Patent Description:
Existing surgical headlights require a significant amount of light to provide sufficient illumination for the surgeon during a typical case. Surgical headlights are also preferably lightweight so that neck and head fatigue of the surgeon is minimized. LEDs are semiconductor devices that emit light by application of electrical power (watts). LEDs are a feasible light source for a surgical headlight luminaire. However, the problem is that LEDs generate heat. One of the major challenges LEDs pose in many applications is removing the heat from the LED. Excess heat must be removed so that the semiconductor junction temperature does not exceed recommended maximum temperature. In addition, as the junction temperature of the LED rises, the efficiency also drops. LED light output is limited by its maximum heat junction temperature, so to increase light output without damaging the LED or reducing its operating efficiency, heat must be transferred quickly and efficiently.

There remains a need for LED surgical headlights which allow efficient transfer of heat energy from the LED so that the LED is sufficiently cooled and retains its light output performance and reliability.

Furthermore, surgical headlights are worn by healthcare professionals to provide illumination to aid visualization during surgical, diagnostic, or therapeutic procedures. Headlight devices typically include a headband, a luminaire, and other components and accessories, which could cause discomfort or neck and head fatigue in the wearer, particularly when <NUM> worn in a long procedure. Thus, there remains a need for surgical headlight devices and systems that provide enhanced comfort when worn by a wearer (e.g., a surgeon) for an extended period of time.

The scope of the invention is set out in the appended claims.

It is an object of the present disclosure to provide a head wearable device comprising a headpiece; a housing on a top surface of the headpiece; a luminaire attached to the headpiece, the luminaire comprising a luminaire housing and at least one light source thermally connected to a heatsink, the at least one light source and the heatsink being located within the luminaire housing; a duct system connected between the luminaire and the housing; a ball joint rotatably connecting the duct system to the luminaire; an air moving device located configured to induce a cooling air flow through an inlet formed in the luminaire housing, through the heatsink, through the ball joint, through the duct system, and out of an exhaust formed in the housing on the top surface of the headpiece; and a controller configured to monitor a temperature of the at least one light source and to modulate an operational setting of the air moving device to maintain the temperature of the at least one light source within a predetermined operating range.

It is a further object of the present disclosure to provide a head wearable device comprising: a headpiece comprising: a headband comprising a top strap and at least two lateral straps; and an occipital basket comprising a strap, the occipital basket being attached to the headband by at least one lateral extension strap pivotably attached by a hinge to a distal end of each respective lateral strap of the headband; a first housing attached to an outer surface of the top strap of the headband; a depth adjuster
attached to the first housing, the depth adjuster comprising a first gear rotatably fixed to a first knob; herein the strap of the occipital basket comprises a slot with a plurality of teeth formed around a longitudinal edge of the slot; wherein the first gear is captively held within the slot and engages with the plurality of teeth; wherein a rotary movement of the first gear causes a longitudinal movement of the strap of the occipital basket to change a distance between the occipital basket and the first housing; wherein a depth of the headpiece changes when the distance between the occipital basket and the first housing changes, or increases or decreases; and wherein the strap comprises a first visual index comprising a first plurality of sequential characters, each of which correspond to one of a plurality of predetermined depth settings of the headpiece; and a second housing attached to an outer surface of the occipital basket; a circumferential adjuster at an outer surface of the occipital basket, the circumferential adjuster comprising a second gear rotatably fixed to a second knob; wherein the lateral extension straps each comprise a slot with a plurality of teeth formed around a longitudinal edge of the slot; wherein the second gear is captively held within the slot of each lateral extension strap and engages with the plurality of teeth of each of the lateral extension straps; wherein a rotary movement of the second gear causes a longitudinal movement of the lateral extension straps to change a circumference of the headpiece; and wherein at least one of the lateral extension straps comprises a second visual index comprising a second plurality of sequential characters, each of which correspond to one of a plurality of predetermined circumferential settings of the headpiece; wherein the lateral extension straps rotate about the hinge, relative to the lateral straps as the depth of the headpiece changes.

Still another object of the present disclosure is to provide a method of adjusting a size of a headpiece of a head wearable device to a head size of a wearer, the headpiece comprising a headband and an occipital basket. The method comprises attaching a first housing to an external surface of a top strap of the headband; inserting a strap of the occipital basket at least partially into the first housing; engaging a first gear with a plurality of teeth formed in a slot, which is longitudinally oriented along a length of the strap of the occipital basket; turning a first knob, which is rotationally locked to the first gear, to adjust a depth of the headpiece; attaching a second housing to an external surface of the occipital basket; inserting an end of at least two lateral extension straps into the second housing, with the end of a first lateral extension strap being inserted from an opposite end of the housing from the end of a second lateral extension strap, wherein the two lateral extension straps are hingedly attached to lateral straps of the headband to define a circumference of the headpiece; engaging a second gear with a plurality of teeth formed in a slot of each of the lateral extension straps such that the second gear is engaged with both of the lateral extension straps; and turning a second knob, which is rotationally locked to the second gear, to adjust a circumference of the headpiece.

In another object of the present disclosure, headlight devices with a padding system are provided. Such headlight devices comprise a headband having a rear portion, two side portions, and a top portion, each of which have a respective inner surface; a padding system comprising a rear pad, which is attached to the inner surface of the rear portion of the headband; a side pad attached to the inner surfaces of the two side portions of the headband; a top pad attached to the inner surface of the top portion of the headband; and, optionally, a brow pad attached to the inner surface of the headband at an intersection of the top portion and the two side portions; wherein at least one of the rear pad and the brow pad comprises a first layer of a first cushioning material having a first durometer, and a second layer of a second cushioning material having a second durometer that is harder than the first durometer.

According to some embodiments of the present subject matter, the first cushioning material is silicone foam having a first durometer, and the second cushioning material is silicone foam having a second durometer that is harder than the first durometer; the second layer of the second cushioning material is closer than the first layer of the first cushioning material to the inner surface of the headband.

According to further embodiments of the present subject matter, the first layer of the first cushioning material and the second layer of the second cushioning material are each perforated; the majority of the perforations in the first layer of the first cushioning material may be generally circular, and the majority of the perforations in the second layer of the second cushioning material may be in a shape other than circular. For example, the perforations in the second layer of the second cushioning material are generally square or rectangular, or generally in a grid-like pattern.

In an aspect of the present disclosure, the second layer of the second cushioning material has more open space on its upper or lower surface due to perforations than the first layer of the first cushioning material. In another aspect of the present disclosure, the total volume of cavity due to perforations in the second layer of the second cushioning material is higher than the total volume of cavity in the first layer of the first cushioning material.

In additional embodiments of the present subject matter, the rear pad has an inner surface in contact with a wearer and an outer surface attached to the inner surface of the rear portion of the headband, and the rear pad comprises a recess on its inner surface; at least one of the top pad and the side pad may comprises urethane foam and forms segments.

It is another object of the present disclosure to provide a headlight device comprising a headband for encircling the head of a wearer; a padding system comprising a pad removably attached to at least a portion of the headband; wherein the pad comprises a first layer of a first cushioning material having a first durometer, and a second layer of a second cushioning material having a second durometer that is harder than the first durometer; and wherein the first layer is perforated in a first perforation pattern, and the second layer is perforated in a second perforation pattern that differs from the first perforation pattern.

In some embodiments, the perforations in the first layer are generally in a first perforation shape and the perforations in the second layer are generally in a second perforation shape that differs from the first perforation shape. The perforation patterns can be chosen taking into consideration the softness and density of each layer specific to the cushioning material used. Punching holes or otherwise creating perforation or cavity in the cushioning material reduces the weight of the padding and thus the stress on the wearer, but the removal of cushioning material may reduce the support that the layer can provide. The perforations in the layers of cushioning material also improve heat dissipation and air-flow. Perforation patterns are selected to achieve a desired level of support and comfort.

According to some embodiments of the present subject matter, a headlight device is provided, the headlight device comprising: a headband for encircling the head of a wearer; a padding system comprising a rear pad removably attached to at least a portion of the headband; wherein the rear pad comprises a first layer of a first cushioning material having a first durometer, and a second layer of a second cushioning material having a second durometer that is different from the first durometer; wherein the first layer is perforated in a first perforation pattern, and the second layer is perforated in a second perforation pattern that differs from the first perforation pattern; wherein the first layer comprises an inner surface in contact with a wearer; wherein the second layer comprises an outer surface attached to the inner surface of the rear portion of the headband; and wherein the rear pad comprises a recess on an inner surface thereof.

Although the embodiments of headlight devices are shown herein, the features of the padding systems disclosed herein can be applied to other head wearable devices. Other features and advantages of the present subject matter will become more apparent from the following detailed description of the subject matter, when taken in conjunction with the accompanying example drawings.

A full and enabling disclosure of the present subject matter is set forth more in the remainder of the specification, including reference to the accompanying, example figures, in which:.

Unless otherwise defined, terms used herein should be construed to have the same meaning as commonly understood by one of ordinary skill in the art to which this subject matter belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with the respective meaning in the context of this specification and the relevant art, and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Aspects of the subject matter are described herein with reference to sectional, perspective, elevation, and/or plan view illustrations that are schematic illustrations of idealized aspects of the subject matter. Variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected, such that aspects of the subject matter should not be construed as limited to particular shapes illustrated herein. This subject matter can be embodied in different forms and should not be construed as limited to the specific aspects or embodiments set forth herein. In the drawings, the size and relative sizes of layers and regions can be exaggerated for clarity.

Unless the absence of one or more elements is specifically recited, the terms "comprising", "including", and "having" as used herein should be interpreted as openended terms that do not preclude the presence of one or more elements. Like numbers refer to like elements throughout this description.

It will be understood that when an element is referred to as being "on" another element, it can be directly on the other element or intervening elements can be present. Moreover, relative terms such as "on", "above", "upper", "top", "lower", or "bottom" are used herein to describe one structure's or portion's relationship to another structure or portion as illustrated in the figures. It will be understood that relative terms such as "on", "above", "upper", "top", "lower" or "bottom" are intended to encompass different orientations of the apparatus in addition to the orientation depicted in the figures. For example, if the apparatus in the figures is turned over, structure or portion described as "above" other structures or portions would now be oriented "below" the other structures or portions.

