Patent Description:
Artificial-reality systems, such as virtual-reality systems or augmented-reality systems, typically display computer-generated content to users in order to create immersive experiences. The content may be displayed on a head-mounted display ("HMD") screen. For example, a virtual-reality system may create three-dimensional renderings to simulate an environment or a virtual space. Alternatively, augmented-reality systems may merge computer-generated content with a user's view of a real-world environment to enhance interactions with the real-world environment. These systems may provide users with the ability to navigate and alter digital content that may provide helpful information about real-world objects. HMD systems sometimes include two optical lenses-one for each eye-positioned in front of the screen. The lenses may magnify and/or provide an appropriate focus to images displayed on the screen. Contamination (e.g., dust particles, fingerprints, etc.) on the lenses or the screen can undesirably block or otherwise obscure portions of a displayed image. Moving parts in HMD systems can sometimes produce or move contamination in front of the displayed image.

Different users have different head and face shapes and sizes. For example, a particular user's eyes may be located closer or farther apart from each other, compared to other users. The distance between the center of an HMD user's pupils is commonly referred to as "interpupillary distance" or "IPD. " Positioning the lenses to match a particular user's IPD improves picture quality for that user. To accommodate different IPDs, some HMDs include a mechanism to adjust an IPD setting and, therefore, a relative position between the optical lenses. Some HMDs include two separate screens coupled to the two respective lenses. Each lens and screen pair may be movable relative to the other lens and screen pair to adjust for IPD. Each lens and screen pair may include a sealed interior to inhibit the introduction of contamination, to improve or maintain picture quality. However, two such screens are generally more expensive to integrate into HMDs compared to a single screen. However, conventional HMD systems with one screen and IPD adjustment capability generally have a configuration that may allow contamination to be introduced onto the screen and/or onto a screen side of the lenses.

Together with the following description, these drawings demonstrate and explain various principles of the present disclosure.

Throughout the drawings, identical reference characters and descriptions indicate similar, but not necessarily identical, elements. While the example embodiments described herein are susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, the example embodiments described herein are not intended to be limited to the particular forms disclosed. Rather, the present disclosure covers all modifications, equivalents, and alternatives falling within the scope of the appended claims.

The present disclosure is generally directed to HMD assemblies that may include a single near-eye display ("NED") screen and two eyecups that are movable relative to each other to adjust for IPDs of different users. An enclosure may be disposed over the single NED screen. The enclosure may include a first transparent component positioned between the first lens and the single NED screen and a second transparent component positioned between the second lens and the single NED screen.

The enclosure, including the first and second transparent components, may provide a clean volume over the single NED screen to reduce contamination on the screen while also allowing for interpupillary adjustments. As will be explained in greater detail below, embodiments of the present disclosure may enable IPD adjustments over a single, sealed display screen. The single display screen may reduce a cost of HMD assemblies with IPD adjustability, compared to conventional HMD assemblies with two separate display screens. Additionally, the enclosure over the single NED screen may facilitate keeping the screen clean and substantially free from contamination, which might otherwise obstruct a user's view of blocked pixels of the display screen. Contamination (e.g., dust, particles, other debris) that may be present between the first and second lenses and the respective first and second transparent components may be substantially out-of-focus. The out-of-focus contamination, if sufficiently small, may be essentially invisible to the user. Even larger contamination may be less visible than if the contamination were positioned at the NED screen surface.

In some examples, the term "substantially" in reference to a given parameter, property, or condition may mean and include to a degree that one of ordinary skill in the art would understand that the given parameter, property, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances. By way of example, depending on the particular parameter, property, or condition that is substantially met, the parameter, property, or condition may be at least <NUM>% met, at least <NUM>% met, or even at least <NUM>% met.

Features from any of the embodiments described herein may be used in combination with one another in accordance with the general principles described herein. These and other embodiments, features, and advantages will be more fully understood upon reading the following detailed description in conjunction with the accompanying drawings and claims.

The following will provide, with reference to <FIG>, detailed descriptions of various example HMD assemblies according to the present disclosure. With reference to <FIG>, the following will provide detailed descriptions of example sliding interfaces for IPD adjustability of HMD assemblies of the present disclosure. With reference to <FIG>, the following will provide detailed descriptions of example HMD assemblies according to additional embodiments of the present disclosure. With reference to <FIG> and <FIG>, the following will provide detailed descriptions of example methods of fabricating HMD assemblies and of adjusting an IPD of HMD assemblies, respectively. With reference to <FIG> and <FIG>, the following will provide detailed descriptions of example artificial-reality systems and environments that may be used in conjunction with HMD assemblies of the present disclosure.

<FIG> illustrate an HMD assembly <NUM> that may include a first eyecup <NUM> and a second eyecup <NUM> positioned over a single NED screen <NUM>, with an enclosure <NUM> positioned between the eyecups <NUM>, <NUM> and the single NED screen <NUM>. <FIG> illustrates a detailed view of certain components of the HMD assembly <NUM>. Referring to <FIG>, the eyecups <NUM>, <NUM>, single NED screen <NUM>, and enclosure <NUM> may be mounted on an HMD support frame <NUM>, which may also support an eye bracket <NUM> that may be shaped and positioned for resting against the user's face when the HMD assembly <NUM> is donned by the user. In some examples, a flexible shroud <NUM> may be positioned over at least portions (e.g., peripheral portions) of the eyecups <NUM>, <NUM>, such as to provide an aesthetic cover and/or a dust cover over underlying components of the HMD assembly <NUM>.

