Abstract:
A three-component, protective headgear or helmet, and circuits therefor is provided with a battery-powered LED head lamp, which may be used by construction workers, search and rescue persons, cyclists, police, fireman, and the like. The battery may be replaceable or rechargeable and has long-term, uniform output characteristics driven by unique circuitry.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. Ser. No. 10/725,766; filed: Dec. 2, 2003; entitled: “THREE-COMPONENT PROTECTIVE HEAD GEAR POWERED BY A RECHARGEABLE BATTERY”; now U.S. Pat. No. 7,075,250. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable 
     INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
     Not Applicable 
     BACKGROUND OF THE INVENTION 
     (1) Field of the Invention 
     This application relates to a new and improved headgear, and more specifically to a headgear or helmet providing a lighting display for use by cyclists, construction and underground workers, search and rescue persons, emergency medical workers, firemen, police, meter readers, and so forth. The lighting display may be used to define a forward pathway or to illuminate objects, or to rearwardly signal a wearer&#39;s presence. 
     (2) Description of Related Art Including Information Disclosed Under 37 C.F.R. 1.97 And 1.98 
     Various types of protective helmets providing lighting displays are known in the prior art, and typical types of these helmets are described in U.S. Pat. Nos. 5,040,099; 5,327,587; 5,329,637; 5,357,409; 5,426,792; 5,479,325; 5,544,027; 5,485,358; 5,564,128; 5,570,946; 5,743,621; 5,758,947; 5,871,271; 6,007,213; 6,009,563; 6,113,244; 6,244,721; 6,328,454; 6,340,234; 6,464,369; and, 6,497,493. 
     However, none of the headgear in these patents disclose a battery powered circuit for an LED array that produces a long term, uniform illumination while providing a useful device for its intended purpose. The headgear structure of this invention may be a single, or a multi-component type, such as two or three. 
     BRIEF SUMMARY OF THE INVENTION 
     A new and improved headgear is provided with a lighting display comprising an LED array powered by built-in, rechargeable batteries through a unique circuit which enables a long-term, suitably constant output. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is an upper perspective view of the assembled headgear of this invention; 
         FIG. 2  is an exploded view of the upper and lower headgear components of the invention and the LED array; 
         FIG. 3  is a sectional side elevation view of the headgear taken along lines  3 - 3  of  FIG. 1 ; 
         FIG. 4  is a circuit diagram of this invention for feeding power from the rechargeable batteries to the LED array; 
         FIG. 5  shows the LED array connected to the rechargeable batteries; and, 
         FIGS. 6A and 6B  show a circuit diagram for a microprocessor controlled LED arrays to produce various display modes and formats. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The headgear  10  of this invention is shown in  FIGS. 1-3 , and comprises an upper helmet portion  11  defining an integrally formed, outer central reinforcing ridge  12  and a corresponding interior reinforcing grid area  13 . Into the grid area  13  are mounted removable or rechargeable lithium ion battery packs  14  and  15  which connect to a circuit board  16 , the circuit itself being shown in  FIG. 4 . Wire connections from the batteries to the circuit board and to the LED arrays are shown in  FIG. 5 . 
     A rearwardly installed LED array  17  is mounted on the upper helmet portion  11  and are connected to the circuit board and driven by the battery packs. The LED array  17  is shielded by a transparent acrylic sheet  18  mounted on the exterior of the upper helmet  11 . The front area of the upper helmet  11  is provided with an enclosure  20  shielded by a curved, transparent acrylic sheet  21  which protects an enclosed, front facing LED array  22 . 
     An interfitting helmet portion  25  is configured to interlock with the upper helmet portion  11 , the two helmet portions being secured together vertically by screws  26 . The helmet portion  25  defines a flat portion  27  which registers with grid area  13  and contacts the lower sides of the battery packs  14 ,  15  thereby securing the battery packs in place. As indicated, the front area of the helmet  25  defines the enclosure  20  into which the front facing LED array  22  is mounted. 
     The LED array  22  is driven through the circuit board  16  from the battery packs  14  and  15  as shown in  FIG. 4 , similarly to the LED array  17  and the circuit of  FIG. 4 , which will be described, infra.  FIGS. 3-5  show an on-off switch  28  connected to the circuit board  16  and circuit of this invention.  FIG. 3  also shows a charging outlet pin  29  for the battery packs  14  and  15 , the charging pin being adjacent to the on-off switch  28 . The batteries also may be removed for recharging or replacement. 
