Imprint lithography using multi-layer coating architecture
Structures for forming an optical feature and methods for forming the optical feature are disclosed. In some embodiments, the structure comprises a patterned layer comprising a pattern corresponding to the optical feature; a base layer; and an intermediate layer bonded to the patterned layer and the base layer.
1 . An apparatus comprising:
a waveguide comprising an optical stack, the optical stack comprising:
a patterned layer comprising a pattern corresponding to an optical feature, wherein the patterned layer is configured to form a pattern of a waveguide;
a base layer; and
an intermediate layer bonded to the patterned layer and to the base layer, wherein the optical feature is disposed over the intermediate layer.
2 . The apparatus of claim 1 , wherein a bond between the patterned layer and the intermediate layer comprises one or more of a covalent bond and a physical bond.
3 . The apparatus of claim 1 , wherein the base layer comprises Polycarbonate.
4 . The apparatus of claim 1 , wherein the intermediate layer has a thickness of 1 μm to 25 μm.
5 . The apparatus of claim 1 , wherein the patterned layer has a thickness of 5 μm to 6 μm.
6 . The apparatus of claim 1 , wherein a width of the patterned layer is 25 mm to 450 mm.
7 . The apparatus of claim 1 , wherein the patterned layer comprises Methacrylate or acrylate.
8 . The apparatus of claim 1 , wherein the intermediate layer comprises a crosslinked polymer coating.
9 . A system comprising:
a wearable head-mounted device comprising a display, wherein:
the display comprises a waveguide comprising an optical stack, the optical stack comprising:
a patterned layer comprising a pattern comprising an optical feature, wherein the patterned layer forms an optical grating;
a base layer; and
an intermediate layer between and bonded to the patterned layer and to the base layer, wherein the optical feature is disposed over the intermediate layer; and
one or more processors configured to execute a method comprising:
presenting, on the display, content associated with a mixed reality environment, wherein presenting the content comprises propagating light via the optical grating.
10 . The system of claim 9 , wherein the patterned layer comprises plastic.
11 . The system of claim 9 , wherein the patterned layer comprises a polymer having epoxy and vinyl dual functionality.
12 . The of claim 9 , wherein the base layer comprises a flexible substrate.
13 . The system of claim 9 , wherein the pattern comprises an antireflective feature having a pitch of 10 nm to 150 nm.
14 . The system of claim 9 , wherein the pattern comprises wire grid polarizers having a dimension of 10 nm to 100 nm.
15 . The system of claim 9 , wherein the pattern comprises optical gratings having a pitch of 100 nm to 1000 nm for optical diffraction.
16 . The system of claim 9 , wherein the pattern comprises an optical alignment fiducials having a pitch of 0.1 μm to 1000 μm.