EXPANDED PTFE CUSHIONS

Abstract

An apparatus can include a cushion including an expanded PTFE layer and a frame that can include two lateral portions and a bridging portion therebetween. The lateral portions and the bridging portion can define a concave surface that is coupled to the cushion to support and provide a concave contour to the cushion.

Description

BACKGROUND

Extended reality devices are gaining in popularity and are utilized in entertainment and professional settings. For example, these devices can be used for gaming; viewing interactive films; studying social interactions; training surgeons, other medical professionals, military, law enforcement, pilots, astronauts, etc.; walking-through engineering plans or other graphically simulated environments, etc. More generally, these devices can generate computerized simulations of essentially realistic experiences and can entertain, train, and educate users. As development progresses and utilization expands in this area, the demand to extended reality viewing devices continues to rise.

BRIEF DESCRIPTION OF DRAWINGS

It is understood that the figures herein are merely representative of examples presented herein and should not be considered as particularly limiting. Furthermore, the FIGS. are not to scale, but rather represent examples thereof.

FIG. 1A schematically depicts a portion of an example expanded PTFE cushion and frame in accordance with examples herein;

FIG. 1B schematically depicts a more detailed view of a portion of an example expanded PTFE cushion and frame in accordance with examples herein;

FIG. 1C schematically depicts an alternative example of a portion of an expanded PTFE cushion and frame in accordance with examples herein;

FIG. 2 depicts an example apparatus including an extended reality display with an expanded PTFE cushion in accordance with examples herein; and

FIG. 3 depicts an example apparatus for receiving an extended reality display with an expanded PTFE cushion in accordance with examples herein.

DETAILED DESCRIPTION

Extended reality devices can be used in connection with a variety of activities, some of which occur for extended periods of time. Extended periods of use and/or activity can present issues relating to discomfort and/or product damage. For example, when an individual wears an extended reality device for an extended period of time, the individual's face, head, and/or ears can become hot and uncomfortable. In another example, if an individual produces sweat while wearing the extended reality device, the sweat can become trapped within the device. This moisture can sometimes affect and damage electronics, or can generate other unpleasant results including moisture retention immediately after use, or even more long term retention of odor, discoloration, padding hardening or cracking, etc. Thus, an extended reality device that may be enclosed in some aspects and still breathable can protect electronic components from moisture, e.g., preventing moisture from getting in and/or allowing perspiration moisture to escape and/or can enhance the comfort and life of such extended reality devices.

In accordance with this, examples herein relate generally to apparatuses that can include a cushion including an expanded PTFE (expanded polytetrafluoroethylene) layer, and a frame. The frame can include two lateral portions and a bridging portion therebetween. The lateral portions and the bridging portion can define a concave surface that is coupled to the cushion to support and provide a concave contour to the cushion. As used herein, a “cushion” refers to a soft pad for providing comfort to a user, and the cushion can be one layer or can be multiple layers, but one of the layers is the expanded PTFE layer. Furthermore, the terms “coupled,” “coupling,” or the like refer to any joining or connecting of two or more structures or materials, either directly to one another or indirectly with intervening structures therebetween. For example, multiple structures or materials can be joined together by a “coupling” layer (e.g., a thermal or chemical joining or bonding); a “coupling” structure or configuration (e.g., a material shaped like a pocket to hold another structure or material in place); a mechanical “coupler” (e.g., a fastener to clip, snap, slide, button, zip, screw, pin, etc., one structure in place relative to another); a magnetic “coupler,” etc. Coupling can occur between or about layers of the cushion, or can occur between the cushion and the frame, for example.