     An integrally formed, reinforcing wrap-around section  11   a  on the helmet portion  11  defines bores  30  coinciding with bores (not shown) in the helmet portion  25  through which pass screws  31  which horizontally secure the helmet portions  11  and  25  together. The screws  26  and  31  thereby secure the helmet portions  11  and  25  both vertically and horizontally. If desired, an edge liner  25   a  of injection molded polypropylene may be employed to engage the edges between the helmet portions  11  and  25 , and thereby effect additional securement between the two helmets. 
     As shown in  FIG. 3 , a protective foam head enclosure  32  such as constructed from polyurethane or polystyrene foam is provided to cushion the wearer&#39;s head from impact against the much harder ABS plastic materials of both the helmet portions  11  and  25 . Similar bores (not shown) in the head enclosure  32  register with the bores  30  and enable the helmet portions  11  and  25  and the head enclosure to be secured together using the screws  31 . 
     The circuit shown in  FIGS. 4 and 5  enables a relatively long and uniform battery power output before charging is required. The lithium ion batteries JP 1  and JP 3  shown in  FIGS. 4 and 5  each deliver about 6600 milliamps at 7.2 volts and are isolated from each other by a diode D 3 . When the on-off switch  28  ( FIG. 3 ) is turned on at JP 1 , the batteries JP 1  and JP 3  will turn on a comparator such as an op amp comparator JP 2 , e.g. an LM358. 
     The comparator JP 2  shows a direct coupled amplifier configuration driven from the battery JP 1  through transistors PNP Q 1  and NPN Q 2 , and through the coupling resistance R 7  to the input pin  1  of JP 2 . Resistances R 1 , R 2 , R 3 , R 6 /R 4  respectively will protect a Zener D 1 , Q 1 , R 5 -JP 2  and LED arrays D 2  ( 17 ,  22 ) from excessive current/voltage. 
     Battery power from JP 3  is applied to the voltage divider R 5  and then to pin  2  of JP 2 , while pins  3 ,  4  of JP 2  are both at ground. Obviously, the op amp comparator JP 2  is driven by both batteries JP 1  and JP 3 . Capacitor C 1  and resistance R 8  are both grounded, and provide ripple filtering, and R 8  also shunts voltage from pin  3  of the JP 2  to the Zener D 1 . JP 2  (at pin  8 ) also drives the Zener which functions as a shunt to maintain the load voltage constant for changing current/voltage variations due to running down of the batteries. In the reverse conduction condition as shown, the Zener D 1  also reduces ripple voltage. 
     When the switch  28  ( FIG. 3 ) is turned on at JP 1 , and voltage from the voltage divider R 5  exceeds the pin  3  reference voltage, the comparator JP 2  (LM358) will turn on, and hence transistors Q 1  and Q 2  (driven from JP 1  and JP 3 ) will then turn on the LED arrays D 2  ( 17 ,  22 ). 
     Typically, the lumen output of the present device for about 93 LEDs is about 4000 MCD@20 milliamps for 5-5½ hours using 7.2 volt batteries. Moreover, the device of this invention frees up the wearer&#39;s hands when viewing an operating field, especially in an emergency situation. 
     It will be appreciated that while a Zener diode is preferred for use in the circuit described, other semiconductor devices with similar turn-on characteristics may be utilized, and they are described in the “SCR MANUAL, INCLUDING TRIACS AND OTHER THYRISTORS” Sixth Edition, 1979 by General Electric, and incorporated herein, by reference. 
     Additionally, the circuit of this invention may be employed for illuminating purposes other than in a helmet, such as an LED array in a flashlight; to function as a traffic signal; as an LED turn on device used with an alarm detection system; and so forth. 
     As distinguished from the mode of operation employing the comparator circuit shown in  FIG. 4 , the microprocessor controlled circuit is shown in  FIGS. 6A ,  6 B, and the circuit itself may be a specific circuit board or form part of the circuit board  16  shown in  FIG. 4 . The microprocessor may be used to actuate LEDs for: helmets (front and/or rear); traffic signal lights; flashlights; vehicles; marine and aircraft lights; airport runway lights, etc., using a combination of blinking and continuous lights, that are shown generally in  FIG. 6B . 
     A battery supply for the circuit shown in  FIGS. 6A ,  6 B may be charged from a power source, including a wall plug, car cigarette lighter, etc., and the batteries are resistively connected R 30  and a diode D 4  to a turn-on switch SW 1 . The diode D 4  also provides a temperature sink, while C 5 , C 3  reduce oscillations from the batteries. 
     Power for the circuit is shown at various circuit locations as +B, +B 1  and +B 2 . Battery power at +B drives major components of the circuit, while battery power at +B 1 , +B 2  drives the LEDS. The front lights (e.g., yellow LED&#39;s) and rear lights (e.g., red LED&#39;s) are shown respectively as CN 2  and CN 1  on the circuit diagram. Since the front and rear lights can be programmed for display as on-off, blinking and continuous modes, various LED display combinations or formats are available. 
