine direction therebetween. The polymer thin film may then be cooled while maintaining the applied strain. System 300 may be used to form a uniaxially oriented polymer thin film 320. Additional rollers, for example rollers 330 and 365, may be added to system 300 to control the conveyance and take-up of the polymer thin film.

[0072] A further example roll-to-roll polymer thin film orientation system is depicted in FIG. 4. System 400 may include multiple heaters and multiple corresponding deformation regions. The incorporation of multiple deformation regions may be used to control the crystalline content of the polymer thin film during stretching and accordingly beneficially impact the uniformity of its optical properties, including strain-induced birefringence.

[0073] System 400 may include a first pair of linear rollers 440, 460 and a first heat source 450, such as an IR source optionally equipped with an IR reflector 455, disposed between the first pair of rollers. System 400 may further include a second pair of linear rollers 465, 495 located downstream of the first pair of linear rollers, and a second heat source 470 (e.g., an IR source optionally equipped with an IR reflector 475), disposed between the second pair of rollers.

[0074] Heat source 450 may be used to heat polymer thin film 480 within the deformation region between the first pair of rollers 440, 460, and heat source 470 may be used to heat polymer thin film 485 within the deformation region between the second pair of rollers 465, 495. Additional rollers 430, 490 may be used to convey a polymer thin film 410.

[0075] In an example embodiment, roller 440 may rotate at a first rate and roller 460 may rotate at a second rate greater than the first rate to stretch the polymer thin film 480 along a machine direction therebetween. Polymer thin film 485 may be stretched along a machine direction between roller 465 and roller 495 in an example where roller 465 may rotate at a third rate and roller 495 may rotate at a fourth rate greater than the third rate to form a uniaxially oriented polymer thin film 420.

[0076] As disclosed herein, as single layers or multilayer stacks, optically anisotropic polymer thin films may be incorporated into a variety of optical elements, such as birefringent gratings, optical retarders, optical compensators, reflective polarizers, and the like. The efficiency of these and other optical elements may depend on the degree of in-plane birefringence exhibited by the polymer thin film(s).

[0077] A polymer thin film may be characterized by in-plane refractive indices (n.sub.x and n.sub.y) and a through-thickness refractive index (n.sub.z). Applicants have demonstrated that the deformation of a semi-crystalline polymer thin film and the attendant strain-induced realignment of crystals within the polymer can generate anisotropic, optically-uniaxial materials where n.sub.x>n.sub.y=n.sub.z. In certain embodiments, n.sub.x may be greater than 1.85 and the in-plane birefringence (n.sub.x-n.sub.y) may be greater than 0.2. Example polymer compositions may include polyethylene naphthalate (PEN) or polyethylene terephthalate (PET), although further polymer compositions are contemplated.

[0078] In accordance with various embodiments, an optically anisotropic polymer thin film may be formed using a thin film orientation system configured to heat and stretch a polymer thin film along one in-plane direction. For instance, a thin film orientation system may be configured to apply an in-plane stress to a polymer thin film along one in-plane direction while allowing the thin film to relax along an orthogonal in-plane direction. In particular embodiments, a polymer thin film may be held along opposing edges by plural movable clips slidably disposed along a diverging track system such that the polymer thin film is stretched in a transverse direction (TD) as it moves along a machine direction (MD) through heating and deformation zones of the thin film orientation system. In some embodiments, an inter-clip spacing along either or both tracks may vary as a function of location within the thin film orientation system. Such a dynamic configuration may be used to effectively decrease the translation velocity of the polymer thin film and avoid the application or realization of stress and the attendant realignment of crystals along the machine direction.

EXAMPLE EMBODIMENTS

[0079] Example 1: A method includes attaching a clip array to opposing edges of a polymer thin film, the clip array having a plurality of first clips slidably disposed on a first track located proximate to a first edge of the polymer thin film and a plurality of second clips slidably disposed on a second track located proximate to a second edge of the polymer thin film, applying a positive in-plane strain to the polymer thin film along a transverse direction by increasing a distance between the first clips and the second clips, and decreasing an inter-clip spacing amongst the first clips and amongst the second clips along a machine direction while applying the in-plane strain to form an optically anisotropic polymer thin film.

[0080] Example 2: The method of Example 1, where the polymer thin film includes two or more polymer layers.

[0081] Example 3: The method of any of Examples 1 and 2, where the polymer thin film includes a polymer selected from polyethylene naphthalate, polyethylene terephthalate, polybutylene naphthalate, and polybutylene terephthalate.