In some examples, relational terms, such as "first," "second," "upper," "lower," "over," "underlying," etc., may be used for clarity and convenience in understanding the disclosure and accompanying drawings and may not necessarily connote or depend on any specific preference, orientation, or order, except where the context clearly indicates otherwise.

The eyecups <NUM>, <NUM> may be configured for positioning in front of intended locations of a user's eyes when the HMD assembly <NUM> is donned by the user. For example, the first eyecup <NUM> may be configured for viewing the single NED screen <NUM> with the user's left eye and the second eyecup <NUM> may be configured for viewing the single NED screen <NUM> with the user's right eye. The first eyecup <NUM> may support a first optical lens <NUM> and the second eyecup <NUM> may support a second optical lens <NUM>. For example, each of the optical lenses <NUM>, <NUM> may be a corrective ophthalmic lens (e.g., a positive-optical power (i.e., magnifying) lens, a negative-optical power (i.e., diminishing) lens, a lens for correction of an aberration, etc.), a zero-power optical lens, an adjustable (e.g., deformable) optical lens, a Fresnel lens, or another optical lens element. Optionally, an anti-reflective coating may be applied to the optical lenses <NUM>, <NUM>.

The first eyecup <NUM> may include a first rigid housing <NUM> at least partially defining a first interior volume <NUM>. Similarly, the second eyecup <NUM> may include a second rigid housing <NUM> at least partially defining a second interior volume <NUM>. A base of the first rigid housing <NUM> may include a first flange <NUM>, which may extend radially outward from a sidewall of the first rigid housing <NUM>. Similarly, a base of the second rigid housing <NUM> may include a second flange <NUM>, which may extend radially outward from a sidewall of the second rigid housing <NUM>.

The optical lenses <NUM>, <NUM> may be sealed (e.g., hermetically sealed) against and supported by the rigid housings <NUM>, <NUM>. The optical lenses <NUM>, <NUM> may be positioned to focus images displayed by the single NED screen <NUM> to the user's eyes when the HMD assembly <NUM> is donned by the user.

The enclosure <NUM> may include a first transparent component <NUM> positioned between the first optical lens <NUM> and the single NED screen <NUM> and a second transparent component <NUM> positioned between the second optical lens <NUM> and the single NED screen <NUM>. An outer region of the first and second transparent components <NUM>, <NUM> may be coupled to the eye-facing surface of the single NED screen <NUM> via a sealing structure <NUM> of the HMD support frame <NUM>. Thus, the enclosure <NUM> may be defined by the first and second transparent components <NUM>, <NUM>, the single NED screen <NUM>, and the sealing structure <NUM>. In some examples, the enclosure <NUM> may be a hermetically sealed enclosure to inhibit the introduction of contaminants (e.g., particles) on the eye-facing surface of the single NED screen <NUM>. Contamination that may be present over the first and second transparent components <NUM> (e.g., outside of the enclosure <NUM>) may be substantially out-of-focus to a user viewing the single NED screen <NUM> through the optical lenses <NUM>, <NUM>.

By way of example and not limitation, the first and second transparent components <NUM>, <NUM> may be or include the same material or two respective different materials. The first and second transparent components <NUM>, <NUM> may include a glass material, a transparent polymeric material (e.g., polycarbonate, polymethylmethacrylate, polyethylene terephthalate, cyclic olefin copolymer, polypropylene, styrene methyl methacrylate, styrene acrylonitrile resin, polystyrene, etc.), and/or a crystalline material, etc. In some examples, the first and second transparent components <NUM>, <NUM> may be substantially planar and may exhibit substantially zero optical power. The first and second transparent components <NUM>, <NUM> may be stationary relative to the single NED screen <NUM>, the eye bracket <NUM>, and the sealing structure <NUM>. By configuring the first and second transparent components <NUM>, <NUM> as stationary relative to the single NED screen <NUM>, the number of moving parts adjacent to the single NED screen <NUM> that might otherwise generate or move contaminants (e.g., particles) may be reduced.

A first sealing element <NUM> may be disposed between the first flange <NUM> and the first transparent component <NUM>. A second sealing element <NUM> may be disposed between the second flange <NUM> and the second transparent component <NUM>. The first and second sealing elements <NUM>, <NUM> may be configured for allowing the first eyecup <NUM> and the second eyecup <NUM> to move (e.g., slide) relative to the first and second transparent components <NUM>, <NUM>, such as to adjust an IPD setting of the HMD assembly <NUM>. The first and second sealing elements <NUM>, <NUM> may be configured to inhibit particles from entering the first and second interior volumes <NUM>, <NUM>.

By way of example and not limitation, the first and second sealing elements <NUM>, <NUM> may each be an O-ring, a foam (e.g., closed-cell foam) ring, a foam ring bonded to a structural base (e.g., a foam ring bonded to a polyethylene terephthalate base), a V-ring, an X-ring, a gasket, etc. The material of the first and second sealing elements <NUM>, <NUM> may be or include a polymer material, such as an elastomeric material, a foam material, a combination thereof, etc..

As noted above, the first eyecup <NUM> and the second eyecup <NUM> may be movable (e.g., in a direction that is parallel to a surface of the single NED screen <NUM>, such as in a left-and-right direction from the perspective of <FIG>) relative to each other to adjust for an IPD of the user's eyes. At least one of the eyecups <NUM>, <NUM> may also be movable relative to the single NED screen <NUM>. In some embodiments, the first eyecup <NUM> and the second eyecup <NUM> may be movable relative to each other over a distance of up to about <NUM>. The eyecups <NUM>, <NUM> may be independently movable relative to the HMD support frame <NUM>, or the eyecups <NUM>, <NUM> may be configured to simultaneously move inward (e.g., toward each other) or outward (e.g., away from each other) at substantially equal distances and rates relative to the single NED screen <NUM>.