     The power distribution portion of the circuit comprises two-stage, resistance-coupled, power transistor amplifiers Q 8  and Q 9 . Transistor Q 8  is resistance connected to a pass transistor Q 7  for supplying power to +B 1 , as shown. Transistor Q 9  is connected through resistances R 27  and R 28  to a pass transistor Q 10  for the +B 2  power source which drives one set of LEDS (yellow) at CN 2 . Transistor Q 9  distributes power to +B 1  and to another set of LEDS (red) at CN 1 , and Q 9  also supplies power to +B through resistances R 27 , R 28  and R 29 . Battery +B also supplies power to pass transistor Q 7  and +B 1 . 
     Use of the two pass transistors Q 7  and Q 10  improves power dissipation and output power regulation, particularly for a varying load, such as a blinking mode. Q 8  and Q 9  are grounded through respective resistances to stabilize transistor operation and to prevent thermal run-away; they may be matched and encapsulated in a single package. Diodes D 11 , D 12  are used as heat sinks to provide additional temperature stability and to prevent drift. 
     A microprocessor IC 2  (Motorola MC14320) is used for programming the circuit system, and is driven from the power supply +B/R 15 /pin  2 , +B/pin  16 , +B/R 14 /pin  10 , +B/R 23 /pins  3 ,  12  and, +B/R 18 /pin  12 . Diodes D 5 , D 9  provide rectified power to IC 2  at pin  12 , and D 10  provides positive voltage from +B/R 23  to IC 2  pin  3 . Pins  8 ,  9  and  15  are grounded, the latter being grounded through an RC filter R 6 , C 2 . Resistance R 4  provides the necessary operating level for the IC 2  microprocessor output. 
     The microprocessor IC 2  is fed a signal from a tactile switch SW 2  through pins  9  and  10 , the tactile switch SW 2  being driven from the power supply +B through an RC filter R 14  and C 4 . Sequence touching of the tactile switch SW 2  will activate corresponding programs of IC 2 , and hence can activate various LED display modes. These display modes can be LED display combinations such as on-off, blinking and continuous. 
     As noted, battery power for CN 2  is from +B 2  which also provides power for LED 2  A (yellow blinking) through an LED interface Q 2  which may be a PNP germanium transistor. +B 2  battery power is also provided for LED 2  B (yellow continuous) through a differential amplifier transistor NPN pair Q 1 , Q 3  which are resistance-coupled to LED 2  B by R 12 . Q 1 , Q 3  also reduce or minimize drift, and for low circuit drift requirements, Q 1  and Q 3  may be matched and encapsulated in a single package. 
     IC 1 A, IC 1 B are inverters from say a 4049 inverter package to control the pulse lighting frequency of LED 2  A and LED 1  A. These two inverters send a clock signal to IC 2  pin  1  through R 16 , and the frequency and duration of the clock signal can be varied by adjusting R 2 , C 1  which in turn determine the blinking frequency of the LED&#39;s. See for example U.S. Pat. No. 5,544,027. 
     The actuation signals to CN 1  are from the microprocessor IC 2  at pins  3  and  12 . Blinking (red) LED 1  A is powered from +B/R 23  and an inverter IC 1 E (which avoids the positive pulses from D 10 ). IC 1 E is coupled to an LED interface NPN transistor Q 6  that is resistance coupled R 22  to LED 1  A of CN 1 . The actuation signal to IC 1 E is from the microprocessor IC 2  at pin  3 . 
     Power for LED 1  B continuous (red) is from +B through Q 4  which drives an interface transistor Q 5  that is resistance coupled R 20  to continuous LED 1  B (red). Q 4 , Q 5  and Q 6  are grounded and function similarly to Q 8 , Q 9  and Q 1 , Q 3  to prevent a run away temperature excursion and to impart drift stability. 
     In one mode of operating the LEDs, when the SW 1  switch is first turned on, the output of IC 1 A, IC 1 B and IC 2  are fed to an OR gate IC 1 C. With IC 1 A and IC 1 B in the “ON” state, the OR gate IC 1 C will pass the pulse signals to the LED interface Q 2  which is resistance-coupled (R 11 ) to LED 2  A (yellow blinking) of CN 2 . 
     The output from pin  11  of IC 2  will be fed through resistance R 4  to the OR gate IC 1 C. Hence, when the switch SW 1  is initially turned on, the program of IC 2  will light LED 2  A as a yellow blinking mode; CN 2  of course will be in an ON mode. 