The term "substrate" or "submount" as used herein in connection with lighting apparatuses refers to a mounting member or element on which, in which, or over which, multiple solid state light emitters (e.g., LEDs) can be arranged, supported, and/or mounted. A substrate can be, e.g., a component substrate, a chip substrate (e.g., a LED substrate), or a sub- panel substrate. Example substrates useful with lighting apparatuses as described herein can, for example, comprise printed circuit boards (PCBs) and/or related components (e.g., including but not limited to metal core printed circuit boards (MCPCBs), flexible circuit boards, dielectric laminates, ceramic based substrates, and the like), ceramic boards having FR4 and/or electrical traces arranged on one or multiple surfaces thereof, high reflectivity ceramics (e.g., alumina) support panels, and/or mounting elements of various materials and conformations arranged to receive, support, and/or conduct electrical power to solid state emitters. Electrical traces described herein provide electrical power to the emitters for electrically activating and illuminating the emitters. Electrical traces may be visible and/or covered via a reflective covering, such as a solder mask material, Ag, or other suitable reflector.

<FIG> show several perspective views of a head wearable device, generally designated <NUM>. In the embodiment shown, the head wearable device <NUM> comprises an adjustable headpiece comprising a headband, generally designated <NUM>, which has a top strap <NUM> and at least two lateral straps 120A/120B, and an occipital basket <NUM> attached to (e.g., removably, fixedly, and/or integrally) the headband <NUM>; a luminaire, generally designated <NUM>, movably attached at the front of the headband <NUM>, a duct system, generally designated <NUM>, to direct exhaust air from the luminaire <NUM> to a hot air exhaust <NUM> formed in the upper housing, generally designated <NUM>, that is attached to the top strap <NUM> of the head wearable device <NUM>; rear adjustment straps 130A/130B; a depth adjuster, generally designated <NUM>, and a headband adjuster, generally designated <NUM>, that are for adjusting the size of the headband <NUM> to the size of a wearer's head; a holster <NUM> with a battery pack and controller that is in electrical communication, via power cord <NUM>, with the luminaire <NUM> and an air moving device (see <NUM>, <FIG>) associated with the duct system <NUM>; and a padding system, generally designated <NUM>, installed on at least some of the inner surfaces of the headband <NUM> and occipital basket <NUM>. As shown, the lateral straps 120A/120B, together with the rear adjustment straps 130A/130B form a thin, flexible plastic ring of an approximately elliptical shape for fitting horizontally on the head of a wearer. The upper housing <NUM> can extend from the front to the rear (e.g., the occipital basket <NUM>) of the headband <NUM>, extend between the lateral straps 120A/120B of the headband <NUM>, or extend between any two points on the ring. Two or more of these portions may form an integral piece, or operably or adjustably connected to each other. Headband may be constructed with more or fewer portions or straps than the embodiment shown and may take any shape. The headbands may cover more or less surface of the wearer's head than the embodiment as shown. While the headpiece is shown in this embodiment as comprising the headband <NUM> and the occipital basket <NUM>, the headpiece may take any shape and may have a substantially continuous outer cover that is either adjustable to a wearer's head size or of fixed dimensions. Similarly, an outer shell may be provided around the headpiece, as needed based on the environment in which the head wearable device is to be worn.

In the embodiment shown, the headband <NUM> comprising the top strap <NUM> and lateral straps 120A/120B is integrally formed from a single piece. An example of this portion of the headband <NUM> is shown in <FIG>, with the top strap <NUM> and lateral straps 120A/120B being shown in a substantially planar (i.e., flat), unformed, configuration. The top strap <NUM> has upper housing <NUM> affixed thereto, into which the top strap <NUM> from the occipital basket <NUM> is inserted to connect the top strap <NUM> to the occipital basket <NUM>. The upper housing <NUM> has an outer shell <NUM>, which has a slot, generally designated <NUM>, formed at a rear of the outer shell <NUM>, into which slot <NUM> the strap <NUM> of the occipital basket <NUM> is inserted to adjust the depth of the head wearable device <NUM>. The strap <NUM> of the occipital basket <NUM> has a slot (see <NUM>, <FIG>) formed along the length thereof, the length of the slot <NUM> defining a maximum amount of adjustment of the depth of the head wearable device <NUM>. As can be seen in greater detail in <FIG>, the slot <NUM> of the strap <NUM> has, on at least one side thereof, a plurality of teeth <NUM> that are configured to interface with, and be moved by, a gear <NUM> that is rotatably mounted within the upper housing <NUM> in the form of a rack-and-pinion arrangement. As such, a rotation of the top adjustment knob <NUM> and, accordingly, the top adjustment gear <NUM>, causes the strap <NUM> of the occipital basket <NUM> to be lengthened or shortened relative to the upper housing <NUM> as the gear <NUM> draws the strap <NUM> into, or pushes the strap <NUM> out of, the upper housing <NUM>. Due to the rack-and-pinion arrangement, precise size adjustments to the depth of the head wearable device <NUM> are contemplated. As such, a plurality of indexing marks, generally designated <NUM>, are provided in an externally visible location on the strap <NUM> of the occipital basket <NUM> so that the depth of the head wearable device <NUM> may be easily and repeatably adjusted to a given value for a plurality of wearers of the head wearable device <NUM>.

The headband <NUM> is further connected to the occipital basket <NUM> by lateral extension straps 130A/130B, which are rotatably coupled to the lateral straps 120A/120B, respectively, at respective hinges, generally designated 140A/140B, which in this embodiment are circular hinges. Each of the lateral extension straps 130A/130B wraps behind the occipital basket <NUM> and is inserted within a housing of the headband adjuster, generally designated <NUM>, which is shown on the rear external surface of the occipital basket <NUM>. As can be seen in <FIG>, the lateral extension straps 130A/130B have a slot 132A/132B formed along the length thereof, respectively, the length of the slot 132A/132B defining a maximum amount of adjustment of the circumference of the head wearable device <NUM>. The slot 132A/132B of each lateral extension strap 130A/130B has, on at least one side thereof, a plurality of teeth 134A/134B that are configured to interface with, and be moved by, a gear (see <NUM>, <FIG>) that is rotatably mounted within the housing of the headband adjuster <NUM> in the form of a rack-and-pinion arrangement. The plurality of teeth 134A on a first of the lateral extension straps 130A are on an opposite side of the slot 132A from the plurality of teeth <NUM> formed in the slot <NUM> of the second lateral extension strap <NUM>, such that a rotating motion of the occipital basket adjustment gear <NUM> causes a simultaneous expansion or contraction, depending on the direction in which the knob <NUM> is rotated, of the headband <NUM> to correspondingly increase or decrease lateral circumference of the head wearable device <NUM>. Due to the rack-and-pinion arrangement, precise size adjustments of the head wearable device <NUM> are contemplated. As such, a plurality of indexing marks, generally designated <NUM>, are provided in an externally visible location on one or more of the lateral extension straps 130A/<NUM> so that the head wearable device <NUM> may be easily and repeatably adjusted to a given size for a plurality of wearers of the head wearable device <NUM>. The slots 132A/<NUM> are shown as being closed at both ends thereof to prevent the lateral extension straps 130A/<NUM> from becoming disengaged from the headband adjuster <NUM>. As such, the lateral extension straps 130A/<NUM> are captively held within the headband adjuster <NUM> when worn by a wearer.

The hinges 140A/<NUM> connecting the lateral straps 120A/<NUM> of the headband <NUM> to the lateral extension straps 130A/<NUM> are configured to pivot about an axis defined through the center of each respective hinge 140A/<NUM>. Any type of hinge may be used and, in fact, the lateral extension straps 130A/<NUM> may be integrally formed with the lateral straps 120A/<NUM> of the headband <NUM>. However, it is advantageous to use the circular hinges 140A/<NUM> shown because, as the strap <NUM> is drawn into or pushed out from the upper housing <NUM> on the headband <NUM> to alter a depth of the head wearable device <NUM>, the position of the occipital basket <NUM> changes at least vertically, relative to the lateral straps 120A/<NUM>, such that the angle between the lateral straps 120A/<NUM> and the lateral extension straps lateral extension straps 130A/<NUM> at the hinges 140A/<NUM> can be altered without deforming the lateral extension straps 130A/<NUM> that might cause any distortions or deformations thereof in the region of the slots 132A/132B, thereby preventing binding of the lateral extension straps 130A/130B within the housing of the headband adjuster <NUM>.

A padding system <NUM> is attached to the inner surfaces of the head wearable device <NUM>, including the inner surfaces of the headband <NUM> and the occipital basket <NUM> where contact would otherwise occur with the head of a wearer of the head wearable device <NUM>. While any suitable type and configuration of padding may be utilized for the padding system <NUM>, the embodiment shown has padding segments that are attached to the inner surfaces of the headband <NUM> and the occipital basket <NUM>. The padding segments may be formed from any suitable material having a suitable degree of padding to provide a desired amount of comfort for a wearer during extended wearing times (e.g., on the order of multiple hours). The padding system comprises a rear pad <NUM>, side pads <NUM>/<NUM>, and a top pad <NUM> attached to the corresponding inner surfaces of the occipital basket <NUM>, the lateral straps 120A/120B, and the top strap <NUM> of the head wearable device <NUM>, respectively. The padding system <NUM> may further comprise a brow pad <NUM> attached to the inner surface of the headband at or about an intersection of the top strap <NUM> and the lateral straps 120A/120B.

Each of the padding segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> described herein can be portions of a large integral pad and do not need to be separate pads. The padding segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> are attached to the headband <NUM> or the occipital basket <NUM>, respectively, by any suitable attachment type, including, for example, adhesive, interlocking snaps, mechanical interlocking tabs, and the like. The padding segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> may be contoured to the shape of the respective strap or occipital basket <NUM> to which the padding segment <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> is attached and may have a size less than or greater than a width of the strap(s) to which each such padding segment <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> is attached. As such, a brow pad is provided at the front of the headband <NUM> at a position that would be against the forehead of a wearer of the head wearable device <NUM>. This brow pad <NUM> may extend, at least to some extent, onto the top strap <NUM> and the two lateral straps 120A/120B. In the embodiment shown, the strap <NUM> of the occipital basket <NUM> and the lateral extension straps 130A/130B are devoid of padding segments, not only because these portions are spaced apart from the surface of the wearer's head while being worn, but also so that mechanical interference does not occur between adjacent components as the dimensions (e.g., the depth and/or the circumference) of the head wearable device <NUM> is adjusted. In the embodiment shown, the padding segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> can be removable for cleaning, maintenance, etc. One or more of the padding segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> can have a different degree of softness from others of the padding segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>. One or more (e.g., each, or all) padding segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> may have more than two layers of cushioning material.