[0082] Example 4: The method of any of Examples 1-3, further including heating the polymer thin film to a temperature greater than a glass transition temperature of at least one component of the polymer thin film while applying the in-plane strain.

[0083] Example 5: The method of any of Examples 1-4, where a crystalline content of the polymer thin film increases while applying the positive in-plane strain.

[0084] Example 6: The method of any of Examples 1-5, where a translation rate of the first and second clips along the machine direction decreases while applying the in-plane strain.

[0085] Example 7: The method of any of Examples 1-6, where the decrease in the inter-clip spacing is proportional to the spacing increase between the first clips and the second clips.

[0086] Example 8: The method of any of Examples 1-7, where the optically anisotropic polymer thin film includes at least approximately 1 volume percent of a crystalline phase.

[0087] Example 9: The method of any of Examples 1-9, where the optically anisotropic polymer thin film is characterized by: (i) a first in-plane refractive index (n.sub.x) along the transverse direction, (ii) a second in-plane refractive index (n.sub.y) along the machine direction, and (iii) a third refractive index (n.sub.z) along a thickness direction substantially orthogonal to both the first direction and the second direction, where the first refractive index is greater than the second refractive index, and the second refractive index is substantially equal to the third refractive index.

[0088] Example 10: The method of Example 9, where n.sub.x is greater than approximately 1.85.

[0089] Example 11: The method of any of Examples 9 and 10, where (n.sub.x-n.sub.y) is greater than approximately 0.2.

[0090] Example 12: The method of any of Examples 1-11, where the inter-clip spacing decreases by an amount within approximately 10% of the square root of a transverse stretch ratio of the polymer thin film.

[0091] Example 13: A film stretching apparatus includes a clip array having a plurality of first clips slidably disposed on a first track and a plurality of second clips slidably disposed on a second track spaced away from the first track, the plurality of first clips and the plurality of second clips configured to reversibly attach to opposing edges of a deformable thin film, and a drive system configured to drive movement of the plurality of first and second clips respectively along the first and second tracks, where a distance between the first track and the second track increases within a deformation zone of the apparatus, and an inter-clip spacing between the plurality of first clips along the first track and between the plurality of second clips along the second track decreases within the deformation zone.

[0092] Example 14: The film stretching apparatus of Example 13, where the drive system includes a plurality of linear stepper motors configured to independently drive each of the plurality of first and second clips.

[0093] Example 15: The film stretching apparatus of any of Examples 13 and 14, where the distance between the first track and the second track increases along a machine direction within the deformation zone.

[0094] Example 16: The film stretching apparatus of any of Examples 13-15, where the distance between the first track and the second track is proportional to the inter-clip spacing.

[0095] Example 17: A film stretching apparatus includes a clip array having a plurality of first clips slidably disposed on a first track and a plurality of second clips slidably disposed on a second track spaced away from the first track, the plurality of first clips and the plurality of second clips configured to reversibly attach to opposing edges of a deformable thin film, and a drive system configured to drive movement of the plurality of first and second clips respectively along the first and second tracks, where a distance between the first track and the second track decreases within a deformation zone of the apparatus, and an inter-clip spacing between the plurality of first clips along the first track and between the plurality of second clips along the second track increases within the deformation zone.

[0096] Example 18: The film stretching apparatus of Example 17, where the drive system includes a plurality of linear stepper motors configured to independently drive each of the plurality of first and second clips.

[0097] Example 19: The film stretching apparatus of any of Examples 17 and 18, where the distance between the first track and the second track increases along a machine direction within the deformation zone.

[0098] Example 20: The film stretching apparatus of any of Examples 17-19, where the distance between the first track and the second track is proportional to the inter-clip spacing.

[0099] Embodiments of the present disclosure may include or be implemented in conjunction with various types of artificial-reality systems. Artificial reality is a form of reality that has been adjusted in some manner before presentation to a user, which may include, for example, a virtual reality, an augmented reality, a mixed reality, a hybrid reality, or some combination and/or derivative thereof. Artificial-reality content may include completely computer-generated content or computer-generated content combined with captured (e.g., real-world) content. The artificial-reality content may include video, audio, haptic feedback, or some combination thereof, any of which may be presented in a single channel or in multiple channels (such as stereo video that produces a three-dimensional (3D) effect to the viewer). Additionally, in some embodiments, artificial reality may also be associated with applications, products, accessories, services, or some combination thereof, that are used to, for example, create content in an artificial reality and/or are otherwise used in (e.g., to perform activities in) an artificial reality.

