US6400876B1
Expired / Lapsed
US
⏱️ 0.0 years remaining
Ultrathin optical panel and a method of making an ultrathin optical panel
Assignee: Brookhaven Science Associates LLC
•
Filing: 2001-03-28
•
Granted: 2002-06-04
•
Expires: 2021-03-28
Abstract
Abstract An ultrathin optical panel, and a method of producing an ultrathin optical panel, are disclosed, including stacking a plurality of glass sheets, which sheets may be coated With a transparent cladding substance or may be uncoated, fastening together the plurality of stacked coated glass sheets using an epoxy or ultraviolet adhesive, applying uniform pressure to the stack, curing the stack, sawing the stack to form an inlet face on a side of the stack and an outlet face on an opposed side of the stack, bonding a coupler to the inlet face of the stack, and fastening the stack, having the coupler bonded thereto, within a rectangular housing having an open front which is aligned with the outlet face, the rectangular housing having therein a light generator which is optically aligned with the coupler. The light generator is preferably placed parallel to and proximate with the inlet face, thereby allowing for a reduction in the depth of the housing.
Inventors
- 👤 Cyrus Biscardi
- 👤 Calvin Brewster
- 👤 Leonard DeSanto
- 👤 James T. Veligdan
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 16:02
CPC Classifications
H; H04; H04N; H04N9/00; H04N9/12; H04N9/31; H04N9/3141; G; G02; G02B; G02B6/00; G02B6/04; G02B6/06; G02B6/08; H04N9/3102; H04N9/3129; H04N5/00; H04N5/74; H04N5/7416; Y; Y10; Y10S; Y10S385/00; Y10S385/901
Claims Analysis
Total Claims: 46
Claim 1
Independent Claim
197 words
A method of producing an optical panel for displaying a projected light image, comprising: laying a first planar sheet in a trough sized slightly larger than the first sheet; filling the trough with a thermally curing epoxy; stacking additional planar sheets atop the first planar sheet, thereby forming a layer of epoxy between each planar sheet; applying uniform pressure to the stack, thereby causing the epoxy to flow to a generally uniform level between planar sheets; baking the stack to cure; cooling the stack; sawing the stack to form an inlet face on a side of the stack and an outlet face on an opposed side of the stack such that the inlet face is substantially parallel to the outlet face; bonding a coupler to the inlet face of the stack, wherein the coupler redirects light that forms the projected light image along a non-perpendicular axis to the inlet face to a perpendicular axis to the inlet face; and fastening the stack, having the coupler bonded thereto, within a rectangular housing having an open front which is aligned with the outlet face, the rectangular housing having therein a light generator which is optically aligned with the coupler.
Claim 2
Independent Claim
197 words
A method of producing an optical panel for displaying a projected light image, comprising: laying a first planar sheet in a trough sized slightly larger than the first sheet; filling the trough with a thermally curing epoxy; stacking additional planar sheets atop the first planar sheet, thereby forming a layer of epoxy between each planar sheet; applying uniform pressure to the stack, thereby causing the epoxy to flow to a generally uniform level between planar sheets; baking the stack to cure; cooling the stack; sawing the stack to form an inlet face on a side of the stack and an outlet face on an opposed side of the stack such that the inlet face is substantially parallel to the outlet face; bonding a coupler to the inlet face of the stack, wherein the coupler redirects light that forms the projected light image along a non-perpendicular axis to the inlet face to a perpendicular axis to the inlet face; and fastening the stack, having the coupler bonded thereto, within a rectangular housing having an open front which is aligned with the outlet face, the rectangular housing having therein a light generator which is optically aligned with the coupler.
Claim 3
Dependent Claim
13 words
The method of claim 1 , wherein the epoxy is black in color.
Claim 4
Dependent Claim
19 words
The method of claim 1 , wherein the epoxy has a lower index of refraction than the planar sheets.
Claim 5
Dependent Claim
23 words
The method of claim 1 , wherein said stacking is repeated until between about 500 and about 800 planar sheets have been stacked.
Claim 6
Dependent Claim
21 words
The method of claim 1 , wherein the generally uniform level of epoxy is about 0.0002″ in depth between planar sheets.
Claim 7
Dependent Claim
15 words
The method of claim 1 , wherein said baking is at about 80 degrees Celsius.
Claim 8
Dependent Claim
15 words
The method of claim 1 , wherein said sawing is performed using a diamond saw.
