Abstract: Embodiments relate to a facial interface in a head-mount display. The facial interface assembly is comprised of three separate layers of various materials that are contoured to assemble into a removable facial interface that may be replaced in the event that it becomes worn due to use. The facial interface assembly is composed of a periphery frame, a semi-rigid frame, and facial interface foam. These three layers are of varying rigidity, and support contours designed to fit together in a flush manner comprising a removable facial interface assembly.

Abstract: A head-mounted-display strap assembly may include a flexible lining member having (1) a head-contact layer positioned to abut a head portion of a user, (2) a mounting layer overlapping the head-contact layer, the mounting layer defining a wiring channel, and (3) a mesh layer disposed between the head-contact layer and the mounting layer such that a portion of the mesh layer overlaps the wiring channel. A method may include (1) attaching a head-contact layer for a head-mounted-display strap assembly to a mesh layer and (2) attaching a mounting layer to the mesh layer such that the mesh layer is disposed between the head-contact layer and the mounting layer the mounting layer defining a wiring channel, and a portion of the mesh layer overlapping the wiring channel. Various other head-mounted-display strap assemblies, head-mounted-display systems, and methods are also disclosed.

Abstract: A method for manufacturing a facial-interface cushion for a head-mounted display may include (1) positioning a foam layer between a recessed mold member and an insertion mold member of a mold assembly, with the foam layer overlapping at least a portion of a mold channel extending along an arcuate path, the foam layer including a reticulated foam material, (2) forcing the insertion mold member against the foam layer in a direction toward the recessed mold member such that at least a portion of the foam layer is forced into the mold channel toward a channel bottom surface, forming a shaped foam element having a curved surface within the mold channel, (3) heating the shaped foam element to soften the shaped foam element and form the facial-interface cushion, and (4) removing the facial-interface cushion from the mold assembly. Various other facial-interface cushions, systems, and methods for head-mounted displays are also disclosed.

Abstract: Embodiments relate to fabricating a lanyard that includes the assembly of a strap sheet, a fabric strip sheet, and a stopper column. The strap sheet is wrapped around the stopper column and the ends of the strap sheet are adhered to itself to form a closed loop of the lanyard. The inner surface of the strap sheet is attached to the stopper column and the ends of the strap sheet are further attached to the fabric strip sheet to form the assembly. The assembly is cut to obtain multiple lanyards that include a portion of the strap sheet (e.g., a strap), a portion of the fabric strip sheet (e.g., a fabric strip), and a portion of the stopper column (e.g., a stopper). One end of each lanyard can be worn by an individual whereas a second end of the lanyard can be coupled to another structure, such as a handheld controller.

Abstract: Disclosed herein is a controller lanyard assembly that minimizes accidental damage to a controller. The controller includes a removable front cover that, when removed, exposes a receptacle that includes a cavity that receives a portion of the lanyard. The cavity of the receptacle is further connected through a channel located on an external surface of the controller. A first portion of the lanyard can reside within the cavity and a second portion of the lanyard can exit through the channel of the controller. The receptacle can further include detents that protrude into the channel, thereby preventing the first portion of the lanyard from exiting the cavity of the receptacle. Altogether, the first portion of the lanyard is coupled to the controller while the second portion of the lanyard is worn by the individual.

Abstract: A haptic skull cap provides different types of haptic feedback to a user, which can be advantageous for providing a more immersive virtual reality experience. The haptic skull cap includes a fabric cap worn by a user. Physically attached to the fabric cap is a linear actuator that provides a focal impact to a user's forehead. Additionally, vibrational motors are physically attached to the fabric cap, where each vibration motor provides vibrational feedback to a different location of the user's head. The haptic skull cap can be worn by a user in conjunction with a head mounted display. Therefore, each type of haptic feedback provided by the haptic skull cap can be synchronized with the visual data stream provided by the head mounted display which further enhances the overall virtual reality experience for a user.

