Patent Publication Number: US-9885471-B2

Title: Multiple electronic tag holder

Description:
CLAIM OF PRIORITY 
     This application claims priority to U.S. Provisional Patent Application Ser. No. 61/642,779, filed May 4, 2012, and is a continuation-in-part of U.S. patent application Ser. No. 12/176,832, filed Jul. 20, 2008, which claims priority to U.S. Provisional Patent Application Ser. No. 60/961,627, filed Jul. 20, 2007. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to accessories for battery packs used to power cap lamps and other electronic devices and, in particular, to a multiple electronic tag holder that receives and powers multiple personal safety device tags in addition to or separately from a cap lamp. 
     BACKGROUND 
     Different types of protective headgear, such as helmets and hard hats, are typically worn by fire fighters, rescue personnel and in industries where protection of the head from falling debris or the like is necessary. Such industries include, but are not limited to construction and mining. 
     Oftentimes it is desirable to attach electronic modules, such as radio frequency identification (RFID) tags, global positioning system (GPS) tags, and natural gas sensor tags to protective headgear. For example, 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 an RFID tag which broadcasts a signal including the identity 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&#39; RFID tags. 
     Like the other types of electronic modules, RFID tags must receive electrical power to operate. Mining cap lamps are typically mounted on helmets 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&#39;s hands remain free to perform tasks. A cap lamp typically receives power from a battery power pack secured to the user&#39;s waist. Electrical wiring, delivers power from the power pack to the lamp on the helmet. 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. 
     Cordless cap lamps, where the battery pack and cap lamp are integrated into a single unit that is worn on the cap, are also known. 
     The Mine Improvement and New Emergency Response Act of 2006 requires mines to implement personal tracking, communication, and emergency plans. When individuals are working in hazardous locations such as a mine, emergency prevention and preparedness is a key element in the survival of those individuals. Prevention is the first line of defense (personal atmospheric monitoring and proximity), however, in the event of an emergency, response time is critical to survival. Response time is significantly influenced by the ability to locate each individual in an emergency situation. Tracking tags are key to locating the individuals rapidly. 
     As regulations continue to drive the need for atmospheric monitoring, tracking and proximity devices, employers will need to deploy the technologies and devices to their workforce. The current devices that an individual may wear are typically singular, self-contained cap lamp systems or units. In view of the above, individuals may be required to carry multiple tag devices that perform different functions in addition to the single self-contained cap lamp unit or system. Each tag device typically has its own self-contained power source. Such an arrangement suffers from a number of disadvantages. For example, self-contained tag devices typically have a power source that is smaller than a cap lamp battery and thus more limited in capacity. In addition, it is difficult to manage the maintenance of individual batteries for each one of the individual tag devices. A number of self-contained devices also increases difficulty of use. 
     A need therefore exists for a system and method that integrates tag devices and allows for individual and multiple tags to be contained and powered from a single power source. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a helmet with a cap lamp secured thereto by an embodiment of an electronic module adapter; 
         FIG. 2  is an enlarged perspective view of the front portion of the helmet, the cap lamp and the electronic module adapter of  FIG. 1 ; 
         FIGS. 3 and 4  are perspective exploded views of the helmet, cap lamp and electronic module adapter of  FIGS. 1 and 2 ; 
         FIG. 5  is an enlarged bottom and back perspective view of the electronic module adapter of  FIGS. 1-4  with the housing lid removed; 
         FIG. 6  is a cross-sectional view of the electronic module adapter of  FIG. 5  taken along line  6 - 6  of  FIG. 5 ; 
         FIG. 7  is a top and front perspective view of the electronic module adapter of  FIG. 5  with the housing lid attached; 
         FIG. 8  is an exploded top perspective view of the electronic module adapter of  FIG. 7 . 
