Patents by Inventor Mauro MELLI
Mauro MELLI has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 11954809Abstract: The present disclosure relates to display systems and, more particularly, to augmented reality display systems. In one aspect, a method of fabricating an optical element includes providing a substrate having a first refractive index and transparent in the visible spectrum. The method additionally includes forming on the substrate periodically repeating polymer structures. The method further includes exposing the substrate to a metal precursor followed by an oxidizing precursor. Exposing the substrate is performed under a pressure and at a temperature such that an inorganic material comprising the metal of the metal precursor is incorporated into the periodically repeating polymer structures, thereby forming a pattern of periodically repeating optical structures configured to diffract visible light. The optical structures have a second refractive index greater than the first refractive index.Type: GrantFiled: April 29, 2022Date of Patent: April 9, 2024Assignee: Magic Leap, Inc.Inventors: Melanie Maputol West, Christophe Peroz, Mauro Melli
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Publication number: 20240036321Abstract: In some embodiments, a near-eye, near-eye display system comprises a stack of waveguides having pillars in a central, active portion of the waveguides. The active portion may include light outcoupling optical elements configured to outcouple image light from the waveguides towards the eye of a viewer. The pillars extend between and separate neighboring ones of the waveguides. The light outcoupling optical elements may include diffractive optical elements that are formed simultaneously with the pillars, for example, by imprinting or casting. The pillars are disposed on one or more major surfaces of each of the waveguides. The pillars may define a distance between two adjacent waveguides of the stack of waveguides. The pillars may be bonded to adjacent waveguides may be using one or more of the systems, methods, or devices herein. The bonding provides a high level of thermal stability to the waveguide stack, to resist deformation as temperatures change.Type: ApplicationFiled: December 21, 2021Publication date: February 1, 2024Inventors: Ling Li, Christophe Peroz, Chieh Chang, Sharad D. Bhagat, Ryan Jason Ong, Ali Karbasi, Stephen Richard Rugg, Mauro Melli, Kevin Messer, Brian George Hill, Melanie Maputol West
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Publication number: 20230417980Abstract: A display system comprises a waveguide having light incoupling or light outcoupling optical elements formed of a metasurface. The metasurface is a multilevel (e.g., bi-level) structure having a first level defined by spaced apart protrusions formed of a first optically transmissive material and a second optically transmissive material between the protrusions. The metasurface also includes a second level formed by the second optically transmissive material. The protrusions on the first level may be patterned by nanoimprinting the first optically transmissive material, and the second optically transmissive material may be deposited over and between the patterned protrusions. The widths of the protrusions and the spacing between the protrusions may be selected to diffract light, and a pitch of the protrusions may be 10-600 nm.Type: ApplicationFiled: September 11, 2023Publication date: December 28, 2023Inventors: Dianmin Lin, Mauro Melli, Pierre St. Hilaire, Christophe Peroz, Evgeni Poliakov
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Publication number: 20230418074Abstract: An optical system comprises an optically transmissive substrate comprising a multilevel metasurface which comprises a grating comprising a plurality of multilevel unit cells. Each unit cell comprises, on a lowermost level, a laterally-elongated first lowermost level nanobeam having a first width and a laterally-elongated second lowermost level nanobeam having a second width larger than the first width. Each unit cell further comprises, on an uppermost level, a laterally-elongated first uppermost level nanobeam above the first lowermost level nanobeam and a laterally-elongated second uppermost level nanobeam above the second lowermost level nanobeam.Type: ApplicationFiled: September 8, 2023Publication date: December 28, 2023Inventors: Dianmin Lin, Mauro Melli, Pierre St. Hilaire, Christophe Peroz, Evgeni Poliakov