In one example, the expanded PTFE layer can have a pore size having an average value from 0.1 microns to 0.5 microns (also referred to herein as “average pore size”). In another example, the expanded PTFE layer can have a level of porosity ranging from 1% to 99%, and/or can include from 1 million to 15 billion pores per square inch. In yet another example, the expanded PTFE layer can include an oleophobic treatment, a hydrophobic treatment, or both an oleophobic treatment and hydrophobic treatment applied thereto. In further detail, the concave contour provided by the frame can include a concave lip inversely shaped to support the cushion for positioning against a convex feature, such as a convex facial or head feature of a user, for example. In another example, the frame can be perforated. In yet another example, the frame can include a metal or a metal alloy selected from steel, titanium, lithium, aluminum, magnesium, nickel, copper, manganese, tungsten, gold, silver, zinc, platinum, molybdenum, or a combination thereof; or can include a polymer selected from polycarbonate (PC), acrylonitrile butadiene styrene (ABS), polycarbonate-acrylonitrile butadiene styrene blend (PB/ABS), polypropolyne, polyglycolide, polyglycolic acid, polylactic acid, polycaprolactone, polyhydroxyalkanoate, polyhydroxybutyrate, polyethylene adipate, polybutylene succinate, poly(3-hydroxybutyrate-co-3-hydroxyvalerate), polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, polyamide (nylon), e.g., having a weight average molecular weight ranging from 70,000 Mw to 300,000 Mw, or a combination thereof. In a further example, the cushion can be coupled to the frame by chemical adhesion, thermal adhesion, sealant, mechanical fastening, or a combination thereof. In another example, the apparatus can be a virtual reality goggle, a virtual reality helmet, an augmented reality goggle, an augmented reality helmet, a mixed reality goggle, a mixed reality helmet, or a combination thereof. In a further example, the cushion can include an additional layer of a different material coupled to the expanded PTFE layer, e.g., fabric, foam, leather, gels, etc.

In another example, an apparatus can include a cushion, a frame, and an extended reality display integrated with the frame. The cushion can include an expanded PTFE layer coupled to a fabric substrate. The frame can include two lateral portions and a bridging portion therebetween that define a concave surface that can be coupled to the cushion to support and provide a concave contour to the cushion. In one example, the fabric substrate can include a woven or fibrous layer which can include ceramic fibers, metal fibers, metal alloy fibers, metal oxide fibers, semi-metal oxide fibers, silicate fibers, glass fibers, carbon fibers, boron fibers, nitride fibers, polymer fibers, leather, or a combination thereof. The term “extended reality display” refers to a display including computer simulated scenario that either stimulates an immersive or even realistic experience, or augments reality with computer simulated graphics. Thus, the extended reality display can be a virtual reality display, an augmented reality display, a mixed reality display, or a combination thereof.

In yet another example, an apparatus can include a cushion and a frame. The cushion can include an expanded PTFE layer coupled to a fabric substrate. The frame can include two lateral portions and a bridging portion therebetween wherein the lateral portions and the bridging portion can define a concave surface that can be coupled to the cushion to support and provide a concave contour to the cushion. The frame can also include an extended reality display receiving portion to receive and secure a separate extended reality display, e.g., a smartphone or other display device. In one example, the fabric substrate can include a woven or fibrous layer which can include ceramic fibers, metal fibers, metal alloy fibers, metal oxide fibers, semi-metal oxide fibers, silicate fibers, glass fibers, carbon fibers, boron fibers, nitride fibers, polymer fibers, leather, or a combination thereof.

It is noted that when discussing the various apparatuses, each of these discussions can be considered applicable to other examples whether or not they are explicitly discussed in the context of that example. Thus, for example, in discussing an expanded PTFE layer related to an extended reality apparatus that includes an integrated extended reality display, such discussion is also relevant to and directly supported in the context of other types of apparatuses and vice versa.

As mentioned, the present examples relate to apparatuses. These apparatuses can include or exclude an extended reality display, which can be either in the form of an extended reality device with an integrated display or an extended reality viewer that accepts an extended reality display, e.g., a smartphone. As used herein, “frame” refers to the structure that forms the support for the apparatus. The frame can be, for example, head-mountable, such as mountable on or about a convex portion of a user's head, e.g., top, crown, temple, parietal ridge, occipital bone, nape, forehead, cheekbones, nose ridge, etc. The type of frame can be determined based on the intended use and design features. For example, a frame that is coupled to an extended reality display can have a different configuration than a frame that is configured to accept an extended reality display. The configuration of the frame can also vary the placement of the cushion(s), e.g. an extended reality helmet can include cushioning in places that are not available on an extended reality goggle, such as the top of the head.

Turning to the apparatus per se, as shown in FIG. 1A, a cushion 120 can include an expanded PTFE layer 102 and a frame 104 which can include two lateral portions 104a and a bridging portion 104b therebetween. The frame can be concaved, as shown at surface 108, for providing structure to the cushion including a concave contour 118 at the cushion. This concave contour can be suitable to provide comfort at the user's head feature, for example, which typically convex at many locations.