     Thus for the above mode, during LED operations when the switch SW 1  is initially closed, the IC 2  microprocessor program will be actuated causing LED 2  A to blink, the blinking frequency signal depending on the R 2 , C 1  setting of the 4049 inverter IC 1 B and IC 1 A. This frequency signal is sent to the inverter gate IC 1 C along with the microprocessor output from IC 2 . The inverter gate IC 1 C will pass both output signals to activate CN 2  and LED 2  A, causing LED 2  A to blink ON yellow, and CN 1  to be ON red. 
     A first touching of the tactile switch SW 2  will turn off LED 2  A, and the output signal from IC 1 C will then be resistance coupled (R 9 ) from +B 2  to the differential amplifiers Q 1  and Q 3 . This will cause LED 2  B to turn ON continuously (yellow) and CN 1  (red) to remain ON. To turn off LED 2  A and turn on LED 2  B, the microprocessor IC 2  will send appropriate signals to IC 1 C from pin  11  and R 4 , and also through the coupling resistance R 13  to the differential amplifier Q 1 , Q 3  to control LED 2  B (yellow ON) at CN 2  and to control LED 1  B (continuous red ON). 
     During the time CN 2  is activated, CN 1  may be disabled by signals from IC 1 C and pins  11 ,  12  of IC 2 . These two IC 2  signals are applied to diodes D 1 , D 2  which drive an inverter IC 1 D. A signal from IC 2  (pin  12 ), is also applied to a gate IC 1 F and diode D 3  (or a Zener). 
     The diode D 3  (or Zener) functions to maintain the load voltage constant for changing current/voltage variations due to running down of the batteries. In the reverse conduction condition as shown, D 3  or the Zener will also smooth and reduce ripple voltage from D 1 , D 2  to the inverter IC 1 D, which will thereby invert the entire reduced positive ripple voltage from D 1  and D 2 . When applied to the opposite positive power supply from +B 1 , the smoothed and reduced inverted signal from IC 1 D is sufficient to disable the +B 1  power source, without affecting the positive +B power supply. 
     As indicated, supra, various modes of LED functions are possible, for example when the SW 1  switch of the unit is first turned on, initially the front lights of LED 2  A may be turn ON in a blinking mode yellow and LED 1  B can turn ON continuously red. 
     A first touching of the tactile switch SW 2  will cause the IC 2  program to turn off the blinking yellow at LED 2  A, turn on a continuous yellow at LED 2  B; LED 1  B remains continuously ON red. 
     A second tactile touching of SW 2  will turn off the continuous yellow mode and red modes and also turn on both CN 1  and CN 2  to blinking. Thus, both CN 1  and CN 2  will be changed from continuous to blinking modes. This is accomplished by sending turn off signals to gate IC 1 C and hence Q 1 , Q 3 ; this will disable +B 2 . With diodes D 1 , D 2  and gate IC 1 F being turned off, the +B 1  power supply will be restored. 
     A third touching of SW 2  will turn SN 2  blinking yellow OFF to continuous yellow ON, while SN 1  will turn red continuous ON, and, the cycle may then be repeated. 
     Operationally, the third touching of the tactile switch SW 2  (supra) will send a turn OFF signal to LED 1  A from the microprocessor IC 2 , pin  3  and the program will actuate Q 4  from pin  12 . This will turn LED 1  B ON continuously red, while LED 2  B of CN 2  will be turned ON continuously yellow. 
     In a second example of an LED display mode or format, when the unit is first turned ON at SW 1 , the IC 2  program will cause LED 2  A to be a blinking yellow ON, and SN 1  red will be OFF. 
     A first touching of the SW 2  tactile switch will cause the IC 2  program to turn yellow SN 2  OFF, and turn LED 1  B ON continuously red. 
     A second touching of SW 2  will turn SN 2  yellow OFF and turn on CN 1  and LED 1  A to a blinking mode (red). 
     A third touching of SW 2  will turn LED 2  A ON blinking yellow and turn on LED 1  A as a blinking red, and the program cycle can be repeated. 
     Thus, the circuit of this invention has the advantage of enabling use of a device in various on-off, blinking and continuous modes. For example, suitable modes could be used to control traffic lights at signal orientations of say 90° and/or 180°. Another mode could include displaying left and right hand turn blinking or continuous yellow and/or red signals, rather than displaying a continuous red turn signal. Minimizing a continuous red signal could reduce waiting turn times for non-existing oncoming or cross traffic, as can frequently be the case. 
     Moreover, the circuit of this invention can also reduce battery power requirements when used for example in helmets and flashlights by using the device in a blinking mode rather than in a continuous mode, the latter which consumes greater energy. Also, battery power consumption can be reduced by changing the blink frequency setting of R 2 , C 1  in the 4049 package.