Optical system for AR headsets, and method for design and manufacturing

1. A projection augmented reality headset (ARHS) comprising;

an imager configured to provide image light;

a partially reflecting combiner, configured to receive the image light from the imager and upon receiving the image light is configured to re-direct the image light towards an eyebox, wherein an eye relief offset exists between the partially reflecting combiner and the eyebox;

wherein the imager includes imaging optics comprising a combination of lens elements having symmetrical free-form lens surfaces that are tilted and decentered, whereby an expanded field-of-view can be attained while providing the eye relief offset.

2. The ARHS of claim 1 , wherein the field-of-view is at least 65 degrees horizontally per eye.

3. The ARHS of claim 1 , wherein the eyebox is at least 10 mm wide horizontally and vertically.

4. The ARHS of claim 1 , wherein the imager has a pixel pitch between 0.5 and 15 micrometers.

5. The ARHS of claim 4 , wherein the maximum linear dimension of the imager is between 0.1 and 3.5 inches.

6. The ARHS of claim 1 , wherein the field-of-view is at least 65 degrees horizontally per eye and the eyebox is at least 10 mm wide horizontally and vertically, and further wherein a modulation transfer function (“MTF”) does not fall below thresholds related to the pixel pitch of the imager across the field-of-view and the eyebox.

7. The ARHS of claim 1 , wherein the imaging optics comprise refractive lens elements that are fabricated from materials compatible with one or more processes selected from the group of processes including: injection-molded, ground, or machined.

8. The ARHS of claim 1 , wherein a computer-aided automatic process is utilized to generate, optimize and set tolerances for the imaging optics and combiner based on a single system of constraints.

9. The imaging optics of claim 1 , wherein a longitudinal chromatic aberration is sufficiently low such that a photopically-weighted polychromatic MTF does not fall below thresholds related to the pixel pitch of the imager.

10. The ARHS of claim 1 , further comprising a software application configured to compensate for blur, distortion, and lateral chromatic aberration, whereby the image quality of the display is improved.

11. The ARHS of claim 1 , further comprising a software application configured to adjust color and brightness according to image content and environmental conditions, whereby the comfort and quality can be improved for the user.

12. A projection augmented reality headset (ARHS) comprising;

an imager configured to provide image light;

a partially reflecting combiner, configured to receive the image light from the imager and upon receiving the image light is configured to re-direct the image light towards an eyebox, wherein an eye relief offset exists between the partially reflecting combiner and the eyebox;

wherein the imager includes imaging optics comprising a combination of lens elements having symmetrical free-form lens surfaces that are tilted and decentered, whereby an expanded field-of-view can be attained while providing the eye relief offset and wherein the partially reflecting combiner is positioned such that the eye relief offset is at least 20 mm, but no more than 40 mm.

13. The ARHS of claim 12 , wherein the partially reflecting combiner comprises a rear surface, which is a partially reflective spherical, conic, aspheric, or freeform surface, and a front surface, which is a transmissive spherical, conic, aspheric, or freeform surface.

14. The ARHS of claim 12 , wherein a partially reflective coated front surface, and the transmissive rear surface may be used together as a Magnin mirror to correct aberrations.

15. The ARHS of claim 12 , wherein the combiner may consist of two cemented elements with a partially reflective second surface.

16. A projection augmented reality headset (ARHS) comprising;

an imager configured to provide image light;

a partially reflecting combiner, configured to receive the image light from the imager and upon receiving the image light is configured to re-direct the image light towards an eyebox, wherein an eye relief offset exists between the partially reflecting combiner and the eyebox;

wherein the imager includes imaging optics comprising a combination of lens elements having symmetrical free-form lens surfaces that are tilted and decentered, whereby an expanded field-of-view can be attained while providing the eye relief offset, wherein the imaging optics comprise a combination of spherical, aspherical, and free-form lens surfaces fabricated from plastic or glass.

17. The ARHS of claim 16 , wherein the combiner includes tilted and/or decentered lens elements to reduce the peak width of the headset to no more than 220 mm while maintaining the wide field-of-view.

18. The ARHS of claim 16 , wherein the lens elements are selected from one or more of a group of lens element types including: Fresnel, diffractive and kinoform lens elements, whereby the size and weight of the system can be reduced.

19. The ARHS of claim 16 , wherein the lens elements are selected from one or more of a group of lens element types including: diffractive and kinoform lens elements, whereby compensation is obtained for the dispersion created by refractive elements.

20. A method for providing a wide field-of-view in a projection augmented reality headset (ARHS), the method comprising;

utilizing an imager to provide image light;

receiving the image light at a partially reflecting combiner;

the partially reflecting combiner re-directing the image light towards an eyebox, wherein an eye relief offset exists between the partially reflecting combiner and the eyebox; and

employing imaging optics comprising a combination of lens elements that are tilted and decentered, such that a field-of-view that is at least 65 degrees horizontally per eye can is created while providing the eye relief offset.