Referring to <FIG>, according to some embodiments of the present disclosure, the rear pad <NUM> comprises a first layer <NUM> of a first cushioning material having a first durometer, and a second layer <NUM> of a second cushioning material having a second durometer that is harder than the first durometer. In an example embodiment, the first cushioning material is silicone foam, and the second cushioning material is also silicone foam, but the silicone foam in the second layer <NUM> has a higher durometer than the silicone foam in the first layer <NUM>. For example, the durometer of the second layer <NUM> can be <NUM>%, <NUM>%, <NUM>%, or up to and including <NUM>% higher than the durometer of the first layer <NUM>. In other words, the silicone foam in the second layer <NUM> is harder (e.g., less compliant) than the silicone foam in the first layer <NUM>. The second layer <NUM> of the second cushioning material is closer than the first layer <NUM> of the first cushioning material to the inner surface of the occipital basket <NUM>. The harder second layer <NUM> provides support, while the softer, conforming first layer <NUM> is in closer contact with the wearer and provides increased comfort to the wearer of the head wearable device <NUM>.

Although <FIG> shows that the first layer <NUM> and the second layer <NUM> of the respective cushioning materials have the same or similar thickness, it is contemplated that the first layer <NUM> can have a different thickness from the second layer <NUM>. The thickness of each layer is preferably no more than <NUM> (<NUM> inch (in. )) and, more preferably, no more than <NUM> (<NUM> in. ), for example, about <NUM> (<NUM> in. ) In an example embodiment, the first layer <NUM>, which is oriented towards (e.g., adjacent the head of) the wearer, is <NUM> (¼") die-cut silicone foam (for example, SISCO® BF-<NUM>, an ultra soft silicone foam manufactured by Rogers Corporation) and the second layer <NUM>, which is oriented towards (e.g., adjacent the surface of) the occipital basket <NUM> is <NUM> (%") die-cut silicone foam (for example, SISCO® HT-<NUM>, a medium cellular silicone foam manufactured by Rogers Corporation), which can be either open cell silicone foam or closed cell silicone foam. In some aspects, the respective durometers of the silicone foam layers can be defined by compression force deflection of the foam silicone. In some embodiments, the durometer is within a range of about (e.g., ±<NUM>%, ±<NUM>%, ±<NUM>%, ±<NUM>%, ±<NUM>%, or ±<NUM>%) <NUM>-<NUM> Shore A, inclusive. HT-<NUM> silicone foam has a density, as measured according to ASTM D <NUM>, of <NUM>/m<NUM> (<NUM> pounds per cubic feet (lb/ft<NUM>))BF-<NUM> silicone foam has a density, as measured according to ASTM D <NUM>, of <NUM>/m<NUM> (<NUM> lb/ft<NUM>. ) For the first layer <NUM>, the die-cut silicone foam (BF <NUM>) can have a compression force deflection of about (e.g., ±<NUM>%, ±<NUM>%, ±<NUM>%, ±<NUM>%, ±<NUM>%, or ±<NUM>%) <NUM> kPa (<NUM> pounds per square inch (psi)). The compression force deflection is a measure of the load bearing ability of a foam material and is the force exerted against a flat compression foot that is larger than the specimen to be tested. The term compression force deflection is also sometimes referred to as "compression load deflection". The compression force deflection metric is measured as the force necessary to achieve a <NUM>% deflection according to ASTM D <NUM>. For the second layer <NUM>, the die-cut silicone foam (for example, SISCO® HT-<NUM>) can have a compression force deflection of within a range including, for example, about (e.g., ±<NUM>%, ±<NUM>%, ±<NUM>%, ±<NUM>%, ±<NUM>%, or ±<NUM>%) <NUM>-<NUM> kPa (<NUM>-<NUM> psi). In some embodiments, the second layer <NUM> of the second cushioning material <NUM> has more open space on its upper or lower surface due to perforations than the first layer <NUM> of the first cushioning material <NUM>, which has, in the embodiment shown, a surface area of about <NUM><NUM> (<NUM> square inches (in<NUM>)). In another aspect, the total surface area of the cavities formed by the perforations <NUM> in the second layer <NUM> of the second cushioning material <NUM> is higher than the total surface area of the cavities formed by the perforations <NUM> in the first layer <NUM> of the first cushioning material <NUM>, for example, the total surface area of the cavities in the second layer <NUM> is about <NUM><NUM> (<NUM> in<NUM>).

In some embodiments, the perforation patterns can be chosen taking into consideration the durometer (e.g., hardness) and density of each layer specific to the cushioning material used. The perforations in the layers of cushioning material also improve heat dissipation and air-flow. For the rear pad <NUM>, the volume of the first cushioning material <NUM> removed from the first layer <NUM> in forming the plurality of perforations <NUM> is about <NUM><NUM> (<NUM> cubic inches (in<NUM>) ) and the volume of the second cushioning material <NUM> removed from the second layer <NUM> in forming the plurality of perforations <NUM> is about <NUM><NUM> (<NUM> in<NUM>).

According to further embodiments of the present subject matter, the first layer <NUM> of the first cushioning material <NUM> and the second layer <NUM> of the second cushioning material <NUM> are each perforated. As shown in <FIG>, the first layer <NUM> has a first perforation pattern comprising a plurality of first perforations <NUM> formed therein. <FIG> shows the second layer <NUM>, which has a second perforation pattern comprising a plurality of second perforations <NUM>. The first perforation pattern and the first perforations <NUM> differ from the second perforation pattern and the second perforations <NUM>. The first perforations <NUM> in the first layer <NUM> are generally arranged in a first perforation shape and the second perforations <NUM> in the second layer <NUM> are generally in a second perforation shape, which may differ from the first perforation shape. For example, the first perforations <NUM>, or at least the majority of the first perforations <NUM>, in the first layer <NUM> of the first cushioning material <NUM>, are generally circular, and the second perforations <NUM>, or at least the majority of the second perforations <NUM>, in the second layer <NUM> of the second cushioning material <NUM> are in a shape other than circular, such as generally square, rectangular, and/or triangular, or generally in a grid-like pattern. The first and second perforations <NUM>/<NUM> are holes or apertures that pass through the thickness of the respective first and second cushioning materials <NUM>/<NUM>. The first and second perforations <NUM>/<NUM> can be created by die-cutting, piercing, boring, or any other conventional methods.

A different perforation pattern can be a result of a higher perforation count of the perforation of the same shape, or perforations of a different shape or different shapes, or a combination of the foregoing. In an aspect of the present disclosure shown in <FIG>, the second layer <NUM> of the second cushioning material <NUM> has more open space on its upper or lower surface due to second perforations <NUM> than the first layer <NUM> of the first cushioning material <NUM>. In another aspect of the present disclosure, the total volume of the cavities formed by the second perforations <NUM> in the second layer <NUM> of the second cushioning material <NUM> is higher than the total volume of the cavities formed by the first perforations <NUM> in the first layer <NUM> of first cushioning material <NUM>. The second layer <NUM> has a cut-out recess, generally designated <NUM>, which substantially defines the size, shape, and/or contour of the cut-out recessed region <NUM> of the rear pad <NUM>, the cut-out recess <NUM> and the cut-out recessed region <NUM> having a size, shape, and/or contour that corresponds to the size, shape, and/or contour of the cut-out <NUM> of the occipital basket <NUM>.

In additional embodiments of the present subject matter, the rear pad <NUM> has an inner surface in contact with a wearer and an outer surface attached to the inner surface of the rear portion of the headband, and the rear pad <NUM> comprises a recess <NUM> formed in the first layer <NUM>.

In each of the respective padding segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>, the cushioning material may be any suitable synthetic foam such as silicone foam, expanded polystyrene, polyurethane, or other types of polymer. In an example embodiment of the present disclosure, the cushioning material in both layers are a silicone foam, for example, the silicon foam materials commercially available at Stockwell Elastomerics, Inc. The differences in the first and second layers <NUM>/<NUM> include the durometer of the first and second cushioning materials <NUM>/<NUM>. Any suitable material may be used as long as the material has a similar durometer as the materials specified herein.

As shown in <FIG>, the rear pad <NUM> is covered by a rear pad cover <NUM>, which can be made of fabric, synthetic polymers, or other suitable materials, such as polyethylene, nylon, glass fibers and the like. The rear pad <NUM> comprises a recessed area <NUM> formed therein, between the opposing padding lobes <NUM> that have, in the embodiment shown, a generally triangular shape. The recessed area <NUM> is provided to relieve pressure from the occipital basket <NUM> being secured over the rear portion of the head of a wearer, thereby accommodating accessories worn by the wearer, such as, for example, straps for the cap, loupe, or glasses and the like, without interfering with the head wearable device <NUM> being sufficiently secured over the wearer's head and to avoid pressure that may push against the back of the wearer's head. Any shape for the rear pad <NUM> is contemplated and, furthermore, the recessed area <NUM> can be in any shape, including, as shown in <FIG>, a generally triangular shape. Recessed area <NUM> can have a reduced thickness compared to the thickness of the rear pad <NUM> overall and/or to the padding lobes <NUM>. In the example embodiment shown, the rear pad cover <NUM> is able to sufficiently surround a rear pad <NUM> having a total volume of about <NUM><NUM> (<NUM> in<NUM> ). In an example embodiment, the rear pad cover <NUM> is made of Darlington <NUM> fabric manufactured by Darlington. The Darlington <NUM> material used in the example embodiment is a <NUM>-way stretch heavy weight tricot, <NUM> gsm (grams per square meter) weight, and is available in various colors. As shown in <FIG>, the back of rear pad cover <NUM> shown in <FIG> may be produced by layering a main body piece 558A, two inner overlap pieces <NUM> and two netting pieces 558C in the order as illustrated, such that the back of the rear pad cover <NUM> has an elastic netting pocket <NUM> on the outer surface of each side flap. The rear pad cover <NUM> comprises a cut-out recessed region <NUM> contoured to the shape of the occipital basket <NUM> and also covers the recess <NUM>. Regardless of the materials specified herein, it is contemplated that at least a portion of the rear pad cover <NUM> may be made from a breathable stretch material with an estimated weight within the range of about <NUM>-<NUM> gsm inclusive.