As shown in <FIG> by way of example, one or more IPD input mechanisms <NUM> (e.g., switches, sliders, knobs, buttons, etc.) may be integrated into the HMD support frame <NUM> and configured to allow the user of the HMD assembly <NUM> to adjust the IPD of the eyecups <NUM>, <NUM> according to preference. Alternatively or additionally, IPD adjustments may be made by one or more electromechanical actuators (e.g., linear actuators, rotational motors, etc.), which may be controlled by a computing system associated with the HMD assembly <NUM> or by the user's manipulation of the IPD input mechanism(s) <NUM>.

A first IPD setting IPD<NUM> may correspond to a distance between a first optical axis A<NUM> of the first optical lens <NUM> and a second optical axis A<NUM> of the second optical lens <NUM> when the first and second optical lenses <NUM> are in a first position, as shown in <FIG>. A second IPD setting IPD<NUM> may correspond to the distance between the first and second optical axes A<NUM>, A<NUM> when the first and second optical lenses <NUM> are in a second position, as shown in <FIG>. In the example shown, the first eyecup <NUM> and the second eyecup <NUM> are closer to each other at the second IPD setting IPD<NUM> comparted to the first IPD setting IPD<NUM>. Thus, the first IPD setting IPD<NUM> may be useful for a user that has a generally wide IPD, and the second IPD setting IPD<NUM> may be useful for a different user that has a generally narrow IPD.

Referring <FIG> and <FIG>, the first transparent component <NUM> may be positioned a first distance D<NUM> from the single NED screen <NUM> and the second transparent component <NUM> may be positioned a second distance D<NUM> from the single NED screen <NUM>. By way of example and not limitation, each of the first distance D<NUM> and the second distance D<NUM> may be in the range of about <NUM> to about <NUM>.

In some embodiments, the first distance D<NUM> may be different from the second distance D<NUM>. For example, the first distance D<NUM> may be at least about <NUM> greater than the second distance D<NUM>. This difference between the first and second distances D<NUM>, D<NUM> may enable a portion of the first and second flanges <NUM>, <NUM> between the first and second eyecups <NUM>, <NUM> to overlap when the first and second eyecups <NUM>, <NUM> are close together (e.g., at the second IPD setting IPD<NUM>), as shown in <FIG>. Thus, the difference between the first and second distances D<NUM>, D<NUM> may facilitate the positioning of the first and second eyecups <NUM>, <NUM> closer together than would otherwise be possible without the difference, since the first and second flanges <NUM>, <NUM> are at different levels and thus do not physically interfere with each other at the second IPD setting IPD<NUM>.

The single NED screen <NUM> may include an electronic display screen for presenting visual content to the user. For example, the single NED screen <NUM> may include a liquid crystal display (LCD), light-emitting diode (LED) display, organic LED (OLED) display, a waveguide for directing light from a projector to the user, and/or any other suitable type of display screen. In some embodiments, the single NED screen <NUM> may be configured for displaying respective stereoscopic images to the user through the first eyecup <NUM> and the second eyecup <NUM> to create an impression of a three-dimensional image.

<FIG> illustrates a detailed cross-sectional view of a portion of an HMD assembly 400A. Like the HMD assembly <NUM> described above with reference to <FIG>, the HMD assembly 400A of <FIG> may include a first eyecup <NUM> and a second eyecup <NUM> respectively disposed over a first transparent component <NUM> and a second transparent component <NUM>. The first eyecup <NUM> may include a first rigid housing <NUM> and the second eyecup <NUM> may include a second rigid housing <NUM>. A first flange <NUM> may extend radially outward from a sidewall of the first rigid housing <NUM>, and a second flange <NUM> may extend radially outward from a sidewall of the second rigid housing <NUM>. A first sealing element <NUM> may be positioned between the first flange <NUM> and the first transparent component <NUM> to form a seal (e.g., a hermetic seal) between the first eyecup <NUM> and the first transparent component <NUM>. Likewise, a second sealing element <NUM> may be positioned between the second flange <NUM> and the second transparent component <NUM> to form a seal (e.g., a hermetic seal) between the second eyecup <NUM> and the second transparent component <NUM>.

By way of example and not limitation, the first flange <NUM> may include a first groove <NUM> in which a portion of the first sealing element <NUM> may be positioned. Thus, the first sealing element <NUM> may be coupled to the first flange <NUM> and may be movable along with the first flange <NUM> relative to the first transparent component <NUM>. A first sliding interface <NUM> may be between the first sealing element <NUM> and the first transparent component <NUM>. Similarly, the second flange <NUM> may include a second groove <NUM> in which a portion of the second sealing element <NUM> may be positioned. The second sealing element <NUM> may be coupled to the second flange <NUM> and may be movable along with the second flange <NUM> relative to the second transparent component <NUM>. A second sliding interface <NUM> may be between the second sealing element <NUM> and the second transparent component <NUM>. In this case, to adjust for a user's IPD, the first and second eyecups <NUM>, <NUM> and the first and second sealing elements <NUM>, <NUM> may be movable relative to the first and second transparent components <NUM>, <NUM>.

