LIGHTED HEADGEAR AND ACCESSORIES THEREFOR

Abstract

There is provided lighted headgear having various configurations, components thereof, and other accessories combined therewith. Also provided are a light module and a battery pack.

Description

FIELD OF THE INVENTION

This disclosure relates to lighting devices and, in particular, to lighted headgear and accessories therefor.

BACKGROUND

Often an individual desires a light source focused to illuminate an area while performing a task, or a light source directed in a general outward direction for visibility. Holding a flashlight is an option, but such lighting devices are often cumbersome and may detract from the task being completed because the flashlight must be held. As a result, hands-free lighting is often desired because the individual desiring illumination does not need to hold the light source. Common types of hands-free lighting include light sources mounted to headgear or eyeglasses.

Lighted headgear may include illumination sources mounted to hats. Often the light source is oriented outwardly in such a manner so that the wearer can be seen by others or oriented downward to provide light forwardly of the wearer so as to illuminate an area in the wearer's field of view. Often, the light source is one or more LEDs. Such LED lighted headgear, which may include LEDs mounted to a typical baseball-style hap or beanie-style cap, are convenient for hands-free lighting in a number of recreational activities, such as camping, hunting, fishing, jogging, or the like.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an upper perspective view of a baseball-style lighted hat having a battery pack and a light module to provide illumination generally forwardly and downwardly.

FIG. 2 is a lower perspective view of the baseball-style lighted hat of FIG. 1 showing the light module secured to the underside of a brim of the baseball-style lighted hat.

FIG. 3 is a lower perspective exploded view of the light module of FIG. 1 showing lower portions of various components of the light module.

FIG. 4 is an upper perspective exploded view of the light module of FIG. 1 showing upper portions of various components of the light module.

FIG. 5 is a front elevation view of a reflector of the light module of FIG. 1 showing reflector walls extending from a rearward opening of the reflector.

FIG. 6 is a cross-sectional view of the reflector of FIG. 5 showing the inclination of the opposing reflective side walls relative to the reflective upper wall.

FIG. 7 is an enlarged perspective view of the light module of FIG. 1 showing a portion of the brim of the baseball-style lighted hat extending between the housing and the mounting plate of the light module.

FIG. 8 is a cross-sectional view taken along the line 8-8 of FIG. 7 showing inclinations of various components of the light module.

FIG. 9 is a cross-sectional view taken along the line 9-9 of FIG. 7 showing inclinations of various components of the light module.

FIG. 10 is a front elevation view a beanie-style lighted cap having a battery pack and a light module to provide illumination generally forwardly.

FIG. 11 is a lower perspective exploded view of the light module of FIG. 10 showing lower portions of various components of the light module.

FIG. 12 is an upper perspective exploded view of the light module of FIG. 10 showing upper portions of various components of the light module.

FIG. 13 is a front elevation view of the light module of FIG. 10 showing reflector walls extending from a rearward opening of the reflector.

FIG. 14 is a cross-sectional view of FIG. 13 showing the inclination of the opposing reflective side walls relative to the reflective upper wall.

FIG. 15 is an enlarged perspective view of the light module of FIG. 10 showing a portion of the beanie-style lighted cap extending between the housing and the mounting plate of the light module.

FIG. 16 is a cross-sectional view taken along the line 16-16 of FIG. 15 showing inclinations of various components of the light module.

FIG. 17 is a cross-sectional view taken along the line 17-17 of FIG. 15 showing inclinations of various components of the light module.

FIG. 18 is an upper perspective view of a battery holder in an unassembled configuration.

FIG. 19 is a lower perspective view of the battery holder of FIG. 18 in an unassembled configuration.

FIG. 20 is a perspective exploded view of the battery holder of FIG. 18 in an unassembled configuration.

FIG. 21 is a front elevation view of the battery holder of FIG. 18 in an assembled configuration.

FIG. 22 is a cross-sectional view of the reflector of FIG. 18 in an assembled configuration.

DETAILED DESCRIPTION

Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments may take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures is combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.

In general, the headgear described herein include one or more illumination sources, which may include, for example, one or more light-emitting diodes (LEDs). One or more power assemblies are provided to energize these illumination sources. The power generators may use traditional batteries or renewable energy, such as solar, wind, or kinetic energy, to generate electrical power that ultimately energizes the light sources that is included on the disclosed headgear. While the following description and illustrations may describe a specific power assembly and illumination source with a specific headgear and lighting configuration, the various components described herein may be included in any of the headgear embodiments. The headgear may include, for example, a baseball-style hat, a beanie-style cap, or other suitable headgear such as visors, helmets, caps, hats, headbands, sweatband, hoods, clothing, or the like. The light modules described herein may also be mounted to other articles of clothing.

The lighted headgear described herein include a head fitting portion for fitting on a head of a user. A light module is mounted to the headgear for projecting light in the generally forward direction. The light modules discussed herein are generally low-profile light modules having ergonomically-actuated actuators. More particularly, the actuators are generally angled such that the actuating member (which may be, for example, a push-button) travels along an axis corresponding to a user's natural push direction. In the baseball-style cap example of FIGS. 1-9, the push direction is generally upward and forward relative to the user's forehead. In the beanie-style example of FIGS. 10-17, the push direction is generally downward and rearward relative to the user's forehead.

The light modules contemplated herein may include a reflector that has reflector walls for directing the light. More particularly, the reflective walls may focus the light in a generally forward direction, and optionally, in a generally downward direction. Focusing light in a generally downward direction may be particularly advantageous in light module secured to the brim of a baseball-style hat. For example, by directing light away from a downward surface of a brim portion of the hat, the reflector may reduce or inhibit glare off the brim portion.

Referring to FIGS. 1 and 2, lighted headgear such as a lighted hat 10 is shown. The lighted hat 10 is be in the form of a baseball-style cap having a head fitting portion, such as crown portion 12, for fitting on a head of a user. The lighted hat 10 also includes a brim portion 14 that extends in a generally forward direction from the head fitting portion. For example, the brim portion 14 projects forwardly from a lower, forward edge 16 of the crown portion 12. In some forms, the lighted hat 10 further includes a hat band 20 disposed around a lower edge portion 22 of the inside of the lighted hat 10. The hat band 20 may be composed of an elastic and/or wicking material to conform the crown portion 12 more closely to a wearer's head and/or wick moisture away from the wearer's head.

