MODULAR RECHARGABLE HEADLAMP

A portable illuminating device is provided. The device has a rechargeable battery that can be re-charged using a wide variety of power sources, making is especially appropriate for use away from conventional power sources. The device can be connected to a wide variety of fittings that allow the device to be attached to users and to other objects. In some arrangements, the device includes a CPU that manages the power voltage and the temperature of the device so that its operation can be optimized.

SUMMARY

A portable illuminating device is provided. The portable illuminating device has a light-emitting element, a secondary battery in electrical communication with the light-emitting element, and a CPU in electrical communication with at least the secondary battery. The secondary battery may be a lithium-ion or lithium-polymer battery. These elements are contained within a housing. There is at least one attachment point on the housing, to which one or more exterior modular units can be attached mechanically and/or electrically. There may be at least one tactile-switch in electrical communication with the CPU. There may also be a heat sink in thermal communication with the light-emitting element.

In one arrangement, the modular unit is a charging device that can charge the secondary battery, or, alternatively, provide power directly to the light-emitting element. The charging device can be one or more of solar cells, USB chargers, hand generators and ac or dc power supplies. The charging device may be configured to communicate electrically through wireless energy transfer.

In some arrangements, the CPU is configured to communicate electrically with the light-emitting element, the secondary battery, and the (electrical) attachment point(s), and to perform operations based on pre-determined instructions. The CPU may also be configured to modify the pre-determined instructions if directed to by user input.

The CPU may be configured to detect the voltage of the secondary battery and to perform predefined functions based on said voltage. In one example, the CPU responds to the voltage of the secondary battery or a modular unit energy supply in electrical communication with the light-emitting element in order to provide a constant power level to the light-emitting element. The CPU may regulate power to the light-emitting element through the use of pulse width modulation. As discussed above, battery voltage fades naturally over time, thus providing less power to a light-emitting element. As the power decreases the light output of the light-emitting element fades, providing less and less illumination. By regulating battery voltage, the CPU can ensure that the light-emitting element provides constant illumination.

There may also be a thermal sensing device in electrical communication with the light-emitting element and the CPU so that the temperature of the light-emitting element may be communicated to the CPU. Thus, the CPU may also regulate power to the light-emitting element to prevent the light-emitting element from exceeding predetermined temperatures. As discussed above, overheating. LEDs can reduce their brightness and shorten their lives.

There may also be an additional integrated circuit (in addition to the CPU discussed above) in electrical communication with any of the following: the CPU, the secondary battery, the thermal sensing devices, and the electrical attachment point. The additional integrated circuit can perform such functions as sensing the configuration of the modular unit or the conditions of the surrounding environment and sending such information to the primary CPU.

In one arrangement, the light-emitting element has at least one LED, which provides white light. In some arrangements, the illuminating device has a plurality of LEDs wherein each of the LEDs is configured to emit light of a different wavelength. In one arrangement, the light from at least one light-emitting element is directed through a lens configured to bend light into a plurality of viewing angles.

In one arrangement, the housing has a first section and a second section. The light-emitting element, the secondary battery, the attachment point(s), and other elements are distributed between the two sections. The first section and the second section may be joined together at a hinge, and the first section and the second section are configured to move with respect to one another. A heat sink in thermal communication with the light-emitting element is open to the outside environment when the first section and the second sections are in an open position, that is when they are moved away from one another.

In another aspect of the invention, a headlamp is provided. The headlamp has at least one LED, a secondary battery in electrical communication with the LED. There is a CPU in electrical communication with the LED and with the secondary battery. The CPU is configured to adjust the voltage of the secondary battery in order to provide a constant power level to the light-emitting element. The LED, the secondary battery, and the CPU are located in a housing. In one arrangement, the housing also has at least one attachment point that provides mechanical and/or electrical connection between the headlamp and one or more exterior modular units.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the invention is provided below along with accompanying figures that illustrate the principles of the invention. The invention is described in connection with such embodiments, but the invention is not limited to any one embodiment. The scope of the invention is limited only by the claims and the invention encompasses numerous alternatives, modifications and equivalents.

Embodiments of the invention are related to a modular portable illuminating device. The term “modular” is used herein to signify that there are self-contained removable elements that can be attached or removed from the primary housing. The self-contained removable elements will herein be referred to as “modular units”. Each modular unit serves a specific function to allow the device to be adapted to better serve an intended use. The modular units may have mechanical and/ electrical functions. The primary unit also contains several features specifically designed to facilitate both mechanical and or electrical integration with modular units.