Claim 9
Dependent Claim
18 words
The method of claim 1 , further comprising polishing the stack with a diamond polisher after said sawing.
Claim 10
Dependent Claim
15 words
The method of claim 1 , further comprising frosting the outlet face after said sawing.
Claim 11
Independent Claim
182 words
A method of producing an optical panel for displaying a projected light image, comprising: individually coating a plurality of planar sheets with a clear cladding material having an index of refraction lower than that of the planar sheets; vertically stacking a plurality of coated planar sheets; fastening together the plurality of stacked coated planar sheets using an epoxy; applying uniform pressure to the stack; baking the stack to cure; sawing the stack to form an inlet face on a side of the stack and an outlet face on an opposed side of the stack such that the inlet face is substantially parallel to the outlet face; bonding a coupler to the inlet face of the stack, wherein the coupler redirects light that forms the projected light image along a non-perpendicular axis to the inlet face to a perpendicular axis to the inlet face; and fastening the stack, having the coupler bonded thereto, within a rectangular housing having an open front which is aligned with the outlet face, the rectangular housing having therein a light generator which is optically aligned with the coupler.
Claim 12
Independent Claim
182 words
A method of producing an optical panel for displaying a projected light image, comprising: individually coating a plurality of planar sheets with a clear cladding material having an index of refraction lower than that of the planar sheets; vertically stacking a plurality of coated planar sheets; fastening together the plurality of stacked coated planar sheets using an epoxy; applying uniform pressure to the stack; baking the stack to cure; sawing the stack to form an inlet face on a side of the stack and an outlet face on an opposed side of the stack such that the inlet face is substantially parallel to the outlet face; bonding a coupler to the inlet face of the stack, wherein the coupler redirects light that forms the projected light image along a non-perpendicular axis to the inlet face to a perpendicular axis to the inlet face; and fastening the stack, having the coupler bonded thereto, within a rectangular housing having an open front which is aligned with the outlet face, the rectangular housing having therein a light generator which is optically aligned with the coupler.
Claim 13
Dependent Claim
13 words
The method of claim 10 , wherein the epoxy is black in color.
Claim 14
Dependent Claim
27 words
The method of claim 10 , wherein said vertical stacking is performed in a trough sized slightly larger than the surface area of one coated planar sheet.
Claim 15
Dependent Claim
21 words
The method of claim 12 , wherein said fastening comprises filling the trough with a thermally curing black epoxy before stacking.
Claim 16
Dependent Claim
24 words
The method of claim 10 , wherein said vertical stacking is repeated until between about 500 and about 800 planar sheets have been stacked.
Claim 17
Dependent Claim
19 words
The method of claim 10 , further comprising frosting the inlet face and the outlet face after said sawing.
Claim 18
Dependent Claim
23 words
The method of claim 10 , further comprising polishing the inlet face and the outlet face with a diamond polisher after said sawing.
Claim 19
Independent Claim
184 words
A method of producing an optical panel for displaying a projected light image, comprising: stacking a plurality of planar sheets, each planar sheet having a width in the range between about 0.5″ and about 1.0″, and a length in the range between about 12″ and 36″; placing a layer of black ultraviolet adhesive between each planar sheet in the stack; curing each layer of the black ultraviolet adhesive using ultraviolet radiation; sawing the stack to form an inlet face on a side of the stack and an outlet face on an opposed side of the stack such that the inlet face is substantially parallel to the outlet face; bonding a coupler to the inlet face of the stack, wherein the coupler redirects light that forms the projected light image along a non-perpendicular axis to the inlet face to a perpendicular axis to the inlet face; and fastening the stack, having the coupler bonded thereto, within a rectangular housing having an open front which is aligned with the outlet face, the rectangular housing having therein a light generator which is optically aligned with the coupler.
Claim 20
Independent Claim
184 words
A method of producing an optical panel for displaying a projected light image, comprising: stacking a plurality of planar sheets, each planar sheet having a width in the range between about 0.5″ and about 1.0″, and a length in the range between about 12″ and 36″; placing a layer of black ultraviolet adhesive between each planar sheet in the stack; curing each layer of the black ultraviolet adhesive using ultraviolet radiation; sawing the stack to form an inlet face on a side of the stack and an outlet face on an opposed side of the stack such that the inlet face is substantially parallel to the outlet face; bonding a coupler to the inlet face of the stack, wherein the coupler redirects light that forms the projected light image along a non-perpendicular axis to the inlet face to a perpendicular axis to the inlet face; and fastening the stack, having the coupler bonded thereto, within a rectangular housing having an open front which is aligned with the outlet face, the rectangular housing having therein a light generator which is optically aligned with the coupler.