In a more detailed example, as shown in FIG. 1B, the cushion 120 can include an expanded PTFE layer 102 and a frame 104 which can include two lateral portions 104a and a bridging portion 104b therebetween. In this example, the frame can be a helmet as shown, and can be designed to rest on a top a crown portion of a user's head 110 via the cushion. In this example, the frame can include perforations 116 to allow the frame to breath (either around or through the cushion that can also be breathable due to the expanded PTFE layer). The frame can be concaved, as shown at surface 108, for providing structure to the cushion, in a manner suitable to provide comfort at the user's head feature, which is typically convex at most locations. As a note, even though FIG. 1B shows a helmet example with a top of user's head as described, FIG. 1B can also be viewed as showing a goggle frame (such as a nose piece) at 104 and the user's head shown at 110 can be viewed as a rounded portion of a user's nose. Thus, FIG. 1B is relevant to both helmet examples as well as headset (or goggle) examples, without limitation. The relationship of the frame to the expanded PTFE layer can be such that the frame can be located on one side of the expanded PTFE layer that may not come into contact, or more than de minimis contact, with a head portion of the user.

The expanded PTFE layer can be a synthetic fluoropolymer of tetrafluoroethylene. This fluoropolymer generally can have a repeating fluorocarbon chain and can have a weight average molecular weight ranging from 5,000 Mw to 100,000 Mw, for example. Expanded PTFE differs from PTFE in that it incorporates pores. For example, expanded PTFE can have a plurality of pores with a pore size having an average value from 0.1 microns to 0.5 microns. The individual pores in the expanded PTFE layer can have a pore size that can range from 0.01 micron to 100 microns. As used herein, “average pore size” or “pore size having an average value” refers to the collective size of all of the pores, taken as an average. When presented as a range of average pore sizes, the range designates a low limit and a high limit for the average pore size. For example, a pore size having an average value of 0.1 microns can include pores having a pore size of 0.1 micron, 0.09 micron, 0.11 micron, 0.08 micron, 0.012 micron, etc. When the collective pore sizes are averaged, the resultant average is indicated as the average pore size. In some examples, the average pore size can range from 0.1 microns to 0.5 microns, from 0.1 microns to 0.4 microns, from 0.1 microns to 0.3 microns, from 0.2 microns to 0.5 microns, or from 0.3 microns to 0.5 microns. In one example, the expanded PTFE layer can have an average pore size ranging from 0.3 microns to 0.5 microns.

The level of porosity, e.g., the number of pores, can also vary. In one example, the expanded PTFE layer can have a dimensional level of porosity that can range from 1% to 99%. In other examples, the level of porosity can range from 10% to 90%, from 20% to 80%, from 15% to 85%, from 30% to 60%, from 50% to 95%, from 60% to 99%, from 70% to 85%, from 85% to 99%, from 90% to 99%, from 95% to 99%, from 96% to 99%, from 97% to 99%, from 98% to 99%, or can be 99%. The level of porosity can be determined by inspection under optical or electronic microscopes and software counting.

In some examples, the expanded PTFE layer can include from 1 million to 15 billion pores per square inch. In another example, the expanded PTFE layer can include from 5 million to 15 billion pores per square inch. In further examples, the expanded PTFE layer can include from 10 million to 50 million pores per square inch, from 1 billion to 10 billion pores per square inch, or from 3 billion to 12 billion pores per square inch. In one example, the expanded PTFE layer can have a level of porosity from 1% to 99% and can include 1 million to 15 billion pores per square inch.

With respect to the layer of the expanded PTFE, the layer can have a varying density. In one example, the expanded PTFE layer can have a density ranging from 0.1 g/cm³to 2.2 g/cm³. In other examples, the expanded PTFE layer can have a density ranging from 0.5 g/cm³to 2 g/cm³, from 1 g/cm³to 1.5 g/cm³, or from 0.2 g/cm³ to 2 g/cm³.

The thickness of the expanded PTFE layer can also vary. In one example, the expanded PTFE layer can have a thickness ranging from 0.005 mm to 2 mm. In other examples, the expanded PTFE layer can have a thickness ranging from 0.01 mm to 1.5 mm, from 0.05 mm to 2 mm, from 0.005 mm to 1 mm, or from 0.1 mm to 1 mm.

The expanded PTFE layer can be permeable to gasses, including air and water vapor, but can be impermeable to liquids. Accordingly, the expanded PTFE layer can exhibit liquid repellency. This repellency can be partially due to the pore size. An average pore size ranging from 0.1 microns to 0.5 microns can be about one ten-thousandth the size of a drop of liquid (e.g., a raindrop). Thus, a drop of liquid cannot pass through the pores while vapor (e.g., water vapor, etc.) can pass through the pores.