The brim portion 14 has an upper major surface 30 and a lower major surface 32. As used herein, the upper major surface 30 faces generally upwardly when the lighted hat 10 is worn by a user, and the lower major surface 32 faces generally downwardly when the lighted hat 10 is worn by a user. The upper major surface 30 is disposed on an upper covering 34, and the lower major surface 32 is disposed on a lower covering 36. The upper and lower coverings 34, 36 is fabric coverings or other suitable material.

The brim portion 14 further includes a brim insert 40 that extends between the upper covering 34 and the lower covering 36. The brim portion 14 includes perimeter edges, such as side edges 42 and a front edge 44 that extends between the side edges 42. The brim portion 14, and more particularly, the lower major surface 32, has a generally fore-and-aft central axis 46 that extends in a forward direction between the side edges 42 and toward the front edge 44. The upper and lower coverings 34, 36 and the brim insert 40 may be joined together, such as by stitching, adhesive, or the like.

The lighted hat 10 includes a light module 50. The light module 50, discussed in greater detail with respect to FIGS. 3-9, is preferably disposed on the lower major surface 32 of the brim portion 14 (e.g., at the generally downwardly-facing surface of the brim portion 14).

The lighted hat 10 further includes a power source 52, and an electrical connection 54 that spans between the power source 52 and the light module 50. The electrical connection 54 may include one or more wires to provide power to the light module 50. The power source 52, discussed in greater detail with respect to FIGS. 18-20, is illustrated as a battery pack that is stored in the hat band 20 of the crown portion 12 of the lighted hat 10.

Referring to FIGS. 3 and 4, the light module 50 includes a housing 60. The housing 60 has a central axis 62 that extends in a generally forward direction. The central axis 62 extends, for example, through or along a base flange 66 of the housing 60.

The housing 60 includes housing walls that extend from the base flange 66, and extend about a housing interior 64. As shown, the housing walls generally define a wedge-shaped housing. In this regard, the housing walls include a forward wall portion 70, a rearward inclined wall portion 72, and opposing side walls 78 that extend between the base flange 66 and the forward wall portion 70 and rearward inclined wall portion 72. In one approach, a side wall 78 forms a rearward curved or rounded side interface with the rearward inclined wall portion 72, and forms a forward curved or rounded side interface with the forward wall portion 70.

The forward wall portion 70 and the rearward inclined wall portion 72 converge to form an apex 74 of the housing 60. In one aspect, the apex 74 is a curved or rounded apex.

The forward wall portion 70 includes one or more opposite sections, referred to herein as side wall portions 76, that at least partially define an opening. For example, two opposing side wall portions 76 cooperate to at least partially form a forward opening 80, also referred to herein as a large light opening, therebetween.

In the approach shown, the side wall portions 76 taper as the side wall portions 76 extend in the forward direction along the central axis 62. For example, the lateral width (e.g., in a direction orthogonal to the central axis 62) of a side wall portion 76 varies from a maximum width closest to a apex 74, to a minimum width farthest from the apex 74. A side wall portion 76 may taper, for example, from a maximum lateral width of approximately 0.25 inches to a minimum lateral width of approximately 0.15 inches.

In this way, the opposing side wall portions 76 define a forward opening 80 that has a lateral width that varies as the forward opening 80 extends in the forward direction along the central axis 62. For example, the lateral width of the forward opening 80 varies from a minimum width closest to a apex 74, to a maximum width farthest from the apex 74. The forward opening 80 may taper, for example, may taper, for example, from a minimum lateral width of approximately 0.4 inches to a maximum lateral width of approximately 0.65 inches.

In one aspect, the forward opening 80 has a lateral width that is larger than a lateral width of at least one of the side wall portions 76. In one example approach, the minimum lateral width of the forward opening 80 is approximately equal to a combined lateral width of the maximum lateral widths of the opposite side wall portions 76, and the maximum lateral width of the forward opening 80 is larger than a combined lateral width of the maximum lateral widths of the opposite side wall portions 76.

The rearward inclined wall portion 72 has a generally planar wall portion that includes an actuator hole 82. As discussed in greater detail elsewhere herein, the actuator hole 82 is sized to receive a user-actuatable actuator, such as a push-button.

The light module 50 further includes a light source 90 mounted at least partially within the housing interior 64. The light source 90 provides illumination outwardly from the housing 60; for example, through the forward opening 80. In one aspect, the light source 90 includes a single LED. In another aspect, the light source 90 includes a plurality of LEDs. A cover or lens 92 may extend across the LED portion of the light source 90.

The light module 50 also includes a switch device 100. The switch device 100 is electrically coupled to the light source 90 and the power source 52 for selectively energizing the light source 90. The switch device 100 includes, for example, a circuit board 102 and an actuator 110. The circuit board 102, which may be a printed circuit board (PCB) that includes electrical circuitry 106, is electrically coupled to the light source 90, as indicated at coupling 104.

The actuator 110 includes a plunger housing 112 that is secured to the circuit board 102. The actuator 110 further includes a plunger 114 that is movable within the plunger housing 112. The actuator 110 further includes a resilient button 116 that extends over the plunger 114. The resilient button 116 may have tactile indicia 118, such as one or both of a depression and a protrusion. In this way, the tactile indicia 118 may provide a user with tactile feedback indicating the user's finger has engaged the resilient button 116.

The light module 50 further includes a heat sink member 94. The heat sink member 94 is formed of, or includes, conductive material. More particularly, the heat sink member 94 is formed of a material with high thermal conductivity, such as an aluminum alloy. As such, the heat sink member 94 may have a thermal conductivity value of between about 120 W/mK to about 240 W/mK to conduct heat away from the light source 90 during operation of the light module 50. The heat conduction by the heat sink member 94 reduces the risk of damaging components of the light module 50 through overheating. In the illustrated and preferred form, the heat sink member 94 has a generally rectangular body. Although depicted as having a single heat sink member 94, the light module 50 may be provided with two or more heat sink members.