[0100] Artificial-reality systems may be implemented in a variety of different form factors and configurations. Some artificial-reality systems may be designed to work without near-eye displays (NEDs). Other artificial-reality systems may include an NED that also provides visibility into the real world (e.g., augmented-reality system 500 in FIG. 5) or that visually immerses a user in an artificial reality (e.g., virtual-reality system 600 in FIG. 6). While some artificial-reality devices may be self-contained systems, other artificial-reality devices may communicate and/or coordinate with external devices to provide an artificial-reality experience to a user. Examples of such external devices include handheld controllers, mobile devices, desktop computers, devices worn by a user, devices worn by one or more other users, and/or any other suitable external system.

[0101] Turning to FIG. 5, augmented-reality system 500 may include an eyewear device 502 with a frame 510 configured to hold a left display device 515(A) and a right display device 515(B) in front of a user’s eyes. Display devices 515(A) and 515(B) may act together or independently to present an image or series of images to a user. While augmented-reality system 500 includes two displays, embodiments of this disclosure may be implemented in augmented-reality systems with a single NED or more than two NEDs.

[0102] In some embodiments, augmented-reality system 500 may include one or more sensors, such as sensor 540. Sensor 540 may generate measurement signals in response to motion of augmented-reality system 500 and may be located on substantially any portion of frame 510. Sensor 540 may represent a position sensor, an inertial measurement unit (IMU), a depth camera assembly, a structured light emitter and/or detector, or any combination thereof. In some embodiments, augmented-reality system 500 may or may not include sensor 540 or may include more than one sensor. In embodiments in which sensor 540 includes an IMU, the IMU may generate calibration data based on measurement signals from sensor 540. Examples of sensor 540 may include, without limitation, accelerometers, gyroscopes, magnetometers, other suitable types of sensors that detect motion, sensors used for error correction of the IMU, or some combination thereof.

[0103] Augmented-reality system 500 may also include a microphone array with a plurality of acoustic transducers 520(A)-520(J), referred to collectively as acoustic transducers 520. Acoustic transducers 520 may be transducers that detect air pressure variations induced by sound waves. Each acoustic transducer 520 may be configured to detect sound and convert the detected sound into an electronic format (e.g., an analog or digital format). The microphone array in FIG. 5 may include, for example, ten acoustic transducers: 520(A) and 520(B), which may be designed to be placed inside a corresponding ear of the user, acoustic transducers 520(C), 520(D), 520(E), 520(F), 520(G), and 520(H), which may be positioned at various locations on frame 510, and/or acoustic transducers 520(I) and 520(J), which may be positioned on a corresponding neckband 505.

[0104] In some embodiments, one or more of acoustic transducers 520(A)-(F) may be used as output transducers (e.g., speakers). For example, acoustic transducers 520(A) and/or 520(B) may be earbuds or any other suitable type of headphone or speaker.

[0105] The configuration of acoustic transducers 520 of the microphone array may vary. While augmented-reality system 500 is shown in FIG. 5 as having ten acoustic transducers 520, the number of acoustic transducers 520 may be greater or less than ten. In some embodiments, using higher numbers of acoustic transducers 520 may increase the amount of audio information collected and/or the sensitivity and accuracy of the audio information. In contrast, using a lower number of acoustic transducers 520 may decrease the computing power required by an associated controller 550 to process the collected audio information. In addition, the position of each acoustic transducer 520 of the microphone array may vary. For example, the position of an acoustic transducer 520 may include a defined position on the user, a defined coordinate on frame 510, an orientation associated with each acoustic transducer 520, or some combination thereof.

[0106] Acoustic transducers 520(A) and 520(B) may be positioned on different parts of the user’s ear, such as behind the pinna, behind the tragus, and/or within the auricle or fossa. Or, there may be additional acoustic transducers 520 on or surrounding the ear in addition to acoustic transducers 520 inside the ear canal. Having an acoustic transducer 520 positioned next to an ear canal of a user may enable the microphone array to collect information on how sounds arrive at the ear canal. By positioning at least two of acoustic transducers 520 on either side of a user’s head (e.g., as binaural microphones), augmented-reality device 500 may simulate binaural hearing and capture a 3D stereo sound field around about a user’s head. In some embodiments, acoustic transducers 520(A) and 520(B) may be connected to augmented-reality system 500 via a wired connection 530, and in other embodiments acoustic transducers 520(A) and 520(B) may be connected to augmented-reality system 500 via a wireless connection (e.g., a Bluetooth connection). In still other embodiments, acoustic transducers 520(A) and 520(B) may not be used at all in conjunction with augmented-reality system 500.

