Patent Abstract:
This invention relates to a miniature, battery operated, air tight light emitting module having a LED/LEDS that projects at least two different frequencies of light energy. The LEDs are mounted in a protective air-tight shell. The LEDs are activated by a magnetic field of associated magnetic rings. The attachment mechanism to hold the module(s) to safety hard hats and helmets consists of an elastic band allowing a module or series of modules to be attached to the exterior surface of various types of helmets.

Full Description:
RELATED APPLICATIONS 
     This application claims the priority of U.S. Provisional Application No. 60/993,368, filed Sep. 13, 2007. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to light emitting systems for helmets, and more particularly, to light emitting systems with LED modules for helmets. 
     2. Description of the Prior Art 
     Various attempts have been made in the art to provide lighting equipments that are useful in low light or no light environment. The lighting devices in the art generally include hardware that is mounted on the helmet. Moore et al., (U.S. Pat. No. 7,221,263) teaches a bicycle or motorcycle helmet that uses accelerometers to activate multiple arrays of LEDs that require high amounts of current for the light output. 
     The prior art also includes helmets with LED lights that are designed to act as an indicator to give various signals, for example, a brake signal, turn signal, or strobe positioning lights. These devices generally include a plurality of auxiliary components and fixed mechanisms to hold them to helmet surfaces as well as mechanisms to activate them remotely. 
     The helmets lighting systems in the prior art generally require additional mounting hardware to affix the lighting system to helmets. Such systems are preferred in a mining safety or other applications requiring no additional fixture attachments to helmets. A plurality of physical switches mounted on exterior battery cases are a big concern for electronic failure, water damage, and opens the potential for batteries to dislodge and short causing sparks which could ignite flammable gasses. 
     Burdick, (U.S. Pat. No. 6,982,633) teaches a motorcycle helmet having a ring of lights with a battery is mounted around the entire circumference of the helmet. However, this system is not suitable for various sized helmets, and in addition, requires substantial energy to keep it lighted continuously for a week or more without heavy batteries which would make it unwieldy to mount on a helmet. 
     Rodriguez et al. (U.S. Pat. No. 6,244,721) and Hanabusa, (U.S. Pat. No. 4,901,210) use a band holding exposed LEDs connected to the helmet with wires connecting to a battery mounted inside or outside of the helmet. The LEDs are powered by an open coin cell battery holder mounted on the rear of the helmet. Both methods include exposed connections and batteries to the air, which is most undesirable in explosive gas environments due to spark potential. Furthermore, these LEDs light the peripheral areas rather than lighting the area directly in front of an observer. 
     The helmet lighting systems in the prior art generally have large power consumption, bulky mounting mechanisms, user unfriendliness, and are fragile. Such helmet lighting systems have not been acceptable for use in the mining safety industry or underground construction sites. There are several areas where light is needed for utility functions for the wearers themselves. Prior art devices that address utility light output on helmets generally include heavy batteries and exposed wiring connections that may represent a spark hazard in potential explosive gas environments. 
     The prior art include lighting systems for safety apparel that use Electro-luminescence (EL) strips sewn into the fabric surfaces to blink on and off. In such lighting systems several “AA” batteries to activate the blinking of the strips are used. It is observed that such systems are prone to breakage, are very dim to view at even moderate distances, and contain wiring prone to breakage that must run the entire length of the EL strip. EL has no IR energy output frequency so is not used with FLIR equipment and it requires wires to run the full length of the light output putting dangerous conductive surfaces near the heart and chest areas of workers. 
     In order to light up surface areas of items such as clothing or backpacks, suitcases, exterior portions of transport vehicles, and the like, incandescent lights, LEDs, or EL are employed in the prior art. However, the extensive wiring and high current draw that reduces the battery life make these lighting systems unsuitable for mining and hazardous operating conditions. Safety jackets presently used by airlines are made with a flashing beacon attached that activates upon contact with water. It is observed that the lifespan of such devices is quite short (measured in hours) because they have no way of shutting them off. Furthermore, they do not contain IR output for long distance detection from aircraft. The prior art safety helmet lighting systems fail to assist search and rescue personnel in locating distressed or injured workers in dust-filled, fog-like, or inclement conditions that prevents visible light from penetrating. Emergency circumstances such as explosions, cave-ins, dense fog, smoke from fires, etc. can prevent light from penetrating the opaque air-borne conditions, thus, preventing rescuers from finding people quickly in need of immediate assistance. 
