Patent Application
20240240777
The present disclosure relates to lighting systems, and more particularly to headlamps.
Headlamps are typically configured to be attached to a user's head or to a hardhat via an attachment mechanism. Headlamps include a light source, which may for example, include a single LED or a plurality of LEDs. The light source is configured to illuminate an area in front of the user. Some headlamps may include a battery pack attached to the headlamp and electrically coupled to the light source to provide power to the light source.
The present disclosure provides, in one aspect, a headlamp that includes a first light assembly including a first LED operable in a first plurality of lighting modes and a second light assembly electrically coupled to the first light assembly. The second light assembly includes a second LED operable in a second plurality of lighting modes, a battery receptacle configured to receive a battery pack, and an actuator operable to toggle the first LED between the first plurality of lighting modes and the second LED between the second plurality of lighting modes.
The present disclosure provides, in another aspect, a headlamp that includes a first light assembly including a first LED and a second light assembly electrically coupled to the first light assembly. The second light assembly includes a housing, a battery pack positioned within the housing, a circuit board positioned between the battery pack and the housing, a second LED supported by the circuit board, a support pad positioned on the battery pack and engaging the circuit board to maintain a space therebetween, and an actuator operable to control operation of the first LED and the second LED.
The present disclosure provides, in another aspect, a headlamp that includes a strap configured to conform to a user's head or to a hardhat, and a first light assembly coupled to the strap. The first light assembly includes a flexible housing and a plurality of first LEDs operable in a first plurality of lighting modes. The headlamp includes a second light assembly coupled to the strap and spaced apart from the first light assembly. The second light assembly includes a second LED operable in a second plurality of lighting modes, a battery receptacle configured to receive a battery pack, and an actuator operable to toggle the plurality of first LEDs between the first plurality of lighting modes and the second LED between the second plurality of lighting modes based upon an amount of time the actuator is depressed. The headlamp also includes a wire extending from the second light assembly to the first light assembly to electrically couple the battery receptacle to the plurality of first LEDs.
Other features and aspects of the disclosure will become apparent by consideration of the following detailed description and accompanying drawings.
Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
Features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the disclosure.
As used herein, the terms “first”, “second”, and “third” maybe used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. The terms “coupled,” “fixed,” “attached to,” and the like refer to both direct coupling, fixing, or attaching, as well as indirect coupling, fixing, or attaching through one or more intermediate components or features, unless otherwise specified herein. As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive- or and not to an exclusive- or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
Terms of approximation, such as “generally,” “approximately,” or “substantially,” include values within ten percent greater or less than the stated value. When used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction. For example, “generally vertical” includes directions within ten degrees of vertical in any direction, e.g., clockwise or counter-clockwise.
Benefits, other advantages, and solutions to problems are described below with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.
In the illustrated embodiment, the strap 14 comprises an elastic material that can be stretched to surround the user's head or the hardhat. The strap 14 is configured to be secured or conform to a user's head or to the hardhat. In other embodiments, the strap 14 maybe a semi-rigid flexible material. The strap 14 includes a main portion 14a and an adjustable portion 14b. The main portion 14a of the strap 14 includes a first end and a second end. The first end of the main portion 14a of the strap 14 is coupled to a first slide buckle 30a, and the second end of the main portion 14a of the strap 14 is coupled a second slide buckle 30b. The adjustable portion 14b of the strap 14 is attached to both the first slide buckle 30a and the second slide buckle 30b such that the strap 14 forms a loop. The adjustable portion 14b may be elongated or shortened by adjusting the attachment of the adjustable portion 14b to either of the first or second slide buckles 30a, 30b. In other embodiments, the adjustable portion 14b may include other adjustment mechanisms. A flap 34 is fixedly coupled to the strap 14 at a first end of the flap 34. The flap 34 includes a first fastener portion 38 (e.g., a hook and loop fastener, such as Velcro®, snaps, etc.) on a second end of the flap 34, and the strap 14 includes a corresponding second fastener portion 42. When the first fastener portion 38 is coupled to the second fastener portion 42, the strap 14 and the flap 34 form a sleeve that partially surrounds the insulated wire 26. In particular, the strap 14 and the flap 34 surround a coiled section of the insulated wire 26.
