Patent Publication Number: US-11019869-B1

Title: Safety apparatus for use with a helmet

Description:
FIELD OF THE INVENTION 
     This invention relates to a safety apparatus, and more particularly to a device for attachment to a hard hat or similar helmet to provide illumination for the wearer&#39;s use and also improve the visibility of the wearer to others at night or while the wearer is in a dark environment such as a tunnel or a mine. 
     BACKGROUND OF THE INVENTION 
     Improvement of the visibility of an individual wearing a helmet can be achieved by the attachment of light emitting devices such as LEDs or reflectors, or preferably, both, to the helmet. It would be convenient to attach the light emitting devices, reflectors, or both, to the helmet by affixing them to a band that extends around the perimeter of the helmet, for example, a band that supports a personal headlamp arranged to project a beam of light forward from the helmet to illuminate objects in the wearer&#39;s field of vision. 
     A problem with the attachment of light emitting devices or reflectors, particularly elongated reflectors, to a headlamp band is that the length of the band needs to be adjusted in order to secure the headlamp to the helmet. In addition, for effective tightening of the headlamp band around the perimeter of a helmet, the band should have some stretchability and resilience. Wires or other electrical conductors that supply current to the light emitting devices will interfere with adjustment of the length of the headlamp band and with stretching of the band, especially if they are incorporated into the interior of the band to reduce the risk of damage. Similarly, elongated reflectors secured to the exterior of the band will interfere with adjustment and stretching of the band. 
     SUMMARY OF THE INVENTION 
     The invention addresses the above problems by providing light emitting devices, and/or reflectors, on an external flexible strip which is attached to the headlamp band by connectors that can be adjusted by movement along the length of the headlamp band. At least one of the connectors is preferably provided with a clip that allows the flexible strip to be at least partly detached from the headlamp band for more convenient packaging and storage. 
     The light emitters on the flexible strip can be powered by the same power source that supplies electrical current to the headlamp, typically an electrochemical power supply inside the headlamp housing. However, separate switches are preferably provided so that the headlamp and the light emitters on the flexible strip can be operated independently. The switch for operating the light emitters on the flexible strip is preferably mounted on the flexible strip. 
     A safety apparatus in accordance with one aspect of the invention comprises a headlamp assembly including a housing and a light emitting device mounted in the housing. A band comprising a loop of flexible material is connected to the housing and adapted to surround a helmet, e.g., a hard hat at least partially in order to support the headlamp assembly on the helmet. The length of the band is adjustable in order to tighten the band about the helmet. An elongated flexible strip having a substantially fixed length, and having light emitting elements, light reflecting elements, or both, at spaced locations along its length, extends along a part of the length of the headlamp-supporting band. The flexible strip is connected to the band at a plurality of locations along the length of the strip, at least one of those locations being adjacent an end of the strip. The connection of the elongated strip to the band, at least at the location adjacent an end of the strip includes a connector adjustably movable lengthwise along at least a portion of the length of the band. 
     Preferably, the headlamp assembly housing contains an electrochemical power supply, and a first switch, connected to the light emitting device and to the power supply, is manually operable to connect the power supply to the light emitting device. 
     When the elongated flexible strip supports a plurality of light emitting elements spaced from one another along its length, an electrical connection is preferably provided from the plurality of light emitting elements to the electrochemical power supply. This electrical connection includes a second manually operable switch for controlling electrical current from the power supply to the plurality of light emitting elements. Thus, the headlamp and he light emitting elements on the flexible strip can be powered from the same power supply but operated independently. The electrical connections from the power supply to the headlamp and to the light emitters on the flexible strip can include circuits for control of brightness, circuits for causing flashing operation, or both. 
     The connector that is adjustably movable lengthwise along at least a portion of the length of the band preferably includes a clip that secures the elongated strip to the connector, but allows manual connection of the elongated flexible strip to the connector, and also, preferably, manual disconnection. 
     In a preferred embodiment, the elongated flexible strip is connected to the band by connectors positioned on the band at locations adjacent, and on opposite sides of, the headlamp assembly housing, and each of these connectors adjustably movable lengthwise along at least a portion of the length of the band. 