<FIG> illustrates a detailed cross-sectional view of a portion of an HMD assembly 400B having a different configuration than the HMD assembly 400A of <FIG>. In this example, the first groove <NUM> may be located in the first transparent component <NUM> and a portion of the first sealing element <NUM> may be positioned in the first groove <NUM>. Thus, the first sliding interface <NUM> may be between the first sealing element <NUM> and the first flange <NUM>. Similarly, the second groove <NUM> may be located in the second transparent component <NUM> and a portion of the second sealing element <NUM> may be positioned in the second groove <NUM>. Thus, the second sliding interface <NUM> may be between the second sealing element <NUM> and the second flange <NUM>. In this case, to adjust for a user's IPD, the first and second eyecups <NUM>, <NUM> may be movable relative to the first and second transparent components <NUM>, <NUM> and relative to the first and second sealing elements <NUM>, <NUM>.

<FIG> is a perspective view of a portion of an HMD assembly <NUM>, according to additional embodiments of the present disclosure. Some components of the HMD assembly <NUM> are removed in <FIG> to better view underlying portions of the HMD assembly <NUM>. The HMD assembly <NUM> of <FIG> may be similar to the HMD assembly <NUM> described above with reference to <FIG>. For example, the HMD assembly <NUM> may include a first eyecup <NUM> and a second eyecup <NUM> positioned over a single NED screen <NUM>. The eyecups <NUM>, <NUM> and the single NED screen <NUM> may be coupled to and supported by an HMD support frame <NUM>. The first eyecup <NUM> may include a first rigid housing <NUM> to which a first optical lens <NUM> may be coupled. The second eyecup <NUM> may include a second rigid housing <NUM> to which a second optical lens (not shown in the view of <FIG> for clarity) may be coupled. The first rigid housing <NUM> may at least partially define a first interior volume <NUM> of the first eyecup <NUM>. Similarly, the second rigid housing <NUM> may at least partially define a second interior volume <NUM> of the second eyecup <NUM>.

The first and second eyecups <NUM>, <NUM> may be positioned over and movable relative to an enclosure <NUM> (shown in dashed lines in <FIG>) that may be positioned over the single NED screen <NUM>. The enclosure <NUM> may be hermetically sealed to inhibit the introduction of contamination on a user-facing surface of the single NED screen <NUM>.

The eyecups <NUM>, <NUM> may be movable relative to each other and/or relative to the single NED screen <NUM>, such as to adjust for the user's IPD. The HMD assembly <NUM> of <FIG> may also include an IPD adjustment mechanism <NUM>, which may include a track <NUM> (e.g., a rod, a slide, etc.), a first IPD adjustment bracket <NUM> slidably coupling the first rigid housing <NUM> to the track <NUM>, and a second IPD adjustment bracket <NUM> slidably coupling the second rigid housing <NUM> to the track <NUM>. The IPD adjustment mechanism <NUM> may, in some examples, also include one or more IPD input mechanisms (not shown in the view of <FIG>, but similar to the IPD input mechanism <NUM> described above) with which the user may interact to control the movement of the eyecups <NUM>, <NUM> for IPD adjustments. In addition or alternatively, a cam, pusher, electromechanical actuator (e.g., a motor, a linear actuator, etc.), or other suitable component may be included to move the IPD adjustment brackets <NUM>, <NUM> and eyecups <NUM>, <NUM> along the track <NUM>.

As illustrated in <FIG>, the IPD adjustment brackets <NUM>, <NUM> may, in some embodiments, each include two spaced apart slider elements <NUM> engaged with and movable along the track <NUM>, such as to provide sufficient stability to the respective eyecups <NUM>, <NUM>. The slider elements <NUM> may be engaged with the track <NUM> in a manner that maintains the eyecups <NUM>, <NUM> in position after an IPD adjustment is made. In some examples, a detent mechanism <NUM> (shown in <FIG> in dashed lines) may be employed to maintain the eyecups <NUM>, <NUM> in their relative position after an IPD adjustment is made. For example, the detent mechanism <NUM> may include a ratchet, a frictional interface, a pin and rack, or another suitable mechanism for maintaining the relative positions of the eyecups <NUM>, <NUM>. In some examples, the HMD assembly <NUM> may optionally include another set of a track and IPD adjustment brackets positioned on an opposite side of the eyecups <NUM>, <NUM> from the track <NUM> and IPD adjustment brackets <NUM>, <NUM> shown in <FIG>, such as for additional mechanical stability.

<FIG> is a front view of an HMD assembly <NUM> that may include a first eyecup <NUM> (e.g., a left eyecup for positioning a first optical lens over a left eye of an intended user) and a second eyecup <NUM> (e.g., a right eyecup for positioning a second optical lens over a right eye of the intended user) positioned over a single NED screen <NUM>. As discussed above, an enclosure may be positioned between the eyecups <NUM>, <NUM> and the single NED screen <NUM>. The eyecups <NUM>, <NUM>, and single NED screen may be mounted on an HMD support frame <NUM>.

The eyecups <NUM>, <NUM> may be movable relative to the HMD support frame <NUM> and/or relative to each other to adjust for a user's IPD. For example, each of the eyecups <NUM>, <NUM> may be slidably coupled to and movable along an upper track <NUM> (e.g., a rod, a slide, etc.) that may be mounted on the HMD support frame <NUM>. The eyecups <NUM>, <NUM> may also be respectively slidably coupled to and movable along a first lower track <NUM> and a second lower track <NUM> that may be mounted on the HMD support frame <NUM>. The first lower track <NUM> and second lower track <NUM> may be positioned on opposite sides of the eyecups <NUM>, <NUM> from the upper track <NUM>. As illustrated in <FIG>, in some examples the first lower track <NUM> and second lower track <NUM> may be separated from each other, such as to accommodate an intended user's nose. In additional examples, the first lower track <NUM> and second lower track <NUM> may be portions of a single, integral, unitary track.