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Patent number: 11840034Abstract: Methods are disclosed for fabricating molds for forming eyepieces having waveguides with integrated spacers. The molds are formed by etching deep holes (e.g., 5 ?m to 1000 ?m deep) into a substrate using a wet etch or dry etch. The etch masks for defining the holes may be formed with a thick metal layer and/or multiple layers of different metals. A resist layer may be disposed over the etch mask. The resist layer may be patterned to form a pattern of holes, the pattern may be transferred to the etch mask, and the etch mask may be used to transfer the pattern into the underlying substrate. The patterned substrate may be utilized as a mold onto which a flowable polymer may be introduced and allowed to harden. Hardened polymer in the holes may form integrated spacers. The hardened polymer may be removed from the mold to form a waveguide with integrated spacers.Type: GrantFiled: February 26, 2021Date of Patent: December 12, 2023Assignee: Magic Leap, Inc.Inventors: Mauro Melli, Chieh Chang, Ling Li, Melanie Maputol West, Christophe Peroz, Ali Karbasi, Sharad D. Bhagat, Brian George Hill
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Patent number: 11796818Abstract: An optical system comprises an optically transmissive substrate comprising a metasurface which comprises a grating comprising a plurality of unit cells. Each unit cell comprises a laterally-elongated first nanobeam having a first width; and a laterally-elongated second nanobeam spaced apart from the first nanobeam by a gap, the second nanobeam having a second width larger than the first width. A pitch of the unit cells is 10 nm to 1 ?m. The heights of the first and the second nanobeams are: 10 nm to 450 nm where a refractive index of the substrate is more than 3.3; and 10 nm to 1 ?m where the refractive index is 3.3 or less.Type: GrantFiled: May 20, 2022Date of Patent: October 24, 2023Assignee: Magic Leap, Inc.Inventors: Dianmin Lin, Mauro Melli, Pierre St. Hilaire, Christophe Peroz, Evgeni Poliakov
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Patent number: 11789198Abstract: A display system comprises a waveguide having light incoupling or light outcoupling optical elements formed of a metasurface. The metasurface is a multilevel (e.g., bi-level) structure having a first level defined by spaced apart protrusions formed of a first optically transmissive material and a second optically transmissive material between the protrusions. The metasurface also includes a second level formed by the second optically transmissive material. The protrusions on the first level may be patterned by nanoimprinting the first optically transmissive material, and the second optically transmissive material may be deposited over and between the patterned protrusions. The widths of the protrusions and the spacing between the protrusions may be selected to diffract light, and a pitch of the protrusions may be 10-600 nm.Type: GrantFiled: January 24, 2022Date of Patent: October 17, 2023Assignee: Magic Leap, Inc.Inventors: Dianmin Lin, Mauro Melli, Pierre St. Hilaire, Christophe Peroz, Evgeni Poliakov
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Publication number: 20230296945Abstract: An optical device includes a liquid crystal layer having a first plurality of liquid crystal molecules arranged in a first pattern and a second plurality of liquid crystal molecules arranged in a second pattern. The first and the second pattern are separated from each other by a distance of about 20 nm to about 100 nm along a longitudinal or a transverse axis of the liquid crystal layer. The first and the second plurality of liquid crystal molecules are configured as first and second grating structures that can redirect light of visible or infrared wavelengths.Type: ApplicationFiled: May 25, 2023Publication date: September 21, 2023Inventors: Chulwoo OH, Mauro MELLI, Christophe PEROZ, Vikramjit SINGH, Frank Y. XU, Michael Anthony KLUG
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Publication number: 20230273450Abstract: Antireflection coatings for metasurfaces are described herein. In some embodiments, the metasurface may include a substrate, a plurality of nanostructures thereon, and an antireflection coating disposed over the nanostructures. The antireflection coating may be a transparent polymer, for example a photoresist layer, and may have a refractive index lower than the refractive index of the nanostructures and higher than the refractive index of the overlying medium (e.g., air). Advantageously, the antireflection coatings may reduce or eliminate ghost images in an augmented reality display in which the metasurface is incorporated.Type: ApplicationFiled: May 2, 2023Publication date: August 31, 2023Inventors: Dianmin Lin, Michael Anthony Klug, Pierre St. Hilaire, Mauro Melli, Christophe Peroz, Evgeni Poliakov
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Patent number: 11693282Abstract: An optical device includes a liquid crystal layer having a first plurality of liquid crystal molecules arranged in a first pattern and a second plurality of liquid crystal molecules arranged in a second pattern. The first and the second pattern are separated from each other by a distance of about 20 nm and about 100 nm along a longitudinal or a transverse axis of the liquid crystal layer. The first and the second plurality of liquid crystal molecules are configured as first and second grating structures that can redirect light of visible or infrared wavelengths.Type: GrantFiled: July 19, 2021Date of Patent: July 4, 2023Assignee: Magic Leap, Inc.Inventors: Chulwoo Oh, Mauro Melli, Christophe Peroz, Vikramjit Singh, Frank Xu, Michael Anthony Klug