The air and gas permeability can be reflected in the Frazier number of the expanded PTFE layer. The Frazier number can be determined using ASTM D737 Standard Test Methods for Air Permeability of Textile Fabrics, version 04(2016). In one example, the expanded PTFE layer can have a Frazier number ranging from 0.1 to 500. In other examples, the expanded PTFE layer can have a Frazier number from 0.2 to 450, from 0.5 to 400, from 0.8 to 350, from 1 to 300, from 5 to 250, from 10 to 200, from 20 to 150, from 40 to 100, from 60 to 80, from 100 to 300, from 150 to 250, from 0.5 to 15, from 0.6 to 10, from 0.8 to 8, from 0.9 to 5, from 1 to 4, from 0.8 to 8, from 0.9 to 5, or from 1 to 4, among other possibilities.

In addition, the expanded PTFE layer can exhibit a high contact angle with liquid. As used herein, “a high contact angle” can refer to a contact angle equal to or greater than 90° or example, a contact angle with liquid for the expanded PTFE layer can be at least 90°, at least 95°, at least 100°, at least 105°, at least 110°, at least 115°, at least 120°, at least 125°, at least 130° or higher. In one example, a contact angle with liquid can be 118°. The contact angle can contribute to the liquid repellency of the expanded PTFE layer. One commercially available example of an expanded PTFE material that can be suitable for use in the cushion can include GORE-TEX® (W.L Gore & Associates, Inc. Delaware).

In some examples, the expanded PTFE layer can be treated. For example, the expanded PTFE layer can include an oleophobic treatment, a hydrophobic treatment, or both an oleophobic treatment and hydrophobic treatment applied thereto. A hydrophobic treatment can be used to further increase the water repellency of the expanded PTFE layer. A hydrophobic treatment can include at least one of lamination, spray coating, dip-coating, chemical vapor deposition (CVD), and physical vapor deposition (PVD), among other possible manners of application of hydrophobic materials. Example hydrophobic materials can include fluoropolymer, perylene, and combinations thereof. An oleophobic treatment can be used to make the expanded PTFE layer resistant to oils. An oleophobic treatment can include at least one of lamination, spray coating, dip-coating, CVD, or PVD of oleophobic materials. Example oleophobic materials can include fluoropolymer, perylene, and combinations thereof.

The cushion can be coupled to the frame. The frame can support and provide a concave contour to the cushion. In one example, the concave contour can be suitable for contact with a convex surface of a portion of a user's head. The cushion can be located around a perimeter of the frame, a portion of the frame that is outside of the viewing area and/or surround the exterior of the viewing area, or a portion or combination thereof. For example, the cushion can be coupled to a portion of the frame that contacts the forehead of the user, a side of the user's face, the nose of the user, the cheeks of the user, the top of a user's head, the sides of the user's head, the back of the user's head, or a portion or combination thereof during use of the apparatus. In one example, the frame can be configured as goggles and the cushion can be coupled to the frame such that the cushion would contact the forehead of the user, a side of the user's face, the nose of the user, the cheeks of the user, and/or a portion or combination thereof during use of the apparatus. In another example, the frame can be configured as goggles and the cushion can be coupled to the frame such that the cushion would contact a side of the user's face during use of the apparatus. In yet another example, the frame can be configured as a helmet and the cushion can be coupled to the frame such that the cushion contacts a side of the user's face, the nose of the user, the cheeks of the user, the sides of the user's head, the back of the user's head, the top of the user's head, or a portion or combination thereof during use of the apparatus.

In further detail, the concave contour provided by the frame can include a concave surface 108, as shown in FIG. 1B, which shape supports and provides a concave contour 118 to the cushion 120, such as where the cushion may be positioned against a convex feature 110. The convex feature can be a convex head or facial feature of the user, for example. The cushion can be coupled to the concave portion of the frame that can be positionable against the convex facial feature of the user. In some examples, the cushion can be coupled to the frame by chemical adhesion, thermal adhesion, sealant, mechanical fastening, or a combination thereof. This coupling is not shown in FIG. 1B, but is shown by way of example in FIG. 1C.