The HMD assembly <NUM> may also include a detent mechanism <NUM> to maintain the eyecups <NUM>, <NUM> in position relative to each other and relative to the HMD support frame <NUM>. In some embodiments, the detent mechanism <NUM> may also be configured to keep each of the eyecups <NUM>, <NUM> substantially equidistant from a lateral centerline of the HMD assembly <NUM>. As illustrated in <FIG>, the detent mechanism <NUM> may include a first rack <NUM> extending inward from the first eyecup <NUM>, a second rack <NUM> extending inward from the second eyecup <NUM>, and a pinion <NUM> engaged with the first rack <NUM> and second rack <NUM>. The pinion <NUM> may be rotatably coupled to the HMD support frame <NUM>. Teeth of the pinion <NUM> may be engaged with teeth of the first rack <NUM> on a first side of the pinion <NUM> and with teeth of the second rack <NUM> on a second, opposite side of the pinion <NUM>. Thus, when the first eyecup <NUM> moves inward (e.g., to the right from the perspective of <FIG>), the second eyecup <NUM> may also move inward (e.g., to the left from the perspective of <FIG>) due to rotation of the pinion <NUM>. Similarly, when the first eyecup <NUM> moves outward (e.g., to the left from the perspective of <FIG>), the second eyecup <NUM> may also move outward (e.g., to the right from the perspective of <FIG>) due to rotation of the pinion <NUM> in an opposite direction.

The detent mechanism <NUM> may include a feature that enables the eyecups <NUM>, <NUM> to be maintained in position once moved. For example, the eyecups <NUM>, <NUM> may be maintained in two, three, four, or five distinct positions by the detent mechanism <NUM>. An example embodiment of the detent mechanism <NUM> capable of maintaining the eyecups <NUM>, <NUM> in position is illustrated in <FIG> and <FIG>.

<FIG> is a back view of the detent mechanism <NUM>, and <FIG> is a side view of the detent mechanism <NUM>. As shown in <FIG>, the pinion <NUM> may be mounted on a detent base <NUM>. As shown in <FIG> and <FIG>, the detent base <NUM> may include grooves <NUM> in a back face thereof that is opposite the pinion <NUM>. One or more detent extensions <NUM> may be mounted to the HMD support frame <NUM> (<FIG>). In the embodiment shown, there are two detent extensions <NUM>, although a single detent extensions <NUM> or more than two detent extensions <NUM> may be used in additional embodiments. The detent extensions <NUM> may be biased (e.g., spring-loaded) toward the detent base <NUM> and positioned relative to at least one of the grooves <NUM> to protrude into the respective grooves <NUM> when the detent extensions <NUM> and the grooves <NUM> are aligned with each other.

For example, as shown in <FIG> and <FIG>, the detent extensions <NUM> may include a ball that is biased toward the detent base <NUM> by a coil spring <NUM>. However, the detent extensions <NUM> of the present disclosure are not limited to this configuration. In additional embodiments, the detent extensions <NUM> may have a cylindrical shape, a hemispherical shape, a pin shape, a shaft with a rounded end, a shaft with an angled end (e.g., having a triangular or trapezoidal longitudinal cross section), or any other suitable shape. In addition, the detent extension <NUM> may be biased toward the detent base <NUM> with a biasing element that is not a coil spring, such as a leaf spring, an elastomer, or another suitable biasing element.

The detent mechanism <NUM> may be configured to position the eyecups <NUM> at predetermined IPD settings. For example, the eyecups <NUM>, <NUM> may be moved inward or outward by a user applying an inward or outward physical force directly on one or both of the eyecups <NUM>, <NUM>. In additional embodiments, an IPD adjustment mechanism may be used, such as the IPD adjustment mechanism <NUM> described above with reference to <FIG> or an electromechanical actuator. When the eyecups <NUM>, <NUM> (<FIG>) are moved inward or outward, the first rack <NUM> and/or the second rack <NUM> may interact with the pinion <NUM> to rotate the pinion <NUM>. Rotation of the pinion <NUM> may in turn rotate the detent base <NUM>. As the detent base <NUM> rotates, the detent extensions <NUM> may be forced out of the respective grooves <NUM> against the biasing force applied by the coil spring <NUM>. As the detent base <NUM> continues to rotate, the detent extensions <NUM> may be biased into other adjacent grooves <NUM>, providing a tactile indication (e.g., a snap or click) to the user that the eyecups <NUM>, <NUM> are at a predetermined IPD setting. The grooves <NUM> may be sized and spaced to correspond to a certain number of predetermined IPD settings, such as two (e.g., large and small), three (e.g., large, medium, and small), four, or five predetermined IPD settings. In one example, the grooves <NUM> may be sized and spaced to correspond to a first small IPD setting of about <NUM> measured between optical axes of the eyecups <NUM>, <NUM>, a second medium IPD setting of about <NUM>, and a third large IPD setting of about <NUM>.

Referring again to <FIG>, in some examples, the HMD assembly <NUM> may also include an IPD indicator <NUM> to provide an indication of the current IPD setting. For example, the IPD indicator <NUM> may include an aperture through a structure coupled to either the first eyecup <NUM> or the second eyecup <NUM>. Beneath the aperture, there may be a visual indication of the IPD setting. For example, the visual indication may include the letters S, M, and L corresponding to a small, medium, and large IPD setting. Other example visual indications may include numbers (e.g., <NUM> through <NUM> corresponding to five IPD settings, or <NUM>, <NUM>, and <NUM> corresponding to the IPD setting in millimeters, etc.), other letters (e.g., A through D corresponding to four IPD settings, "min," "med," and "max" corresponding to minimum, medium, and maximum IPD settings, etc.), colors (e.g., green, yellow, and red corresponding to three IPD settings, etc.), a diagram (e.g., showing eyes at different distances from each other, etc.), or combinations thereof. When the detent mechanism <NUM> is used to set the eyecups <NUM>, <NUM> to one of the predetermined IPD settings, the aperture of the IPD indicator <NUM> may be aligned with one of the visual indications of the IPD settings, such that a user can view the visual indication through the aperture to determine the current IPD setting.