Claim 21
Dependent Claim
23 words
The method of claim 17 , wherein said stacking is repeated until between about 500 and about 800 planar sheets have been stacked.
Claim 22
Dependent Claim
19 words
The method of claim 17 , further comprising frosting the inlet face and the outlet face after said sawing.
Claim 23
Dependent Claim
23 words
The method of claim 17 , further comprising polishing the inlet face and the outlet face with a diamond polisher after said sawing.
Claim 24
Independent Claim
211 words
A method of producing an optical panel for displaying a projected image, comprising: laying a first planar sheet in a trough sized slightly larger than the first sheet; filling the trough with a thermally curing epoxy; stacking additional planar sheets atop the first planar sheet, thereby forming a layer of epoxy between each planar sheet; applying uniform pressure to the stack, thereby causing the epoxy to flow to a generally uniform level between planar sheets; baking the stack to cure; cooling the stack; sawing the stack to form an inlet face on a side of the stack and an outlet face on an opposed side of the stack such that the inlet face is substantially parallel to the outlet face; bonding a coupler to the inlet face of the stack, wherein the coupler redirects light along a non-perpendicular axis to the inlet face to a perpendicular axis to the inlet face, and wherein the light forms an image which is projected through the optical panel and is formed at the outlet face; and fastening the stack, having the coupler bonded thereto, within a rectangular housing having an open front which is aligned with the outlet face, the rectangular housing having therein a light generator which is optically aligned with the coupler.
Claim 25
Independent Claim
211 words
A method of producing an optical panel for displaying a projected image, comprising: laying a first planar sheet in a trough sized slightly larger than the first sheet; filling the trough with a thermally curing epoxy; stacking additional planar sheets atop the first planar sheet, thereby forming a layer of epoxy between each planar sheet; applying uniform pressure to the stack, thereby causing the epoxy to flow to a generally uniform level between planar sheets; baking the stack to cure; cooling the stack; sawing the stack to form an inlet face on a side of the stack and an outlet face on an opposed side of the stack such that the inlet face is substantially parallel to the outlet face; bonding a coupler to the inlet face of the stack, wherein the coupler redirects light along a non-perpendicular axis to the inlet face to a perpendicular axis to the inlet face, and wherein the light forms an image which is projected through the optical panel and is formed at the outlet face; and fastening the stack, having the coupler bonded thereto, within a rectangular housing having an open front which is aligned with the outlet face, the rectangular housing having therein a light generator which is optically aligned with the coupler.
Claim 26
Dependent Claim
13 words
The method of claim 21 , wherein the epoxy is black in color.
Claim 27
Dependent Claim
19 words
The method of claim 21 , wherein the epoxy has a lower index of refraction than the planar sheets.
Claim 28
Dependent Claim
23 words
The method of claim 21 , wherein said stacking is repeated until between about 500 and about 800 planar sheets have been stacked.
Claim 29
Dependent Claim
21 words
The method of claim 21 , wherein the generally uniform level of epoxy is about 0.0002″ in depth between planar sheets.
Claim 30
Dependent Claim
15 words
The method of claim 21 , wherein said baking is at about 80 degrees Celsius.
Claim 31
Dependent Claim
15 words
The method of claim 21 , wherein said sawing is performed using a diamond saw.
Claim 32
Dependent Claim
18 words
The method of claim 21 , further comprising polishing the stack with a diamond polisher after said sawing.
Claim 33
Dependent Claim
15 words
The method of claim 21 , further comprising frosting the outlet face after said sawing.
Claim 34
Independent Claim
196 words
A method of producing an optical panel for displaying a projected image, comprising: individually coating a plurality of planar sheets with a clear cladding material having an index of refraction lower than that of the planar sheets; vertically stacking a plurality of coated planar sheets; fastening together the plurality of stacked coated planar sheets using an epoxy; applying uniform pressure to the stack; baking the stack to cure; sawing the stack to form an inlet face on a side of the stack and an outlet face on an opposed side of the stack such that the inlet face is substantially parallel to the outlet face; bonding a coupler to the inlet face of the stack, wherein the coupler redirects light along a non-perpendicular axis to the inlet face to a perpendicular axis to the inlet face, and wherein the light forms an image which is projected through the optical panel and is formed at the outlet face; and fastening the stack, having the coupler bonded thereto, within a rectangular housing having an open front which is aligned with the outlet face, the rectangular housing having therein a light generator which is optically aligned with the coupler.