         FIG. 9  is an exploded top perspective view of a first embodiment of the multiple electronic tag holder of the present invention and a cap lamp; 
         FIG. 10  is an assembled top perspective view of the multiple electronic tag holder and cap lamp of  FIG. 9  with the cover omitted for clarity; 
         FIG. 11  is an enlarged side elevational view of the multiple electronic tag holder of  FIG. 10 ; 
         FIG. 12  is an end elevational view of the multiple electronic tag holder of  FIG. 11 ; 
         FIG. 13  is an enlarged bottom perspective view of the cover of the multiple electronic tag holder of  FIG. 9 ; 
         FIG. 14  is an assembled enlarged bottom perspective view of the multiple electronic tag holder of  FIG. 9 ; 
         FIG. 15  is top perspective view of the multiple electronic tag holder of  FIG. 14  and a battery pack; 
         FIG. 16  is a top perspective view of the multiple electronic tag holder and battery pack of  FIG. 15  in an assembled configuration; 
         FIG. 17  is a schematic of an embodiment of the printed circuit board of the multiple electronic tag holder of  FIGS. 9-12 ; 
         FIG. 18  is a schematic of an alternative embodiment of the printed circuit board of the multiple electronic tag holder of  FIGS. 9-12 ; 
         FIG. 19  is a schematic of the multiple electronic tag holder of  FIGS. 9-16  and a battery pack; 
         FIG. 20  is a schematic of a second embodiment of the multiple electronic tag holder of the present invention and a battery pack; 
         FIG. 21  is a schematic of a third embodiment of the multiple electronic tag holder of the present invention; 
         FIG. 22  is a schematic of a fourth embodiment of the multiple electronic tag holder of the present invention; 
         FIG. 23  is a schematic of a fifth embodiment of the multiple electronic tag holder of the present invention; 
         FIG. 24  is a schematic of an embodiment of the multiple electronic tag holder of the present invention as used with a vest. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     As explained in greater detail below, the invention may be used with radio frequency identification (RFID) tags and other types of electronic modules including, but not limited to, global positioning system (GPS) tags, and natural gas sensor tags. 
     A helmet, such as used in mining, is indicated at  12  in  FIGS. 1-4 . As illustrated in  FIG. 1 , the helmet includes a front panel  14  and a visor  16 . A cap lamp is indicated at  18  in  FIGS. 1-4 . As an example only, the cap lamp may be a model LI-16 cap lamp sold by Koehler-Bright Star, Inc, of Hanover Township, Pa. As is known in the art, the cap lamp receives power via a power cord, indicated at  22  in  FIGS. 1 and 2 , from a battery pack (not shown) typically worn strapped to the waist of the miner or in another location. The cap lamp  18  is typically mounted to the front panel  14  of the helmet by a clip positioned on the back side of the cap lamp. This clip typically engages a slot, such as the one indicated at  19  in  FIG. 3 . As a result, the cap lamp may be removed from the helmet for recharging or servicing. 
     The helmet clip normally used to mount the cap lamp to the helmet is removed from the cap lamp. An electronic module adapter, indicated in general at  23  in  FIGS. 1-7 , includes a housing  24  that, as explained in greater detail below, defines a chamber which houses electronic module circuitry and batteries. For example, the electronic module circuitry may be a self powered RFID tag (printed circuit board with three coin cell batteries). Alternatively, the electronic module adapter may act as a mounting point (like a docking station) or power source, with batteries present in the electronic module adapter, for a variety of interchangeable electronic devices. Instead of batteries, the electronic module adapter may receive power from the power cord  22  ( FIG. 1 ). 
     As indicated in  FIGS. 1-4 , the electronic module adapter housing  24  mounts to the cap lamp with two screws  26   a  and  26   b  via a cap lamp mounting bracket. The cap lamp mounting bracket features a pair of flanges  28   a  and  28   b  ( FIGS. 3-5 and 7 ) formed on the front side of the housing. The flanges  28   a  and  28   b  include mounting holes, indicated at  30   a  and  30   b  in  FIGS. 3 and 7 , through which the screws  26   a  and  26   b  pass. The cap lamp mounting bracket may feature an alternative arrangement, such as a clip that engages the cap lamp or a recess that receives a clip mounted on the cap lamp. 