The front of the rear pad cover <NUM> can be fabric such as Darlington fabrics, <NUM>-way stretch spandex, while the back of the rear pad cover <NUM> can be nylon/UBL (unbroken loop) fabric <NUM>, which is a part of a hook-and-loop fastening system, with optional snaps <NUM> provided to more securely attach the rear pad cover <NUM> over the rear pad <NUM>. Other materials are suitable for use in the padding system <NUM>, and can be selected depending on cleaning and comfort requirements.

The rear pad <NUM> can be assembled by aligning the front of rear pad cover <NUM> shown in <FIG>, the first layer <NUM> of the first cushioning material shown in <FIG>, the second layer <NUM> of the second cushioning material shown in <FIG>, and the back of the rear pad cover <NUM> shown in <FIG>, and then sewing along the periphery of the covers. The stretch- mesh netting pockets <NUM> on the back of the rear pad cover <NUM> is made of an elastic material, such as spandex mesh, and is removably disposed about the outer surface of the corresponding side flaps of the occipital basket <NUM> to help secure the rear pad cover <NUM> to the occipital basket <NUM>. The recess in the rear pad <NUM> can be formed by adding stitches along the corresponding recess <NUM> in the first layer <NUM> of the first cushioning material in the rear pad <NUM>.

Referring to <FIG>, the brow pad <NUM> comprises a first layer <NUM> of a first cushioning material having a first durometer, and a second layer <NUM> of a second cushioning material having a second durometer that is different (e.g., harder) than the first durometer. The first layer <NUM> is perforated in a first perforation pattern, comprising first perforations <NUM>, and the second layer <NUM> is perforated in a second perforation pattern, comprising second perforations <NUM>, which differ from the first perforation pattern. In an example embodiment, the first layer <NUM> of the first cushioning material of the brow pad <NUM> is configured as a comfort layer arranged adjacent the head of the wearer and is formed from <NUM> (¼") die- cut silicone foam (BF <NUM>), while the second layer <NUM> of the second cushioning material is spaced apart from the head of the wearer and is formed <NUM> (¼") die-cut silicone foam (for example, SISCO® HT-<NUM>).

Although the example embodiments of rear pad <NUM> and brow pad <NUM> both include a softer, inner, first layer of cushioning material and a harder, outer, second layer of cushioning material, other layering options are contemplated, depending on the cleanability and comfort standards and the desired fit, feel, and comfort level. In some embodiments, the SISCO® silicone foams disclosed herein can be described as being a range of materials, including extra firm (HT-<NUM>), firm (HT-<NUM>), medium (HT-<NUM>), soft (HT-<NUM>), extra soft (BF-<NUM>), and ultra soft (BF-<NUM>). HT-<NUM> has a compression force deflection within a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi) and, preferably, a compression force deflection of <NUM> kPa (<NUM> psi). HT-<NUM> has a compression force deflection range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi) and, preferably, a compression force deflection of <NUM> Pa (<NUM> psi). HT-<NUM> has a compression force deflection within a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi) and, preferably, a compression force deflection of <NUM> kPa (<NUM> psi). HT-<NUM> has a compression force deflection within a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi) and, preferably, a compression force deflection of <NUM> kPa (<NUM> psi). BF-<NUM> has a compression force deflection within a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi) and, preferably, a compression force deflection of <NUM> kPa (<NUM> psi). BF-<NUM> has a compression force deflection of about <NUM> kPa (<NUM> psi). Some other possible combinations of generally hard, medium, and soft layers include medium inner - medium outer, hard outer - medium inner, and soft outer - soft outer layering combinations. Any of the extra firm, firm, medium, soft, extra soft, and ultra soft materials may be combined to form the first and second layers of padding.

Examples of such combinations for any of padding segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> can include a first layer comprising extra firm (having a first durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)) silicone foam and a second layer comprising silicone foam of any of the following types: firm (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), medium (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), soft (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), extra soft (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), or ultra soft (having a second durometer with a compression force deflection of about <NUM> kPa (<NUM> psi)).

Other examples of such combinations for any of padding segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> can include a first layer comprising firm (having a first durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)) silicone foam and a second layer comprising silicone foam of any of the following types: extra firm (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), medium (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), soft (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), extra soft (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), or ultra soft (having a second durometer with a compression force deflection of about <NUM> kPa (<NUM> psi)).

Another set of examples of such combinations for any of padding segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> can include a first layer comprising medium (having a first durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)) silicone foam and a second layer comprising silicone foam of any of the following types: extra firm (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), firm (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), soft (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), extra soft (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), or ultra soft (having a second durometer with a compression force deflection of about <NUM> kPa (<NUM> psi)).

In still other examples, such combinations for any of padding segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> can include a first layer comprising soft (having a first durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)) silicone foam and a second layer comprising silicone foam of any of the following types: extra firm (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), firm (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), medium (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), extra soft (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), or ultra soft (having a second durometer with a compression force deflection of about <NUM> kPa (<NUM> psi)).

In further examples, such combinations for any of padding segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> can include a first layer comprising extra soft (having a first durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)) silicone foam and a second layer comprising silicone foam of any of the following types: extra firm (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), firm (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), medium (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), soft (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), or ultra soft (having a second durometer with a compression force deflection of about <NUM> kPa (<NUM> psi)).

In yet further examples, such combinations for any of padding segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> can include a first layer comprising ultra soft (having a first durometer with a compression force deflection of about <NUM> kPa (<NUM> psi)) silicone foam and a second layer comprising silicone foam of any of the following types: extra firm (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), firm (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), medium (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), soft (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), or extra soft (having a second durometer with a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)).

In some embodiments, the second layer <NUM> of the second cushioning material has more open space on its upper or lower surface due to perforations than the first layer <NUM> of the first cushioning material, which has, in the embodiment shown, a surface area of about <NUM><NUM> (<NUM> in<NUM>). In another aspect, the total surface area of the cavities formed by the perforations <NUM> in the second layer <NUM> of the second cushioning material is higher than the total surface area of the cavities formed by the perforations <NUM> in the first layer <NUM> of the first cushioning material, for example, the total surface area of the cavities in the second layer <NUM> is about <NUM><NUM> (<NUM> in<NUM>).

In some embodiments, the perforation patterns can be chosen taking into consideration the durometer (e.g., hardness) and density of each layer specific to the cushioning material used. The perforations in the layers of cushioning material also improve heat dissipation and air-flow. For the brow pad <NUM>, the volume of the first cushioning material removed from the first layer <NUM> in forming the plurality of perforations <NUM> is about <NUM><NUM> (<NUM> in<NUM> ) and the volume of the second cushioning material removed from the second layer <NUM> in forming the plurality of perforations <NUM> is about <NUM><NUM> (<NUM> in<NUM>).

The differences between the respective first and second perforation patterns can also aid in visually deciphering the first layer <NUM> from the second layer <NUM>. The outer layer of primarily circle die-cuts may be laid out over the grid formed by the second perforations <NUM> formed in the second layer <NUM> to optimize air-flow between the first layer <NUM> and the second layer <NUM>. Additionally, a higher perforation count may be used in the first layer <NUM> on the foam to increase the degree of compression and softness of the first compression material. The first perforations <NUM> comprise round holes to provide flexibility to explore actual hole count among the different designs, but as described above the first perforations <NUM> do not have to be circular. The actual design and perforation patterns should take into account the amount of material removed, not simply the shape of the die-cuts.

Referring to <FIG>, the top cover <NUM>/<NUM> of the side pads <NUM>/<NUM> can be made of fabric, for example, Darlington <NUM> fabric manufactured by Darlington, which is a <NUM>-way stretch Heavy Weight Tricot with a <NUM> gsm weight. The pad shown here is a side pad <NUM>/<NUM> for one side portion of the headband <NUM>. The side pad <NUM>/<NUM> for the other side portion of the headband <NUM> is a mirror image of the side pad <NUM>/<NUM> as shown.

The rear <NUM>/<NUM> of the side pad <NUM>/<NUM> includes an attachment that secures the side pad <NUM>/<NUM> to the lateral strap 120A/120B of the headband <NUM>. An example of a suitable attachment includes a hook-and- loop fastener system. The side pad <NUM>/<NUM> is filled with open-cell urethane foam or other suitable cushioning material to provide the desired level of support and comfort. A depression <NUM>/<NUM> can be formed by stitching across the side pad <NUM>/<NUM>, thereby creating two or more padding segments in the side pad <NUM>/<NUM>.

Referring to <FIG>, like the side pad shown in <FIG>, the top pad <NUM> can be made of fabric, for example, Darlington <NUM> fabric. In the embodiment shown, the rear <NUM> of the top pad <NUM> includes a hook and loop fastener strip. Other suitable attachment types are contemplated. The top pad <NUM> is filled with open-cell urethane foam or any other suitable cushioning material, and the foam can be of any suitable thickness, for example,%" urethane foam support.

Although the top pad <NUM> and the side pad <NUM>/<NUM> are described herein each in singular form, there may be more than one top pad <NUM> and at least two side pads <NUM>/<NUM> for the two lateral straps 120A/120B of the headband <NUM>. Each of these pads may have similar constructions but different shapes, lengths, thickness, curvatures, and the like to adapt the respective pad to the corresponding contour of the strap of the headband <NUM> for attachment. In addition, although the respective pads are shown as segmented pieces, one or more of the padding segments may be connected or all may be formed as an integral portion of the padding system <NUM>.

The padding segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> in the padding system <NUM> can be attached the headband <NUM> and the occipital basket <NUM> in various ways, either permanently or removably, for example, by hook and loop fasteners, snapping members, stitching, adhesive, ties, and any other suitable types of attachment known in the art. In an example embodiment, the brow, side and top pads <NUM>, <NUM>, <NUM>, and <NUM> are all backed with a die-cut loop material to anchor them to the headband <NUM>.