Even with the detent mechanism <NUM>, the HMD assembly <NUM> may benefit from a position sensor to accurately measure and/or verify the current IPD setting of the HMD assembly <NUM>. <FIG> illustrates a portion of an HMD assembly <NUM> with an IPD position sensor <NUM>. In some respects, the HMD assembly <NUM> may be similar to the HMD assembly <NUM> of <FIG>. For example, the HMD assembly <NUM> may include a first eyecup <NUM>, a second eyecup <NUM>, a single NED screen <NUM>, a track <NUM> along which the eyecups <NUM>, <NUM> may be movable for adjusting an IPD setting, an HMD support frame <NUM>, a detent mechanism <NUM>, and an IPD indicator <NUM>.

The IPD position sensor <NUM> may be configured to sense a lateral position of one or both of the eyecups <NUM>, <NUM> relative to each other and/or relative to the HMD support frame <NUM>. For example, the IPD position sensor <NUM> may include a Hall effect sensor, a rotary encoder, a linear encoder, or another suitable position sensor. In the example shown in <FIG>, the IPD position sensor <NUM> is illustrated as a Hall effect sensor configured to sense a magnitude of a magnetic field of a moving magnet. The IPD position sensor <NUM> may include a probe <NUM> mounted to the HMD support frame <NUM> and a permanent magnet <NUM> mounted to one of the eyecups <NUM>, <NUM>. When the eyecups <NUM>, <NUM> are laterally moved, the permanent magnet <NUM> may move relative to the probe <NUM>. The movement of the permanent magnet <NUM> may result in a change in magnitude of a magnetic field sensed by the probe <NUM>. This change in magnitude sensed by the probe <NUM> may be correlated to a relative position between the probe <NUM> and the permanent magnet <NUM>, and ultimately to a relative position between the eyecups <NUM>, <NUM>. The data from the IPD position sensor <NUM> may be used to determine the actual IPD setting of the eyecups <NUM>, <NUM>, such as for use by software to adjust an image displayed on the single NED screen <NUM>, to provide an indication to the user of the IPD setting, etc..

In the embodiment illustrated in <FIG>, the probe <NUM> is mounted on the HMD support frame <NUM> and the permanent magnet <NUM> is mounted on one of the eyecups <NUM>, <NUM>. However, the present disclosure is not limited to this configuration. In additional embodiments, the probe <NUM> may be mounted on one of the eyecups <NUM>, <NUM> and the permanent magnet <NUM> may be mounted on the HMD support frame <NUM>, or the probe may be mounted on one of the eyecups <NUM>, <NUM> and the permanent magnet <NUM> may be mounted on the other of the eyecups <NUM>, <NUM>. In yet further embodiments, the permanent magnet <NUM> may be replaced by a non-permanent magnet, such as an electromagnet. In additional embodiments, as noted above, the IPD position sensor <NUM> may be another type of position sensor other than a Hall effect sensor.

<FIG> is a flow diagram illustrating a method <NUM> of fabricating an HMD assembly, according to at least one embodiment of the present disclosure. At operation <NUM>, a first transparent component and a second transparent component may be positioned and hermetically sealed over a single NED screen to form an enclosure. Operation <NUM> may be performed in a variety of ways. For example, the first transparent component may be positioned a first distance from the single NED screen and the second transparent component may be positioned a second, different distance from the single NED screen. In some embodiments, the hermetic seal may be accomplished with sealing structure that may couple the transparent components to the single NED screen.

At operation <NUM>, a first eyecup supporting a first lens may be slidably positioned over the first transparent component. Operation <NUM> may be performed in a variety of ways. For example, a first sealing element may be positioned between the first eyecup and the first transparent component. A first sliding interface may be between the first eyecup and the first sealing element or, alternatively, may be between the first transparent component and the first sealing element.

At operation <NUM>, a second eyecup supporting a second lens may be slidably positioned over the second transparent component. Operation <NUM> may be performed in a variety of ways. For example, a second sealing element may be positioned between the second eyecup and the second transparent component. A second sliding interface may be between the second eyecup and the second sealing element or, alternatively, may be between the second transparent component and the second sealing element. The first eyecup and the second eyecup may be movable relative to each other, such as to adjust for an IPD of a user of the HMD assembly. In some embodiments, the respective distances between the single NED screen and the first and second transparent components may be different, such as to allow flanges extending radially outward from the eyecups to at least partially overlap each other when an IPD setting of the eyecups is at its minimum operating position.

In some examples, the method <NUM> may also include additional operations. For example, an IPD adjustment mechanism may be assembled to the first eyecup and to the second eyecup in a position to move the first eyecup and the second eyecup relative to each other, such as to adjust for an IPD.

<FIG> is a flow diagram illustrating a method <NUM> of adjusting an interpupillary distance of an HMD assembly, according to at least one embodiment of the present disclosure. At operation <NUM>, a first eyecup may be moved over a fist transparent component that is positioned over a single NED screen. At operation <NUM>, a second may be moved over a second transparent component that is positioned over the single NED screen. Operations <NUM> and <NUM> may be performed in a variety of ways. For example, the eyecups may be moved toward or away from each other to adjust for a user's IPD. The single NED screen, the first transparent component, and the second transparent component may define a hermetically sealed enclosure.