As shown inFIG. 1, a portable illuminating device100is provided, according to an embodiment of the invention. The illuminating device100has a housing110that has a variety of elements. The illuminating device100has a light-emitting element120configured to provide light external to the device100. In one arrangement, there is a heat sink (not shown), such as a metal plate, in thermal communication with the light-emitting element120. The light-emitting element120is in electrical communication with a secondary or rechargeable battery130. The secondary battery130(and optionally, the light-emitting element120) is in electrical communication with a CPU (central processing unit)140that is programmed for overall control of the components of the illuminating device100.

In one arrangement, the illuminating device100has a mechanical connector150that allows various auxiliary modular units (not shown) to be mechanically attached to the illuminating device100. In another arrangement, the illuminating device100has an electrical connector160that allows various auxiliary modular units (not shown) to be electrically attached to the illuminating device100and thereby be in electrical communication with circuitry inside the device100.

In one arrangement, the mechanical connector150and the electrical connector160are included together in one fitting (not shown). In one arrangement, the illuminating device100has a switch170with which a user can call upon various functions of the device100. The switch170is in electrical communication with the CPU140. In one arrangement, the illuminating device100has a second integrated circuit (IC) (not shown) that is in electrical communication with the secondary battery130and is also in communication with at least one of the CPU140, the electrical connector160, the light-emitting element120, a temperature sensing device (not shown), and the switch170. The second integrated circuit can perform such functions as sensing the configuration of the modular unit or the conditions of the surrounding environment and sending such information to the primary CPU140. The CPU140can use the information in applying control instructions to the device100. In one arrangement, the illuminating device has a second switch (not shown) that is in electrical communication with the CPU. Collectively, the light-emitting element120, the secondary battery130, the CPU140, the fittings150,160, and the switch170will be referred to herein as the components of the illuminating device100.

In one arrangement, the modular unit has a ridged member such as a bracket or clamp. In another arrangement, the modular unit has a flexible member such as a strap. In yet another arrangement, the modular unit has an elastic member such as an elastic band, rubber, or silicone. Such members make it possible to attach the modular unit to an object or user.

The light-emitting element120can contain one or more bulbs and/or LEDs. The light-emitting element120can be one or more of a conventional light bulb, such as an incandescent or fluorescent bulb, a halogen bulb or a light-emitting diode (LED). In one arrangement, the bulbs and/or LEDs are all the same color. In another arrangement, the one or more bulbs/LEDs emit light of different wavelengths (colors). Specific bulbs/LEDs can be used to provide illumination in various specialized conditions. In one arrangement, there are one or more lenses configured to bend light from bulbs/LEDs into a plurality of viewing angles. Each bulb or LED may be controlled individually by the CPU140. In another arrangement, the bulbs and/or LEDs are controlled as one unit by the CPU140. In one arrangement, one or more of the bulbs/LEDs is configured to signal information about the status of the overall illuminating device100.

The secondary battery130can be any rechargeable battery as is known or may be known in the art. Examples of such batteries include, but are not limited to, lithium, lithium ion and nickel metal hydride batteries. The secondary battery130can be charged from any of a plurality of power sources. Examples of such sources include, but are not limited to, primary batteries, external rechargeable batteries, solar cells, wind generators, conventional ac power sources, and car chargers. Power sources to be used for recharging the secondary battery130can be put into electrical communication with the secondary battery130through any of a variety of connections. Examples of such connections include, but are not limited to, electrical contacts located in the electrical connector160, USB fittings, micro-USB fittings, any standardized power connection and any wireless charging mechanism capable of transmitting electrical power through non-conductive medium including but not limited to inductive charging.