The occipital basket <NUM> comprises at least one padding segment <NUM> removably attached thereto. As shown in <FIG>, the occipital basket <NUM> comprises a cut-out <NUM>, or notch, formed at the bottom edge thereof that defines a location where a wearer's hair can exit the occipital basket <NUM> without substantially interfering with the occipital basket <NUM> fitting securely against the rear of the wearer's head. The cut-out <NUM> is also formed to accommodate any features of a head wearable garment (e.g., a knot used to secure a surgical cap over the head of the wearer). In the embodiment of <FIG>, the rear pad <NUM> is a unitary (e.g., integral or monolithic) padding segment that is attached to the occipital basket <NUM> by a retention strap <NUM> (see <FIG>) and netting <NUM> (see <FIG>) that contain each of the lower corners of the occipital basket <NUM> (e.g., on opposite sides of the cut-out) therein and an upper strap <NUM> (see <FIG>) which passes around the strap <NUM> of the occipital basket <NUM> and is secured thereto by snaps <NUM> (see <FIG>) or any other suitable fastener. As shown at least in <FIG>, the rear pad <NUM> on the occipital basket <NUM> has an outer contour/profile shape that is substantially similar to that of the occipital basket <NUM> itself, including the cut-out <NUM>. Furthermore, the rear pad <NUM> on the occipital basket <NUM> comprises a cut-out recessed region <NUM> to accommodate a wearer's hair style without interfering with the head wearable device <NUM> being sufficiently secured over the wearer's head and to avoid pressure that may push against the back of the wearer's head.

<FIG> shows an embodiment of the head wearable device <NUM>, similar to that shown in <FIG>, fitted on and over a human skull, generally designated <NUM>, to demonstrate possible and what can be preferred placement of the padding segments (e.g., <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) relative to skull region joinder lines or sutures, such as for example sutures <NUM>, <NUM>, <NUM>, and/or <NUM>, that exist between adjacent skull plates of the skull <NUM> and are configured to be positioned on a head without covering or being disposed or positioned over any or a substantial portion of the skull sutures such as sutures <NUM> shown. As shown, the padding segments are spaced such that, in at least some configurations, the weight of the head wearable device <NUM> is not placed on or over the skull sutures. For example, the shape of the lateral straps 120A/120B and the hinges 140A/140B avoid placement over, and do not contact and/or put pressure on, the squamous suture <NUM> and the lambdoid suture <NUM>, while the top pad <NUM> does not contact at least a portion of the sagittal suture <NUM>. As such, the side pads <NUM>/<NUM> of the lateral straps 140A/140B do not contact or apply pressure over any suture (e.g., <NUM>, <NUM>, <NUM>, and/or <NUM>) of the skull <NUM> of the wearer of the head wearable device <NUM>. In the embodiment shown, a gap, generally designated <NUM>, is present between segments of the top pad <NUM> so that the top pad <NUM> does not contact the head of the wearer in a region covering or over the coronal suture <NUM> of the skull <NUM> of the wearer. Stated differently, the top pad <NUM> is spaced apart from the head of the wearer over one or more sutures <NUM> of the wearer's skull <NUM>. As such, the top pad <NUM> does not contact the wearer's head at areas of the sutures <NUM> of the wearer's skull <NUM>. A gap, generally designated <NUM>, <NUM>, is present between segments of the side pads <NUM>, <NUM> so that the side pads <NUM>, <NUM> do not contact the head of the wearer in a region covering or over a suture <NUM> of the skull <NUM> of the wearer. The side pad <NUM>, <NUM> is therefore against the head but can be laterally spaced apart from the head of the wearer over one or more sutures <NUM> of the wearer's skull <NUM>. As such, the side pads <NUM>, <NUM> do not contact the wearer's skull at the sutures <NUM> of the wearer's skull <NUM>. In some embodiments, the top pad <NUM> and/or the side pads <NUM>, <NUM> can be adjusted positionally so that the gap <NUM>, <NUM>, <NUM> can be positioned over the suture <NUM> of the skull of the wearer to provide enhanced comfort for the wearer during extended periods of use of the head wearable device <NUM>. While <FIG> is a view of one side of the head wearable device <NUM> over a skull <NUM> of the wearer, the opposing view is identical to (e.g., is a mirror image of) the side view of FIG. <NUM>, such that the features shown therein and described hereinabove are present for both sides of the head wearable device <NUM> relative to the skull <NUM> of the wearer.

The luminaire <NUM> comprises an external housing <NUM> and is attached at the forward edge of the headband <NUM> by any suitable mechanical linkage, generally designated <NUM>. In some embodiments, the mechanical linkage <NUM> is a statically attached mounting point to which the luminaire <NUM> is rigidly and/or pivotably attached. In the embodiment shown, the mechanical linkage <NUM> comprises a mount that is connected to the front of the headband <NUM> and linkage bars <NUM> that are pivotably connected together by linkage rollers <NUM>. As shown in <FIG>, the mechanical linkage <NUM> is secured to the headband <NUM> by mounting hardware (e.g., screws and washers), generally designated <NUM>, which pass through the thickness of the headband <NUM> at the front thereof. The mechanical linkage <NUM> is provided to allow the angle of the luminaire <NUM> relative to the headband <NUM> and the distance of the luminaire <NUM> from the headband <NUM> to be controlled independently. The luminaire <NUM> comprises, as is shown at least partially in <FIG>, at least one LED <NUM> (e.g., any suitable light source), which can be mounted on a substrate. Such a substrate can be affixed (e.g., rigidly) to a heatsink <NUM> located within the luminaire housing <NUM> to conduct heat generated by the at least one LED <NUM> into the heatsink <NUM>. Such a substrate can have surface-mount connection points for the LED's power and sensing electrical needs. The substrate can be formed such that the LED <NUM> and the heatsink <NUM> are located in opposing first and second regions of the luminaire housing <NUM>, the first region being adjacent the lens cell and the second region being located away from (e.g., spaced apart from) the LED <NUM>. The substrate may be configured to allow for a straight-line optical cell configuration, as opposed to a bent-configuration, thereby eliminating the need for a mirror to perform the optical bend necessary for such configurations. In some embodiments, such a substrate can be a laminated printed circuit board (PCB) and/or comprises copper to provide enhanced thermal conductivity between the LED <NUM> and the heatsink <NUM> to the substrate. The use of copper in such a substrate can be advantageous, as copper's high thermal conductivity allows for the efficient conduction of heat from the LED <NUM> to the heatsink <NUM> for dissipation into a cooling air stream flowing into the luminaire housing <NUM> via the inlet <NUM>, two of which are formed on opposing sides of the luminaire housing <NUM>. The heatsink <NUM> can be of any suitable construction, including, for example, extrusion, soldering, skiving, and the like, and can comprise any suitably conductive material, such as, for example, aluminum or copper.

The luminaire housing <NUM> is connected, via a pivoting ball joint <NUM>, to a duct <NUM> system. The ball joint <NUM> is formed of two half-members <NUM> assembled together to form the ball joint <NUM> and the luminaire housing <NUM> is clamped around the outer lateral edges of the ball joint <NUM> to allow the luminaire housing <NUM> to rotate independently of and about the ball joint <NUM>. The ball joint <NUM> is rotatable about an axis that is perpendicular to the duct system <NUM>, unlike known solutions that rotate about an axis parallel to the air flow path to avoid inducing kinks or other obstructions into the air flow path. The ball joint <NUM> has a hole <NUM> formed radially about a portion of the circumference of the ball joint <NUM>. The ball joint <NUM> has an exhaust port <NUM> formed in the circumference of the ball joint <NUM> and directed radially away from the center of the ball joint <NUM>. The exhaust port <NUM> and the hole <NUM> are located around the circumference of the ball joint <NUM>. As such, the ball joint <NUM> defines an airflow path through the body thereof, with the hole <NUM> and the exhaust port <NUM> being defined, respectively, as the inlet and the outlet of the airflow path through the ball joint <NUM>. The cross-sectional area of the hole <NUM> has a size to provide sufficient air flow across the heatsink <NUM> of the luminaire <NUM> to sufficiently cool the LED <NUM>. In the embodiment shown, the hole <NUM> and the exhaust port <NUM> are formed such that they are located substantially diametrically opposite each other about the circumference of the ball joint <NUM>. The ball joint <NUM> has locating features <NUM> formed therein and/or thereon that define a range of rotary movement of the luminaire housing <NUM> and the ball joint <NUM> relative to each other. This range of rotary movement defined by the locating features <NUM> is such that the hole <NUM> remains positioned internal to the luminaire housing <NUM> at all operating positions of the luminaire <NUM> relative to the headband <NUM> to avoid creating an unwanted air inlet in the luminaire housing <NUM> upstream of the heatsink <NUM>. Similarly, the lateral sides <NUM> of the ball joint <NUM> can be solid or be sealed with a gasket to prevent any air leakage into and/or out of the duct system <NUM>. In some embodiments, such as is shown in <FIG>, the hole <NUM> comprises two discrete holes <NUM>, one hole <NUM> being formed in each side of the two half-members <NUM> of the ball joint <NUM>.

The ball joint <NUM> is lockingly connected at the exhaust port <NUM> thereof to a flexible duct <NUM> that can have, for example, a corrugated construction that allows for bending deflections as well as elongations or contractions thereof when the position of the luminaire <NUM> relative to the headband <NUM> is changed (e.g., by adjusting the position of the mechanical linkage <NUM>). The exhaust port <NUM> of the ball joint <NUM> comprises, in the embodiment shown, a snapping interlock system <NUM> to ensure sufficient mechanical interlocking between the exhaust port <NUM> and the flexible duct <NUM>. The flexible duct <NUM> is connected at a distal end thereof to a rigid duct <NUM> attached to the upper housing <NUM> on the top strap of the headband. This rigid duct <NUM> has, at a distal end thereof from the flexible duct <NUM>, an air moving device <NUM> attached thereto, the outlet of the air moving device <NUM> being oriented to blow out from a hot air exhaust <NUM>. The luminaire housing <NUM> has at least two air inlets <NUM> formed therein (e.g., integrally) at locations configured to draw ambient air across the heatsink <NUM>. The air moving device <NUM> can be of any suitable type, including a fan, blower, piezoelectric device, or the like.

A sensor is provided to monitor a temperature of the LED, either directly or indirectly, and a controller is provided to thermostatically control the air moving device <NUM> to maintain the temperature of the LED <NUM> within a prescribed operating temperature range. In examples of indirect thermal management, the temperature of a substrate to which the LED <NUM> may be attached and/or mounted, the heatsink <NUM>, and/or the air flow passing through the duct system <NUM> may be monitored, preferably in conjunction with the operational state (e.g., as a percentage of maximum air flow) of the air moving device <NUM>. Gaskets <NUM> are provided on the inlet and/or the outlet faces of the air moving device <NUM> to prevent introducing leakage paths within the duct system <NUM>.