     If light reflecting elements are utilized, they are preferably fixed to the elongated flexible strip at spaced locations along the length of the strip, and each of the reflecting elements is elongated along the direction of the length of the portion of the strip to which it is fixed. 
     The safety apparatus may include a connecting device engageable with a rear surface of a helmet. When the connecting device is utilized, the band can have first and second portions extending from the headlamp assembly to the connecting device. Each of these first and second portions can be adjustably connected to the connecting device so that the overall length of the band can be adjusted in order to fit the safety apparatus to a helmet. This connecting device can include a clip allowing connection of the elongated strip to connecting device and also allowing disconnection. Disconnection of the flexible strip from the helmet-fitting band, or at least partial disconnection, facilitates packaging of the safety device by allowing the helmet-fitting band and the flexible strip to be folded separately from each other. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view showing the safety apparatus installed on a helmet; 
         FIG. 2  is a perspective view showing the safety apparatus of the invention removed from the helmet; 
         FIG. 3  is a perspective view showing the safety apparatus with its illuminated strip partially removed from the helmet band; 
         FIG. 4  is a partial perspective view of a portion of the safety apparatus, illustrating how the illuminated strip is engaged with a clip on the helmet band; and 
         FIG. 5  is an electrical schematic showing the connections of an electrochemical power supply to controls for operating the headlamp and for operating the series of light emitting devices on the flexible strip. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As shown in  FIG. 1 , the safety apparatus  10  is removably installed on a helmet  12 . In the example shown, the helmet is a conventional polyethylene hard hat of the kind worn by miners, construction workers, and others requiring protection from head injury.  FIG. 2  shows the same safety apparatus  10  removed from the helmet so that details of its structure, hidden by the helmet in  FIG. 1 , can be seen. 
     Referring to  FIGS. 1 and 2 , the safety apparatus comprises a flexible band  14 , which is formed into a loop surrounding the helmet at a location a short distance above the brim of the helmet. The band has two end portions  16  and  18 , each of which extends through a pair of slots formed in a molded connecting device  20  engageable with a rear surface of the helmet. Each end portion extends rearward through one slot of a pair of adjacent slots and then forward through the other slot of the same pair. The length of the loop can be adjusted by manipulation of the end portions  16  and  18  of the band to tighten the loop and thereby the band to the helmet. 
     An intermediate portion of the band extends through slots in a headlamp-mounting plate  22  on which is mounted a headlamp assembly  24  comprising a housing  26 , a light-emitting device, such as a light-emitting diode (not shown), a lens  28  for concentrating the emitted light into a beam, and a push-button switch for making and breaking an electrical connection between the light emitting device and an electrochemical power supply, which can be a single electrochemical cell, or a battery, inside the housing  26 . The housing  26  is preferably mounted on and between a pair of opposed brackets, one of which is bracket  30 , to allow tilting adjustment of the headlamp beam. 
     Except for the connecting device  20 , the apparatus described thus far is similar to a conventional personal headlamp of the kind described in U.S. Pat. No. 7,568,812, granted on Aug. 4, 2009. The disclosure of U.S. Pat. No. 7,568,812 is here incorporated by reference. The band  14  is preferably formed of a resilient natural or synthetic rubber that can be stretched in order to exert a tensile force holding the band firmly to the helmet  10  when the ends  16  and  18  of the band are pulled in the slots of the connecting device  20  to tighten the band. Alternatively the band can be made from other stretchable materials, such as a woven fabric and includes stretchable yarns 
     The principal feature that distinguishes the apparatus of the invention from a conventional personal headlamp is an external strip  32 , which includes a series of light-emitting devices  34  e.g., light-emitting diodes or LEDs, or a series of elongated light reflecting elements  36 , and preferably both. The light emitting devices  34  are preferably, but not necessarily, in alternating, interspersed relationship with the light reflecting elements  36 . 