The CPU140is programmed to activate and deactivate various electrical connections among the components of the illuminating device100based on data the CPU140collects from the components of the device100, according to an embodiment of the invention.FIG. 2is a schematic diagram that shows the logic used by the CPU in one embodiment of the invention. In one embodiment of the invention, the CPU140performs checks on the secondary battery130voltage at pre-defined time intervals. In some arrangements, the CPU140checks the secondary battery130voltage at pre-defined time intervals or continuously. The CPU140can perform mathematical calculations using the detected battery voltage to determine how to regulate the power so that the connected light-emitting elements120receive the power at a constant level. One method of providing a constant power level to the light-emitting element120is through the use of pulse width modulation (PWM) in which the duty cycle (or percentage of time that electricity is flowing to the light-emitting element120) changes as battery voltage changes. If the CPU140detects a battery voltage outside of a prescribed acceptable voltage range the CPU140can check for the presence of external power supplies by sensing a voltage on the electrical connector160. If an external power supply is detected, the CPU140can create electrical connections that bypass the secondary battery130and power the illuminating device100from the external power supply. If no external power supply is detected the CPU140can initiate a shut-down (sleep) sequence to prevent operation in undesired conditions. In another arrangement, if the battery voltage is higher than is acceptable, the CPU140can disconnect electrical contact between the secondary battery130and external power sources that are attempting to charge the battery. In certain arrangements, the CPU140can create electrical contact between the secondary battery and electrical elements (not shown) that drain power from the secondary battery until the voltage is within prescribed the acceptable limits. Electrical elements that drain capacity may include but are not limited to resistors, power resistors, light-emitting elements.

In yet another arrangement, the CPU140can illuminate one or more bulbs/LEDs in the light-emitting element120to indicate the status of the illuminating device100to the user. An example of such an indicator is the flashing of one bulb/LED to indicate that the secondary battery130power is low. Other conditions that the CPU140can detect and indicate to the user may include but are not limited to the following: the CPU is preparing to turn the device off, the illuminator is being switched to an alternative power supply, the secondary battery voltage is outside of prescribed acceptable limits, the user should begin charging the battery to get above minimum voltage, the user should drain the battery to get below maximum voltage, the secondary battery is being charged, the secondary battery has finished charging.

In one embodiment of the invention, the CPU looks for and automatically switches to an alternate power supply (if available) when the secondary battery130reaches a predefined state of charge. Alternate power supplies come from the list that includes but is not limited to: primary batteries, external rechargeable batteries, solar cells, wind generators, ac power cords, car-chargers.

In one embodiment of the invention, the user can choose manually between the secondary battery130and an alternate power supply. The user may communicate the desire to switch to an alternate power supply through the use of the switch170, a secondary switch (not shown) internal to the housing100or a secondary switch (not shown) external to the housing100.

In one embodiment of the invention the CPU140is programmed to drive light emitting elements with regulated power. Under prescribed conditions, the CPU increases the power to the light-emitting element120to the maximum power rating for the light-emitting element120for a pre-programmed period of time. In another arrangement, the CPU increases the power to the light-emitting element120to somewhere between normal operating power and the maximum power rating for the light-emitting element120for a pre-programmed period of time. Increased power results in increased illumination. But, of course, the secondary battery130is drained more quickly at increased power.

In another embodiment of the invention, the CPU140is in electrical communication with a temperature-sensing device (not shown) that measures the temperature of the light-emitting element120. The CPU140can modulate the power supplied to the light-emitting element120in order to provide maximum light without allowing the light-emitting element120to reach unsafe temperatures. Unsafe temperatures may be defined as temperature that either limit the life-span of the light-emitting element or may cause harm to the user.

In another embodiment of the invention, the CPU140regulates current and voltage that are applied to the secondary battery during charging from external power sources. Such regulation makes it possible to charge the secondary battery130from a wide variety of sources, as discussed above. Such regulation also makes it possible to charge the secondary battery130from sources that, when un-regulated, provide a voltage or current that is too high or too low to charge the secondary battery safely.

In another embodiment of the invention, the CPU140monitors the temperature of the secondary battery130and compares the temperature to a prescribed acceptable range of temperature. When the temperature of the battery is too high or too low to permit safe charging of the secondary battery the CPU may prevent charging and may also provide a visual indicator to the user.

In one embodiment of the invention, the illuminating device100is configured to communicate with various auxiliary modular units. In one arrangement, there are mechanical modular units. A mechanical unit can connect to the housing110of the illuminating device100through the mechanical connection150. There can be more than one mechanical connection

150. In one arrangement, the mechanical modular unit is a strap that can be used to attach the illuminating device100to a user's body, such as for use as a headlamp or to a leg or an arm. In another arrangement, the mechanical modular unit has a fitting that can be used to attach the illuminating device100to a helmet, a vehicle or a structure. A person of ordinary skill in the art can understand readily that specialized fittings can be made to attach the illuminating device100to any desirable member.