In some embodiments, the ball joint <NUM> comprises two half- members <NUM> ultrasonically welded together to form the body of the ball joint <NUM>, which is held in place within an end of the luminaire housing <NUM> sealingly clamped between flanges thereof, which may, in some embodiments, itself be ultrasonically welded together from separate and discrete housing members 210A/210B. This sealing clamping of the luminaire housing <NUM> about the ball joint <NUM> can, in some embodiments, be achieved by placing one or more gaskets circumferentially between the ball joint-luminaire housing interface being sealed. In some such embodiments, the one or more gaskets can be installed within a groove formed in a surface of the ball joint <NUM>, the luminaire housing <NUM>, or both. The two half-members <NUM> have a central cavity, generally designated <NUM>, formed therein when assembled together. In the embodiment shown, the ball joint <NUM> sits loosely (e.g., sufficiently loose to allow the pivoting motion of the luminaire housing <NUM> relative to the ball join <NUM>) at the proximal end (relative to the headpiece) of the luminaire housing <NUM>, with O-ring gaskets being provided in a recess around central protrusion <NUM> to produce an air tight interface between the ball joint <NUM> and the luminaire housing <NUM> to minimize leakage paths in the airflow path. As shown, the ball joint <NUM> can pivot freely within the proximal end of the luminaire housing <NUM> over a range of motion as determined by the vertical position of both the luminaire <NUM> and any accompanying downstream exhaust components (e.g., the flexible duct <NUM>, the rigid duct <NUM>, etc.). The housing <NUM> is connected to the mechanical linkage <NUM> at mounting tab <NUM>.

As such, a method of cooling a luminaire <NUM> of a head wearable device <NUM> is provided. The method comprises providing an LED <NUM> within a luminaire housing <NUM>, forming at least one air inlet <NUM> in the luminaire housing <NUM>, attaching a heatsink <NUM>, directly or indirectly (e.g., via a substrate) to the LED <NUM>, arranging the heatsink <NUM> adjacent the at least one air inlet <NUM> of the luminaire housing <NUM>, connecting the luminaire housing <NUM> to the ball joint <NUM>, forming a hole <NUM> and an exhaust port <NUM> in the ball joint <NUM>, connecting a first end of the flexible duct <NUM> to the ball joint <NUM> at the exhaust port <NUM>, connecting a rigid duct <NUM> to the flexible duct <NUM> at the second end of the flexible duct <NUM>, installing the air moving device <NUM> within a hot air exhaust <NUM> of the upper housing <NUM>, monitoring the temperature of the LED <NUM> within the luminaire <NUM>, and controlling the air moving device <NUM> to produce an air flow from the at least one inlet <NUM> in the luminaire housing <NUM>, through the heatsink <NUM>, through the ball joint <NUM>, through the flexible duct <NUM>, through the rigid duct <NUM>, through the air moving device <NUM>, and exhausted from the hot air exhaust <NUM> formed in the upper housing <NUM>, which is attached to a top strap <NUM> of a headband <NUM> of the head wearable device <NUM>.

Power can be provided to the head wearable device <NUM> via a power cord <NUM> attached to the upper housing <NUM>. In some embodiments, the power cord <NUM> is of a twist-lock type, such that power cannot be accidentally disconnected from the head wearable device <NUM> merely by pulling the power cord <NUM> out of the holster <NUM> without an accompanying twisting motion at the connector interface. The power cord <NUM> may be connected to a holster <NUM> that is wearably attached to a wearer of the head wearable device <NUM>. In some embodiments, the holster <NUM> is configured to have one or more battery packs installed therein, which allows the wearer of the head wearable device <NUM> unrestricted movement. In some embodiments, the holster <NUM> is configured to be connected to a substantially continuous power source (e.g., a wall electrical outlet) for substantially indefinite operation. The holster <NUM> comprises an intensity control (e.g., a rotary control knob) that regulates power to the LED <NUM> from either battery or the direct power supply and controls the intensity emitted from the LED <NUM> and, consequently, also from the luminaire <NUM>.

The luminaire <NUM> is configured to produce a pure white light output without a yellow ring being present around the perimeter of the light output area. Apertures may be used in optical devices such as cameras and telescopes to limit light entering the device. Such apertures may be manufactured from any suitable material, including from a thin metal and may, in some aspects, advantageously be either anodized black or painted black to minimize unwanted reflections within the optical path. It is known that such apertures may be suspended mechanically within the lens cell in any manner and orientation, as dictated by the optical design and subsequent testing iterations. The presently disclosed luminaire <NUM> is thus configured to restrict unwanted stray light (aberrations) from exiting the optical path, thereby ensuring a near ideal white-spot presentation. It is known that aberrations in the spot presentation can result from light scattering in the optical train due to source light reflections off of internal mechanical components, LED "yellow light phenomenon," and the like. It is advantageous to ensure that the optical train will yield a substantially homogeneous white-spot presentation. The presently disclosed embodiment optimizes the projection of white light while helping to restrict both stray light reflections and yellow light from exiting the optical path. As shown, the light projecting portion of the luminaire <NUM> is configured to produce a white-spot presentation having an adjustable focal point and/or focal length, thereby allowing for a white-spot presentation having an adjustable size (e.g., diameter). The focal length and spotlight size is adjustable by turning the adjustment knob <NUM> (see <FIG>) provided on the luminaire <NUM>. The outer lens <NUM> is contained within an outer lens structure, generally <NUM>, at the outlet of the optical train.

<FIG> is a partially exploded view of the head wearable device <NUM>, showing the attachment of the luminaire <NUM>, via the mechanical linkage <NUM>, to the headband <NUM> and the flexible duct <NUM> to the rigid duct <NUM>. <FIG> is a partially exploded view of the components of the depth adjuster <NUM> for the position of the strap <NUM> of the occipital basket <NUM> relative to the upper housing <NUM> attached to the top strap <NUM> of the headband <NUM>. In some embodiments, the occipital basket <NUM> is pivotable to better adjust to the head shape of the wearer. The depth adjuster <NUM> shown in <FIG> comprises a gear <NUM> that engages with teeth <NUM> (see <FIG>) formed on the inner surface of the slot <NUM> (see <FIG>) of the strap <NUM> that is being positionally adjusted relative to the upper housing <NUM> and the top strap <NUM>. The gear <NUM> projects through the upper housing <NUM> and is fixedly and rotationally coupled to an adjustment knob <NUM>. The adjustment knob <NUM> is rotatably locked to the gear <NUM> by connector plate <NUM> and screw <NUM>. A cover plate <NUM> is attached to the adjustment knob <NUM>, but in some embodiments the cover plate <NUM> can be integrally formed as the adjustment knob <NUM>. As such, a rotary movement of the knob <NUM> causes a corresponding rotary movement of the gear <NUM> and a corresponding lengthening or shortening of the strap <NUM> which engages with the gear <NUM>. <FIG> is a partially exploded view of the components of the headband adjuster <NUM> for the circumference of the head wearable device <NUM>. The headband adjuster <NUM> shown in <FIG> is largely similar to the depth adjuster shown in <FIG>, but the rear housing comprises a two-part rear housing that has a base <NUM> that allows for visualization of the engagement of the teeth 134A/134B of the lateral extension straps 130A/130B with the gear <NUM> when assembling the head wearable device <NUM>. This visualization internal to the headband adjuster <NUM> ensures that the lateral extension straps 130A/130B are each equally engaged around the gear <NUM> so the components of the head wearable device <NUM> are symmetrical about a vertical plane arranged along the longitudinal axis of the head wearable device <NUM>. The headband adjuster <NUM> further comprises a cover panel <NUM> that engages at least partially over the base <NUM> to obscure the engagement of the gear <NUM> with the lateral extension straps 130A/130B during normal operation of the head wearable device <NUM>. The gear <NUM> projects through a hole formed in the occipital basket <NUM> and the base <NUM> is secured to the occipital basket <NUM> at a predetermined mounting point, for example, by screws <NUM>. The gear <NUM> is then fixedly and rotationally coupled to an adjustment knob <NUM> by screw <NUM>, which passes through the occipital basket <NUM>. The adjustment knob <NUM> is rotatably locked to the gear <NUM> by connector plate <NUM> and screw <NUM>. A cover plate <NUM> is attached to the adjustment knob <NUM>, but in some embodiments the cover plate <NUM> can be integrally formed as the adjustment knob <NUM>. As such, a rotary movement of the adjustment knob <NUM> causes a corresponding rotary movement of the gear <NUM> and a corresponding lengthening or shortening of the circumference of the head wearable device <NUM>.

A method of adjusting a size of a headpiece of a head wearable device to a head size of a wearer, the headpiece comprising a headband <NUM> and an occipital basket <NUM>, is provided. The method comprises attaching an upper housing <NUM> to an external surface of a top strap <NUM> of the headband <NUM>; inserting a strap <NUM> of the occipital basket <NUM> at least partially into the upper housing <NUM>; engaging a first gear <NUM> with a plurality of teeth <NUM> formed in a slot <NUM>, which is longitudinally oriented along a length of the strap <NUM> of the occipital basket <NUM>; turning a first adjustment knob <NUM>, which is rotationally locked to the first adjustment gear <NUM>, to adjust a depth of the headpiece; attaching a second housing to an external surface of the occipital basket <NUM>; inserting an end of at least two lateral extension straps 130A/130B into the second housing, with the end of a first lateral extension strap 130A being inserted from an opposite end of the housing from the end of a second lateral extension strap <NUM>, wherein the two lateral extension straps 130A/130B are hingedly attached to lateral straps 120A/120B of the headband <NUM> to define a circumference of the headpiece; engaging a second gear <NUM> with a plurality of teeth 134A/134B formed in a slot 132A/132B of each of the lateral extension straps 130A/130B such that the second gear <NUM> is engaged with both of the lateral extension straps 130A/130B; and turning a second adjustment knob <NUM>, which is rotationally locked to the second adjustment gear <NUM>, to adjust a circumference of the headpiece.