Accordingly, the present disclosure includes HMD assemblies and related methods that may enable IPD adjustments that inhibit (e.g., reduce or eliminate) the introduction of contamination onto a display screen. At the same time, the disclosed HMD assemblies may include a single NED screen, which may reduce a cost of fabricating and operating the HMD assemblies. Various configurations and materials are disclosed, each of which may be advantageously employed for a variety of uses and applications.

As noted above, embodiments of the present disclosure may include or be implemented in conjunction with various types of artificial-reality systems. Artificial-reality content may include video, audio, haptic feedback, or some combination thereof, any of which may be presented in a single channel or in multiple channels (such as stereo video that produces a three-dimensional (3D) effect to the viewer). Additionally, in some embodiments, artificial reality may also be associated with applications, products, accessories, services, or some combination thereof, that are used to, e.g., create content in an artificial reality and/or are otherwise used in (e.g., to perform activities in) an artificial reality.

Artificial-reality systems may be implemented in a variety of different form factors and configurations. Artificial-reality systems may include an NED that provides visibility into the real world (e.g., an augmented-reality system) or that visually immerses a user in an artificial reality (e.g., virtual-reality system <NUM> in <FIG>). While some artificial-reality devices may be self-contained systems, other artificial-reality devices may communicate and/or coordinate with external devices to provide an artificial-reality experience to a user. Examples of such external devices include handheld controllers, mobile devices, desktop computers, devices worn by a user, devices worn by one or more other users, and/or any other suitable external system.

As noted, some artificial-reality systems may substantially replace one or more of a user's sensory perceptions of the real world with a virtual experience. One example of this type of system is a head-worn display system, such as the virtual-reality system <NUM> in <FIG>, that mostly or completely covers a user's field of view. The virtual-reality system <NUM> may include a front rigid body <NUM> and a band <NUM> shaped to fit around a user's head. The virtual-reality system <NUM> may also include output audio transducers <NUM>(A) and <NUM>(B). Furthermore, while not shown in <FIG>, the front rigid body <NUM> may include one or more electronic elements, including one or more electronic displays, one or more inertial measurement units (IMUs), one or more tracking emitters or detectors, and/or any other suitable device or system for creating an artificial reality experience.

Artificial-reality systems may include a variety of types of visual feedback mechanisms. For example, display devices in the virtual-reality system <NUM> may include one or more liquid crystal displays (LCDs), light-emitting diode (LED) displays, organic LED (OLED) displays, and/or any other suitable type of display screen. As discussed above artificial-reality systems may include a single display screen for both eyes. Some artificial-reality systems may also include optical subsystems having one or more lenses (e.g., conventional concave or convex lenses, Fresnel lenses, adjustable liquid lenses, etc.) through which a user may view a display screen.

In addition to or instead of using display screens, some artificial-reality systems may include one or more projection systems. For example, display devices in the virtual-reality system <NUM> may include micro-LED projectors that project light (using, e.g., a waveguide) into display devices, such as clear combiner lenses that allow ambient light to pass through. The display devices may refract the projected light toward a user's pupil and may enable a user to simultaneously view both artificial-reality content and the real world. Artificial-reality systems may also be configured with any other suitable type or form of image projection system.

Artificial-reality systems may also include various types of computer vision components and subsystems. For example, the virtual-reality system <NUM> may include one or more optical sensors, such as two-dimensional (2D) or 3D cameras, time-of-flight depth sensors, single-beam or sweeping laser rangefinders, 3D LiDAR sensors, and/or any other suitable type or form of optical sensor. An artificial-reality system may process data from one or more of these sensors to identify a location of a user, to map the real world, to provide a user with context about real-world surroundings, and/or to perform a variety of other functions.

Artificial-reality systems may also include one or more input and/or output audio transducers. In the example shown in <FIG>, the output audio transducers <NUM>(A), and <NUM>(B) may include voice coil speakers, ribbon speakers, electrostatic speakers, piezoelectric speakers, bone conduction transducers, cartilage conduction transducers, and/or any other suitable type or form of audio transducer. Similarly, input audio transducers may include condenser microphones, dynamic microphones, ribbon microphones, and/or any other type or form of input transducer. In some embodiments, a single transducer may be used for both audio input and audio output.

While not shown in <FIG>, artificial-reality systems may include tactile (i.e., haptic) feedback systems, which may be incorporated into headwear, gloves, body suits, handheld controllers, environmental devices (e.g., chairs, floormats, etc.), and/or any other type of device or system. Haptic feedback systems may provide various types of cutaneous feedback, including vibration, force, traction, texture, and/or temperature. Haptic feedback systems may also provide various types of kinesthetic feedback, such as motion and compliance. Haptic feedback may be implemented using motors, piezoelectric actuators, fluidic systems, and/or a variety of other types of feedback mechanisms. Haptic feedback systems may be implemented independent of other artificial-reality devices, within other artificial-reality devices, and/or in conjunction with other artificial-reality devices.