[0107] Acoustic transducers 520 on frame 510 may be positioned along the length of the temples, across the bridge, above or below display devices 515(A) and 515(B), or some combination thereof. Acoustic transducers 520 may be oriented such that the microphone array is able to detect sounds in a wide range of directions surrounding the user wearing the augmented-reality system 500. In some embodiments, an optimization process may be performed during manufacturing of augmented-reality system 500 to determine relative positioning of each acoustic transducer 520 in the microphone array.

[0108] In some examples, augmented-reality system 500 may include or be connected to an external device (e.g., a paired device), such as neckband 505. Neckband 505 generally represents any type or form of paired device. Thus, the following discussion of neckband 505 may also apply to various other paired devices, such as charging cases, smart watches, smart phones, wrist bands, other wearable devices, hand-held controllers, tablet computers, laptop computers, other external compute devices, etc.

[0109] As shown, neckband 505 may be coupled to eyewear device 502 via one or more connectors. The connectors may be wired or wireless and may include electrical and/or non-electrical (e.g., structural) components. In some cases, eyewear device 502 and neckband 505 may operate independently without any wired or wireless connection between them. While FIG. 5 illustrates the components of eyewear device 502 and neckband 505 in example locations on eyewear device 502 and neckband 505, the components may be located elsewhere and/or distributed differently on eyewear device 502 and/or neckband 505. In some embodiments, the components of eyewear device 502 and neckband 505 may be located on one or more additional peripheral devices paired with eyewear device 502, neckband 505, or some combination thereof.

[0110] Pairing external devices, such as neckband 505, with augmented-reality eyewear devices may enable the eyewear devices to achieve the form factor of a pair of glasses while still providing sufficient battery and computation power for expanded capabilities. Some or all of the battery power, computational resources, and/or additional features of augmented-reality system 500 may be provided by a paired device or shared between a paired device and an eyewear device, thus reducing the weight, heat profile, and form factor of the eyewear device overall while still retaining desired functionality. For example, neckband 505 may allow components that would otherwise be included on an eyewear device to be included in neckband 505 since users may tolerate a heavier weight load on their shoulders than they would tolerate on their heads. Neckband 505 may also have a larger surface area over which to diffuse and disperse heat to the ambient environment. Thus, neckband 505 may allow for greater battery and computation capacity than might otherwise have been possible on a stand-alone eyewear device. Since weight carried in neckband 505 may be less invasive to a user than weight carried in eyewear device 502, a user may tolerate wearing a lighter eyewear device and carrying or wearing the paired device for greater lengths of time than a user would tolerate wearing a heavy standalone eyewear device, thereby enabling users to more fully incorporate artificial-reality environments into their day-to-day activities.

[0111] Neckband 505 may be communicatively coupled with eyewear device 502 and/or to other devices. These other devices may provide certain functions (e.g., tracking, localizing, depth mapping, processing, storage, etc.) to augmented-reality system 500. In the embodiment of FIG. 5, neckband 505 may include two acoustic transducers (e.g., 520(I) and 520(J)) that are part of the microphone array (or potentially form their own microphone subarray). Neckband 505 may also include a controller 525 and a power source 535.

[0112] Acoustic transducers 520(I) and 520(J) of neckband 505 may be configured to detect sound and convert the detected sound into an electronic format (analog or digital). In the embodiment of FIG. 5, acoustic transducers 520(I) and 520(J) may be positioned on neckband 505, thereby increasing the distance between the neckband acoustic transducers 520(I) and 520(J) and other acoustic transducers 520 positioned on eyewear device 502. In some cases, increasing the distance between acoustic transducers 520 of the microphone array may improve the accuracy of beamforming performed via the microphone array. For example, if a sound is detected by acoustic transducers 520(C) and 520(D) and the distance between acoustic transducers 520(C) and 520(D) is greater than, e.g., the distance between acoustic transducers 520(D) and 520(E), the determined source location of the detected sound may be more accurate than if the sound had been detected by acoustic transducers 520(D) and 520(E).