In the assembled configuration, the heat sink member 94 is electrically coupled to the circuit board 102, and the light source 90 is secured to a heat sink member 94. More particularly, the heat sink member 94 is disposed between the light source 90 and the circuit board 102 such that the light source 90 is separated from the circuit board 102 by the heat sink member 94. As shown, the heat sink member 94 may be installed in an inclined orientation. The inclination of the heat sink member 94 generally corresponds to that of the forward wall portion 70. In this way, the heat sink member 94 extends generally parallel to the forward wall portion 70.

The light module 50 further includes a reflector 130. The reflector 130 is a discrete reflector that is mounted (e.g., removably mounted) to the housing 60 within the housing interior 64. More particularly, the reflector 130 is mounted at the forward opening 80 of the housing 60.

The reflector 130 includes a rearward opening 132 that is aligned with the light source 90 to permit light emitted from the light source 90 to pass therethrough. The reflector 130 further includes a plurality of reflective walls that may extend generally forwardly and outwardly from the rearward opening 132 to the forward opening 80 (e.g., into engagement with the housing 60). As used herein, a generally forward direction may refer to the forward direction along axis 62, and a generally outward direction may refer to a direction generally away from a central axis of light source 90. As such, the light source 90 may emit light in a direction that is generally forward and generally downward from the light module 50.

Referring to FIGS. 3-6, the plurality of reflective walls includes, for example, a reflective upper wall 140. The reflective upper wall 140 may extend generally forwardly from the rearward opening 132. As such, light emitted through the forward opening 80 is reflected generally downwardly (e.g., away from the generally downwardly-facing surface of the brim portion 14 of FIGS. 1 and 2).

The plurality of reflective walls further includes one or more reflective side walls. For example, the reflector 130 includes a pair of opposing reflective side walls 142. The reflective upper wall 140 may extend between the opposing reflective side walls 142. The opposing reflective side walls 142 may taper away from each other as the opposing reflective side walls 142 extend away (e.g., generally downwardly) from the reflective upper wall 140. In one aspect, the reflective upper wall 140 extends away from the rearward opening 132 further than at least one, and preferably both, of the opposing reflective side walls 142. Furthermore, the opposing reflective side walls 142 may taper away from each other as the opposing reflective side walls 142 extend away (e.g., generally forwardly) from the rearward opening 132.

The plurality of reflective walls further includes a reflective lower wall 144. The reflective lower wall 144 may extend generally forwardly from the rearward opening 132. In one aspect, the opposing reflective side walls 142 extend away from the rearward opening further than the reflective lower wall 144. The reflective upper wall 140 may extend forwardly from the rearward opening 132 further than the opposing reflective side walls 142, the reflective lower wall 144, or both the reflective lower wall 144 and each opposing reflective side walls 142.

Referring again to FIGS. 3 and 4, the light module 50 further includes a backplate or mounting plate 150. The mounting plate 150 is securable to the housing 60, or vice versa. The mounting plate 150 may include a guide slot 152 that extends through the mounting plate 150; for example, through an entire thickness of the mounting plate 150. The guide slot 152 may extend from an outer periphery 154 (e.g., an outer peripheral edge) of the mounting plate 150 to a central region 156 of the mounting plate 150. The guide slot 152 is sized to receive an electrical connection therein (e.g., electrical connection 54 of FIGS. 1 and 2). As such, the electrical connection 54 may extend from the power source 52, through the guide slot 152 of the mounting plate 150, into the housing interior 64, and to the switch device 100.

One or more fasteners 160 are provided for securing housing 60 to the mounting plate 150. Similarly, one or more fasteners 162 are provided for securing the heat sink member 94 to the reflector 130. The fasteners 160 may be, for example, threaded fasteners, rivets, or the like.

Referring to FIGS. 7-9, in an assembled configuration, the mounting plate 150 is disposed at a brim-facing surface 170 of the lower covering 36, and the housing 60 is disposed at the lower major surface 32 of the lower covering 36 of the brim portion 14.

One or both of the rearward inclined wall portion 72 and the forward wall portion 70 may be inclined relative to the central axis 62. In one aspect, the rearward inclined wall portion 72 may extend at an oblique angle 180 relative to the central axis 62. The oblique angle 180 may be, for example, an acute angle in the range of approximately (e.g., +/−3 degrees) 5 degrees to approximately 40 degrees, and more particularly, is approximately 10 degrees. The forward wall portion 70 may also or may instead extend at an oblique angle 182 relative to the central axis 62.

The actuator 110 of the switch device 100 is associated with the rearward inclined wall portion 72. More particularly, the resilient button 116 of the actuator 110 is received in the actuator hole 82 of the rearward inclined wall portion 72. The actuator hole 82 includes a central hole axis 190 that intersects the central axis 62 at an oblique angle 192.

The actuator 110 is configured to travel in a linear actuation direction 200 when pushed by the user. During actuation, the resilient button 116 is deformed by the user to depress the plunger 114 in the linear actuation direction 200, which is arranged to be upwardly and forwardly relative to the generally downwardly-facing surface (e.g., lower major surface 32) of the brim portion 14 for ease of operation by the user.

In the depicted assembled configuration, the linear actuation direction 200 is orthogonal to the inclined circuit board 102. In one aspect, inclined circuit board 102 is mounted relative to the housing 60 (e.g., at least partially within the housing interior 64) such that the inclined circuit board 102 extends obliquely relative to the central axis 62.

The reflector 130 cooperates with the housing 60 to at least partially form a recessed light opening 210 of the light module 50. In the arrangement shown, the reflective upper wall 140 tapers downwardly away from the brim portion 14 as the reflective upper wall 140 extends generally forwardly from the rearward opening 132. The reflective lower wall 144 tapers downwardly away from the reflective upper wall 140 as the reflective lower wall 144 extends generally forwardly from the rearward opening 132.

In one approach, the reflective upper wall 140 tapers downwardly away from the brim portion 14 at a first oblique angle 220 as the reflective upper wall 140 extends generally forwardly from the rearward opening 132. The reflective lower wall tapers 144 downwardly away from the brim portion 14 at a second oblique angle 222 as the reflective lower wall 144 extends generally forwardly from the rearward opening 132. The second oblique angle 222 is different (e.g., greater) than the first oblique angle 220.