The material used to form the frame can vary. In one example, the frame can be a metal or a metal alloy selected from steel, titanium, lithium, aluminum, magnesium, nickel, copper, manganese, tungsten, gold, silver, zinc, platinum, molybdenum, or a combination thereof; or can be a polymer selected from polycarbonate, acrylonitrile butadiene styrene, polycarbonate-acrylonitrile butadiene styrene blend, polyglycolide, polyglycolic acid, polylactic acid, polycaprolactone, polyhydroxyalkanoate, polyhydroxybutyrate, polyethylene adipate, polybutylene succinate, poly(3-hydroxybutyrate-co-3-hydroxyvalerate), polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, polyamide (or nylon), e.g., having a weight average molecular weight ranging from 70,000 Mw to 300,000 Mw, or a combination thereof; or can include both the metal or metal alloy and the polymer.

In one example, the frame can be a polyamide having a weight average molecular weight ranging from 70,000 Mw to 300,000 Mw. Example polyamides can include nylon PA 11 (“PA-11”), nylon PA 12 (“PA-12”), nylon PA 6 (“PA-6”), nylon PA 8 (“PA-8”), nylon PA 9 (“PA-9”), nylon PA 66 (“PA-66”), nylon PA 612 (“PA-612”), nylon PA 812 (“PA-812”), nylon PA 912 (“PA-912”), and the like. In one example, the nylon can be a high molecular weight nylon—e.g., polyamide 12, polyamide 6, polyamide 8, polyamide 11, polyamide 66, and combinations thereof.

The thickness of the frame can also vary. In one example, the thickness can range from 0.05 mm to 5 mm. In other examples, the thickness can range from 0.1 mm to 5 mm, from 0.05 mm to 3 mm, from 0.1 mm to 3 mm, from 0.5 mm to 4 mm, or from 1 mm to 5 mm.

In some examples, the frame or a portion thereof can be perforated, as shown generally at 116 in FIG. 1B. Perforating the frame can permit vapor transfer through the frame. When perforated, the pores can vary in size and amount. When the frame incorporates pores, the pore size, amount, and location can be configured to allow for vapor transfer but can also be configured to reduce or prevent outside light transference to the area of the extended reality display. For example, pores in the frame can range from 0.01 microns to 100 microns. In yet other examples the pores in the frame can range from 0.01 micron to 50 microns, from 0.1 microns to 75 microns, or from 1 micron to 100 microns. The quantity of pores can also vary. For example, the frame can have a level of porosity ranging from 1% to 99%. In yet other examples, the level of porosity for the frame can range from 5% to 85%, from 10% to 99%, from 30% to 60%, from 25% to 75%, or from 1% to 50%.

The shape of the frame can vary depending on the desired application. In some examples, the frame can be shaped to be worn on a user's head or any portion thereof. For example, the frame can be in the configuration of a goggle or a helmet. In some examples, the frame can further include an attachment strap and/or an earpiece. The strap and/or earpiece may be any strap or earpiece usable with the present extended reality apparatuses and are thus not particularly limited. However, in some examples, the strap and/or the earpieces can include a layer of expanded PTFE. In one example, the frame can be in addition to and separate from the extended reality display and the frame can be configured to accept an extended reality display. For example, the frame can include an extended reality display receiving portion to receive and secure an extended reality display. In another example, the frame can be coupled to an extended reality display. The extended reality display can be a virtual reality display, an augmented reality display, a mixed reality display, or a combination thereof.

In some examples, the cushion of the apparatus can further include additional layers to enhance properties or features of the cushion and/or the apparatus can include additional design features. For example, in addition to the components described in FIG. 1B, namely the cushion 120 including the expanded PTFE layer 102, and the frame 104, the cushion can include other materials or layers, such as a fabric substrate, a gel layer, a bonding layer, other padding layer(s) such as foams, etc., or a combination thereof.

In another example, as shown in FIG. 1C, a cushion 120 can include the expanded PTFE layer 102, a fabric substrate 106, and a frame 104. A coupling layer(s) or other couplers, shown at (c) between individual layers of the cushion and/or between the cushion and the frame 104, can also be present. The coupling layer is to be considered representative, and can be provided by thermal bonding, adhesive, mechanical fastening, magnetic fastening, etc. There could also be additional cushion layers (not shown), which may or may not include bonding. For example, a foam pad could be positioned, but not bonded, between two layers of the cushion. Thus, FIG. 1C is not intended to be limiting, but rather an example of an apparatus. It is also noted that the layers shown in FIG. 1C are indicated as being concave as per the broken and curved lines showing curved extension of the layers shown and described in FIG. 1C (at both a surface of the frame and a surface of the cushion). That being stated, in some examples, not every feature along a frame is contoured. For example, there may be flattened portions and/or convex portions along with concave portions of the frame (at locations where the frame may otherwise come into contact with a portion of a user's head during use). To show a concave feature in FIG. 1C, curved arrows are provided indicating that a portion of the frame (and thus the cushion) can be concave at some locations, even if not at all locations.

