Patent Description:
Surgical lights are used in operating rooms to provide increased light to a specific area of the room. For example, the surgical light may be positioned in an operating room and configured to provide increased light to a specific area of a surgical patient. The light may include a light housing containing a light source and a distance sensor that measures a distance from the light housing to the object to be illuminated, such that attributes of the light emitted from the light housing may be altered based on the distance detected by the distance sensor. However, conventional sensor systems may be susceptible to blockage that results in inaccurate measurements. For example, a head of a surgeon or other medical professional may block the sensor and consequently cause inaccurate distance measurements.

Below some background documents will be identified and briefly discussed.

<CIT> relates to a method for improving the illumination of an illuminated area, especially an operating area, of an illuminating device with at least two light modules. The method includes the emission of an illuminant characteristic of the light module with a preset amplitude from each light module. The reflected amplitudes of all characteristic light types are detected. The detected amplitudes for each light module are compared. The light intensity of at least one light module is varied on the basis of the comparison of the detected amplitudes for each light module.

<CIT> relates to an energy-saving device of surgical light including a suspension or support system.

<CIT> relates to a shadow-less lighting lamp with a brightness compensation mechanism.

<CIT> relates to a handle device for a surgical light. The handle device may include a grip element which is prepared for being arranged on a lamp holding body of the surgical light and which forms a grip surface at an outer area. A sensor module is detachably connected to the grip element, with the sensor module including at least one distance sensor which is designed for detecting a position of an object. The present application further includes a surgical light including such a handle device.

<CIT> relates to surgical lights and systems and method for maximizing the output of surgical lights by measuring with a distance sensor the distance from a light housing to an object to be illuminated and altering attributes of the emitted light depending on the measured distance.

The invention is defined by the features of the independent claims <NUM> and <NUM>.

Embodiments of the invention may include one or more of the following additional features separately or in combination.

The plurality of distance sensors may be mounted along a periphery of the housing in a spaced relationship relative to each other.

The plurality of distance sensors may be evenly spaced.

The plurality of distance sensors may be obliquely angled relative to a center line of focus of the surgical light head.

The plurality of distance sensors may be obliquely angled relative to the center line of focus by an angle that is between <NUM> and <NUM> degrees.

The plurality of distance sensors may include a single inner distance sensor arranged proximate the center line of focus and a plurality of outer distance sensors that are radially spaced relative to the inner distance sensor.

The surgical light head may further include an annular shape first lens that has a rotation axis, wherein the housing includes a housing cover including a cavity within which the annular shape first lens is rotatable about the rotation axis, wherein the housing cover includes a second lens, and wherein the outer distance sensors are arranged radially outwardly relative to the annular shape first lens and the second lens.

The field of views may be defined by cones having an opening angle that is between <NUM> and <NUM> degrees.

The plurality of distance sensors may include between five and ten distance sensors that are separate and spaced about the housing.

The housing may define a plurality of seats configured for supporting the plurality of distance sensors. The seats may be obliquely angled toward a center line of focus of the surgical light head.

The plurality of seats may be molded with the housing as a single monolithic component.

The plurality of seats may include a single inner seat formed proximate the center line of focus and a plurality of outer seats that are formed on a periphery of the housing and radially spaced from the inner seat.

The surgical light head may include a plurality of distance sensor assemblies that each include a corresponding one of the plurality of distance sensors and a printed circuit board assembly including an electrical interface communicatively coupled between the housing and the corresponding one of the plurality of distance sensors.

Each of the plurality of distance sensor assemblies may include an optical component that covers the corresponding one of the plurality of distance sensors. The optical component may be sealed to the housing and coupled to the printed circuit board assembly. The corresponding one of the plurality of distance sensors may be configured to transmit and receive distance sensing signals through the optical component.

The surgical light head may include an adhesive layer disposed between the optical component and the housing.

The printed circuit board assembly and the optical component may be adhered by an acrylate adhesive material.

The distance sensor and the optical component may define an air gap therebetween.

The surgical light head may include a plurality of locating posts formed on the housing that are engageable with the optical component.

The plurality of locating posts may be integrally formed with the housing as a single monolithic component.

The locating posts may have a tapered shape.

The plurality of distance sensors may be infrared distance sensors.

According to another aspect of the disclosure, a surgical light head includes a housing defining a center line of focus of the surgical light head, a plurality of distance sensors, and a plurality of tilted seats formed on the housing and configured for supporting the plurality of distance sensors. The plurality of tilted seats are obliquely angled toward the center line of focus.

The plurality of tilted seats may be molded with the housing as a single monolithic component.

The plurality of tilted seats may include a single inner seat formed proximate the center line of focus and a plurality of outer seats that are formed on a periphery of the housing and radially spaced from the inner seat.

The surgical light head may include an annular shape first lens that has a rotation axis. The housing may include a housing cover including a cavity within which the annular shape first lens is rotatable about the rotation axis, wherein the housing cover includes a second lens, and the outer seats may be arranged radially outwardly relative to the annular shape first lens and the second lens.

The plurality of tilted seats may be obliquely angled relative to the center line of focus by an angle that is between <NUM> and <NUM> degrees.

Each of the plurality of distance sensor assemblies may include an optical component that covers the corresponding one of the plurality of distance sensors. The optical component may be matingly engageable against a corresponding one of the tilted seats and coupled to the printed circuit board assembly and the corresponding one of the plurality of distance sensors may be configured to transmit and receive distance sensing signals through the optical component.

The surgical light head may include an adhesive layer disposed between the optical component and the corresponding one of the tilted seats.