In another arrangement, there are electrical modular units. A modular electrical unit can connect to the housing110of the illuminating device100through the electrical connection160. In another arrangement, the electrical unit is a power source used to recharge the secondary battery130. In yet another arrangement, the electrical unit is a power source used to provide power directly to the light emitting element when the built in secondary battery is low on power. Examples of such power sources include, but are not limited to primary batteries, external rechargeable batteries, solar cells, wind generators, conventional ac power sources, and car chargers. In another arrangement, the modular electrical unit is a power source that can be used to provide electrical power to the light emitting element120.

In one embodiment of the invention, the mechanical connection150and the electrical connection160are within one fitting (not shown) on the illuminating device100. A modular unit that includes both a mechanical element and an electrical element can thus have one point of contact to the illuminating device100. In one arrangement, such a modular unit is a flexible, electrically-conductive member that can be used both to attach the illuminating device100to an object or user and to provide electrical communication within one unit. Such a member can be configured to provide a retracting force that assists in mechanical attachment. In another arrangement, such a member can also be configured to include a hand generator. Stretching and releasing the member can generate electricity within the generator, and the electrically-conductive portion of the member can provide a path through which the generated electricity can recharge the secondary battery130.

In one embodiment of the invention, a tactile switch170is in electrical communication with the CPU140. In one arrangement there is a second tactile switch (not shown) in communication with the CPU140. In one arrangement, there are prescribed codes through which the switch170can communicate with the CPU. In an exemplary embodiment, double clicking of the switch170turns on the illuminating device100, single clicking of the switch170cycle through illumination modes previously programmed into the CPU, and holding the switch170for an extended period turns off the unit. Other switch manipulations can direct the CPU to display information about the state of the illuminating device100, such as level of charge in the secondary battery130. This information can be communicated to the user through specified lighting functions (e.g., flashing) of the light-emitting element120. As a person of ordinary skill in the art will readily understand, any number of functions can be programmed into the CPU and activated through prescribed switch codes.

In another arrangement, electrical communication with the CPU through the switch can be used to reprogram the CPU allowing the user to change the functions of the primary unit. Examples of such functions include, but are not limited to brightness, working limits of voltage and temperature, combinations of electrical connections between the CPU and light emitting elements, parameters controlling the user interface.

FIG. 3is a schematic cross-section illustration that shows an illuminating device300, according to another embodiment of the invention. A light-emitting element320is connected to a housing310of the illuminating device300through a hinge380. The housing310contains some or all of the other elements of the illuminating device300and described above forFIG. 1, and there is electrical communication between the housing310and the light-emitting element320. There may be a heat sink325in thermal communication with the light-emitting element320. The light-emitting element320can be tilted away from the housing310as desired by the user. When tilted away from the housing310, the heat sink325is exposed to the surrounding environment, allowing it to dissipate heat produced by the light-emitting element320. In addition, the hinge380allows the user to tilt the light-emitting element320to direct its light in various directions.

As shown inFIG. 3, there is also an optional cosmetic insert390that can be used with the illuminating device100. The light-emitting element320has a fitting (not shown) to which such a cosmetic insert390can attach. Such inserts390can be from any suitable material, such as wood, plastic, metal, glass, stone. Such inserts390can also be used with the embodiment of the illuminating device100shown inFIG. 1.

FIG. 4is a plot comparing the brightness of an exemplary headlamp as described herein with the brightness of a standard illuminating device as a function of time. It can be seen that over time the brightness of a standard illuminating device drops precipitously as battery voltage drops. It can also be seen that a standard illuminating device does not regulate power supplied to the light-emitting element and may allow the light-emitting element to get very hot. Elevated temperatures may reduce the functioning lifespan of light-emitting elements.FIG. 4also depicts the brightness of an illuminating device, according to an embodiment of the current invention. It can be seen that the brightness approximates a flat line as the CPU monitors battery voltage and attempts to provide the light-emitting element with a constant level of power. It can also be seen that at the end of the test the brightness shuts off digitally as opposed to slowly decaying; this prevents the battery from operating in unsafe low-voltage conditions.

This invention has been described herein in considerable detail to provide those skilled in the art with information relevant to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by different equipment, materials and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself.