Power cord mounted electronic module for portable lamp

A cap lamp system features a battery pack, a cap lamp housing containing a cap lamp bulb and a power cord connected between the battery pack and the cap lamp housing. The power cord provides power to the cap lamp bulb from the battery pack. An electronic module includes a housing defining a chamber and electronic circuitry is positioned within the chamber of the housing. The electronic module is positioned in circuit with the power cord. The electronic module may receives power from the battery pack and the electronic circuitry of the electronic module may includes a battery that powers the module.

FIELD OF THE INVENTION

The present invention relates to portable lamps such as cap lamps and other portable light sources and, more particularly, to an electronic module that is mounted on a power cord running between a battery pack and a cap lamp or other portable lighting source.

BACKGROUND

Mining cap lamps are typically mounted on hard hats worm by miners to provide illumination in underground mine shafts. Such cap lamps are well known in the mining equipment industry and provide illumination while the miner's hands remain free to perform tasks. A cap lamp typically receives power from a battery power pack secured to the user's waist. An electrical power cord delivers power from the power pack to the lamp on the helmet.

Modern day mines often include a miner tracking system so that the location of miners may be tracked for safety purposes. Such systems often include sensors positioned throughout the mine shafts. A miner wears a radio frequency identification (RFID) tag which broadcasts a signal including the identify of the miner wearing the RFID tag. When the miner passes a miner tracking system sensor, the sensor receives the signal from the RFID tag. The sensors communicate with a central computer which tracks the location of miners wearing the RFID tags based on which sensors have received signals from the miners' RFID tags.

The RFID tags must receive electrical power to operate. Traditionally, wires have been soldered to the battery terminals of the cap lamp power pack and to the RFID tags so that the RFID tags receive power from the battery of the cap lamp power pack. A problem with such an arrangement, however, is that such modifications are time consuming and inconvenient. In addition, and more importantly, the quality of the soldered connections is often inconsistent which leads to reliability issues, especially in the harsh mining environment. The exposed wires of such a power takeoff are also exposed which makes them even more vulnerable to damage.

Furthermore, additional devices or modules that are powered by electricity may be useful if carried by a worker in a mine or other harsh environment. Such devices include, but are not limited to, communication devices, gas sensors and dust sensors.

A need therefore exists for a system or device whereby electronic modules such as RFID tags, communication devices, gas sensors, dust sensors other electronic devices may be securely and safely mounted to miners, rescue workers or other individuals.

DETAILED DESCRIPTION OF EMBODIMENTS

While the invention is described below in terms of use with a battery, cap lamp and helmet for mining, it is to be understood that it may be applied to other types of portable lighting and head gear.

A cap lamp is indicated in general at8inFIG. 1. As is illustrated, for example, in U.S. Pat. No. 4,481,458 to Lane, the cap lamp may be mounted on a helmet of the type used in mining. The cap lamp includes a bulb10positioned within a housing12. As an example only, the cap lamp may be a model Mark V cap lamp sold by Koehler-Bright Star, Inc. of Hanover Township, Pa., who is assignee of the present application. The cap lamp8is typically mounted to a front panel of the helmet by a clip or other fastener positioned on the back side of the cap lamp (not shown inFIG. 1). As a result, the cap lamp may be removed from the helmet for recharging or servicing.

The cap lamp8receives power via a power cord, indicated in general at14, that provides power to the cap lamp from a battery pack16. The battery pack is typically worn strapped to the waist of the miner or in another location. As an example only, the battery pack may be a model Li-16 battery pack sold by sold by Koehler-Bright Star, Inc. of Hanover Township, Pa., who is assignee of the present application.

As is illustrated inFIGS. 1 and 2, the power cord14features two segments or portions18aand18b. As illustrated inFIGS. 1 and 2, an electronic module20is positioned in circuit with the segments18aand18bof the power cord. As illustrated inFIG. 2, the electronic module features a housing22which defines a chamber24within which is positioned electronic circuitry26. In this embodiment, and in the additional embodiments described below, the electronic circuitry may be a radio frequency identification tag (RFID) tag, communication device, gas sensor, dust sensor or any other electronic device that may be useful if carried by a miner or other worker. In this embodiment and the embodiments described below, the housing22preferably is molded or otherwise constructed out of plastic and features an opening that is sealed with a gasketed cover once the electronic circuitry26is positioned within chamber24. Other durable materials may be used instead for constructing the housing. The electronic circuitry26receives power from the power cord segments18aand18band also allows power to travel to the cap lamp.

A second embodiment of the electronic module is presented inFIG. 3. Like the embodiment ofFIGS. 1 and 2, this electronic module27uses a power cord featuring segments28aand28band includes a housing32defining a cavity34within which electronic circuitry36is positioned. As in the case of the embodiment ofFIGS. 1 and 2, the electronic circuitry36is powered by the power cord segments and allows power to travel to the cap lamp. In the embodiment ofFIG. 3, however, the segments28aand28bare removably connected to the housing via connectors38aand38b, respectively. As a result, the electronic module may be removed from the power cord and the two segments28aand28bfastened together via connectors38aand38b. As a result, the electronic module may be removed from being in circuit between the cap lamp and the battery pack.

An embodiment of the electronic module that is powered by an on-board battery is illustrated inFIGS. 4 and 5. With reference toFIG. 4, the electronic module40features a housing42which defines a chamber44within which is positioned electronic circuitry46. In the case of this embodiment, however, the power cord48does not power the electronic module. Instead, the electronic module features an on-board battery52which powers the electronic circuitry. The electronic module, never-the-less, is still positioned on the power cord48. A protective coating of rubber, plastic or some other flexible, protective material is indicated in phantom at54inFIG. 4covers the electronic module40and power cord48. This same coating is present in the embodiment ofFIGS. 1 and 2and is visible inFIG. 1.

An exploded perspective view of the electronic module, which is indicated in general at42, is provided inFIG. 5. As in previous embodiments, the housing42preferably is molded or otherwise constructed out of plastic and features an opening56that is sealed with a gasketed cover58once the electronic circuitry46and battery52are positioned within the housing chamber. Once the housing and cover are assembled, with the electronic circuitry and battery positioned inside, the electronic module may be covered with the protective coating54ofFIG. 4.

As noted previously, the construction described with regard toFIGS. 4 and 5may be used with the embodiments ofFIGS. 1-3

While the electronic circuitry may be a powered or self-powered electronic device, such as a printed circuit board with or without a coin cell battery, the electronic module may act as a mounting point (like a docking station) and/or power source, for a variety of interchangeable electronic devices. This is true whether the electronic module includes batteries or not. In the case of no batteries, the “docked” removable electronic device could receive power from the power cord.