[0113] Controller 525 of neckband 505 may process information generated by the sensors on neckband 505 and/or augmented-reality system 500. For example, controller 525 may process information from the microphone array that describes sounds detected by the microphone array. For each detected sound, controller 525 may perform a direction-of-arrival (DOA) estimation to estimate a direction from which the detected sound arrived at the microphone array. As the microphone array detects sounds, controller 525 may populate an audio data set with the information. In embodiments in which augmented-reality system 500 includes an inertial measurement unit, controller 525 may compute all inertial and spatial calculations from the IMU located on eyewear device 502. A connector may convey information between augmented-reality system 500 and neckband 505 and between augmented-reality system 500 and controller 525. The information may be in the form of optical data, electrical data, wireless data, or any other transmittable data form. Moving the processing of information generated by augmented-reality system 500 to neckband 505 may reduce weight and heat in eyewear device 502, making it more comfortable to the user.

[0114] Power source 535 in neckband 505 may provide power to eyewear device 502 and/or to neckband 505. Power source 535 may include, without limitation, lithium ion batteries, lithium-polymer batteries, primary lithium batteries, alkaline batteries, or any other form of power storage. In some cases, power source 535 may be a wired power source. Including power source 535 on neckband 505 instead of on eyewear device 502 may help better distribute the weight and heat generated by power source 535.

[0115] As noted, some artificial-reality systems may, instead of blending an artificial reality with actual reality, substantially replace one or more of a user’s sensory perceptions of the real world with a virtual experience. One example of this type of system is a head-worn display system, such as virtual-reality system 600 in FIG. 6, that mostly or completely covers a user’s field of view. Virtual-reality system 600 may include a front rigid body 602 and a band 604 shaped to fit around a user’s head. Virtual-reality system 600 may also include output audio transducers 606(A) and 606(B). Furthermore, while not shown in FIG. 6, front rigid body 602 may include one or more electronic elements, including one or more electronic displays, one or more inertial measurement units (IMUS), one or more tracking emitters or detectors, and/or any other suitable device or system for creating an artificial reality experience.

[0116] Artificial-reality systems may include a variety of types of visual feedback mechanisms. For example, display devices in augmented-reality system 500 and/or virtual-reality system 600 may include one or more liquid crystal displays (LCDs), light emitting diode (LED) displays, organic LED (OLED) displays, digital light project (DLP) micro-displays, liquid crystal on silicon (LCoS) micro-displays, and/or any other suitable type of display screen. Artificial-reality systems may include a single display screen for both eyes or may provide a display screen for each eye, which may allow for additional flexibility for varifocal adjustments or for correcting a user’s refractive error. Some artificial-reality systems may also include optical subsystems having one or more lenses (e.g., conventional concave or convex lenses, Fresnel lenses, adjustable liquid lenses, etc.) through which a user may view a display screen. These optical subsystems may serve a variety of purposes, including to collimate (e.g., make an object appear at a greater distance than its physical distance), to magnify (e.g., make an object appear larger than its actual size), and/or to relay (to, e.g., the viewer’s eyes) light. These optical subsystems may be used in a non-pupil-forming architecture (such as a single lens configuration that directly collimates light but results in so-called pincushion distortion) and/or a pupil-forming architecture (such as a multi-lens configuration that produces so-called barrel distortion to nullify pincushion distortion).

[0117] In addition to or instead of using display screens, some artificial-reality systems may include one or more projection systems. For example, display devices in augmented-reality system 500 and/or virtual-reality system 600 may include micro-LED projectors that project light (using, e.g., a waveguide) into display devices, such as clear combiner lenses that allow ambient light to pass through. The display devices may refract the projected light toward a user’s pupil and may enable a user to simultaneously view both artificial-reality content and the real world. The display devices may accomplish this using any of a variety of different optical components, including waveguide components (e.g., holographic, planar, diffractive, polarized, and/or reflective waveguide elements), light-manipulation surfaces and elements (such as diffractive, reflective, and refractive elements and gratings), coupling elements, etc. Artificial-reality systems may also be configured with any other suitable type or form of image projection system, such as retinal projectors used in virtual retina displays.

[0118] Artificial-reality systems may also include various types of computer vision components and subsystems. For example, augmented-reality system 500 and/or virtual-reality system 600 may include one or more optical sensors, such as two-dimensional (2D) or 3D cameras, structured light transmitters and detectors, time-of-flight depth sensors, single-beam or sweeping laser rangefinders, 3D LiDAR sensors, and/or any other suitable type or form of optical sensor. An artificial-reality system may process data from one or more of these sensors to identify a location of a user, to map the real world, to provide a user with context about real-world surroundings, and/or to perform a variety of other functions.