In some embodiments, the method comprises providing a first visual index along a length of the strap <NUM> of the occipital basket <NUM>, the first visual index <NUM> comprising sequential alphanumeric characters to designate predetermined depth settings for the headpiece; providing a second visual index <NUM> along a length of at least one of the lateral extension straps 130A/130B, the second visual index <NUM> comprising sequential alphanumeric characters to designate predetermined circumference settings for the head wearable device <NUM>; determining a wearer preference for the depth and circumference of the head wearable device 1corresponding to the first and second visual indexes <NUM>/<NUM>; placing the head wearable device <NUM> on the wearer's head; adjusting the first adjustment knob <NUM> such that the first visual index <NUM> indicates that the wearer preference for the depth of the head wearable device <NUM> has been achieved; and adjusting the second adjustment knob <NUM> such that the second visual index <NUM> indicates that the wearer preference for the circumference of the head wearable device <NUM> has been achieved.

In some aspects, a head wearable device comprises a headpiece; a housing attached to the headpiece; a luminaire attached to the headpiece, the luminaire comprising a luminaire housing and at least one light source located within the luminaire housing; a duct system connecting the luminaire to the housing; a ball joint rotatably connecting the duct system to the luminaire; and an air moving device configured to induce a cooling air flow through an inlet in the luminaire housing, through the heatsink, through the ball joint, through the duct system, and out of an exhaust in the housing on the top surface of the headpiece. In some embodiments of the head wearable device, the housing is attached to a top surface of the headpiece In some embodiments, the head wearable device comprises a controller configured to monitor a temperature of the at least one light source and to modulate an operational setting of the air moving device to maintain the temperature of the at least one light source within a predetermined operating range. In some embodiments of the head wearable device, the headpiece comprises a headband, which has at least a top strap and two lateral straps, and an occipital basket, wherein the headband is connected to the occipital basket and the headband and the occipital basket are independently adjustable relative to each other. In some embodiments of the head wearable device, the at least one light source comprises a light emitting diode (LED). In some embodiments of the head wearable device, the ball joint is pivotably and/or swivelably connected to the luminaire. In some embodiments of the head wearable device, the duct system comprises a flexible duct connected to a rigid duct. In some embodiments of the head wearable device, the air moving device is positioned inside the housing, within the rigid duct, in a position adjacent to the exhaust in the housing. In some embodiments of the head wearable device, the luminaire is attached to the headpiece by a mechanical linkage such that an angle and/or position of the luminaire relative to the headpiece is adjustable. In some embodiments of the head wearable device, the flexible duct comprises a corrugated construction such that a length thereof can be shortened or lengthened as the angle and/or position of the luminaire relative to the headpiece is adjusted. In some embodiments of the head wearable device, the ball joint defines a range of angular motion for the luminaire and comprises a passage and an exhaust port formed in a circumferential wall of the ball joint, the range of angular motion being such that the passage remains in a position to provide an air flow path from the luminaire housing into the ball joint. In some embodiments of the head wearable device, the passage and the exhaust port are arranged on substantially opposite sides of the ball joint. In some embodiments of the head wearable device, the passage is not externally visible from the luminaire housing at any point along the range of angular motion. In some embodiments, the head wearable device comprises a heatsink located within the luminaire housing. In some embodiments of the head wearable device, the luminaire is configured to optimize a projection of white light and restrict both stray light reflections and yellow light from exiting the lens cell. In some embodiments of the head wearable device, the lens cell is configured to produce a substantially homogeneous white-spot presentation. In some embodiments of the head wearable device, the lens cell comprises an adjustable focal length and/or focal point. In some embodiments, the head wearable device comprises a power cord attached to the upper housing attached to the top strap of the headband, the power cord being configured to receive power from a holster. In some embodiments of the head wearable device, the power is provided from a rechargeable battery or a continuous power source, and wherein the holster is configured to adjust an intensity of light output from the at least one light source.

In some aspects, a head wearable device comprises a headpiece comprising: a headband comprising a top strap and at least two lateral straps; an occipital basket comprising a strap, the occipital basket being attached to the headband by at least one lateral extension strap pivotably attached by a hinge to a distal end of each respective lateral strap of the headband; a first housing attached to an outer surface of the top strap of the headband; a depth adjuster attached to the first housing, the depth adjuster comprising a first gear rotatably fixed to a first knob; wherein the strap of the occipital basket comprises a slot with a plurality of teeth formed around a longitudinal edge of the slot; wherein the first gear is captively held within the slot and engages with the plurality of teeth; wherein the depth adjuster is configured such that a rotary movement of the first gear causes a longitudinal movement of the strap of the occipital basket to change a distance between the occipital basket and the first housing; wherein a depth of the headpiece changes when the distance between the occipital basket and the first housing changes, or increases or decreases; and wherein the strap comprises a first visual index comprising a first plurality of sequential characters, each of which correspond to one of a plurality of predetermined depth settings of the headpiece; and a second housing attached to an outer surface of the occipital basket; a headband adjuster at an outer surface of the occipital basket, the headband adjuster comprising a second gear rotatably fixed to a second knob; wherein the lateral extension straps each comprise a slot with a plurality of teeth formed around a longitudinal edge of the slot; wherein the second gear is captively held within the slot of each lateral extension strap and engages with the plurality of teeth of each of the lateral extension straps; wherein the headband adjuster is configured such that a rotary movement of the second gear causes a longitudinal movement of the lateral extension straps to change a circumference of the headpiece; and wherein at least one of the lateral extension straps comprises a second visual index comprising a second plurality of sequential characters, each of which correspond to one of a plurality of predetermined circumferential settings of the headpiece; wherein the head wearable device is configured such that the lateral extension straps rotate about the hinge, relative to the lateral straps as the depth of the headpiece changes. In some embodiments of the head wearable device, the first and second visual indexes comprise alphanumeric characters. In some embodiments of the head wearable device, the first visual index and the second visual index comprise different ranges and/or types of alphanumeric characters. In some embodiments of the head wearable device, the first visual index comprises a plurality of sequential letters and the second visual index comprises a plurality of sequential numbers. In some embodiments of the head wearable device, the first visual index comprises a plurality of sequential numbers and the second visual index comprises a plurality of sequential letters. In some embodiments, the head wearable device comprises padding on an inner surface of the headband and the occipital basket. In some embodiments of the head wearable device, a notch is formed into a lower edge of the occipital basket to prevent a wearer's hair from interfering with proper fitment of the headpiece about a head of a wearer. In some embodiments of the head wearable device, the padding on the occipital basket comprises a recessed area to prevent the wearer's hair from interfering with proper fitment of the headpiece about the head of the wearer. In some embodiments of the head wearable device, the padding is removably attached to the headband and the occipital basket. In some embodiments of the head wearable device, the padding is spaced apart from a surface of a head of a wearer of the head wearable device at a suture between adjacent plates of a skull of the wearer of the head wearable device.

In some aspects, a method of adjusting a size of a headpiece of a head wearable device to a head size of a wearer is provided, the headpiece comprising a headband and an occipital basket, and the method comprising attaching a first housing to an external surface of a top strap of the headband; inserting a strap of the occipital basket at least partially into the first housing; engaging a first gear with a plurality of teeth formed in a slot, which is longitudinally oriented along a length of the strap of the occipital basket; turning a first knob, which is rotationally locked to the first gear, to adjust a depth of the headpiece; attaching a second housing to an external surface of the occipital basket; inserting an end of at least two lateral extension straps into the second housing, with the end of a first lateral extension strap being inserted from an opposite end of the housing from the end of a second lateral extension strap, wherein the two lateral extension straps are hingedly attached to lateral straps of the headband to define a circumference of the headpiece; engaging a second gear with a plurality of teeth formed in a slot of each of the lateral extension straps such that the second gear is engaged with both of the lateral extension straps; and turning a second knob, which is rotationally locked to the second gear, to adjust a circumference of the headpiece. In some embodiments, the method comprises providing a first visual index along a length of the strap of the occipital basket, the first visual index comprising sequential alphanumeric characters to designate predetermined depth settings for the headpiece; providing a second visual index along a length of at least one of the lateral extension straps, the second visual index comprising sequential alphanumeric characters to designate predetermined circumference settings for the headpiece; determining a wearer preference for the depth and circumference of the headpiece corresponding to the first and second visual indexes; placing the head wearable device on the wearer's head; adjusting the first knob such that the first visual index indicates that the wearer preference for the depth of the headpiece has been achieved; and adjusting the second knob such that the second visual index indicates that the wearer preference for the circumference of the headpiece has been achieved. In some embodiments of the method, the first visual index and the second visual index comprise different ranges and/or types of alphanumeric characters. In some embodiments of the method, the first visual index comprises a plurality of sequential letters, the second visual index comprises a plurality of sequential numbers, and the wearer preference is designated by one of the plurality of sequential letters and one of the plurality of sequential numbers. In some embodiments of the method, the first visual index comprises a plurality of sequential numbers and the second visual index comprises a plurality of sequential letters. In some embodiments, the method comprises attaching padding on an inner surface of the headband and the occipital basket. In some embodiments, the method comprises forming a notch into a lower edge of the occipital basket to prevent a wearer's hair from interfering with proper fitment of the headpiece about a head of a wearer. In some embodiments, the method comprises forming a recessed area in the padding on the occipital basket to prevent the wearer's hair from interfering with proper fitment of the headpiece about the head of the wearer. In some embodiments of the method, the padding is removably attached to the headband and the occipital basket. In some embodiments, the method comprises spacing the padding apart from a surface of a head of a wearer of the head wearable device at a suture between adjacent plates of a skull of the wearer of the head wearable device.