Claim 35
Independent Claim
196 words
A method of producing an optical panel for displaying a projected image, comprising: individually coating a plurality of planar sheets with a clear cladding material having an index of refraction lower than that of the planar sheets; vertically stacking a plurality of coated planar sheets; fastening together the plurality of stacked coated planar sheets using an epoxy; applying uniform pressure to the stack; baking the stack to cure; sawing the stack to form an inlet face on a side of the stack and an outlet face on an opposed side of the stack such that the inlet face is substantially parallel to the outlet face; bonding a coupler to the inlet face of the stack, wherein the coupler redirects light along a non-perpendicular axis to the inlet face to a perpendicular axis to the inlet face, and wherein the light forms an image which is projected through the optical panel and is formed at the outlet face; and fastening the stack, having the coupler bonded thereto, within a rectangular housing having an open front which is aligned with the outlet face, the rectangular housing having therein a light generator which is optically aligned with the coupler.
Claim 36
Dependent Claim
13 words
The method of claim 30 , wherein the epoxy is black in color.
Claim 37
Dependent Claim
27 words
The method of claim 30 , wherein said vertical stacking is performed in a trough sized slightly larger than the surface area of one coated planar sheet.
Claim 38
Dependent Claim
21 words
The method of claim 32 , wherein said fastening comprises filling the trough with a thermally curing black epoxy before stacking.
Claim 39
Dependent Claim
24 words
The method of claim 30 , wherein said vertical stacking is repeated until between about 500 and about 800 planar sheets have been stacked.
Claim 40
Dependent Claim
19 words
The method of claim 30 , further comprising frosting the inlet face and the outlet face after said sawing.
Claim 41
Dependent Claim
23 words
The method of claim 30 , further comprising polishing the inlet face and the outlet face with a diamond polisher after said sawing.
Claim 42
Independent Claim
198 words
A method of producing an optical panel for displaying a projected image, comprising: stacking a plurality of planar sheets, each planar sheet having a width in the range between about 0.5″ and about 1.0″, and a length in the range between about 12″ and 36″; placing a layer of black ultraviolet adhesive between each planar sheet in the stack; curing each layer of the black ultraviolet adhesive using ultraviolet radiation; sawing the stack to form an inlet face on a side of the stack and an outlet face on an opposed side of the stack such that the inlet face is substantially parallel to the outlet face; bonding a coupler to the inlet face of the stack, wherein the coupler redirects light along a non-perpendicular axis to the inlet face to a perpendicular axis to the inlet face, and wherein the light forms an image which is projected through the optical panel and is formed at the outlet face; and fastening the stack, having the coupler bonded thereto, within a rectangular housing having an open front which is aligned with the outlet face, the rectangular housing having therein a light generator which is optically aligned with the coupler.
Claim 43
Independent Claim
198 words
A method of producing an optical panel for displaying a projected image, comprising: stacking a plurality of planar sheets, each planar sheet having a width in the range between about 0.5″ and about 1.0″, and a length in the range between about 12″ and 36″; placing a layer of black ultraviolet adhesive between each planar sheet in the stack; curing each layer of the black ultraviolet adhesive using ultraviolet radiation; sawing the stack to form an inlet face on a side of the stack and an outlet face on an opposed side of the stack such that the inlet face is substantially parallel to the outlet face; bonding a coupler to the inlet face of the stack, wherein the coupler redirects light along a non-perpendicular axis to the inlet face to a perpendicular axis to the inlet face, and wherein the light forms an image which is projected through the optical panel and is formed at the outlet face; and fastening the stack, having the coupler bonded thereto, within a rectangular housing having an open front which is aligned with the outlet face, the rectangular housing having therein a light generator which is optically aligned with the coupler.
Claim 44
Dependent Claim
23 words
The method of claim 37 , wherein said stacking is repeated until between about 500 and about 800 planar sheets have been stacked.
Claim 45
Dependent Claim
19 words
The method of claim 37 , further comprising frosting the inlet face and the outlet face after said sawing.
Claim 46
Dependent Claim
23 words
The method of claim 37 , further comprising polishing the inlet face and the outlet face with a diamond polisher after said sawing.
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