Yesterday Patently Apple introduced “Orion Watch,” a new ongoing coverage of Meta’s Orion related patents. The first two patents covered “Translation with Audio Spatialization,” and “Input Methods for Smartglasses.” Today, in Part 2, our report covers “Multi-Layer Lens for Orion Optics.”

Multi-Layer Lenses for Orion Optics

Artificial reality (AR) 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 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 instances, artificial reality may also be associated with applications, products, accessories, services, or some combination thereof, that are used to create content in an artificial reality or are otherwise used (e.g., perform activities) in an artificial reality. Head-mounted displays (HMOs) may often be used to present visual content to a user for use in artificial reality applications. HMDs may include one or more near-eye displays with one or more lenses.

Meta’s patent covers methods, apparatuses, or systems for creating or using a multi-layer lens. In an example, a device may include memory and a processor communicatively connected with the memory. The processor may effectuate operations that include transmitting instructions to create a first layer lens at a first position; detecting a cooling of the first layer lens to a threshold temperature; sending instructions to move the first layer lens to a second position; and transmitting instructions to combine the first layer lens with a second layer lens to create a single lens. The combining may be based on creating a second layer lens on top of the first layer lens or on bottom of the first layer lens.

In an example, a method may include casting a first layer lens; detecting the first layer lens is at a threshold stress level; based on the first layer lens being detected at the threshold stress level, injection molding a second layer lens on the first layer lens; and creating a multi-layer lens by combining the first layer lens and the second layer lens. The injection molding may include creating a flange incorporated into the second layer lens of the multi-layer lens.

Meta’s patent FIG. 1 below illustrates an example head-mounted display (HMD) #100 / Smartglasses associated with presenting a user artificial reality content over their view of the world. HMD/Smartglasses may include enclosure #102 (e.g., an eyeglass frame) or wave guide #108 - also referred herein as lens #108 that may include one or more lenses that may be configured to direct images to a user's eye.

In some examples, the Smartglasses may be implemented in the form of augmented-reality glasses. Accordingly, the lens may be at least partially transparent to visible light to allow the user to view a real-world environment through lens. As disclosed in more detail in Meta’s patent, the lens may be formed based on a combination of a plurality of lenses (e.g., two, three, or more layers).

Meta’s patent FIG. 2 below illustrates an example lens. The lens #108 may include a plurality of lenses (e.g., multiple layers), such as lens #109 (e.g., a first layer) or lens #110 (e.g., a second layer). The lens may include flanges #115 and may be used for mounting the lens to the enclosure #102. There may be a shrink factor associated with a material used to make each lens.

The disclosed subject matter allows for a process that does not use the conventional high pressures and causes less stress on the lens #108, therefore minimizing retardation or birefringence. Further, the disclosed multi-layer lens increases the possible cavitation from a convention of four or less to at least double (e.g., eight or more), which may significantly reduce cost relative to conventional systems. Utilizing a multi-layer lens approach may permit for a higher cavitation and faster cycle time on the first layer.

This first layer becomes less critical and more achievable to make. For the second layer or more layers, higher cavitation can be achieved because a much thinner wall section that is being handled is managed appropriately. This thinner wall section may vary in dimensions and amount of material used and may be determined based on the material of the first layer, the material of the second layer, the thickness of the first layer, or the thickness of the second layer, among other things. Examples of the ratios between the thicker first layer and the second layer may include a first layer that may be approximately 60%-80% of the thickness of the total multi-layer lens, while the second layer (or more layers) may be approximately 20%-40% of the thickness of the total multi-layer lens, which may depend on lens geometry.

Meta’s patent FIG. 3 above illustrates an exemplary system that may be implemented for multi-layer lens for virtual reality optics.

More Specifically, FIG. 3 there may be a location #111 in which molding, casting, fabricating, or the like may occur in order to create lens #109. At location #112, there may be a cooling or annealing station for the created lens #109 that may be placed at location #113, and another layer (e.g., lens #110) may be appropriately added to lens #109. Devices at locations 111-113 may be communicatively connected with each other or server #116 that may send instructions to devices (e.g., electronic heating devices, electronic cooling devices, conveyor belts, robotic equipment, manufacturing equipment, or other devices).

Meta’s patent FIGS. 4 and 5 above illustrate exemplary methods for multi-layer lens for virtual reality optics.

Meta’s U.S. patent application was published on November 1, 2024 under number 20240012193.