     A lighting system having light weight batteries is needed that provides light for extended periods of time and that allows others around to identify the position and orientation of the user. A lighting system is further needed that is intrinsically safe for use in potentially explosive gaseous environments and that is flexible to mount on safety helmets of various sizes. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective of a preferred embodiment of a LED lighting system of the present invention; 
         FIG. 2  is a top view of a module of the LED lighting system of  FIG. 1 ; 
         FIG. 3  is a side view of the module of  FIG. 2 ; 
         FIG. 4  is a top view of the module of  FIG. 2  that shows the electronics of the module; 
         FIG. 5  is a top perspective of another alternative embodiment of LED lighting system of  FIG. 1  with two modules; 
         FIG. 6  is a top perspective of another embodiment of LED lighting system of  FIG. 5 ; 
         FIG. 7  is a top view of another embodiment of the LED light emitting system of  FIG. 1  with four modules; and 
         FIG. 8  is a top perspective view of the LED lighting system of  FIG. 7  mounted on the helmet. 
     
    
    
     SUMMARY OF THE INVENTION 
     A LED lighting system for emitting visible and invisible energy frequencies in low visibility and hazardous environments having a predefined object with an exterior surface, an elastic band attached to the exterior surface of the object, a LED module connected to the elastic band for emitting infra red and visible light in low visibility and hazardous environments is provided. 
     Each of the LED modules includes a shell that is securely mounted on a base plate preferably with a gasket. The body of the shell also includes at least one pair of LEDs. The module includes a quiescent circuit, a magnetic reed switch and at least one coin cell. In a preferred embodiment of the present invention the module is coupled with a first band and a second band. The second band includes a snap attachment to open and close the band around an object. 
     In another embodiment of the present invention, the LED light emitting system includes a pair of modules that are coupled with a pair of elastic bands. The first module has a first end and a second end so that the first end includes a first loop and a second end includes a second loop. The second module has a first end with a first loop and a second with a second loop. A first end of a first band is coupled with the second loop of the first module. A second end of the first band is coupled with the first loop of the second module. A first end of a second band is coupled with the first loop of the first module and a second end of the second band is coupled with the second loop of the second module. 
     Each of the magnetic rings is in close proximity to the magnetic reed switch of the respective module in the first position of the magnetic ring. In the first position, the magnetic ring is in close proximity with the reed switch that closes the electronic circuit to switch on the respective LEDs of the module. The magnetic ring is moved away from the reed switch of the respective module in the second position to open the reed switch and shut off the respective LEDs. 
     In another alternative embodiment of the present invention, the LED lighting system includes at least two pairs of LED modules that are coupled with at least two pairs of flexible bands. Each of the LED modules has an associated magnetic ring and a stopper. A first pair of modules and second pair of modules are approximately symmetrically positioned with respect to a vertical axis-YY. A first and a second module of the first pair include at least two white LEDs each. A third and a fourth module of the second pair of modules includes at least one color LED and one IR diode each. 
     A stopper is associated with each of the modules. The stopper advantageously restricts the motion of the respective rings along a predefined path on the band. The lighting system of the present invention is mountable on helmets, poles or similar objects of various sizes and with the elastic flexible bands. The white LEDs emit continuous white light to light up surrounding areas. A plurality of color LEDs are used to distinguish the rank of people working in dark areas. The packed electronics in the shell of the module reduces the possibility of accidents due to electric spark in hazardous environment. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Although specific terms are used in the following description for sake of clarity, these terms are intended to refer only to particular structure of the invention selected for illustration in the drawings, and are not intended to define or limit the scope of the invention. 
     Referring to  FIG. 1 , a LED lighting system in accordance with an embodiment of the present invention is shown. The LED lighting system  10  includes a LED module  12 , a first band  14 , a second band  16  and a snap attachment  18 . A magnetic ring  20  and a stopper  22  that are associated with the LED module  12  are preferably positioned on first band  14 . The magnetic ring  20  is movable between the module  12  and the stopper  22  along the first band  14  as indicated by arrow  1 . Bands  14  and  16  are preferably flexible at least in part and preferably made of elastic material. The LED light emitting system  10  has a closed configuration and an open configuration. 