In some aspects, a headlight device comprises a headband comprising a rear portion, a side portion and a top portion, the headband having an inner surface; a padding system comprising: a rear pad attached to the inner surface of the rear portion of the headband; a side pad attached to the inner surface of the side portion of the headband; a top pad attached to the inner surface of the top portion of the headband; and, optionally, a brow pad attached to the inner surface of the headband about an intersection of the top portion and the side portion; wherein at least one of the rear pad and the brow pad comprises a first layer of a first cushioning material having a first durometer, and a second layer of a second cushioning material having a second durometer that is harder than the first durometer. In some embodiments of the headlight device, the first cushioning material is silicone foam having a first durometer, and the second cushioning material is silicone foam having a second durometer that is harder than the first durometer. In some embodiments of the headlight device, the second layer of the second cushioning material is closer than the first layer of the first cushioning material to the inner surface of the rear portion of the headband. In some embodiments of the headlight device, the first layer of the first cushioning material and the second layer of the second cushioning material are each perforated. In some embodiments of the headlight device, the majority of the perforations in the first layer of the first cushioning material are generally circular, and the majority of the perforations in the second layer of the second cushioning material are in a shape other than circular. In some embodiments of the headlight device, the perforations in the second layer of the second cushioning material are generally square or rectangular, or generally in a grid-like pattern. In some embodiments of the headlight device, the second layer of the second cushioning material has more open space on its upper or lower surface due to perforations than the first layer of the first cushioning material. In some embodiments of the headlight device, the total volume of cavity due to perforations in the second layer of the second cushioning material is higher than the total volume of cavity in the first layer of the first cushioning material. In some embodiments of the headlight device, the rear pad has an inner surface in contact with an wearer and an outer surface attached to the inner surface of the rear portion of the headband, and the rear pad comprises a recess on its inner surface. In some embodiments of the headlight device, at least one of the top pad and the side pad comprises urethane foam and forms segments. In some embodiments of the headlight device, at least one of the top pad, the side pad, and the rear pad is spaced apart from a surface of a head of a wearer of the head wearable device at a suture between adjacent plates of a skull of the wearer of the head wearable device. In some embodiments of the headlight device, the first cushioning material comprises an extra firm silicone foam, the first durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> pounds per square inch (psi)), and wherein the second cushioning material comprises a different silicone foam, the second durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi). In some embodiments of the headlight device, the first cushioning material comprises a firm silicone foam, the first durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> pounds per square inch (psi)), and wherein the second cushioning material comprises a different silicone foam, the second durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi) or <NUM>-<NUM> kPa (<NUM>-<NUM> psi). In some embodiments of the headlight device, the first cushioning material comprises a medium silicone foam, the first durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> pounds per square inch (psi)), and wherein the second cushioning material comprises a different silicone foam, the second durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa or <NUM>-<NUM> kPa (<NUM>-<NUM> or <NUM>-<NUM> psi). In some embodiments of the headlight device, the first cushioning material comprises a firm silicone foam, the first durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> pounds per square inch (psi)), and wherein the second cushioning material comprises a different silicone foam, the second durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa or <NUM>-<NUM> kPa (<NUM>-<NUM> or <NUM>-<NUM> psi). In some embodiments of the headlight device, the first cushioning material comprises a firm silicone foam, the first durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> pounds per square inch (psi)), and wherein the second cushioning material comprises a different silicone foam, the second durometer of which has a compression force deflection in a range of about <NUM> kPa or <NUM>-<NUM> kPa (<NUM> or <NUM>-<NUM> psi). In some embodiments of the headlight device, the first cushioning material comprises a firm silicone foam, the first durometer of which has a compression force deflection of about <NUM> kPa (<NUM> pounds per square inch (psi)), and wherein the second cushioning material comprises a different silicone foam, the second durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi).

In some aspects, a headlight device comprises a headband for encircling the head of a wearer; a padding system comprising a pad removably attached to at least a portion of the headband; wherein the pad comprises a first layer of a first cushioning material having a first durometer, and a second layer of a second cushioning material having a second durometer that is harder than the first durometer; and wherein the first layer is perforated in a first perforation pattern, and the second layer is perforated in a second perforation pattern that differs from the first perforation pattern. In some embodiments of the headlight device, the first layer of the first cushioning material is a layer of silicone foam having a first durometer, and the second layer of the second cushioning material is a layer of silicone foam having a second durometer that is harder than the first durometer. In some embodiments of the headlight device, the second layer of the second cushioning material is closer than the first layer of the first cushioning material to the inner surface of the rear portion of the headband. In some embodiments of the headlight device, the majority of the perforations in one of the first and second layers are circular, and the majority of the perforations in the other layer are in a shape other than circular. In some embodiments of the headlight device, the perforations in the other layer are generally square or rectangular or generally in a grid-like pattern. In some embodiments of the headlight device, the second layer of the second cushioning material has more open space on its upper or lower surface due to perforations than the first layer of the first cushioning material. In some embodiments of the headlight device, the total volume of cavity due to perforations in the second layer of the second cushioning material is higher than the total volume of cavity in the first layer of the first cushioning material. In some embodiments of the headlight device, the pad is spaced apart from a surface of a head of a wearer of the head wearable device at a suture between adjacent plates of a skull of the wearer of the head wearable device. In some embodiments of the headlight device, the first cushioning material comprises an extra firm silicone foam, the first durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> pounds per square inch (psi)), and wherein the second cushioning material comprises a different silicone foam, the second durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi). In some embodiments of the headlight device, the first cushioning material comprises a firm silicone foam, the first durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> pounds per square inch (psi)), and wherein the second cushioning material comprises a different silicone foam, the second durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa or <NUM>-<NUM> kPa (<NUM>-<NUM> or <NUM>-<NUM> psi). In some embodiments of the headlight device, the first cushioning material comprises a medium silicone foam, the first durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> pounds per square inch (psi)), and wherein the second cushioning material comprises a different silicone foam, the second durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa or <NUM>-<NUM> kPa (<NUM>-<NUM> or <NUM>-<NUM> psi). In some embodiments of the headlight device, the first cushioning material comprises a firm silicone foam, the first durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> pounds per square inch (psi)), and wherein the second cushioning material comprises a different silicone foam, the second durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa or <NUM>-<NUM> kPa (<NUM>-<NUM> or <NUM>-<NUM> psi). In some embodiments of the headlight device, the first cushioning material comprises a firm silicone foam, the first durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> pounds per square inch (psi)), and wherein the second cushioning material comprises a different silicone foam, the second durometer of which has a compression force deflection in a range of about <NUM> kPa or <NUM>-<NUM> kPa (<NUM> or <NUM>-<NUM> psi). In some embodiments of the headlight device, the first cushioning material comprises a firm silicone foam, the first durometer of which has a compression force deflection of about <NUM> kPa (<NUM> pounds per square inch (psi)), and wherein the second cushioning material comprises a different silicone foam, the second durometer of which has a compression force deflection in a range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi).

In some aspects, a method is provided of cooling a luminaire of a head wearable device comprises providing an LED within a luminaire housing; forming at least one air inlet in the luminaire housing; attaching a heatsink to a substrate to which the LED is mounted; arranging the heatsink adjacent the at least one air inlet of the luminaire housing; connecting the luminaire housing to a ball joint; forming a hole and an exhaust port in the ball joint; connecting a first end of the flexible duct to the ball joint at the exhaust port; connecting a rigid duct to the flexible duct at the second end of the flexible duct; installing the air moving device within a hot air exhaust of the upper housing; monitoring the temperature of the LED within the luminaire; and controlling the air moving device to produce an air flow to cool the LED. In some embodiments, the method comprises attaching the upper housing to a top surface of a headpiece of the head wearable device. In some embodiments, the method comprises attaching a power cord to the upper housing to receive power from a holster. In some embodiments, the method comprises adjusting an intensity of light output from the at least one light source via the holster, wherein the power comprises a rechargeable battery or a continuous power source. In some embodiments of the method, the headpiece comprises a headband, which has at least a top strap and two lateral straps, and an occipital basket, wherein the headband is connected to the occipital basket and the headband and the occipital basket are independently adjustable relative to each other. In some embodiments, the method comprises attaching the luminaire to the headpiece via a mechanical linkage, such that an angle and/or position of the luminaire relative to the headpiece is adjustable. In some embodiments of the method, the flexible duct comprises a corrugated construction such that a length thereof can be shortened or lengthened as the angle and/or position of the luminaire relative to the headpiece is adjusted. In some embodiments, the method comprises monitoring, via a controller, a temperature of the at least one light source and modulating an operational setting of the air moving device to maintain the temperature of the at least one light source within a predetermined operating range. In some embodiments of the method, the at least one light source comprises a light emitting diode (LED). In some embodiments of the method, connecting the luminaire housing to the ball joint comprises a pivotable and/or swivelable connection. In some embodiments, the method comprises defining, via the ball joint, a range of angular motion for the luminaire and comprises a passage and an exhaust port formed in a circumferential wall of the ball joint, wherein the range of angular motion is such that the passage remains in a position to provide an air flow path from the luminaire housing into the ball joint. In some embodiments, the method comprises arranging the passage and the exhaust port on substantially opposite sides of the ball joint. In some embodiments of the method, the passage is not externally visible from the luminaire housing at any point along the range of angular motion. In some embodiments, the method comprises arranging a heatsink within the luminaire housing. In some embodiments, the method comprises optimizing a projection of white light and restricting both stray light reflections and yellow light from exiting the lens cell. In some embodiments, the method comprises producing, via the lens cell, a substantially homogeneous white-spot presentation. In some embodiments of the method, the lens cell comprises an adjustable focal length and/or focal point.

In some further aspects, a headlight device is provided, the headlight device comprising: a headband for encircling the head of a wearer; a padding system comprising a rear pad removably attached to at least a portion of the headband; wherein the rear pad comprises a first layer of a first cushioning material having a first durometer, and a second layer of a second cushioning material having a second durometer that is different from the first durometer; wherein the first layer is perforated in a first perforation pattern, and the second layer is perforated in a second perforation pattern that differs from the first perforation pattern; wherein the first layer comprises an inner surface in contact with a wearer; wherein the second layer comprises an outer surface attached to the inner surface of the rear portion of the headband; and wherein the rear pad comprises a recess on an inner surface thereof.

While the embodiments disclosed herein are provided merely for purposes of illustration, the features included in each of these embodiments may be combined in any possible combination, as would be readily understood by those having ordinary skill in the art.

Claim 1:
A headlight device (<NUM>) comprising:
a headband (<NUM>) for encircling the head of a wearer;
a padding system (<NUM>) comprising a pad removably attached to at least a portion of the headband; wherein the pad comprises a first layer (<NUM>) of a first cushioning material having a first durometer, and a second layer (<NUM>) of a second cushioning material
having a second durometer that is different from the first durometer; and
characterized in that
the first layer (<NUM>) is perforated in a first perforation pattern (<NUM>), and the second layer (<NUM>) is perforated in a second perforation pattern (<NUM>) that differs from the first perforation pattern.