Strap assembly, system, and method for head-mounted displays

1. A head-mounted-display strap assembly comprising:

a flexible lining member comprising:

a head-contact layer positioned to abut a head portion of a user;

a mounting layer positioned to be mounted to a backing member, the mounting layer overlapping the head-contact layer and defining a wiring channel; and

a mesh layer disposed between the head-contact layer and the mounting layer such that a portion of the mesh layer overlaps the wiring channel, the mesh layer comprising a mesh fabric including a plurality of interconnected fibers, wherein the mounting layer comprises a thermoplastic polymer attaching the mounting layer to the mesh layer.

2. The head-mounted-display strap assembly of claim 1 , further comprising an electronic cable at least partially disposed within the wiring channel defined by the mounting layer.

3. The head-mounted-display strap assembly of claim 2 , further comprising the backing member comprising a mounting surface, wherein:

the mounting layer of the flexible lining member is disposed adjacent to the mounting surface of the backing member; and

at least a portion of the electronic cable is positioned between the mesh layer and the backing member.

4. The head-mounted-display strap assembly of claim 3 , wherein the mounting layer of the flexible lining member is attached to the mounting surface of the backing member.

5. The head-mounted-display strap assembly of claim 3 , wherein:

a mounting recess is defined within the backing member, a portion of the mounting recess being defined by the mounting surface; and

at least a portion of the flexible lining member is disposed within the mounting recess.

6. The head-mounted-display strap assembly of claim 1 , wherein the thermoplastic polymer is bonded to the mesh layer.

7. The head-mounted-display strap assembly of claim 1 , wherein at least a portion of the thermoplastic polymer is disposed within a plurality of holes defined in the mesh layer.

8. The head-mounted-display strap assembly of claim 1 , wherein the mesh layer comprises a polymeric mesh fabric.

9. The head-mounted-display strap assembly of claim 1 , wherein the flexible lining member defines an opening extending through the head-contact layer, the mounting layer, and the mesh layer.

10. The head-mounted-display strap assembly of claim 9 , wherein the mesh layer defines a plurality of slits surrounding the opening.

11. A head-mounted-display system comprising:

a head-mounted display; and

a strap assembly coupled to the head-mounted display, the strap assembly comprising:

a backing member;

a flexible lining member mounted to the backing member, the flexible lining member comprising:

a head-contact layer positioned to abut a head portion of a user;

a mounting layer overlapping the head-contact layer, the mounting layer abutting the backing member and defining a wiring channel; and

a mesh layer disposed between the head-contact layer and the mounting layer such that a portion of the mesh layer overlaps the wiring channel, the mesh layer comprising a mesh fabric including a plurality of interconnected fibers, wherein the mounting layer comprises a thermoplastic polymer attaching the mounting layer to the mesh layer; and

an electronic cable at least partially disposed within the wiring channel defined by the mounting layer such that at least a portion of the electronic cable is positioned between the mesh layer and the backing member.

12. The head-mounted-display system of claim 11 , wherein the strap assembly comprises a back piece defining an opening extending through the backing member and the flexible lining member.

13. The head-mounted-display system of claim 11 , wherein the thermoplastic polymer is bonded to the mesh layer and to a mounting surface of the backing member.

14. The head-mounted-display system of claim 11 , wherein the mesh layer comprises a polymeric mesh fabric.

15. A method comprising:

attaching a head-contact layer for a head-mounted-display strap assembly to a mesh layer comprising a mesh fabric including a plurality of interconnected fibers; and

attaching a mounting layer to the mesh layer such that the mesh layer is disposed between the head-contact layer and the mounting layer, the mounting layer defining a wiring channel, and a portion of the mesh layer overlapping the wiring channel, wherein:

the head-contact layer is positioned to abut a head portion of a user;

the mounting layer is positioned to be mounted to a backing member; and

the mounting layer comprises a thermoplastic polymer attaching the mounting layer to the mesh layer.

16. The method of claim 15 , wherein attaching the mounting layer to the mesh layer comprises heating the mounting layer to a temperature sufficient to bond the thermoplastic polymer to the mesh layer.

17. The method of claim 15 , further comprising positioning at least a portion of an electronic cable within the wiring channel.

18. The method of claim 17 , further comprising attaching the mounting layer to the backing member such that at least the portion of the electronic cable is positioned between the mesh layer and the backing member.

19. The method of claim 18 , wherein attaching the mounting layer to the backing member comprises heating the mounting layer to a temperature sufficient to bond the thermoplastic polymer to a mounting surface of the backing member.

20. The method of claim 15 , wherein attaching the head-contact layer to the mesh layer comprises bonding the head-contact layer to the mesh layer by a bonding layer disposed between the head-contact layer and the mesh layer.