Method for producing light-guide optical elements

1. A method for producing light-guide optical elements (LOEs) each having a pair of mutually-parallel major external surfaces for guiding image illumination propagating within the LOE by internal reflection at the major external surfaces, each LOE further having an active region comprising a set of mutually-parallel partially-reflecting surfaces located between, and oriented non-parallel to, the major external surfaces, and at least one secondary region, at least one of said partially-reflecting surfaces terminating at a boundary between the active region and the secondary region, the method comprising the steps of:

(a) bonding together a plurality of parallel-faced plates at a plurality of interfaces so as to form a stack of plates, one face at each of said interfaces having a coating to provide partially-reflecting optical properties;

(b) cutting and polishing said stack of plates to form a boundary plane intersecting at least one of said interfaces;

(c) bonding a block of transparent material to said stack at said boundary plane to form a precursor structure; and

(d) slicing said precursor structure along a plurality of parallel planes so as to form a plurality of slices, each slice containing a part of said stack for providing the active region of the LOE and a part of said block to provide the secondary region of the LOE.

2. The method of claim 1 , wherein said boundary plane is cut along a plane obliquely oriented relative to a plane of said interfaces.

3. The method of claim 1 , wherein said block of transparent material is index-matched to said plurality of plates.

4. The method of claim 1 , wherein said block of transparent material is a block of optically continuous material.

5. The method of claim 1 , wherein said block of transparent material is a continuous uniform block.

6. The method of claim 1 , further comprising, prior to said slicing, cutting said precursor structure along at least one edge plane, a part of said edge plane defining, after said slicing, an edge of each LOE.

7. The method of claim 1 , wherein said plurality of parallel planes are perpendicular to said interfaces.

8. The method of claim 1 , wherein said plurality of parallel planes are obliquely angled relative to said interfaces.

9. The method of claim 1 , further comprising forming an edge to the active region of the LOE, wherein said boundary is non-parallel to the edge so that a length of said partially-reflecting surfaces in a direction parallel to said major external surfaces progressively decreases from partially-reflecting surface to partially-reflecting surface along at least a quarter of the set of partially-reflecting surfaces.

10. The method of claim 1 , wherein said coatings are configured to provide sequentially varying reflectivity for successive of said interfaces.

11. The method of claim 1 , wherein said plates have thicknesses differing from each other such that said interfaces are non-uniformly spaced.

12. The method of claim 1 , further comprising the steps of:

(a) cutting and polishing said stack of plates to form an additional boundary plane intersecting at least one of said interfaces, said additional boundary plane being non-coplanar with said boundary plane; and

(b) bonding an additional block of transparent material to said stack at said boundary plane to form said precursor structure,

and wherein said slicing is performed so that each slice additionally contains a part of said additional block.

13. An intermediate work product sliceable along a plurality of parallel planes to form a plurality of light-guide optical elements (LOEs) each having a pair of mutually-parallel major external surfaces for guiding image illumination propagating within the LOE by internal reflection at the major external surfaces, each LOE further having an active region comprising a set of mutually-parallel partially-reflecting surfaces located between, and oriented non-parallel to, the major external surfaces, and at least one secondary region, at least one of said partially-reflecting surfaces terminating at a boundary between the active region and the secondary region, the intermediate work product comprising:

(a) a stack formed from a plurality of parallel-faced plates bonded together at a plurality of interfaces, one face at each of said interfaces having a coating to provide partially-reflecting optical properties, said stack being cut and polished at a boundary plane intersecting at least one of said interfaces; and

(b) a block of transparent material bonded to said stack at said boundary plane, and

wherein said block of transparent material is index-matched to said plurality of plates.

14. An intermediate work product sliceable along a plurality of parallel planes to form a plurality of light-guide optical elements (LOEs) each having a pair of mutually-parallel major external surfaces for guiding image illumination propagating within the LOE by internal reflection at the major external surfaces, each LOE further having an active region comprising a set of mutually-parallel partially-reflecting surfaces located between, and oriented non-parallel to, the major external surfaces, and at least one secondary region, at least one of said partially-reflecting surfaces terminating at a boundary between the active region and the secondary region, the intermediate work product comprising:

(a) a stack formed from a plurality of parallel-faced plates bonded together at a plurality of interfaces, one face at each of said interfaces having a coating to provide partially-reflecting optical properties, said stack being cut and polished at a boundary plane intersecting at least one of said interfaces; and

(b) a block of transparent material bonded to said stack at said boundary plane, and

wherein said coatings are configured to provide sequentially varying reflectivity for successive of said interfaces.

15. An intermediate work product sliceable along a plurality of parallel planes to form a plurality of light-guide optical elements (LOEs) each having a pair of mutually-parallel major external surfaces for guiding image illumination propagating within the LOE by internal reflection at the major external surfaces, each LOE further having an active region comprising a set of mutually-parallel partially-reflecting surfaces located between, and oriented non-parallel to, the major external surfaces, and at least one secondary region, at least one of said partially-reflecting surfaces terminating at a boundary between the active region and the secondary region, the intermediate work product comprising:

(a) a stack formed from a plurality of parallel-faced plates bonded together at a plurality of interfaces, one face at each of said interfaces having a coating to provide partially-reflecting optical properties, said stack being cut and polished at a boundary plane intersecting at least one of said interfaces; and

(b) a block of transparent material bonded to said stack at said boundary plane, and

wherein said plates have thicknesses differing from each other such that said interfaces are non-uniformly spaced.