As such, the light source 90 is oriented to emit light in a direction 212 that is generally forwardly transverse to the linear actuation direction 200. The reflector 130 may act to prevent or inhibit light emitted from the light source 90 from casting on (and reflecting off of) the lower major surface 32 of the brim portion 14 (e.g., at the generally downwardly-facing surface of the brim portion 14). In this way, a field of view of a user that is generally forward and generally downward from the lighted hat 10 is illuminated, while glare in the user's line of sight is reduced or inhibited.

Referring to FIG. 10, lighted headgear such as a lighted cap 300 is shown. The lighted cap 300 is in the form of a knit cap, which may be referred to as a beanie. The lighted cap 300 has a head fitting portion 302 for fitting on a head of a user. The head fitting portion 302 includes a crown portion 304, which may be referred to as a tapering portion, and an annular portion 306 that extends below the crown portion 304 when worn on a head of a user. The lighted cap 300 includes a cap band 308 disposed at a lower region of the annular portion 306 (e.g., inside of the lighted cap 300). The lighted cap 300, and more particularly, the cap band 308, includes a forwardly-facing surface 310 when worn.

The lighted cap 300 further includes a light module 320. The light module 320, discussed in greater detail with respect to FIGS. 11-17, is disposed at the cap band 308, and more particularly, at the forwardly-facing surface 310.

The lighted cap 300 further includes a power source 322, and an electrical connection 324 that spans between the power source 322 and the light module 320. The electrical connection 324 may include one or more wires to provide power to the light module 320. The power source 322, discussed in greater detail with respect to FIGS. 18-20, is illustrated as a battery pack that is stored in the cap band 308 of the annular portion 306 of the lighted cap 300.

Referring to FIGS. 11 and 12, the light module 320 includes a housing 330. The housing 330 has a central axis 332 that extends in a generally forward direction. The central axis 332 extends, for example, through or along a base flange 336 of the housing 330.

The housing 330 includes housing walls that extend from the base flange 336, and extend about a housing interior 334. The housing walls may generally define a wedge-shaped housing. In this regard, the housing walls include a lower wall portion 340, an upper wall portion 342, and opposing side walls 338 that extend between the base flange 336 and the lower wall portion 340 and upper wall portion 342. In one approach, a side wall 338 has a rearward side wall portion that forms a rearward curved or rounded side interface with the upper wall portion 342, and a forward side wall portion that forms a forward curved or rounded side interface with the lower wall portion 340.

The lower wall portion 340 and the upper wall portion 342 converge to form an apex 344 of the housing 330. In one aspect, the apex 344 is a curved or rounded apex.

The lower wall portion 340 includes one or more opposite sections, referred to herein as side wall portions 346, that at least partially define an opening. For example, two opposing side wall portions 346 cooperate to at least partially form a lower opening 350, also referred to herein as a large light opening, therebetween.

The lower opening 350 has a lateral width (e.g., in a direction orthogonal to the central axis 332) that is larger than a lateral width of at least one of the side wall portions 346. In one aspect, the lateral width of the lower opening 350 is larger than the lateral width of one of the opposite side wall portions 346, but smaller than a combined lateral width of the lateral widths of both of the opposite side wall portions 346. For example, each side wall portion 346 may have a lateral width of approximately 0.27 inches such that the side wall portions 346 have a combined lateral width of approximately 0.54 inches, and the lower opening 350 may have a lateral width of approximately 0.53 inches.

In still another aspect, the lateral width of the lower opening 350 is larger than a combined lateral width of the lateral widths of both of the opposite side wall portions 346. For example, each side wall portion 346 may have a lateral width of approximately 0.25 inches such that the side wall portions 346 have a combined lateral width of approximately 0.5 inches, and the lower opening 350 may have a lateral width of approximately 0.53 inches.

The upper wall portion 342 has a generally planar wall portion that includes an actuator hole 352. As discussed in greater detail elsewhere herein, the actuator hole 352 is sized to receive a user-actuatable actuator, such as a push-button. In the approach shown, the lower wall portion 340 is a lower inclined wall portion, and the upper wall portion 342 is an upper inclined wall portion.

The light module 320 further includes a light source 360 that is mounted at least partially within the housing interior 334. The light source 360 may provide illumination outwardly from the housing 330; for example, through the lower opening 350. In one aspect, the light source 360 includes a single LED. In another aspect, the light source 360 includes a plurality of LEDs. A cover or lens 362 may extend across the LED portion of the light source 360.

The light module 320 also includes a switch device 370. The switch device 370 is electrically coupled to the light source 360 and the power source 322 for selectively energizing the light source 360. The switch device 370 includes, for example, a circuit board 372 and an actuator 380. The circuit board 372, which may be a printed circuit board (PCB) that includes electrical circuitry 376, is electrically coupled to the light source 360, as indicated at coupling 374.

The actuator 380 includes a plunger housing 382 that is secured to the circuit board 372. The actuator 380 further includes a plunger 384 that is movable within the plunger housing 382. The actuator 380 further includes a resilient button 386 that extends over the plunger 384. The resilient button 386 may have tactile indicia 388, such as one or both of a depression and a protrusion. In this way, the tactile indicia 388 may provide a user with tactile feedback indicating the user's finger has engaged the resilient button 386.

The light module 320 further includes a heat sink member 364. The heat sink member 364 is formed of, or includes, conductive material. More particularly, the heat sink member 364 is formed of a material with high thermal conductivity, such as an aluminum alloy. As such, the heat sink member 364 may have a thermal conductivity value of between about 120 W/mK to about 240 W/mK to conduct heat away from the light source 360 during operation of the light module 320. The heat conduction by the heat sink member 364 reduces the risk of damaging components of the light module 320 through overheating. In the illustrated and preferred form, the heat sink member 364 has a generally rectangular body. Although depicted as having a single heat sink member 364, the light module 320 may be provided with two or more heat sink members.

In the assembled configuration, the heat sink member 364 is electrically coupled to the circuit board 372, and the light source 360 is secured to a heat sink member 364. More particularly, the heat sink member 364 is disposed between the light source 360 and the circuit board 372 such that the light source 360 is separated from the circuit board 372 by the heat sink member 364. As shown, the heat sink member 364 may be installed in an inclined orientation. The inclination of the heat sink member 364 generally corresponds to that of the lower wall portion 340. In this way, the heat sink member 364 extends generally parallel to the lower wall portion 340.