     As illustrated in  FIGS. 5-8 , a headgear mounting bracket in the form of helmet clip  32 , is attached to the back side of the electronic, module adapter housing  24 . More specifically, as illustrated in  FIG. 8 , the clip  32 , which in the illustrated embodiment is made of metal, is secured to the housing via screws  34   a  and  34   b , which engage openings  36   a  and  36   b  (not shown) formed in the housing  24 . Alternatively, the clip  32  may be formed of plastic and either attached to or integrally molded with the housing  24 . The housing  24  may also be constructed of metal with the clip  32  attached to it or integrally formed with the housing. 
     As illustrated in  FIGS. 1-4 , the helmet clip  32  (headgear mounting bracket) of the electronic module adapter  23  attaches to the front panel  14  of the helmet  12  and takes the place of the original cap lamp helmet clip. As a result, the helmet clip of the electronic module adapter is used to mount the whole assembly (including the electronic module adapter and cap lamp) to the helmet. The headgear mounting bracket may take a variety of alternative forms as long as it engages the helmet so as to secure the electronic module adapter housing thereto. 
     As illustrated in  FIGS. 5, 6 and 8 , electronic module circuitry in the form of a circular circuit board  40  has mounted thereon a stark of battery coin cells  42 , which provide power to the circuit board  40 . The electronic module circuitry circuit board may be for a variety of electronic functions, including, but not limited to, an RFID tag, a UPS tag and/or a natural gas sensor. As illustrated in  FIGS. 5, 6 and 8 , the circuit board and batteries are inserted into the chamber  43  defined by the electronic module adapter housing  24  and the bottom is closed with bottom lid  44  ( FIGS. 7 and 8 ), which may be sealed to keep dust and dirt out of the interior of the electronic module adapter. As noted previously, the batteries  42  may be omitted if the circuit board instead receives power from the cap lamp power cord  22  ( FIG. 1 ). 
     The circuit board and batteries may be secured within the chamber  43  by adhesive, screws or other fastening arrangements known in the art. The bottom lid  44  may be attached to the housing  24  by adhesive, screws or other fastening arrangements known in the art. 
     A first embodiment of the multiple electronic tag holder of the present invention is indicated in general at  50  in  FIG. 9 . The tag holder  50  of  FIG. 9  receives power from a battery or battery pack via springs  52   a  and  52   b , as explained below. Power is provided to a cap lamp  54  via a power cord  56  (i.e. power cord  56  is connected to cap lamp  54 ). The battery may be any type of battery known in the prior art, but is preferably a lithium-ion battery. 
     As illustrated in  FIGS. 19-12 , the tag holder  50  includes base plate  62 , upon which is mounted a printed circuit board (PCB)  64 . Base plate  62  is preferably molded from plastic. The PCB  64  includes a socket  66  as well as tag power terminals  68   a  and  68   b  (best shown in  FIG. 12 ). A pair of conductive terminal extenders  72   a  and  72   b  are connected to the PCB and pass through the tops of terminal extender columns  74   a  and  74   b.    
     The terminal extender columns are preferably molded into the base plate  62 . As illustrated in  FIG. 14 , the terminal extender columns are hollow and are provided with conductive inserts  76   a  and  76   b  that are in electronic communication with terminal extenders  72   a  and  72   b , respectively. A pair of tag cradles  78   a  and  78   b  are also molded into the base plate  62 . 
     Power may be distributed to tags positioned in the holder by the socket  66 , tag power terminals  68   a  and  68   b  or terminal extenders  72   a  and  72   b.    
     As illustrated in  FIGS. 9 and 13 , a cover  82  is provided with a top opening  84  through which a cord strain  86  passes. The cord strain is secured in place on the cover  82  via a strain bracket  88  which is secured to the inner top surface of the cover by screws  92  ( FIG. 12 ). 
     The cover  82  and base plate  62  form the housing of the tag holder  50 . 
     Cord  56 , which powers the cap lamp  54 , is attached to the cord strain  86  and a pair of wires  94   a  and  94   b  emerge from the end of the cord  56  that opens within/under the cover. The cords are provided with clips  96   a  and  96   b  that are sized to engage and be installed to the terminal extenders  72   a  and  72   b . As explained, below, current from a battery or battery pack flows through the terminal extenders, clips  96   a  and  96   b  and then thorough wires  94   a  and  94   b  of the cord  56  so that the cap lamp  54  is powered. 