With respect to the fabric substrate, this structure can be coupled (bonded or fastened) along the entire length of the expanded PTFE layer, or to just a portion thereof. For example, the expanded PTFE layer and the fabric substrate may be bonded together to form a pocket for receiving other cushion material, such as foam, gel, other fabric, abrasion resistant layers or shells, other types of layers, etc. On the other hand, if the expanded PTFE layer and the fabric provide sufficient cushioning, these two layers may be present without including other materials and can be bonded or fastened together as the composite layered system. In some examples, the fabric substrate can be laminated to the expanded PTFE layer. Laminating can include exposing the fabric layer to a temperature near, at, and/or above a glass transition temperature and/or melting temperature of fibers in the fabric layer and contacting the fabric layer with the expanded PTFE layer to mechanically couple the fabric layer to the expanded PTFE layer. In another example, alternatively, or in addition to the laminating, chemical adhesion, thermal adhesion, sealant, mechanical fastening, etc., can be employed to couple the fabric layer to the expanded PTFE layer. In other examples, though the fabric substrate can be positioned relative the expanded PTFE (directly coupled, indirectly coupled, etc.), in one example, the fabric can be at an outermost layer along a concave surface of the cushion (provided by the concave surface of the frame) where the cushion, and thus the fabric substrate, may contact a user's convex head or facial feature.

The fabric substrate can include a woven or fibrous layer. The woven or fibrous layer can include ceramic fibers, metal fibers, metal alloy fibers, metal oxide fibers, semi-metal oxide fibers, silicate fibers, glass fibers, carbon fibers, boron fibers, nitride fibers, polymer fibers, leather, or a combination thereof. In one example, the fabric substrate can include a metal fiber, a metal alloy fiber, a metal oxide fiber, a semi-metal oxide fiber, or a combination thereof. Example metal, metal alloy, or metal oxide fibers can include titanium fibers, ruthenium fibers, rhodium fibers, palladium fibers silver fibers, osmium fibers, iridium fibers, platinum fibers, gold fibers, mercury fibers, rhenium fibers, copper fibers, niobium fibers, tantalum fibers, alloys, or a combination thereof. In another example, the fabric substrate can include a glass fiber. Example glass fibers can include alumino-borosilicate glass fibers, alumino-lime silicate fibers, alumino-silicate glass fibers, alkali-lime glass fibers, or a combination thereof. In yet another example, the fabric substrate can be a carbon fiber. Example carbon fibers can include natural carbon fibers and/or synthetic carbon fibers. For example, the carbon fiber can be formed of polyacrylonitrile (“PAN”), rayon, pitch, carbon nanotube fibers, aramid carbon fibers, or a combination thereof.

In some examples, the fibers can include continuous fibers, discontinuous fibers, or a combination thereof. The diameter of the fibers can also vary. In some examples, the fibers can have an average diameter ranging from 5 μm to 10 μm. In yet other examples, the fibers can have an average diameter ranging from 6 μm to 8 μm, from 5 μm to 7 μm, or from 6 μm to 10 μm.

The individual fibers can be arranged in various orientations and/or directions in this layer. In one example, the fibers can be aligned unidirectionally. Unidirectionally aligned fibers can exhibit isotropic material properties and can exhibit stronger mechanical properties (e.g., elastic modulus, flexural modulus, etc.) along a unidirectional alignment than the same type of fibers that are aligned in an orthogonal direction. As used herein, “unidirectional aligned” or “unidirectionally aligned” fibers refer to fibers in a fabric layer having at least 80% of the fibers by volume, aligned in the same direction. Orthogonal direction refers to aligned fibers in a fabric layer having 79% or fewer fibers by volume, aligned in different directions.

The fibers in the fiber layer can be woven. Woven fibers can be in various possible formats including plain, twill, satin, triaxial, stitched, basket, continuous strand mat, and/or veil formats.