The light module 320 further includes a reflector 400. The reflector 400 is a discrete reflector that is mounted (e.g., removably mounted) to the housing 330 within the housing interior 334. More particularly, the reflector 400 is mounted at the lower opening 350 of the housing 330. The reflector 400 includes a rearward opening 402 that is aligned with the light source 360 to permit light emitted from the light source 360 to pass therethrough. The reflector 400 includes a plurality of reflective walls that may extend generally forwardly and outwardly from the rearward opening 402 to the lower opening 350 (e.g., into engagement with the housing 330). As used herein, a generally forward direction may refer to the forward direction along axis 332, and a generally outward direction may refer to a direction generally away from a central axis of light source 360. As such, the light source 360 may emit light in a direction that is generally forward and generally downward from the light module 320.

Referring to FIGS. 11-14, the plurality of reflective walls include, for example, a reflective upper wall 410. The reflective upper wall 410 may extend generally forwardly from the rearward opening 402. As such, light emitted through the lower opening 350 is reflected generally downwardly and/or generally forwardly.

The plurality of reflective walls further includes one or more reflective side walls. For example, the reflector 400 includes a pair of opposing reflective side walls 412. The reflective upper wall 410 may extend between the opposing reflective side walls 412. The opposing reflective side walls 412 may taper away from each other as the opposing reflective side walls 412 extend away from the rearward opening 402. In one aspect, the reflective upper wall 410 and each of the opposing reflective side walls 412 extend equidistant from the rearward opening 402 to the lower opening 350.

The plurality of reflective walls further includes a reflective lower wall 414. The reflective lower wall 414 may extend generally forwardly from the rearward opening 402 to the lower opening 350. In one aspect, the reflective lower wall 414 and the reflective upper wall 410 extend equidistant from the rearward opening 402 to the lower opening 350. In another aspect, the reflective upper wall 410 extends a greater distance from the rearward opening 402 to the lower opening 350.

Referring again to FIGS. 11 and 12, the light module 320 further includes a backplate or mounting plate 420. The mounting plate 420 is securable to the housing 330, or vice versa. The mounting plate 420 may include a guide slot 422 that extends through the mounting plate 420; for example, through an entire thickness of the mounting plate 420. The guide slot 422 may extend from an outer periphery 424 (e.g., an outer peripheral edge) of the mounting plate 420 to a central region 426 of the mounting plate 420. The guide slot 422 is sized to receive an electrical connection therein (e.g., electrical connection 324 of FIG. 10). As such, the electrical connection 324 may extend from the power source 322, through the guide slot 422 of the mounting plate 420, into the housing interior 334, and to the switch device 370.

One or more fasteners 430 are provided for securing housing 330 to the mounting plate 420. Similarly, one or more fasteners 432 are provided for securing the heat sink member 364 to the reflector 400. The fasteners 430 may be, for example, threaded fasteners, rivets, or the like.

Referring to FIGS. 15-17, in an assembled configuration, the mounting plate 420 is disposed at a rearward-facing surface 440 of the annular portion 306 (e.g., at the cap band 308), and the housing 330 is disposed at the forwardly-facing surface 310 of the cap band 308. The housing 330 is secured to the mounting plate 420 such that at least a portion of the head-fitting portion (e.g., annular portion 306) extends between and in engagement with the mounting plate 420 and the housing 330.

One or both of the upper wall portion 342 and the lower wall portion 340 may be inclined relative to the central axis 332. In one aspect, the upper wall portion 342 extends at an oblique angle 450 relative to the cap band 308 (e.g., relative to the forwardly-facing surface 310 of the cap band 308) such that the upper wall portion 342 tapers away from the forwardly-facing surface 310 as the upper wall portion 342 extends downwardly (e.g., along the Z axis of FIG. 16). The oblique angle 180 may be, for example, an acute angle in the range of approximately (e.g., +/−3 degrees) 5 degrees to approximately 45 degrees, and more particularly, is approximately 10 degrees.

The lower wall portion 340 may also or may instead extend at an oblique angle 452 relative to the cap band 308 (e.g., relative to the forwardly-facing surface 310 of the cap band 308). In this way, the lower wall portion 340 includes a lower inclined wall portion inclined obliquely relative to the forwardly-facing surface 310 to taper toward the forwardly-facing surface 310 as the lower inclined wall portion extends downwardly (e.g., along the Z axis of FIG. 16).

The actuator 380 of the switch device 370 is associated with the upper wall portion 342. More particularly, the resilient button 386 of the actuator 380 is received in the actuator hole 352 of the upper wall portion 342. The actuator hole 352 includes a central hole axis 460 that intersects the forwardly-facing surface 310 of the cap band 308 at an oblique angle 462.

The actuator 380 is configured to travel in a linear actuation direction 470 when pushed by the user. During actuation, the resilient button 386 is deformed by the user to depress the plunger 384 in the linear actuation direction 470, which is arranged to be downwardly and rearwardly relative to the generally forwardly-facing surface 310 of the cap band 308 for ease of operation by the user.

The reflector 400 cooperates with the housing 330 to at least partially form a recessed light opening 480 of the light module 320. As such, light emitted from the light source 360 is oriented in a direction 482 that is generally forward and downward from the light module 320. In this way, an area that is forward and generally downward from the lighted hat 10 is illuminated.

Referring to FIGS. 18-22, a battery holder 500 is shown. The battery holder 500 may be used for the power source 52 of FIGS. 1 and 2, and/or the power source 322 of FIG. 10.

The battery holder 500 includes a frame assembly 502 that includes a first end cover 504 and a second end cover 506. The first end cover 504 includes a first battery contact element 510 that includes a first pair of battery contact elements. In one aspect, the first battery contact element 510 is a unitary conversion plate (e.g., a positive-negative conversion spring contact plate). In another aspect, the first battery contact element 510 includes discrete positive and negative contacts.