     The module  12  includes a pair of opposed loops that are mounted on opposed ends of the LED module  12 . First band  14  is coupled to module  12  with a first loop  24  and second band  16  is coupled to module  12  with a second loop  26 . The ends of the bands  14  and  16  are removably coupled with the snap attachment  18 . A free end of first band  14  includes a female part  28  of the attachment  18  and a free end of the second band  16  includes a male part  30  of the attachment  18 . The male part  30  is inserted in the female part  28  with a snap fit to close the attachment  18  to define the close configuration of the LED light emitting system. The snap attachment is opened by pressing a trigger on the male part  30  to open the LED light emitting system  10 . It is, however, understood that connecting mechanisms, for example, a riveted snaps, Velcro, magnetic coupling can also be employed instead of the snap attachment  18 . 
     Referring to  FIGS. 2 and 3 , the LED light utility module  12  in accordance with a preferred embodiment of the present invention is described. The LED module  12  includes a box shaped shell  32  that is securely mounted on an approximately rectangular base plate  34 . It is, however, understood that the shell  32  of round, oval, and other shapes are also contemplated. The shell  32  is preferably made of plastic material. A rubber gasket is preferably positioned between the shell  32  and the base plate  34 . The base plate  34  is preferably made of plastic material. Each light module is removable from a series of attachable modules that are connected with one or more module/modules with elastic bands. 
     The module  12  is a completely sealed with a non-replaceable type battery. The module  12  also includes associated electronic arrangement that is positioned on the base plate  34  to operate the LEDs. The covering shell  32  has a pair of plastic lensed light emitting diodes (LEDs). A first LED  36  emits visible light preferably constantly in a predetermined color and a second LED  38  intermittently blinks to emit IR energy. The IR LEDs blinks when the power is on. 
     As shown in  FIG. 4 , the module  12  includes a quiescent circuit  40 , a magnetic reed switch  42  and a coin cell  44 . The quiescent circuit  40  includes current lowering resistors. The magnetic reed switch  42  is preferably a tiny glass sealed vacuum that is approximately (2 mm×10 mm) in size. The sealed vacuum of the reed switch  42  encloses magnetic contacts that close when any magnetic field is brought in close proximity with the reed switch  42 . A magnetic field is used to activate the LEDs inside the sealed unit of the module  12 . 
     The magnetic ring  20  has a first position and a second position as indicated by the arrow  1 ′- 2 ′. In the first position, magnetic ring  20  is in close proximity to the magnetic reed switch  42  and the magnetic ring  20  is away from the reed  42  switch in the second position. In the first position, the circuit is closed to allow the power from coin cell  44  to flow from a negative terminal to the two LEDs  36  and  38  and thereby returning to the positive terminal on the coin cell(s)  44  through the reed switch  42  and a quiescent circuit  40 . 
     The magnetic ring  20  is moved to the second position to turn off the LEDs  36  and  38  in the module  12 . The second position is achieved by moving the magnetic ring  20  away from the side of the module  22 , thus, removing the magnetic field necessary to keep the reed switch  42  closed. In the second position the reed switch  42  opens and the LEDs  36  and  38  shut off. 
     In another alternative embodiment of the light emitting system  10 , the module  12  includes only one cord or band and snap attachment  18 . The continuous cord is threaded through the first loop  24  of the module  12  and the cord exits through the second loop  26  of the module  12  continuing to the snap attachment  18 . The module  12  also includes a hook and loop type Velcro self-stick removable piece on an outer surface of base plate  34 . The self stick attachment is well known in the art. The self stick attachment advantageously allows sticking the module  12  to a desired object. 
     Now referring to  FIG. 5 , another alternative embodiment of the LED light emitting system  10  in accordance with the present invention is shown. In this one embodiment, the LED system  50  includes a first LED module  52 , a second LED module  54 , a first band  56  and a second band  58 . A first magnetic ring  60  is associated with first module  52  and a second magnetic ring  62  is associated with second module  54 . In one embodiment, each of magnetic rings  60  and  62  are movable along band  58 . A first stopper  64  and a second stopper  66  are also positioned near respective magnetic rings  60  and  62  on the second band  58 . 
     The first LED module  52  has a first end  68  and a second end  70 . First end  68  includes a first loop  72  and the second end  70  includes a second loop  74 . First band  56  having a first end  78  and a second end  80 , and the second band  58  with a first end  84  and a second end  86  are coupled with the modules  52  and  54  to define the lighting system  50  of the present invention. The band  58  is preferably made of elastic material to allow adjustment while mounding the system  50  on a desired object. 