The first light assembly 18 further includes a support piece 50 disposed within the housing 46 and coupled to the back housing portion 46b. An LED strip 54 is coupled to the support piece 50. The LED strip 54 includes a base 54a and at least one LED 54b (i.e., an LED chip, also referred to herein as “at least one front LED 54b”) coupled to the base 54a. The LED 54b may also be referred to as a first LED 54b. The at least one front LED 54b of the first light assembly 18 is configured to operate in a first plurality of lighting modes, as will be described in more detail below. In the illustrated embodiment, the at least one front LED 54b includes a plurality of LEDs (i.e., LED chips) coupled to the base 54a. The plurality of LEDs 54b are configured to illuminate an area in front of the user when the headlamp 10 is attached to the user's head or the hardhat. In some embodiments, the LEDs 54b may be configured to emit white light (e.g., by use of a phosphor, lens, or the like). In the illustrated embodiment, the plurality of LEDs 54b are distributed uniformly on the base 54a in a single line parallel to the longitudinal axis L of the housing 46. In other words, the plurality of LEDs 54b are arranged on the base 54a in a line parallel to the longitudinal axis L of the housing 46. In other embodiments, the plurality of LEDs 54b may be distributed otherwise on the base 54a. For example, the plurality of LEDs 54b may be distributed on the base 54a in two or more lines, or the plurality of LEDs 54b may be distributed in clusters on the base 54a. A lens 58 is received by the front housing portion 46a to cover and protect the LED strip 54. In the illustrated embodiment, the lens 58 is a transparent plastic. The support piece 50, LED strip 54, and lens 58 are all flexible. Accordingly, the support piece 50, LED strip 54, and lens 58 can be bent or deformed with the housing 46.
The front housing portion 46a defines an aperture 62 sized to receive the insulated wire 26. The aperture 62 is located on a side or end of the front housing portion 46a. The LED strip 54 includes an electrical attachment portion 54c for coupling to the insulated wire 26. As such, the LED strip 54 is electrically connected to the second light assembly 22 by the insulated wire 26.
As shown in
A charging port 102 configured to receive a charge from an external power supply is provided on the circuit board 82. The charging port 102 is accessible through the housing 66. As such, a charging cable can be coupled to the second light assembly 22 to charge the battery pack 86. In the illustrated embodiment, the charging port 102 is a USB-C port configured to receive a USB-C cable. In other embodiments, the charging port 102 may be a different type of charging port 102. A cover 106 is coupled to the housing 66 adjacent the charging port 102. The cover 106 may be made of a flexible material, such as rubber. The cover 106 is movable between a first position in which the cover 106 covers the charging port 102 and a second position in which the charging port 102 is exposed.
With continued reference to
The first housing portion 66a includes an aperture 118 sized to receive the insulated wire 26. The apertures 118 is located on a side or end of the first housing portion 66a. A gasket 120 (e.g., a rubber ring) surrounds the insulated wire 26 and fits within the aperture 118. The gasket 120 inhibits liquid and other debris from entering the housing 66. The battery pack 86 is coupled to the insulated wire 26. As such, the LED strip 54 in the first light assembly 18 is electrically connected to the battery pack 86 in the second light assembly 22 via the wire 26. An actuator 122 (
In the illustrated embodiment, the electronic processor 126 includes a memory 130 (for example, a non-transitory, computer-readable medium) that includes one or more devices (for example, RAM, ROM, flash memory, hard disk storage, etc.) for storing data and/or computer code for completing or facilitating the various processes, layers, and modules described herein. The electronic processor 126 is configured to retrieve data from the memory 130 and execute, among other things, instructions related to the control processes, algorithms, and methods described herein. The electronic processor 126 is also configured to store/write information on/to the memory 130. For example, the memory 130 can store information regarding the last used mode of the headlamp 10 before the headlamp 10 is turned OFF.
In the illustrated embodiment, the actuator 122 includes a contact that receives power through the circuit board 82 and is configured to provide a status of the actuator 122 back to the electronic processor 126, which receives a signal from the actuator 122 based on the status. The electronic processor 126, in turn, interprets the status and signal of the actuator 122 and sends a signal in accordance with the flowchart showing the process in
The operational modes of the headlamp 10 comprise the first plurality of lighting modes of the at least one front LED 54b and the second plurality of lighting modes of the at least one rear LED 110. The first plurality of lighting modes includes an OFF mode, a high output luminescence ON mode (“HIGH mode”), a medium output luminescence ON mode (“MEDIUM mode”), and a low output luminescence ON mode (“LOW mode”). The second plurality of lighting modes include an OFF mode, a non-flashing ON mode (“STEADY mode”), a fast flashing ON mode (“FAST FLASH mode”), and a slow flashing ON mode (“SLOW FLASH mode”). In other embodiments, the headlamp 10 may include fewer or more modes. Additionally, or alternatively, the headlamp 10 may include different types of modes. In alternative embodiments, one of the at least one front LED 54b and the at least one rear LED 110 may only operate in a single lighting mode. In the OFF modes, the at least one front LED 54b and the at least one rear LED 110 do not emit light.
During operation of the headlamp 10, the expectation of the user is that each mode emits a brightness/light type suitable for a desired application or scenario. The multiple modes of the headlamp 10 allow the user to advantageously switch between outputs without requiring the user to switch headlamps. Stated another way, the headlamp 10 is configured to accomplish the functions of a variety of headlamps such that the user can rely on a single headlamp 10 rather than needing multiple headlamps depending on the desired application (e.g., a first headlamp 10 with high lumen output for area lighting, a second headlamp 10 with medium lumen output for recreation, a separate flashing safety light, etc.).
With specific reference to the flowchart of
At process block 204, the headlamp 10 is turned ON/OFF, such as by a user actuating the actuator 122. At process block 208, a condition of the actuator 122 (e.g., is the actuator 122 depressed/being pressed) is determined. A condition, state, and previous operating mode may each be stored to the memory 130 and accessed by the electronic processor 126 simultaneously. The memory 130 may further store the code/data needed to implement the process 200. In some embodiments, the data is stored directly on the circuit board 82.
At process block 210, the electronic processor 126 determines whether the actuator 122 is being actuated. If the actuator 122 is not being actuated, then the process 200 loops back to reading the conditions at block 208. If the actuator 122 is being actuated, the process 200 proceeds to block 212, where the electronic processor 126 reads a amount of time that the actuator 122 is being actuated. The actuation duration may be measured in seconds by the electronic processor 126.
In some embodiments, the actuator 122 is depressible for three different amounts of time (t) and is configured to provide a signal to the electronic processor 126 based on the different amounts of time (t). The actuator 122 may be actuated a first amount of time to toggle the at least one front LED 54b between the first plurality of lighting modes. In one example, the actuator 122 may be actuated the first amount of time to turn ON the at least one front LED 54b. In the illustrated embodiment, the first amount of time may less than 1 second. The first amount of time may also be considered a momentary actuation or short depression that corresponds to a first signal. The actuator 122 may be actuated for the short depression to cycle the at least one front LED 54b between the HIGH, MEDIUM, and LOW modes. The actuator 122 may be actuated a second amount of time that is different than the first amount of time to turn on the at least one rear LED 110. The actuator 122 may be actuated a second amount of time to toggle the at least one rear LED 110 between the second plurality of lighting modes. In one example, the actuator 122 may also be actuated the second amount of time to cycle the at least one rear LED 110 between the STEADY, FAST FLASH, and SLOW FLASH modes. In the illustrated embodiment, the second amount of time is greater (e.g., longer) than the first amount of time and may be 1 or more seconds (e.g., approximately 1 to 3 seconds). The second amount of time may also be considered a medium depression that corresponds to a second signal different than the first signal. The actuator 122 may be actuated a third amount of time that is different than the first and second amounts of time to turn both the at least one front LED 54b and the at least one rear LED 110 OFF. The actuator 122 may be actuated the third amount of time to toggle both the at least one front LED 54b and the least one rear LED 110. In the illustrated embodiment, the third amount of time is greater (e.g., longer) than the second amount of time and may be 3 or more seconds (e.g., approximately 3 to 5 seconds). The third amount of time may also be considered a long depression that corresponds to a third signal different than the first and second signals. The first amount of time, the second amount of time, and third amount of time may also be referred to as a first length of time, a second length of time, and a third length of time respectively.
In the illustrated embodiment, once the time of actuation is determined in block 212, the process 200 proceeds to block 216, where the electronic processor 126 associates a command based on the duration or time of actuation. At process block 216, the electronic processor 126 determines if the time of actuation is within the first duration of time (e.g., the time of actuation is less than 1 second) by receiving a signal from the actuator 122. If the time of actuation is within the first duration of time, the process 200 proceeds to block 220, where the electronic processor 126 retrieves the state of the at least one rear LED 110. If the time of actuation is not within the first duration of time (e.g., the time of actuation is greater than 1 second), the process 200 proceeds to block 222, where the electronic processor 126 determines if the time of actuation is within the third duration of time (e.g., the time of actuation is greater than 3 seconds) by receiving a signal from the actuator 122. If the time of actuation is within the third duration of time, the process 200 proceeds to block 226, where the electronic processor 126 turns OFF both the at least one front LED 54b and the at least one rear LED 110. The process 200 then returns to block 208, in which a condition of the actuator 122 is determined. If the time of actuation is not within the third duration of time (e.g., the time of actuation is greater than 1 second and less than 3 seconds), the process 200 proceeds to block 230, where the electronic processor 126 retrieves the state of the at least one rear LED 110.
After a short depression, if the state is OFF (i.e., the at least one rear LED 110 is OFF), then the electronic processor 126 turns the at least one rear LED 110 ON and sets the operating mode to the STEADY mode, as shown at block 234. The process then proceeds to block 238, where the electronic processor 126 retrieves the state of the at least one front LED 54b. After a short depression, if the state is ON (i.e., the at least one rear LED 110 is ON), then the process also proceeds to block 238. In this manner, the at least one rear LED 110 is always ON while the at least one front LED 54b is ON. In other embodiments, blocks 220 and 234 may not be present.
If the at least one front LED 54b is OFF, the process proceeds to block 242, where the electronic processor 126 will set the at least one front LED 54b ON in the HIGH mode. In the illustrated embodiment, the HIGH mode is automatically set as the default operating mode such that the electronic processor 126 will set the at least one front LED 54b to the HIGH mode after the at least one front LED 54b has been OFF. In other embodiments, the MEDIUM mode or LOW mode may alternatively be set as a default operating mode. If the state is ON (i.e., at least one front LED 54b is ON), then the electronic processor 126 reads the current operating mode of the at least one front LED 54b and cycles the at least one front LED 54b to the next mode (i.e., HIGH, MEDIUM, or LOW) in the order of operating modes. For example, if the at least one front LED 54b ON in the HIGH mode (block 246), the electronic processor 126 will switch the at least one front LED 54b to the MEDIUM mode, as shown at block 250; if the at least one front LED 54b ON in the MEDIUM mode (block 254), the electronic processor 126 will switch the at least one front LED 54b to the LOW mode, as shown at block 258; and if the at least one front LED 54b ON in the LOW mode (block 262), the electronic processor 126 will switch the at least one front LED 54b to the HIGH mode, as shown at block 266.
In the illustrated embodiment, the order of operating modes for the at least one front LED 54b may be cycled through in a re-occurring order from HIGH to MEDIUM to LOW to HIGH to MEDIUM to LOW, etc. In other embodiments, the order of modes may be reversed. Additionally, the at least one front LED 54b may be cycled through less than or more than three modes. Although the example process 200 allows the electronic processor 126 to turn the at least one front LED 54b ON when the time of actuation is less than 1 second (block 216), other processes for the headlamp 10 may allow the electronic processor 126 to turn the at least one front LED 54b ON when the time of actuation is greater than 1 second. After setting the mode of the at least one front LED 54b, the process returns to block 208, where the electronic processor 126 determines the condition of the actuator 122.
Referring back to block 212, if the time of actuation read in block 216 is within the second duration of time (e.g., greater than 1 second and less than 3 seconds), the process 200 proceeds to block 230, in which the electronic processor 126 retrieves the state of the at least one rear LED 110. If the at least one rear LED 110 is OFF, the process proceeds to block 270, where the electronic processor 126 will set the at least one rear LED 110 ON in the STEADY mode. In the illustrated embodiment, the STEADY mode is automatically set as the default operating mode such that the electronic processor 126 will set the at least one rear LED 110 to the STEADY mode after the at least one rear LED 110 has been OFF. In other embodiments, the FAST FLASH mode or SLOW FLASH mode may alternatively be set as a default operating mode. If the state is ON (i.e., the at least one rear LED 110 is ON), then the electronic processor 126 reads the current operating mode of the at least one rear LED 110 and cycles the at least one rear LED 110 to the next mode (i.e., STEADY, FAST FLASH, or SLOW FLASH) in the order of operating modes. For example, if the at least one rear LED 110 ON in the FAST FLASH mode (block 274), the electronic processor 126 will switch the at least one rear LED 110 to the SLOW FLASH mode, as shown at block 278; if the at least one rear LED 110 ON in the SLOW FLASH mode (block 282), the electronic processor 126 will switch the at least one rear LED 110 to the STEADY mode, as shown at block 286; and if the at least one rear LED 110 ON in the STEADY mode (block 290), the electronic processor 126 will switch the at least one rear LED 110 to the FAST FLASH mode, as shown at block 294.
In the illustrated embodiment, the order of operating modes for the at least one rear LED 110 may be cycled through in a re-occurring order from STEADY to FAST FLASH to SLOW FLASH to STEADY to FAST FLASH to SLOW FLASH, etc. In other embodiments, the order of modes may be reversed. Additionally, the at least one rear LED 110 may be cycled through less than or more than three modes. Although the example process 200 allows the electronic processor 126 to cycle through operating modes for the at least one rear LED 110 when the time of actuation is within 1 to 3 seconds (blocks 216, 222), other processes for the headlamp 10 may allow the electronic processor 126 to cycle through operating modes for the at least one rear LED 110 when the time of actuation not within 1 to 3 seconds. After setting the mode of the at least one rear LED 110, the process 200 returns to block 208, where the electronic processor 126 determines the condition of the actuator 122.
In some embodiments, the third amount of time may have a maximum length. For example, if the time of actuation read in block 222 is greater than 5 seconds, the electronic processor 126 may consider the actuation to be an accidental depression and not change the state of the at least one front and rear LEDs 54b, 110.
In the illustrated embodiment, the actuator 122 includes a single actuatable member, such as a single push-button or switch, that allows the user to step through the process 200. In other embodiments, the actuator 122 may include separate actuatable members that are independently operable to control the at least one front LED 54b and the at least one rear LED 110. In still other embodiments, the actuator 122 may include a single actuatable member to turn the at least one front and rear LEDs, ON and OFF as described above, but may include a separate actuatable member (e.g., a mode actuator) to change the operating modes of the at least one front and rear LEDs 54b, 110.
Although the disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the disclosure as described. Various features of the disclosure are set forth in the following claims.
This application is a continuation of U.S. Non-Provisional patent application Ser. No. 18/353,259, filed on Jul. 17, 2023, which claims priority to U.S. Provisional Patent Application No. 63/391,222, filed on Jul. 21, 2022, the entire contents of each of which are incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 63391222 | Jul 2022 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 18353259 | Jul 2023 | US |
| Child | 18620437 | US |