By providing haptic sensations, audible content, and/or visual content, artificial-reality systems may create an entire virtual experience or enhance a user's real-world experience in a variety of contexts and environments. For instance, artificial-reality systems may assist or extend a user's perception, memory, or cognition within a particular environment. Some systems may enhance a user's interactions with other people in the real world or may enable more immersive interactions with other people in a virtual world. Artificial-reality systems may also be used for educational purposes (e.g., for teaching or training in schools, hospitals, government organizations, military organizations, business enterprises, etc.), entertainment purposes (e.g., for playing video games, listening to music, watching video content, etc.), and/or for accessibility purposes (e.g., as hearing aids, visuals aids, etc.). The embodiments disclosed herein may enable or enhance a user's artificial-reality experience in one or more of these contexts and environments and/or in other contexts and environments.

As noted, the artificial-reality system <NUM> may be used with a variety of other types of devices to provide a more compelling artificial-reality experience. These devices may include haptic interfaces with transducers that provide haptic feedback and/or that collect haptic information about a user's interaction with an environment. The artificial-reality systems disclosed herein may include various types of haptic interfaces that detect or convey various types of haptic information, including tactile feedback (e.g., feedback that a user detects via nerves in the skin, which may also be referred to as cutaneous feedback) and/or kinesthetic feedback (e.g., feedback that a user detects via receptors located in muscles, joints, and/or tendons).

Haptic feedback may be provided by interfaces positioned within a user's environment (e.g., chairs, tables, floors, etc.) and/or interfaces on articles that may be worn or carried by a user (e.g., gloves, wristbands, etc.). As an example, a vibrotactile system may be in the form of a wearable glove and/or wristband. The haptic device may include a flexible, wearable textile material that is shaped and configured for positioning against a user's hand and wrist, respectively. This disclosure also includes vibrotactile systems that may be shaped and configured for positioning against other human body parts, such as a finger, an arm, a head, a torso, a foot, or a leg. By way of example and not limitation, vibrotactile systems according to various embodiments of the present disclosure may also be in the form of a glove, a headband, an armband, a sleeve, a head covering, a sock, a shirt, or pants, among other possibilities. In some examples, the term "textile" may include any flexible, wearable material, including woven fabric, non-woven fabric, leather, cloth, a flexible polymer material, composite materials, etc..

Haptic wearables may be implemented in a variety of types of artificial-reality systems and environments. <FIG> shows an example artificial-reality environment <NUM> including one head-mounted virtual-reality display and two haptic devices (i.e., gloves), and in other embodiments any number and/or combination of these components and other components may be included in an artificial-reality system. For example, in some embodiments there may be multiple head-mounted displays each having an associated haptic device, with each head-mounted display and each haptic device communicating with the same console, portable computing device, or other computing system.

Head-mounted display <NUM> generally represents any type or form of virtual-reality system, such as the virtual-reality system <NUM> in <FIG>. Haptic device <NUM> generally represents any type or form of wearable device, worn by a use of an artificial-reality system, that provides haptic feedback to the user to give the user the perception that he or she is physically engaging with a virtual object. In some embodiments, the haptic device <NUM> may provide haptic feedback by applying vibration, motion, and/or force to the user. For example, the haptic device <NUM> may limit or augment a user's movement. To give a specific example, the haptic device <NUM> may limit a user's hand from moving forward so that the user has the perception that his or her hand has come in physical contact with a virtual wall. In this specific example, one or more actuators within the haptic advice may achieve the physical-movement restriction by pumping fluid into an inflatable bladder of the haptic device. In some examples, a user may also use the haptic device <NUM> to send action requests to a console. Examples of action requests include, without limitation, requests to start an application and/or end the application and/or requests to perform a particular action within the application.

The haptic devices <NUM> may include any suitable number and/or type of haptic transducer, sensor, and/or feedback mechanism. For example, the haptic devices <NUM> may include one or more mechanical transducers, piezoelectric transducers, and/or fluidic transducers. The haptic devices <NUM> may also include various combinations of different types and forms of transducers that work together or independently to enhance a user's artificial-reality experience.

The process parameters and sequence of the steps described and/or illustrated herein are given by way of example only and can be varied as desired.

The preceding description has been provided to enable others skilled in the art to best utilize various aspects of the example embodiments disclosed herein. This example description is not intended to be exhaustive or to be limited to any precise form disclosed. Many modifications and variations are possible without departing from the scope of the claims. The embodiments disclosed herein should be considered in all respects illustrative and not restrictive. Reference should be made to the appended claims in determining the scope of the claimed invention.

Claim 1:
A head-mounted display assembly, comprising:
a first eyecup (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) and a second eyecup (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) configured for respectively positioning a first lens and a second lens in front of intended locations of a user's eyes when the head-mounted display assembly is donned by the user;
a single near-eye display screen configured for displaying an image to the user through the first eyecup and the second eyecup (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>); and
an enclosure (<NUM>, <NUM>) over the single near-eye display screen, the enclosure (<NUM>, <NUM>) comprising: a first transparent component (<NUM>, <NUM>, <NUM>) positioned between the first lens and the single near-eye display screen; and a second transparent component (<NUM>, <NUM>, <NUM>) positioned between the second lens and the single near-eye display screen,
wherein the first eyecup (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) and the second eyecup (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) are movable relative to each other and relative to the first transparent component (<NUM>, <NUM>, <NUM>) and the second transparent component (<NUM>, <NUM>, <NUM>) to adjust for an interpupillary distance of the user's eyes; and
characterized in that
the first transparent component (<NUM>, <NUM>, <NUM>) and the second transparent component (<NUM>, <NUM>, <NUM>) are positioned a distance from the single near-eye display screen such that contaminants disposed on the first transparent component (<NUM>, <NUM>, <NUM>) and the second transparent component (<NUM>, <NUM>, <NUM>) are substantially out of focus to a user viewing the single near-eye display screen through the first lens and the second lens.