     The light emitting devices  34  are connected to a power source inside the headlamp assembly  24  through a cable  37 , and through conductors (not shown) connected to cable  37  and disposed inside strip  32 . Because of the internal conductors, and also because of the reflectors, the strip has very limited stretchability. To allow the flexible band  14  to be adjusted to fit the helmet, the strip  32  is attached to the band  14  in such a way that the band  14  is movable in the direction of its elongation relative to the strip  32 . Thus, as shown in  FIGS. 2 and 3 , clips  38  and  40  are provided on portions of the band  14  at locations near, and on opposite sides of, the headlamp assembly  24 . The band  14  extends though slots in these clips in such a way as to allow the band to be moved longitudinally relative to the clips. In other words, the positions of the clips  38  and  40  along the length of the band can be adjusted. As shown in  FIG. 3 , for example, the band  14  extends into a slot  42  on the back of clip  40 , passes behind a wall  44  on the back of the clip and extends outward from a slot  46  on the opposite edge of the wall  44 . Each clip has an upper clamping member and a lower clamping member for engagement with a portion of the strip  32 . Thus, as shown in  FIGS. 3 and 4 , clip  38  is provided with an upper clamping member  48  and a lower clamping member  50 , which engage recesses  52  and  54  respectively on the upper and lower edges of the strip  32  so that the strip  32  can be removably connected to the band  14 . Broken lines  56  and  58  in  FIG. 4  illustrate the relative movement of the clip  38  on band  14  in directions indicated by line  60 . 
     When the band  14  is adjusted to fit the helmet by movement of its end portions  16  and  18  relative to the connecting device  20 , the clips  38  and  40  can be moved relative to the band  14  so that strip  32  closely fits the exterior of the band  14  as shown in  FIG. 1 . The strip  32  is fitted to the connecting device  20  by the cooperation of upper and lower clamping members with recesses in the strip  32 . These upper and lower clamping members and recesses, which are not shown in the drawings, are similar to the clamping members  48  and  50  and the recesses  52  and  54  shown in  FIGS. 3 and 4 . 
     As shown in  FIGS. 2 and 3 , the connecting device  20  is formed with concave upper and lower edges  56  and  58  for engagement with the convex surface at the rear of helmet  18 . When the band is tightened about the helmet, portions of the band fit into a recess in the connecting device between the upper and lower edges  56  and  58 . 
     Although the headlamp and the light emitting devices are preferably operated from the same power source, i.e., the electrochemical power supply located inside the headlamp assembly, the light emitting devices on the strip  32  may be, and preferably are, operable independently of the headlamp. Moreover, multiple modes of illumination may be employed. 
     In the embodiment shown, the emission of light through lens  28  is controlled by a push-button  62  shown in  FIGS. 1-3 . This push-button can not only turn the light beam on and off, but can also set brightness levels and establish a flashing mode. 
     The emission of light through light emitting devices  34  is controlled by a push-button  64  adjacent the end of strip  32  remote from cable  37 . This push-button can be used to turn the light emitting devices on and off and can also be used to establish a flashing mode. 
     As shown in  FIG. 5 , the headlamp assembly housing  26 , illustrated by a broken line rectangle, contains an electrochemical power supply  66 , typically consisting of a two-cell battery. The battery is connected, through an on/off flash and brightness control circuit  68 , to a light emitting diode (LED)  70 , which serves as the headlamp. The control circuit  66  is operated by push-button switch  62 , which, by successive depressions, can turn the LED on in a bright mode, a dimmed mode, and a flashing mode, and then turn the LED off. The light emitting devices  34 , which are also preferably light emitting diodes are powered by the same electrochemical power supply  66  through an on/off, flash control circuit  72  by the operation push-button switch  64 , which on successive depressions, can turn the light-emitting devices  34  on in a continuous mode, establish a flashing mode, and turn the devices  34  off. Suitable circuits for use as control circuits  68  and  72  are well-known in the field of personal headlamps, and examples can be found in U.S. Pat. No. 8,044,636, granted on Oct. 25, 2011. The disclosure of U.S. Pat. No. 8,044,636 is here incorporated by reference.