Similarly, the second end cover 506 includes a second battery contact element 512 that includes a second pair of battery contact elements. In one aspect, the second battery contact element 512 is a unitary conversion plate (e.g., a positive-negative conversion spring contact plate). In another aspect, the second battery contact element 512 includes discrete positive and negative contacts.

The battery holder 500 includes a wiring hub 520 that extends from the frame assembly 502; for example, from a lower region of the first end cover 504. The wiring hub 520 may guide an electrical connection 522 extending from the frame assembly 502. The electrical connection may generally correspond to the electrical connection 54 of FIGS. 1 and 2 and/or the electrical connection 324 of FIG. 10.

As shown in FIGS. 19 and 22, the first end cover 504 includes laterally-extending channels 530 extending along an end surface 532 of the first end cover 504. The laterally-extending channels 530 are defined by at least laterally-extending sidewalls of the first end cover 504. More particularly, in the approach shown, the laterally-extending channels 530 are defined by laterally-extending sidewalls and a laterally-extending upper wall.

A laterally-extending channel 530 includes a recess 540. For example, the two recesses shown in FIG. 19 may extend longitudinally from the end surface 532 a greater distance than the laterally-extending sidewalls of the laterally-extending channel 530. In this way, each recess 540 defines an abutment surface 542, which may be a side wall of a recess 540. In one aspect, the wiring hub 520 extends from the end surface 532 of the first end cover 504 between the recesses 540.

Referring to FIG. 20, the first end cover 504 further includes longitudinally-extending channels 550. The longitudinally-extending channels 550 may extend from the laterally-extending channels 530 at side end portions 552 of the first end cover 504. A longitudinally-extending channel 550 is defined between side prongs 554 that extend longitudinally from a base portion 556 of the first end cover 504. A longitudinally-extending channel 550 is contiguous with a corresponding laterally-extending channel 530 to define a contiguous side channel in the first end cover 504.

The side prongs 554 include generally curved interior surfaces that face in the general direction of a central axis 560 of the battery holder 500. The generally curved interior surfaces are dimensioned to interface (e.g., retain or secure) a cylindrical battery.

The first end cover 504 further includes intermediate prongs 570 that extend longitudinally from the base portion 556 of the first end cover 504 between corresponding side prongs 554. The intermediate prongs 570 include generally curved interior surfaces that face in the general direction the generally curved interior surfaces of the side prongs 554. The intermediate prongs 570 cooperate with a first set of side prongs 554 at one side of the first end cover 504 to form a first portion of a battery lower compartment therebetween, and cooperate with a second set of side prongs 554 at an opposite side of the first end cover 504 to form a second portion of the lower battery compartment therebetween.

The second end cover 506 includes a laterally-extending channel 580 extending along an end surface 582 of the second end cover 506. In one aspect, the laterally extending channel 580 extends along an entire lateral length of the end surface 582. The second end cover 506 further includes longitudinally-extending channels 590. The longitudinally-extending channels 590 may extend from the laterally-extending channel 580 at side end portions 592 of the second end cover 506. A longitudinally-extending channel 550 is defined between side prongs 594 that extend longitudinally from a base portion 596 of the second end cover 506. A longitudinally-extending channel 590 is contiguous with the laterally-extending channel 580 to define a contiguous side channel in the second end cover 506.

The side prongs 594 include generally curved interior surfaces that face in the general direction of the central axis 560 of the battery holder 500. The generally curved interior surfaces is dimensioned to interface (e.g., retain or secure) a cylindrical battery.

The second end cover 506 further includes intermediate prongs 600 that extend longitudinally from the base portion 596 of the second end cover 506 between corresponding side prongs 594. The intermediate prongs 600 include generally curved interior surfaces that face in the general direction the generally curved interior surfaces of the side prongs 594. The intermediate prongs 600 may cooperate with a first set of side prongs 594 at one side of the second end cover 506 to form a first portion of an upper battery compartment therebetween, and may cooperate with a second set of side prongs 594 at an opposite side of the second end cover 506 to form a second portion of the upper battery compartment therebetween.

The second end cover 506 further includes a hole 602. The hole 602 may be a through-hole or a blind hole that is disposed in the base portion 596 of the second end cover 506; for example, within the laterally-extending channel 580.

The battery holder 500 includes a resilient clip member 610. The resilient clip member 610 may be a component of the frame assembly 502. In one aspect, the resilient clip member 610 is a detachable resilient clip member. As shown, the resilient clip member 610 has a generally U-shaped configuration. In another aspect, the resilient clip member 610 is an integrally-formed resilient clip member that is integrally formed, for example, with the first end cover 504 or the second end cover 506.

The resilient clip member 610 includes a first resilient arm 612, a second resilient arm 614, and a base portion 616 that extends between the first resilient arm 612 and the second resilient arm 614 to interconnect the first resilient arm 612 and the second resilient arm 614. The first resilient arm 612 is an elongated arm that extends from the base portion 616 to a first free end portion 620. The first free end portion 620 includes a first latching hook 622. The first latching hook 622 may extend from the first free end portion 620 in the general direction of the base portion 616. Additionally or alternatively, the first free end portion 620 includes a first release tab 624. The first release tab 624 extends from the first free end portion 620 in a direction generally opposite the base portion 616 (e.g., opposite the first latching hook 622). The first release tab 624 may assist a user in manipulating the first resilient arm 612 (e.g., from an assembled or latched configuration to an unassembled or unlatch configuration).

Similarly, the second resilient arm 614 is an elongated arm that extends from the base portion 616 to a second free end portion 630. The second free end portion 630 includes a second latching hook 632. The second latching hook 622 extends from the second free end portion 630 in the general direction of the base portion 616. Additionally or alternatively, the second free end portion 630 includes a second release tab 634. The second release tab 634 extends from the second free end portion 630 in a direction generally opposite the base portion 616 (e.g., opposite the second latching hook 632). The second release tab 634 may assist a user in manipulating the second resilient arm 614 (e.g., from an assembled or latched configuration to an unassembled or unlatch configuration).

The resilient clip member 610 further includes a guide peg 640. The guide peg 640 is provided, for example, at an interior surface of the base portion 616. The guide peg 640 is dimensioned to be received within the hole 602 of the second end cover 506. In this way, the guide peg 640 and the hole 602 may cooperate to assist a user in aligning the resilient clip member 610 with the second end cover 506. In another aspect, the second end cover 506 is provided with a guide peg, and the resilient clip member 610 is provided with a hole to assist a user in aligning the resilient clip member 610 with the second end cover 506.

