Facial interfaces for head-mounted displays and related systems and methods

Patent metadata

Field	Value
Publication number	US-11526015-B2
Application number	US-202016797086-A
Country	US
Kind code	B2
Filing date	Feb 21, 2020
Priority date	Feb 21, 2020
Publication date	Dec 13, 2022
Grant date	Dec 13, 2022

Abstract

A head-mounted display may include a frame for supporting an electronic display for viewing by an intended user donning the head-mounted display. The frame may include a flange disposed on a perimeter area of the frame and a facial interface configured to abut against an intended user's face wherein the facial interface comprises a foam body and an undercut region in the foam body that is sized and shaped for detachably engaging with the flange of the frame. Various other apparatuses, systems, and methods are also disclosed.

First claim

What is claimed is:

1. A method comprising:
positioning a mold insert in a mold that has an internal cavity defining a shape of a facial interface for a head-mounted display;
applying a non-porous material to a surface of the mold;
after applying the non-porous material to the surface of the mold, injecting a liquid material into the mold to surround at least a base of the mold insert;
curing the liquid material to form a foam body with an undercut region defined by the mold insert;
removing the foam body from the mold; and
decoupling the mold insert from the foam body.

2. The method of claim 1 , further comprising applying a microtexture coating to a surface of the foam body.

3. The method of claim 1 , further comprising securing at least two pegs into the mold insert by attaching heads of the at least two pegs to the mold insert, wherein injecting the liquid material into the mold comprises surrounding respective bases of the at least two pegs with the liquid material.

4. The method of claim 3 , wherein:
the undercut region is configured to engage a flange of a frame of a head-mounted display; and
the heads of the at least two pegs are configured to detachably secure the facial interface to the frame of the head-mounted display.

5. The method of claim 1 , wherein curing the liquid material to form the foam body comprises forming a closed-cell foam.

6. The method of claim 1 , wherein curing the liquid material to form the foam body comprises forming an open-cell foam.

7. A method comprising:
positioning a mold insert in a mold that has an internal cavity defining a shape of a facial interface for a head-mounted display;
securing at least two pegs into the mold insert by attaching heads of the at least two pegs to the mold insert;
injecting a liquid material into the mold to surround at least a base of the mold insert and to surround respective bases of the at least two pegs with the liquid material;
curing the liquid material to form a foam body with an undercut region defined by the mold insert;
removing the foam body from the mold; and
decoupling the mold insert from the foam body.

8. The method of claim 7 , wherein:
the undercut region is configured to engage a flange of a frame of a head-mounted display; and
the heads of the at least two pegs are configured to detachably secure the facial interface to the frame of the head-mounted display.

9. The method of claim 7 , wherein the mold is shaped to result in the foam body having a closed loop shape.

10. The method of claim 7 , further comprising applying a microtexture coating to a surface of the foam body.

11. The method of claim 7 , wherein, after curing the liquid material to form the foam body, the bases of the at least two pegs are surrounded by the foam body.

Assignees

• Meta Platforms Tech Llc

Inventors

• Ellis Shane Michael
• Bristol Peter Wesley
• Sullivan Joseph Patrick
• Chuang Brian Lawrence
• Pickett David Michael
• Hayenga Kristen Renee
• Qin Xiao Xiong

Classifications

• G02B27/0176 Primary

  characterised by mechanical features · CPC title

• G06F1/163

  Wearable computers, e.g. on a belt · CPC title

• G02C11/10

  Electronic devices other than hearing aids · CPC title

• B29L2031/3475

  Displays, monitors, TV-sets, computer screens · CPC title

• B29C44/42

  using pressure difference, e.g. by injection or by vacuum · CPC title