[0119] Artificial-reality systems may also include one or more input and/or output audio transducers. In the examples shown in FIG. 6, output audio transducers 606(A) and 606(B) may include voice coil speakers, ribbon speakers, electrostatic speakers, piezoelectric speakers, bone conduction transducers, cartilage conduction transducers, tragus-vibration transducers, and/or any other suitable type or form of audio transducer. Similarly, input audio transducers may include condenser microphones, dynamic microphones, ribbon microphones, and/or any other type or form of input transducer. In some embodiments, a single transducer may be used for both audio input and audio output.

[0120] While not shown in FIG. 5, artificial-reality systems may include tactile (i.e., haptic) feedback systems, which may be incorporated into headwear, gloves, body suits, handheld controllers, environmental devices (e.g., chairs, floormats, etc.), and/or any other type of device or system. Haptic feedback systems may provide various types of cutaneous feedback, including vibration, force, traction, texture, and/or temperature. Haptic feedback systems may also provide various types of kinesthetic feedback, such as motion and compliance. Haptic feedback may be implemented using motors, piezoelectric actuators, fluidic systems, and/or a variety of other types of feedback mechanisms. Haptic feedback systems may be implemented independent of other artificial-reality devices, within other artificial-reality devices, and/or in conjunction with other artificial-reality devices.

[0121] By providing haptic sensations, audible content, and/or visual content, artificial-reality systems may create an entire virtual experience or enhance a user’s real-world experience in a variety of contexts and environments. For instance, artificial-reality systems may assist or extend a user’s perception, memory, or cognition within a particular environment. Some systems may enhance a user’s interactions with other people in the real world or may enable more immersive interactions with other people in a virtual world. Artificial-reality systems may also be used for educational purposes (e.g., for teaching or training in schools, hospitals, government organizations, military organizations, business enterprises, etc.), entertainment purposes (e.g., for playing video games, listening to music, watching video content, etc.), and/or for accessibility purposes (e.g., as hearing aids, visual aids, etc.). The embodiments disclosed herein may enable or enhance a user’s artificial-reality experience in one or more of these contexts and environments and/or in other contexts and environments.

[0122] The process parameters and sequence of the steps described and/or illustrated herein are given by way of example only and can be varied as desired. For example, while the steps illustrated and/or described herein may be shown or discussed in a particular order, these steps do not necessarily need to be performed in the order illustrated or discussed. The various exemplary methods described and/or illustrated herein may also omit one or more of the steps described or illustrated herein or include additional steps in addition to those disclosed.

[0123] The preceding description has been provided to enable others skilled in the art to best utilize various aspects of the exemplary embodiments disclosed herein. This exemplary description is not intended to be exhaustive or to be limited to any precise form disclosed. Many modifications and variations are possible without departing from the spirit and scope of the present disclosure. The embodiments disclosed herein should be considered in all respects illustrative and not restrictive. Reference should be made to the appended claims and their equivalents in determining the scope of the present disclosure.

[0124] Unless otherwise noted, the terms “connected to” and “coupled to” (and their derivatives), as used in the specification and claims, are to be construed as permitting both direct and indirect (i.e., via other elements or components) connection. In addition, the terms “a” or “an,” as used in the specification and claims, are to be construed as meaning “at least one of.” Finally, for ease of use, the terms “including” and “having” (and their derivatives), as used in the specification and claims, are interchangeable with and have the same meaning as the word “comprising.”

[0125] It will be understood that when an element such as a layer or a region is referred to as being formed on, deposited on, or disposed “on” or “over” another element, it may be located directly on at least a portion of the other element, or one or more intervening elements may also be present. In contrast, when an element is referred to as being “directly on” or “directly over” another element, it may be located on at least a portion of the other element, with no intervening elements present.

[0126] While various features, elements or steps of particular embodiments may be disclosed using the transitional phrase “comprising,” it is to be understood that alternative embodiments, including those that may be described using the transitional phrases “consisting” or “consisting essentially of,” are implied. Thus, for example, implied alternative embodiments to a polymer thin film that comprises or includes polyethylene naphthalate include embodiments where a polymer thin film consists essentially of polyethylene naphthalate and embodiments where a polymer thin film consists of polyethylene naphthalate.