In one example, the cushion can further include a foam or gel layer to enhance comfort and/or fit, as mentioned briefly above. In one example, a foam layer can be included. The foam layer can be a polyurethane foam, polystyrene foam, neoprene, latex, or a combination thereof. In another example, a gel layer can be included. The gel can be a polyurethane gel, polyurethane gel elastomer, silicone gel, superabsorbent polymer, or a combination thereof. In some examples, the cushion or gel layer can be positioned between the expanded PTFE layer and the frame.

In another example, the apparatus can further include a coupling layer(s). For example, the coupler or coupling layer can be located between the expanded PTFE layer and the frame, the expanded PTFE layer and the fabric substrate, the fabric substrate and a polymeric abrasion resistant shell, the frame and a polymeric abrasion resistant shell, the frame and an extended reality display, or a combination thereof. The type of coupling can also vary. In one example, a bonding layer can be provided by chemical adhesion, thermal adhesion, sealant, a mechanical fastening, or a combination thereof. A bonding layer can be used to adhere individual layers or components to other layers or components.

In yet other examples, the apparatus can further include an abrasion resistant layer. This layer can be used to protect the structure of the apparatus. In one example, the abrasion resistant layer can be a polymeric-abrasion resistant shell. In some examples, the polymeric-abrasion resistant shell can include an acrylic polymer, alkyd polymer, epoxy polymer, or a copolymer thereof. The polymeric-abrasion resistant shell can be located on the exterior of the apparatus and/or on the interior of the apparatus. The interior locations, when included would not block viewing of the extended reality display. In one example, the polymeric-abrasion resistant shell can be adjacent to the expanded PTFE layer. In another example, the polymeric-abrasion resistant shell can be located adjacent to the frame. In yet another example, the polymeric-abrasion resistant shell can be adjacent to an extended reality display or can be adjacent to a portion of the frame that can be configured to receive an extended reality display.

A perspective view of one specific example of an extended reality apparatus 200 is shown in FIG. 2. There, the extended reality apparatus can include a cushion 220 with an expanded PTFE layer and fabric substrate applied to the cushion (not shown, but shown by example in FIGS. 1B and 1C) a frame 204. The frame can include two lateral portions 204a and a bridging portion therebetween 204b which together define a concave surface. There can also be other concave surfaces on the frame where the cushion can be applied, and thus, the lateral portions and the bridging portion are shown by way of example. The frame can also be coupled to the cushion to provide support and to provide contour to the cushion at a contoured lip 208 thereof (which is concave at this location as defined by the surface between the lateral portions and the bridging portion therebetween). An extended reality display 212 can be coupled to the frame. In this example, the extended reality display is shown integrated with the frame. As shown in FIG. 2 the frame further includes strap(s) 214 that allow a user to secure and fasten the extended reality apparatus to their head. Rather than a strap, this device could be reconfigured as a helmet, or use some other system for holding the goggle around the eyes of the user. In this example, the extended reality apparatus is shown as a set of goggles, but could be configured as a helmet (as shown in part in FIG. 1B) or in some other arrangement suitable to hold the display and/or other peripherals in place with respect to a user.

In another example, the apparatus can be a viewer, where the frame includes an extended reality display receiving portion to receive and secure an extended reality display, such as a smartphone. For example, an extended reality apparatus 300 as shown in FIG. 3 includes the frame 304 that includes an extended reality display receiving portion 316, such as a hinged cover that allows an extended reality display 312 (as a separate unit) to be placed inside and secured within the frame. The frame can include two lateral portions 304a and a bridging portion therebetween 304b which together define a concave surface. There can also be other concave surfaces on the frame where the cushion can be applied, and thus, the lateral portions and the bridging portion are shown by way of example. The frame can be coupled to the cushion to provide support and to provide a concave contour to the cushion at a contoured lip 208 thereof (which is concave at this location as defined by the surface between the lateral portions and the bridging portion). Also shown in FIG. 3 is a cushion 320 with an expanded PTFE layer, and a strap 314. Again, in this example, the extended reality apparatus is shown as a set of goggles, but could be configured as a helmet (as shown in part in FIG. 1B) or in some other arrangement suitable to hold the display and/or other peripherals in place with respect to a user.

The apparatus can include a variety of peripherals or other features. These peripherals can include, but are not limited to, headphones, a microphone, volume controls, display controls, lenses, a carrying case, a control box, tracking sensors, controllers, USB port and/or cables, HDMI ports and/or cable, other state of the art ports and/or cables for other types of hardware, hard drives, memory, smart cards and/or memory sticks, power connector, etc. In some examples, the apparatus can be wired or wireless.