Abstract: A method for manufacturing a facial-interface cushion for a head-mounted display may include (1) positioning a foam layer between a recessed mold member and an insertion mold member of a mold assembly, with a first end portion of the foam layer overlapping a second end portion of the foam layer, (2) forcing the insertion mold member against the foam layer in a direction toward the recessed mold member, thereby forming a shaped foam element including a first end portion that is compressed against a second end portion between the insertion mold member and the recessed mold member, and (3) heating the shaped foam element to form a facial-interface cushion by softening the shaped foam element and bonding the first end portion of the shaped foam element to the second end portion of the shaped foam element. Various other facial-interface cushions, systems, and methods for head-mounted displays are also disclosed.

Abstract: A head-mounted-display assembly may include a knitted layer formed of a plurality of fibers and extending in three dimensions. The knitted layer may include (1) a first region having a first degree of at least one physical property, (2) a second region having a second degree of the at least one physical property, and (3) a transition region extending between the first region and the second region. The transition region of the knitted layer may progressively change in degree of the at least one physical property proceeding from the first region toward the second region. Various other apparatuses, systems, and methods are also disclosed.

Abstract: Methods and apparatus are provided for affixing hardware components to garments. Hardware components are provided with an operative component and an adhesive surface. The operative component interacts with one or more other operative components and/or with one or more other features of the garment (e.g. with cords, straps or the like connected to the garment and/or with the fabric of the garment) and/or with one or more external devices. The adhesive surface is bonded to a corresponding interior surface of a fabric layer of the garment using an adhesive located between the adhesive surface and the corresponding surface of the fabric layer. The hardware component is projected from an interior of the fabric layer, through an aperture defined by the fabric layer, and to an exterior of the fabric layer.

Abstract: Embodiments relate to a facial interface in a head-mount display. The facial interface assembly is comprised of three separate layers of various materials that are contoured to assemble into a removable facial interface that may be replaced in the event that it becomes worn due to use. The facial interface assembly is composed of a periphery frame, a semi-rigid frame, and facial interface foam. These three layers are of varying rigidity, and support contours designed to fit together in a flush manner comprising a removable facial interface assembly.

Abstract: A detachable head-mounted-display cushion may include a cushion layer having a user-side surface dimensioned to abut a facial portion of a user and a display-side surface dimensioned to abut a mounting surface of a facial-interface system for a head-mounted display. The detachable head-mounted-display cushion may also include a magnetic-coupling mechanism configured to removably attach the cushion layer to the mounting surface of the facial-interface system. A corresponding head-mounted-display system may include a head-mounted display, a facial-interface mounting member for the head-mounted display, a cushion layer abutting the facial-interface mounting member, and a magnetic-coupling mechanism removably attaching the cushion layer to the facial-interface mounting member. A method may include positioning a cushion layer abutting a facial-interface mounting member for a head-mounted display and removably attaching the cushion layer to the facial-interface mounting member with a magnetic-coupling mechanism.

Abstract: Embodiments relate to a strap system having a securing plate and a strap. The securing plate is configured to be secured to a body of a head-mounted display in a rotatable manner. The securing plate includes a flat portion, a rear loop located at a first end of the flat portion, and a front loop located at a second end of the flat portion. The strap is inserted through the rear loop and the front loop of the securing plate. An end portion of the strap is flipped over the front loop and secured to a portion of the strap on the flat potion of the securing plate to fix the strap to the securing plate.

Abstract: Disclosed herein is a lanyard adjuster that adjusts the length of a lanyard that passes through the lanyard adjuster. The lanyard adjuster includes a housing and a plate residing within the housing. The plate includes flanges that couple with locking slots of the housing to achieve a locked configuration. In the locked configuration, the plate contacts and applies a force on segments of the lanyard that passes through the lanyard adjuster. Therefore, the lengths of the lanyard on either side of the lanyard adjuster are fixed. The plate can be further decoupled from the housing to enable adjustment of the lengths of the lanyard on either side of the lanyard adjuster.