     With reference to  FIG. 9 , an upper seal ring  102  is positioned between the cover  82  and the base plate  62  when the cover and base plate are assembled together (as illustrated in  FIG. 14 ) to keep contaminants such as dust and moisture out of the tag holder. Screws  104  secure the base plate to the cover. 
     The tag holder of  FIGS. 9-12  is configured to hold two electronic tags, indicated at  110  and  112 . Electronic tag  110  features a connector  114  that engages PCB socket  66 , while electronic tag  112  is connected to power terminals  68   a  and  68   b  via connection wires  116   a  and  116   b  (best shown in  FIG. 12 ) and screws  118 . Electronic tag  112  also engages and is supported in cradles  78   a  and  78   b  of the base plate  62 . 
     As examples only, suitable tags include as functionality proximity, location and communication (both verbal and non-verbal) and may be obtained, for example, from Aeroscout of Redwood City, Calif. (such as the model Tag-3100), Becker Wholesale Mine Supply, L.L.C. of North Huntingdon, Pa. (such as the model TCTO 200ZA) and Newtrax Technologies Inc. of Montreal, Canada (such as the model Wn-202-02). 
     Attachment of the tag holder  50  to a battery pack  120  is illustrated in  FIGS. 14-16 . As an example only, battery pack  120  may be a lithium-ion WHEAT LI battery pack available from Koehler-Bright Star LLC of Hanover Township, Pa. As illustrated in  FIG. 14 , the cover  82  of the tag holder  50  features tabs  122   a  and  122   b . As shown in  FIGS. 15 and 16 , the battery pack features corresponding tabs  124   a  and  124   b.    
     With reference to  FIG. 15 , contact springs  52   a  and  52   b  are positioned over the posts  126   a  and  126   b  of the battery pack. A lower gasket  128  is positioned on top of the battery pack and the tag holder  50  is then positioned above the battery pack and lowered into the position illustrated in  FIG. 16 . As illustrated in  FIG. 14 , and described previously, the base plate  62  of the tag holder is provided with conductive inserts  76   a  and  76   b  positioned within the hollow extender columns  74   a  and  74   b . When the tag holder  50  is assembled to the battery pack  120  ( FIG. 16 ), contact springs  52   a  and  52   b  enter the bottom openings of the hollow extender columns  74   a  and  74   b  and engage the conductive inserts  76   a  and  76   b . As a result, current from the battery pack posts  126   a  and  1261  ( FIG. 15 ) flows through the contact springs  52   a  and  52   b  and into terminal extenders  72   a  and  72   b  and the PCB  64  so that, with reference to  FIG. 9 , the tags  110  and  112  and cap lamp  54  are powered. The contact springs  52   a  and  52   b  permit variations in battery pack post height to be accommodated. In addition, this allows the tag holder internal circuitry to be protected from ingress of dust and liquid materials even when the tag holder is not connected to a battery pack. 
     Machine screws, indicated at  132  in  FIGS. 9 and 15 , engage suitable openings in the aligned tabs  124   a  and  124   b  of the battery pack and tabs  122   a  and  122   b  of the battery tag cover so that the tag holder  50  is secured on top of the battery pack  120 . The lower gasket  128  prevents entry of contaminants such as dust and moisture between the attached tag holder and battery pack. 
     The battery pack  120  may optionally include a cap lamp circuit board to provide an optical warning of a low battery (such as by flashing and/or dimming the cap lamp), and/or other functionality. An example of such a cap lamp circuit board is provided in, commonly owned U.S. patent application Ser. No. 12/008,790, the contents of which are hereby incorporated by reference. 