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Publication number: 20230168425Abstract: Display devices include waveguides with metasurfaces as in-coupling and/or out-coupling optical elements. The metasurfaces may be formed on a surface of the waveguide and may include a plurality or an array of sub-wavelength-scale (e.g., nanometer-scale) protrusions. Individual protrusions may include horizontal and/or vertical layers of different materials which may have different refractive indices, allowing for enhanced manipulation of light redirecting properties of the metasurface. Some configurations and combinations of materials may advantageously allow for broadband metasurfaces. Manufacturing methods described herein provide for vertical and/or horizontal layers of different materials in a desired configuration or profile.Type: ApplicationFiled: January 15, 2023Publication date: June 1, 2023Inventors: Mauro Melli, Mohammadreza Khorasaninejad, Christophe Peroz, Pierre St. Hilaire, Dianmin Lin
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Patent number: 11664194Abstract: A Procedural EBL system implements a user-provided oracle function (e.g., associated with a specific pattern) to generate control instructions for electron beam drive electronics in an on-demand basis. A control system may invoke the oracle function to query the pattern at individual point locations (e.g., individual x,y locations), and/or it may query the pattern over an area corresponding to a current field being addressed by the beam and stage positioner, for example. This Procedural EBL configuration manages control and pattern generation so that the low-level drive electronics and beam column may remain unchanged, allowing it to leverage existing EBL technologies.Type: GrantFiled: February 23, 2021Date of Patent: May 30, 2023Assignee: MAGIC LEAP, INC.Inventors: Victor Kai Liu, Mauro Melli
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Patent number: 11609365Abstract: A method of fabricating non-uniform gratings includes implanting different densities of ions into corresponding areas of a substrate, patterning, e.g., by lithography, a resist layer on the substrate, etching the substrate with the patterned resist layer, and then removing the resist layer from the substrate, leaving the substrate with at least one grating having non-uniform characteristics associated with the different densities of ions implanted in the areas. The method can further include using the substrate having the grating as a mold to fabricate a corresponding grating having corresponding non-uniform characteristics, e.g., by nanoimprint lithography.Type: GrantFiled: August 8, 2019Date of Patent: March 21, 2023Assignee: Magic Leap, Inc.Inventors: Mauro Melli, Christophe Peroz
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Patent number: 11579353Abstract: Display devices include waveguides with metasurfaces as in-coupling and/or out-coupling optical elements. The metasurfaces may be formed on a surface of the waveguide and may include a plurality or an array of sub-wavelength-scale (e.g., nanometer-scale) protrusions. Individual protrusions may include horizontal and/or vertical layers of different materials which may have different refractive indices, allowing for enhanced manipulation of light redirecting properties of the metasurface. Some configurations and combinations of materials may advantageously allow for broadband metasurfaces. Manufacturing methods described herein provide for vertical and/or horizontal layers of different materials in a desired configuration or profile.Type: GrantFiled: November 4, 2020Date of Patent: February 14, 2023Assignee: Magic Leap, Inc.Inventors: Mauro Melli, Mohammadreza Khorasaninejad, Christophe Peroz, Pierre St. Hilaire, Dianmin Lin
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Publication number: 20230016301Abstract: Plasma etching processes for forming patterns in high refractive index glass substrates, such as for use as waveguides, are provided herein. The substrates may be formed of glass having a refractive index of greater than or equal to about 1.65 and having less than about 50 wt % SiO2. The plasma etching processes may include both chemical and physical etching components. In some embodiments, the plasma etching processes can include forming a patterned mask layer on at least a portion of the high refractive index glass substrate and exposing the mask layer and high refractive index glass substrate to a plasma to remove high refractive index glass from the exposed portions of the substrate. Any remaining mask layer is subsequently removed from the high refractive index glass substrate. The removal of the glass forms a desired patterned structure, such as a diffractive grating, in the high refractive index glass substrate.Type: ApplicationFiled: July 19, 2022Publication date: January 19, 2023Inventors: Mauro Melli, Christophe Peroz, Vikramjit Singh