It is noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise.

As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary.

Concentrations, dimensions, amounts, and other numerical data may be presented herein in a range format. It is to be understood that such range format is used merely for convenience and brevity and should be interpreted flexibly to include the numerical values explicitly recited as well as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a weight ratio range of 1 wt % to 20 wt % should be interpreted to include the explicitly recited limits of 1 wt % and 20 wt %, but also to include individual weights such as 2 wt %, 11 wt %, 14 wt %, and sub-ranges such as 10 wt % to 20 wt %, 5 wt % to 15 wt %, etc.

Claims

1. An apparatus, comprising:

a cushion including an expanded PTFE layer; and

a frame including two lateral portions and a bridging portion therebetween, wherein the lateral portions and the bridging portion define a concave surface that is coupled to the cushion to support and provide a concave contour to the cushion.

2. The apparatus of claim 1, wherein the expanded PTFE layer has an average pore size from 0.1 micron to 0.5 micron.

3. The apparatus of claim 1, wherein the expanded PTFE layer has a level of porosity ranging from 1% to 99% and includes from 1 million to 15 billion pores per square inch.

4. The apparatus of claim 1, wherein the expanded PTFE layer includes an oleophobic treatment, a hydrophobic treatment, or both an oleophobic treatment and hydrophobic treatment applied thereto.

5. The apparatus of claim 1, wherein the concave contour provided by the frame includes a concave lip inversely shaped to support the cushion for positioning against a convex feature.

6. The apparatus of claim 1, wherein the frame is perforated.

7. The apparatus of claim 1, wherein the frame comprises a metal or a metal alloy selected from the group consisting of steel, titanium, lithium, aluminum, magnesium, nickel, copper, manganese, tungsten, gold, silver, zinc, platinum, molybdenum, and a combination thereof.

8. The apparatus of claim 1, wherein the frame comprises a polymer selected from the group consisting of polycarbonate, acrylonitrile butadiene styrene, polycarbonate-acrylonitrile butadiene styrene blend, polyglycolide, polyglycolic acid, polylactic acid, polycaprolactone, polyhydroxyalkanoate, polyhydroxybutyrate, polyethylene adipate, polybutylene succinate, poly (3-hydroxybutyrate-co-3-hydroxyvalerate), polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, polyamide, and a combination thereof.

9. The apparatus of claim 8, wherein the polymer is the polyamide and has a weight average molecular weight ranging from 70,000 Mw to 300,000 Mw.

10. The apparatus of claim 1, wherein the apparatus is an extended reality apparatus selected from the group consisting of a virtual reality goggle, a virtual reality helmet, an augmented reality goggle, an augmented reality helmet, a mixed reality goggle, a mixed reality helmet, and a combination thereof.

11. The apparatus of claim 1, wherein the cushion includes an additional layer of a different material coupled to the expanded PTFE layer.

12. An apparatus, comprising:

a cushion including an expanded PTFE layer coupled to a fabric substrate;

a frame including two lateral portions and a bridging portion therebetween, wherein the lateral portions and the bridging portion define a concave surface that is coupled to the cushion to support and provide a concave contour to the cushion; and

an extended reality display integrated with the frame.

13. The apparatus of claim 12, wherein the fabric substrate comprises a woven or fibrous layer including fibers selected from the group consisting of ceramic fibers, metal fibers, metal alloy fibers, metal oxide fibers, semi-metal oxide fibers, silicate fibers, glass fibers, carbon fibers, boron fibers, nitride fibers, polymer fibers, and a combination thereof.

14. An apparatus, comprising

a cushion including an expanded PTFE layer coupled to a fabric substrate; and

a frame including two lateral portions and a bridging portion therebetween, wherein the lateral portions and the bridging portion define a concave surface that is coupled to the cushion to support and provide a concave contour to the cushion, wherein the frame includes an extended reality display receiving portion to receive and secure a separate extended reality display.

15. The apparatus of claim 14, wherein the fabric substrate comprises a woven or fibrous layer including fibers selected from the group consisting of ceramic fibers, metal fibers, metal alloy fibers, metal oxide fibers, semi-metal oxide fibers, silicate fibers, glass fibers, carbon fibers, boron fibers, nitride fibers, polymer fibers, and a combination thereof.