On Thursday, the U.S. Patent Office published a patent application of Apple's that relates to a way of making the Apple Vision Pro lighter using a new cartridge system that goes far beyond a simple power pack. The cartridge(s) could also be used as a controller device with cooling fans and connect to various parts of the headset, to the user or on a table.

Apple notes in their patent background that Head-mountable displays (HMDs) are developed to be comfortably worn for extended periods of time. The ever increasing desire to improve performance, functionality, and battery life of HMDs results in a device that includes several electrical components, each of which add weight to the system. There is a constant balance between maximizing user comfort while maintaining or excelling the performance and functionality of the device. Unbalanced weight distribution experienced by a user while wearing the head-mountable display, particularly weight distributed in front of the user's face, can negatively impact the user's experience. Thus, there is a need for a light-weight HMD assembly that does not sacrifice performance or functionality.

Further, the desire to improve functionality and performance while reducing the form factor of the device creates a challenge of properly cooling or ventilating the device. Accordingly, there is a need to more efficiently dissipate heat from the HMD.

Apple's patent application covers systems and methods provide an HMD with a removable or deployable cartridge. The cartridge can include one or more electronic components of the HMD. For example, the cartridge can include at least one of a processor, a battery, memory, sensors, or fans of the HMD. In some examples, the cartridge can be referred to as a processing cartridge, a puck, an accessory, an electronic accessory, or a processor. As used herein, “cartridge” can refer to any container, enclosure, or housing that carries components and is made ready for insertion into or attachment on an HMD.

In some examples, the cartridge can include a housing to contain the various components of the cartridge. The housing can be made from metal, plastic, or any other suitable material to protect and house electronic components.

In some examples, the cartridge can weigh approximately 100-150 grams. The cartridge can account for approximately 25-30% of the weight of the assembly. Thus, removing the cartridge from the HMD can greatly enhance wearer comfort, even over extended periods of time.

The cartridge can be housed, attached, mounted, or otherwise carried by the HMD. As used herein, “HMD assembly”, “assembly”, or system can refer to the HMD (i.e., display unit) and the cartridge, regardless of whether the cartridge is attached or deployed from the HMD. The HMD assembly can include an attachment interface to removably connect the cartridge and the HMD. The attachment interface can include features present on both the cartridge and the HMD. In some examples, the attachment interface is solely on the cartridge or the HMD and engages with parts of the other to attach.

The HMD can include a housing that at least partially forms a slot, a hole, a cavity or a recess to receive the cartridge. As used herein, a “slot” can refer to any hole, gap, cavity, recess, or depression and is not limited to any particular geometry. The cartridge can sit in the slot and can be removed as desired by the user. Thus, the HMD assembly can include multiple configurations or modes. In a first mode, the cartridge can be positioned within the slot. While the cartridge is positioned in the slot, the cartridge can provide image data to the HMD via a cable connection or a direct electrical connection. In a second configuration, the cartridge can be removed from the slot. When removed from the slot, the cartridge can still provide image data to the HMD via a wired or wireless connection. When removed, the cartridge can be positioned in many different convenient locations. For example, the cartridge can be held by the user, placed in a pocket, placed on a table or desk, attached to the HMD retention band, and the like.

Further, the desire to improve functionality and performance while reducing the form factor of the device creates a challenge of properly cooling or ventilating the device to prevent overheating. Accordingly, there is a need to more efficiently dissipate heat from the HMD. The deployable cartridge can advantageously reduce heat within the system by including one or more on-board fans to cool the internal volume of the cartridge and/or the internal volume of the HMD. Further, when the cartridge is removed from the HMD, the internals of the HMD can more efficiently dissipate heat through the volume of the cavity left by removed the cartridge.

In some examples, the cartridge can include one or more input elements for the user to provide input to the HMD. In other words, the cartridge can include a remote controller or other input functionality for the HMD. Thus, the cartridge can include the CPU for the controller, the power source for the HMD, and also include input elements for the HMD, all while not being integrally or structurally attached to the HMD.

The cartridge can include a wide range of sensors in order to detect the environment of the cartridge. The sensors on the cartridge can include visual sensors, thermal sensors, motion sensors, light sensors, force sensors, moisture sensors, audio sensors, capacitive sensors, and the like.

 In some examples, the cartridge can include a triangulated IMU system that can use sensor fusion with visual inputs to detect inputs on the virtual keyboard. Visual sensors from the HMD can be combined with sensors from the cartridge to generate the virtual keyboard.

For full details, review Apple's patent application 20250044833. Inventors includes Apple's Paul X Wang and Jeremey Franklin.