     The first end  78  of the first band  56  is coupled with second loop  74  of the first module  52 , and the second end  80  of the first band  56  is coupled with the first loop  88  of the second module  54 . The first end  84  of the second band  58  is coupled with first loop  72  of the first module  52 , and the second end  86  of the second band  58  is coupled with the second loop  90  of the second module  54 . The length of the second band  58  is approximately four times the length of first band  56 . The length of the first band  56  is approximately 5″ and the length of the second band  58  is approximately 20″. It is, however, understood that the lengths of the bands may vary with the application. 
     Referring to  FIG. 6 , in another embodiment of the LED light emitting system  50 , the second band  58  includes a snap attachment  92  that is adapted to facilitate mounting and removal of the LED light emitting system  50  on an object, such as, a helmet or a pole. The snap attachment  92  divides the second band  58  into two parts. The two parts are removably connected to open and close the band  58 . The snap attachment  92  has a male part  94  and female part  96 . The male part  94  and female part  96  are snap-fitted to close the band  58 . The system  50  is preferably positioned on a desired object and then the band  58  is closed with the snap attachment  92 . The snap attachment is opened to remove the band  58 , thereby, removing the LED lighting system  50 . 
     Now referring to  FIGS. 7 and 8 , another embodiment of the lighting system in accordance with the present invention is shown. In this one embodiment, the lighting system  100  includes at least two pairs of LED modules coupled with at least two pairs of flexible bands. In the light emitting system  100 , each module snaps or attaches to successive module to form a light emitting rope in various frequencies dependent upon which modules are snapped together. 
     The lighting system  100  has a first end  102  and a second end  104 . A first pair of modules includes a first module  106  and a second module  108 . Modules  106  and  108  define a first portion  110  of the LED lighting system  100  along with respective magnetic rings and stoppers. Modules  106  and  108  are approximately symmetrically positioned in the LED lighting system  100  with respect to a vertical axis-YY. Modules  106  and  108  are approximately equidistant from the first end  102 . Each of the modules  106  and  108  preferably include two white LEDs. 
     A second pair of modules includes a third module  112  and a forth module  114 . Modules  112  and  114  define a second portion  116  of the LED lighting system  100  along with respective magnetic rings and stoppers. Modules  112  and  114  are approximately symmetrically positioned in the LED lighting system  100  with respect to vertical axis-YY. Modules  112  and  114  are approximately equidistant from the second end  104 . Each of the modules  112  and  114  preferably respectively include a color LED and an IR diode. 
     Now referring to  FIGS. 1 to 8 , the lighting system  10  of the present invention is mounted on an object such as a helmet preferably on a bottom ring of the helmet. The light emitting system  10  is attached to the exterior surface of various types of helmets by pulling the unit over the exterior surface to the surrounding brim or base of the helmet. The self stick removable Velcro attachment advantageously helps to position the module  12  to any desired object. The self sticking attachment prevents the module  12  from drifting due to a shock. 
     Modules are removable to allow for independent operation. The modules are removed by uncoupling the loops from the respective bands. Each of the modules is advantageously detachable from the other modules of the light emitting system  10 . The detached module is an independent light source for other applications. The stand alone module is attachable to a desired object preferably with an attaching means, for example, Velcro strips, two-way adhesive strips etc. 
     The flexible elastic bands securely hold the system on the body of the helmet. A user positions the system  10  according to the requirement on the helmet. In the first position, the LEDs are on to emit respective light. The lighting system  10  is deactivated by moving the magnetic ring  20  from the first position to the second position. In the first position, the magnetic field of ring  20  activates the magnetic reed switch  42  to blink the LEDs. LEDs  36  and  38  can be switched off by moving the magnetic ring  20  to the second position. 
     The stoppers  22  associated with each of the modules  12  advantageously prevent the motion of the respective rings  20  beyond the position of the stopper  22  on the band  14 . The lighting system  10  of the present invention easily adapts to helmets of various sizes and configurations without need of any mounting hardware. The electronic circuitry and the batteries are completely encased in air-tight body shell  32  without any exposed wires, connections, batteries, or switches. 
     Two frequencies of Infrared band and visible light are preferably emitted by the light emitting system  10  of the present invention. The first IR frequency is approximately in a range of 850 nm.-1200 nm. that is invisible to the naked eye. The second visible frequency is in the visible light spectrum. The LEDs  36  and  38  emit special visible and invisible energy frequencies that penetrate opaque materials such as dust and fog so rescuers can find distressed and injured people quickly in adverse visibility environments. The LED lighting system  10  is mountable on various objects to increase their visibility as well as low-profile to prevent accidental impact with external objects. 
     The light emitting system  10  of the present invention preferably includes two small coin cells  44  powering multiple light emitting diodes (LEDs)  36  and  38  connected to a current reducing resistor  40  and a magnetic reed style switch  42  for activation. The module  12  preferably includes multiple LEDs giving off visible white light energy and/or LEDs giving off IR energy or a combination of both white light and IR LEDs. By employing LEDs emitting continuous white light, the visible energy is projected outward away from the user for utility use to light up surrounding areas and is visible to surrounding workers. 
     Various colors and combinations of LEDs may be incorporated into the light emitting system  10  for attachment to helmets. For example, a yellow LED color output module may be placed on the rear of the elastic band to signify to surrounding workers the orientation position of fellow workers in pitch black environments such as is found in mines. Other colors may signify and distinguish the rank of people working in dark areas between engineers, construction, medical, and safety personnel. 
     The system  10  of the present invention is safe enough to avoid accidents in hazardous environment. The electronic and electrical components are not in contact with surrounding air due to the shell  32 . No spark hazard can exist where a possible shorting of contacts could accidentally set off an explosion. The use of magnetic ring  20  and reed switch  42  eliminates possibility of electric spark. 
     The shell  32  is made of non-conductive compound. The shell  32  encapsulates the interior portion of the module preferably through an airtight rubber gasket. The shell  32  and base plate  34  arrangements in the module makes the module robust. The system  10  can withstand high impact, hostile weather and extreme environmental conditions including under water, chemical and physical abrasiveness, and is not prone to connection failures due to extreme temperature changes. 
     LED light module  12  is removable from a series of attachable modules to adjust according to the size of an object on which it is being mounted. The elastic band also adds flexibility of mounting on objects of various sizes to the LED light system  10 . The light modules  12  can be coupled with other light modules of different LED light to form a light emitting rope using the method described above. 
     The IR LEDs  38  conserve energy by blinking on and off. IR LEDs are not able to be seen with normal eye and do not offer any distraction by blinking on and off. The IR blinking LED  38  is preferably replaceable with a RED LED to increase visibility. The system is attachable to a helmet worn by miners or construction workers. Although the IR LED  38  cannot be seen without use of special detection equipment, it is designed to blink a high intensity flash in the IR frequency spectrum to allow searchers/rescuers/emergency personnel to locate the device through environments such as dust-filled, smoke laden, blizzard, and other conditions that make it impossible to see normal light in the visible spectrum with the naked eye. 
     In more adverse conditions where smoke and dust prevail such as in a coal mine, the pulsing IR diode  38  acts like a beacon in the fog penetrating opaque materials to be detected using special FLIR (Forward Looking Infrared) equipment such as the type used in the military for night vision exercises. 
     A lighting system  50  with two pairs of modules on the helmet worn by miners offers an advantage of peripheral vision lighting, and additional orientation positioning for other miners to observe. The smaller diameter light output penetrates through fog and smoke far more efficiently than brighter reflective lensed type lights used for miner helmets. The small diameter LEDs  36  and  38  are easily seen through fog as single points of light therefore the positions of the people wearing them are easily determined. 
     The lighting system  10  of the present invention requires extremely low current draw. Gasket positioned in between the shell  32  and the base plate  34  advantageously makes the system  10  a waterproof system. The system  10  does not require external switches to activate and deactivate the LED lights. The light emitting LED system is tiny enough to be mounted on, such as, for example, a belt pack, vest, backpack, jacket, duffel bag, raincoat, safety vest. The light emitting LED system  10  is intended for use with fireman waterproof coats, DOT safety vests, police and emergency worker vests, electrical workers, linemen, as well as duffel bags, securing straps for transport vehicles, sails, belt packs, and back packs. 
     The embodiments of the invention shown and discussed herein are merely illustrative of modes of application of the present invention. Reference to details in this discussion is not intended to limit the scope of the claims to these details, or to the figures used to illustrate the invention.

Technology Classification (CPC): 5