     With reference to  FIG. 9 , the PCB  64  regulates and controls the power provided by the battery so that each electronic tag  110  and  112  receives power at the individually required voltage and current levels. A schematic of an embodiment of the PCB  64  is provided in  FIG. 17 . The PCB  64  features a positive terminal extender  72   a  and a negative terminal extender  72   b  that, as described above, are connected to the battery or the corresponding terminals of a battery pack. Lines  142   a  and  142   b  are connected to the PCB socket  66  and the positive and negative terminal extenders, respectively. Line  142   b  is provided with resistor  144  and fuse  146  so that the correct current is provided to the socket  66  to power the electronic tag plugged into the socket and for safety purposes. Lines  152   a  and  152   b  similarly are connected to the tag positive and negative terminals  68   a  and  68   b  and the positive and negative terminal extenders, respectively. Line  152   b  is provided with resistor  154  and fuse  156  so that the correct current is provided to the tag terminals  68   a  and  68   b  to power the electronic tag attached thereto and for safety purposes. 
     The PCB of  FIG. 17  is a basic board for providing, power to electronic tags, such as tags  110  and  112  of  FIGS. 9-12 , and the design may change based on required functionality and the number and types of tags attached. For example, the PCB can provide one or multiple functions such as distributing power, limiting power, short circuit protection, send and receive signals for warnings or other communications (including verbal or non-verbal, with the latter including blinking light, warning light, buzzer etc.). 
     An example of an alternative embodiment of or circuitry that may be added to, the PCB is provided in  FIG. 18 . The interrupt circuitry of  FIG. 18  flashes the cap lamp as a warning indicator under the direction of a tag having, for example, a gas or dust sensor or where the tag is a communications device and an emergency evacuation signal is received. More specifically, with reference to  FIG. 18 , terminals  162   a  and  162   b  receive power from a battery or battery pack to which the tag holder is connected to. The cap lamp is connected to the circuitry via terminals  164   a  and  164   b . A transistor  166  (a P-ch MOSFET) conducts from source to drain during normal operation of the tag interrupt PCB so that the cap lamp is ON. 
     An electronic tag is attached to the interrupt PCB of  FIG. 18  at terminals  168   a  and  168   b . When the tag receives a wireless signal with an emergency communication, or senses a hazardous condition, a positive pulse width signal is sent to the tag interrupt PCB via terminals  168   a  and  168   b . The positive pulsed signal is applied to the base of a transistor  174 , allowing it to turn on and pull the base of transistor  175  to LOW, thus turning it off Once the base of transistor  175  is LOW, the transistor is open from collector to emitter, and the gate of MOSFET  166  rises to the same level as the source of MOSFET  166 , due to resistor  176 . Once the gate voltage of  166  rises above the gate threshold of the device, the device turns off, current is no longer flowing, and the cap lamp LED is off. When the positive signal from the electronic tag connected to terminals  168   a  and  168   b  is removed (i.e. is no longer positive), the gate of MOSFET  166  goes low and the transistor returns to a conducting mode, and the cap lamp is ON. 
     With reference to  FIG. 19 , while two tags are shown for the multiple electronic tag holder  50  of  FIGS. 9-16 , the PCB may be configured to provide power to three or more tags. In addition, the circuit board  64  may be omitted and the power from the battery pack  120  provided to the tags  110 ,  112  and  182  by alternative circuitry contained within the tag holder  50  as indicated in phantom at  183 ). In addition, the tag holder  50  may include buttons connected to the circuit board ( 184 ) and/or one or more of the nuts ( 186 ) for emergency functions such as calling for help or an emergency-stop button that sends signal via tags to a system to stop approaching vehicle to avoid crushing injuries. 
     A second embodiment of the multiple electronic tag holder is illustrated in  FIG. 20 , where multiple tag circuit boards  192   a ,  192   b  and  192   c  replace the single tag circuit board  64  of  FIG. 19 . Each one of the tag circuit boards may be specially configured to power and enable operation of corresponding tags  194   a ,  194   b  and  194   c.    
     With reference to  FIG. 20 , a PCB  192   a  may be configured with a motion sensor  196  and attached to a communications electronic tag  194   a  so that if the worker does not move for a predetermined period of time, help requested via the communications tag. The PCB may alternatively also feature communications components. The motion sensor could take the form of an inertia sensor, an infrared light device (such as the Panasonic EKMC) or an accelerometer (such as the Panasonic GS1). 