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Publication number: 20230016683Abstract: In some embodiments, a display device includes one or more waveguides having a vapor deposited light absorbing film on edges of the waveguide to mitigate ghost images. In some embodiments, the film is formed directly on the edge of the waveguide by a vapor deposition, such as an evaporative deposition process. In some embodiments, the light absorbing films may comprise carbon, for example carbon in the form of one or more allotropes of carbon, such as fullerenes, or black silicon.Type: ApplicationFiled: September 23, 2022Publication date: January 19, 2023Inventor: Mauro Melli
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Patent number: 11467409Abstract: In some embodiments, a display device includes one or more waveguides having a vapor deposited light absorbing film on edges of the waveguide to mitigate ghost images. In some embodiments, the film is formed directly on the edge of the waveguide by a vapor deposition, such as an evaporative deposition process. In some embodiments, the light absorbing films may comprise carbon, for example carbon in the form of one or more allotropes of carbon, such as fullerenes, or black silicon.Type: GrantFiled: November 25, 2020Date of Patent: October 11, 2022Assignee: Magic Leap, Inc.Inventor: Mauro Melli
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Publication number: 20220283438Abstract: An optical system comprises an optically transmissive substrate comprising a metasurface which comprises a grating comprising a plurality of unit cells. Each unit cell comprises a laterally-elongated first nanobeam having a first width; and a laterally-elongated second nanobeam spaced apart from the first nanobeam by a gap, the second nanobeam having a second width larger than the first width. A pitch of the unit cells is 10 nm to 1 ?m. The heights of the first and the second nanobeams are: 10 nm to 450 nm where a refractive index of the substrate is more than 3.3; and 10 nm to 1 ?m where the refractive index is 3.3 or less.Type: ApplicationFiled: May 20, 2022Publication date: September 8, 2022Inventors: Dianmin Lin, Mauro Melli, Pierre St. Hilaire, Christophe Peroz, Evgeni Poliakov
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Publication number: 20220262082Abstract: The present disclosure relates to display systems and, more particularly, to augmented reality display systems. In one aspect, a method of fabricating an optical element includes providing a substrate having a first refractive index and transparent in the visible spectrum. The method additionally includes forming on the substrate periodically repeating polymer structures. The method further includes exposing the substrate to a metal precursor followed by an oxidizing precursor. Exposing the substrate is performed under a pressure and at a temperature such that an inorganic material comprising the metal of the metal precursor is incorporated into the periodically repeating polymer structures, thereby forming a pattern of periodically repeating optical structures configured to diffract visible light. The optical structures have a second refractive index greater than the first refractive index.Type: ApplicationFiled: April 29, 2022Publication date: August 18, 2022Inventors: Melanie Maputol West, Christophe Peroz, Mauro Melli
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Patent number: 11396473Abstract: Plasma etching processes for forming patterns in high refractive index glass substrates, such as for use as waveguides, are provided herein. The substrates may be formed of glass having a refractive index of greater than or equal to about 1.65 and having less than about 50 wt % SiO2. The plasma etching processes may include both chemical and physical etching components. In some embodiments, the plasma etching processes can include forming a patterned mask layer on at least a portion of the high refractive index glass substrate and exposing the mask layer and high refractive index glass substrate to a plasma to remove high refractive index glass from the exposed portions of the substrate. Any remaining mask layer is subsequently removed from the high refractive index glass substrate. The removal of the glass forms a desired patterned structure, such as a diffractive grating, in the high refractive index glass substrate.Type: GrantFiled: October 10, 2019Date of Patent: July 26, 2022Assignee: Magic Leap, Inc.Inventors: Mauro Melli, Christophe Peroz, Vikramjit Singh