The battery holder 500 is depicted in an unassembled configuration in FIGS. 18-20. In the unassembled configuration, one or both of the first free end portion 620 and the second free end portion 630 are disengaged from the first end cover 504. Also in the unassembled configuration, the first and second resilient arms 612, 614 are outwardly divergent. That is, the first and second resilient arms 612, 614 taper away from each as they extend along the central axis 560 away from the base portion 616.

Referring to FIGS. 21 and 22, the battery holder 500 is depicted in an assembled configuration. In the assembled configuration, the first and second resilient arms 612, 614 extend from the second end cover 506 to the first end cover 504 such that the free end portions 620, 630 engage the first end cover 504 to releasably secure the second end cover 506 to the first end cover 504. Also in the assembled configuration, the first end cover 504, the second end cover 506, and the first and second resilient arms 612, 614 cooperate to define at least one substantially open battery compartment 650. In one aspect, the battery compartment 650 is dimensioned to receive a single battery 652. In another aspect, the battery compartment 650 is dimensioned to receive a plurality of batteries, such as two batteries 652. The one or more batteries 652 may be cylindrical batteries disposed longitudinally between the first and second battery contact elements 510, 512 and laterally between the first and second resilient arms 612, 614.

Also in the assembled configuration, the base portion 616 is at least partially received within the laterally-extending channel 580 of the second end cover 506. In one aspect, the base portion 616 is received within the laterally-extending channel 580 such that an outwardly-facing surface of the base portion 616 is flush, or substantially flush, with an outwardly-facing surface of the end surface 582 of the second end cover 506. Furthermore, the first and second resilient arms 612, 614 are at least partially received within the longitudinally-extending channels 590 of the second end cover 506. In one aspect, the first and second resilient arms 612, 614 are received within the longitudinally-extending channels 590 such that outwardly-facing surfaces of the first and second resilient arms 612, 614 are flush, or substantially flush, with outwardly-facing surfaces of side end portions 592 of the second end cover 506.

The first and second resilient arms 612, 614 extend longitudinally along the battery compartment 650 (including along batteries 652, if installed) toward the first end cover 504. The first and second resilient arms 612, 614 are at least partially received within the longitudinally-extending channels 550 of the first end cover 504. In one aspect, the first and second resilient arms 612, 614 are received within the longitudinally-extending channels 550 such that outwardly-facing surfaces of the first and second resilient arms 612, 614 are flush, or substantially flush, with outwardly-facing surfaces of side end portions 552 of the first end cover 504. As such, in the assembled configuration, the first and second resilient arms 612, 614 are generally parallel. The free end portions 620, 630 are at least partially received within the laterally-extending channels 530 that extend along the end surface 532 of the first end cover 504.

The first and second latching hooks 622, 632 are adapted to secure the second end cover 506 to the first end cover 504 via the first and second resilient arms 612, 614. More particularly, the first and second latching hooks 622, 632 extend into the recesses 540 of the first end cover 504 and into engagement with the abutment surfaces 542 formed in the recesses 540. Upon engagement, lateral movement of the free end portions 620, 630 (e.g., in a direction substantially orthogonal to the central axis 560) is substantially inhibited. Furthermore, one or both of the first and second battery contact elements 510, 512 includes a spring that imparts a longitudinally-biasing force through the one or more batteries 652 that biases the first and second end covers 504, 506 in opposite directions. Such opposing longitudinally-biasing forces act to retain the free end portions 620, 630 of the first and second resilient arms 612, 614 within the laterally-extending channels 530 of the first end cover 504.

As such, in the assembled configuration, the free end portions 620, 630 of the first and second resilient arms 612, 614 engage the abutment surfaces 542 to releasably secure the second end cover 506 to the first end cover 504. The resilient clip member 610 interfaces the various laterally-extending and longitudinally-extending channels of the first and second end covers 504, 506 to provide a low profile battery holder 500.

In the approach shown, the battery holder 500 includes first and second substantially open side-by-side compartments that are sized and shaped to fixedly retain first and second cylindrical-shaped batteries 652. The first and second end covers 504, 506 are disposed opposite to each other and spaced apart at the opposite ends of the frame assembly 502 such that the first and second batteries 652 are securely engaged with corresponding ones of the contact elements and are not fully enclosed by the frame assembly 502.

As discussed, the free end portions 620, 630 are provided with release tabs 624, 634 to assist a user in manipulating the first and second resilient arms 612, 614 (e.g., from the assembled or latched configuration to an unassembled or unlatch configuration). In this way, the resilient clip member 610 is configured to releasably connect the first and second end covers 504, 506 together to form the frame assembly 502, and to allow the first and second end covers 504, 506 covers to be disconnected from each other for removal and replacement of the batteries 652.

Although depicted as a discrete, detachable resilient clip member 610, one or more portions of the resilient clip member 610 may be integrated with first end cover 504, the second end cover 506, or a combination of the first end cover 504 and the second end cover 506. For example, the resilient clip member 610 may be integrally formed with the second end cover 506 such that the second end cover 506 includes integrally-formed elongated resilient arms.

While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes is made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments is combined to form further embodiments of the invention that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics is compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes may include, but are not limited to cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. As such, embodiments described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and is desirable for particular applications.

Claims

1-47. (canceled)

48. A light module for mounting to an article of clothing, the light module comprising: a housing having an interior;a light source mounted in the interior;an inclined forward wall portion of the housing having a large light opening through which light from the light source is emitted;opposite inclined wall sections of the inclined forward wall portion laterally spaced from each other on either side of the large light opening, with the large light opening having a maximum lateral width that is larger than a maximum lateral width of at least one of the opposite inclined wall sections of the inclined forward wall portion;a switch device electrically coupled to the light source and having an actuator operable to switch the light source between on and off states; anda rearward wall portion of the housing extending obliquely to the inclined forward wall portion and having an actuator opening in which a user-operated portion of the actuator is received.