     In a third embodiment of the multiple electronic tag holder, illustrated in  FIG. 21 , the battery pack takes the form of a cordless cap lamp, where housing  202  contains not only the battery  204 , (optional) tag circuit board  206  and tag devices  208   a  and  208   b , but also the cap lamp itself  210 , including light source  212  which may be, as an example only, and LED bulb. As switch  214  is also provided to energize the cap lamp. 
     A fourth embodiment of the multiple electronic tag holder, illustrated in  FIG. 22 , is similar to the embodiment of  FIG. 19 , but omits the cap lamp and the battery  222  is also placed in the housing  218 . As a result, it is a device that may be carried by the user where multiple tag devices  220   a - 220   c  are powered by a single battery  222  through tag circuit board  224 . Of course the battery may be positioned external to the housing  218  as either a battery pack or battery. 
     A fifth embodiment of the multiple electronic tag holder, illustrated in  FIG. 23 , is similar to the embodiment of  FIG. 20 , but omits the cap lamp and the battery  230  is also positioned within the housing  232 . As a result, it is a device that may be carried by the user where multiple tag devices  234   a - 234   c  are powered by a single battery  230  through multiple tag circuit boards  236   a - 236   c.    
     A system using an embodiment of the invention is indicated in general at  240  in  FIG. 24  and includes a vest  242  that features electronic tags that are powered via a battery pack  244  and power cord  246 . As illustrated in  FIG. 24 , the vest  242  features pockets  248   a - 248   d  within which electronic tags  254   a - 254   d  are positioned. Tag devices  254   a  and  254   b  are powered by branch  256  of the power cord  246  while tag devices  254   c  and  254   d  are powered by branch  258  of the power cord. As a result, branches  256  and  258  and power cord  246  form a power manifold for powering the tag devices via the battery pack  244 . In addition, or alternatively, the branches  256  and  258  may be used to power suspenders  259   a  and  259   b  or other vest illuminated features constructed from ribbon tape optical fiber, or other illuminating material, to make the worker more visible to avoid collisions with machines or vehicles where ambient lighting is minimal (such as in a mine). 
     As illustrated in  FIG. 24 , the battery pack  244  contains a battery  260  and an (optional) tag circuit board  262 . Alternatively, the system may include multiple tag circuit boards with a tag circuit board positioned in each pocket of the vest along with the corresponding tag device. The battery  260  may be any type of battery known in the prior art, but is preferably a lithium-ion battery. 
     The electronic tags in the embodiments described above can include any combination of any tag devices known in the art, with the corresponding tag circuit board(s) adapted to provide the correct lower requirements and functions (if used) from the single battery. The electronic tags may be individually removed from the multiple electronic tag holders and replaced with other types of electronic tags (as long as there is compatibility with the PCB), which provides the multiple electronic tag holder of the invention with great flexibility and facilitates updating/upgrading with updated/upgraded electronic tags. 
     As noted previously, examples of some tag devices that can be incorporated into the battery pack of the invention include, but are not limited to, tracking and proximity tag devices, which are both used to track personnel and equipment in various locations such as mines, large jobsites, and hazardous areas for the satiety of each individual, gas sensor tags and various tag devices incorporating technologies that are used to track individuals that are in hazardous locations and require each individual to wear some sort of monitoring device. These technologies include, or work with various technologies, but are not limited to, the following:
         (a) Leaky Feeder Systems   (b) Mesh Systems   (c) Medium Frequency Radio Systems   (d) Radio Frequency Identification (RFID)   (e) Inertial Navigation   (f) Through the Earth       

     The embodiments of the present invention described above thus offer several advantages. They provide integration of multiple electronic tags with a cap lamp and power source which allows for more available power to the tags. This can be critical in an emergency situation where longer run time is needed. In addition, they each provide one singular, integrated system that allows the user to minimize the number of individual devices that need to be carried and keep all tags in a uniform, compact housing. They limit battery maintenance to one device, and increase overall ease of use. 
     While the preferred embodiments of the invention have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made therein without departing from the spirit of the invention, the scope of which is defined by the appended claims.