49. The light module of claim 48 further comprising a backplate for mounting adjacent the article of clothing, wherein the inclined forward wall portion is inclined obliquely relative to the backplate.

50. The light module of claim 48 wherein a lateral width of the large light opening varies from a minimum lateral width proximate to the light source to the maximum lateral width distal from the light source.

51. The light module of claim 48 wherein at least one opposite inclined wall section tapers outwardly from a central axis of the light source as the at least one opposite inclined wall section extends away from the rearward wall portion.

52. The light module of claim 48 wherein the inclined forward wall portion and the rearward wall portion are joined to each other to form an obtuse angle therebetween within the housing.

53. The light module of claim 48 further comprising a reflector secured to the housing, the reflector including a rearward opening aligned with the light source and at least one reflective wall extending forwardly from the rearward opening.

54. The light module of claim 53 wherein the reflector includes a first reflective wall, a second reflective wall, and a pair of opposing reflective side walls extending between the first and second reflective walls for reflecting light from the light source.

55. The light module of claim 54 wherein the first reflective wall extends forwardly from the rearward opening farther than the second reflective wall.

56. The light module of claim 54 wherein the pair of opposing reflective side walls extend forwardly from the rearward opening farther than the second reflective wall.

57. The light module of claim 54 wherein the pair of opposing reflective side walls taper outwardly from a central axis of the light source as the pair of opposing reflective side walls extend forwardly from the rearward.

58. The light module of claim 54 wherein the pair of opposing reflective side walls are inclined relative to the first reflective wall to form obtuse angles with the first reflective wall.

59. A light module comprising: a housing having an interior;a light source mounted in the interior;a first inclined wall portion including an opening configured to permit light generated by the light source to pass therethrough;a second inclined wall portion having a user-operated actuator interface, anda switch device electrically coupled to the light source for selectively energizing the light source, the switch device having an actuator associated with the second inclined wall portion and being configured to travel in a linear actuation direction when pushed by a user, the linear actuation direction being arranged to be generally oblique relative to the first inclined wall portion for ease of operation by the user.

60. The light module of claim 59 further comprising a backplate for mounting adjacent an article of clothing, wherein the first inclined wall portion is inclined obliquely relative to the backplate.

61. The light module of claim 59 further comprising a reflector secured to the housing, the reflector including a rearward opening aligned with the light source and at least one reflective wall extending forwardly from the rearward opening.

62. The light module of claim 61 wherein the reflector includes a first reflective wall and a second reflective wall that tapers away from the first reflective wall as the second reflective wall extends away from the rearward opening.

63. The light module of claim 61 wherein the reflector includes a first reflective wall and a pair of opposing reflective side walls that extend from the first reflective wall and taper away from each other as the pair of opposing reflective side walls extend away from the rearward opening.

64. The light module of claim 59 wherein the switch device includes an inclined circuit board is mounted in the housing to extend obliquely relative to the first inclined wall portion, the inclined circuit board being electrically coupled to the light source and the switch device.

65. A light module comprising: a housing including a mounting surface having a fore-and-aft axis, an inclined wall portion that extends obliquely relative to the mounting surface and that includes a light opening, and an actuator wall portion that extends obliquely relative to the inclined wall portion;a light source mounted in the housing to direct light through the light opening; anda switch device electrically coupled to the light source for selectively energizing the light source, the switch device having an actuator associated with the actuator wall portion and being configured to travel in a linear actuation direction when pushed by a user, the linear actuation direction being arranged to be oblique to the inclined wall portion.

66. The light module of claim 65 wherein the inclined wall portion and the actuator wall portion are joined to each other to form an obtuse angle therebetween within the housing.

67. The light module of claim 65 wherein the inclined wall portion and the actuator wall portion each have a generally planar configuration.

68. The light module of claim 65 further comprising a reflector secured to the housing, the reflector including a rearward opening aligned with the light source and at least one reflective wall extending forwardly from the rearward opening.

69. The light module of claim 68 wherein the reflector includes a plurality of reflective walls having corner junctures therebetween, the plurality of reflective walls including a first reflective wall, a second reflective wall, and a pair of opposing reflective side walls extending between the first and second reflective walls for reflecting light from the light source.

70. The light module of claim 65 wherein the linear actuation direction is oblique to a central axis of the light source.

71. The light module of claim 65 wherein the light module is configured to be secured to headgear.

72. The light module of claim 71 in combination with the headgear, wherein the headgear includes a head-fitting portion and a brim portion extending generally forwardly from the head-fitting portion, wherein the mounting surface is arranged to be adjacent the brim portion.

73. The light module of claim 71 in combination with the headgear, wherein the headgear includes a head-fitting portion having a forwardly-facing surface when worn, wherein the mounting surface is arranged to be adjacent the forwardly-facing surface.

74. The light module of claim 73 wherein the headgear is a beanie-style cap.

75. Lighted headgear comprising: a head fitting portion for fitting on a head of a user;a brim portion that extends in a generally forward direction from the head fitting portion, the brim portion having a generally downwardly-facing surface and including a central axis that extends in the generally forward direction; anda light module mounted to the generally downwardly-facing surface of the brim portion, the light module including:a housing having a forward wall portion that includes a forward opening, and a rearward wall portion that extends obliquely relative to the forward wall portion,a light source mounted in the housing to direct light through the forward opening, anda switch device electrically coupled to the light source for selectively energizing the light source, the switch device having an actuator associated with the rearward wall portion and being configured to travel in a linear actuation direction when pushed by the user, the linear actuation direction being arranged to be upwardly relative to the generally downwardly-facing surface of the brim portion for ease of operation by the user.

76. The lighted headgear of claim 75 wherein the light source emits light in a direction that is generally forwardly and downwardly from the light module.

77. The lighted headgear of claim 75 wherein the actuator includes a resilient button and a plunger, and the rearward wall portion has an opening for receiving the resilient button, the resilient button being deformable by the user to depress the plunger in the linear actuation direction.

78. The lighted headgear of claim 75 wherein the rearward wall portion is an inclined rearward wall portion that extends obliquely relative to the central axis.

79. The lighted headgear of claim 75 wherein the linear actuation direction is arranged to be upwardly and forwardly relative to the generally downwardly-facing surface of the brim portion.