The surgical light head may include a plurality of locating posts that are formed on the plurality of tilted seats and engageable with a corresponding one of the plurality of distance sensor assemblies.

The locating posts may protrude from a corresponding one of the plurality of tilted seats and have a tapered shape that tapers in a protrusion direction away from the corresponding one of the plurality of tilted seats.

The surgical light head may include a plurality of light emitting elements arranged in the housing and configured to direct light at a target region of interest that defines the center line of focus. The plurality of distance sensors may be obliquely angled toward the center line of focus when seated in the tilted seats, whereby at least two of the distance sensors have field of views that overlap to define a common detection region of interest. The common detection region of interest may at least partially overlap with the target region of interest.

The plurality of distance sensors may include a single inner distance sensor and a plurality of outer distance sensors that are radially spaced relative to the inner distance sensor.

According to another aspect of the disclosure, a surgical light head includes a housing, and a plurality of distance sensor assemblies integrated into the housing. Each of the plurality of distance sensor assemblies includes a distance sensor, a printed circuit board assembly having an electrical interface communicatively coupled between the housing and the distance sensor, and an optical component that covers the distance sensor, with the optical component being sealed to the housing and coupled to the printed circuit board assembly. The distance sensor is configured to transmit and receive distance sensing signals through the optical component.

The housing may define a plurality of tilted seats configured for supporting the plurality of distance sensor assemblies, with the tilted seats being obliquely angled toward a center line of focus of the surgical light head.

The surgical light head may include a plurality of locating posts formed on the tilted seats that are engageable with the optical component.

The surgical light head may include a plurality of light emitting elements arranged in the housing and configured to direct light at a target region of interest, with at least two of the distance sensor assemblies having field of views that overlap to define a common detection region of interest. The common detection region of interest may at least partially overlaps with the target region of interest.

The plurality of distance sensor assemblies may be mounted along a periphery of the housing in a spaced relationship relative to each other.

The surgical light head may include an annular shape first lens that has a rotation axis, with the housing including a housing cover including a cavity within which the annular shape first lens is rotatable about the rotation axis. The housing cover may include a second lens, and the outer distance sensor assemblies may be arranged radially outwardly relative to the annular shape first lens and the second lens.

The plurality of distance sensor assemblies may be evenly spaced.

The plurality of distance sensor assemblies may be obliquely angled relative to a center line of focus of the surgical light head.

The plurality of distance sensor assemblies may be obliquely angled relative to the center line of focus by an angle that is between <NUM> and <NUM> degrees.

The plurality of distance sensor assemblies may include a single distance sensor assembly arranged proximate the center line of focus and a plurality of outer distance sensor assemblies that are radially spaced relative to the inner distance sensor assembly.

The plurality of distance sensor assemblies may include between five and ten distance sensor assemblies that are separate and spaced about the housing.

According to another aspect of the disclosure, a method of proximity detecting for a surgical light head includes arranging a plurality of light emitting elements in a housing to direct light at a target region of interest, and arranging at least two distance sensors to have field of views that overlap to define a common detection region of interest. The common detection region of interest at least partially overlaps with the target region of interest.

Arranging the at least two distance sensors may include angling the at least two distance sensors toward a center line of focus of the surgical light head.

According to another aspect of the disclosure, a method of forming a surgical light head includes arranging a plurality of light emitting elements in a housing, spacing a plurality of distance sensors along a periphery of the housing, and orienting the plurality of distance sensors to be obliquely angled toward a center line of focus of the surgical light head.

The method may include molding a housing having a plurality of tilted seats as a single monolithic component, with the plurality of tilted seats being obliquely angled toward the center line of focus, and arranging the plurality of distance sensors against the plurality of tilted seats to position the plurality of distance sensors.

The method may include communicatively coupling the housing and one of the plurality of distance sensors with a printed circuit board assembly, mounting the printed circuit board assembly to an optical component, covering the distance sensor with the optical component, with the distance sensor being configured to transmit and receive distance sensing signals through the optical component, and sealing the optical component relative to the housing.

The method may include molding locating posts with the housing as a single monolithic component and engaging the optical component with the locating posts.

The method may include using a heat staking process to secure the optical component to the housing.

The method may include defining an air gap between the distance sensor and the optical component.

The following description and the annexed drawings set forth certain illustrative embodiments of the invention. These embodiments are indicative, however, of but a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and novel features according to aspects of the invention will become apparent from the following detailed description when considered in conjunction with the drawings.

While the present invention can take many different forms, for the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. Any alterations and further modifications of the described embodiments, and any further applications of the principles of the invention as described herein, are contemplated as would normally occur to one skilled in the art to which the invention relates.

The present application is directed to a proximity detection system and method that may be suitable for use in various applications. An exemplary application includes surgical lights such as those used in operating rooms to provide increased light to a specific area of the room. For example, the proximity detection system may be implemented in a light head structure of the surgical light. Still other suitable applications include transportation applications, such as in vehicles, or more particularly, in self-driving vehicles, and home automation applications. For example, the proximity detection system described herein may be used for motion sensing in a room of a home.

The proximity detection system and method according to the present application includes an arrangement of distance sensors, such as infrared distance sensors, to determine blockage of light from a main light source, such that the system can adjust the light being emitted to ensure that a target of illumination is adequately illuminated. In an exemplary application, blockage may be caused by the head of a medical personnel in an operating room or other medical equipment. The arrangement of distance sensors includes at least two distance sensors that have a spaced relationship and are configured to have overlapping field-of-views (FOVs) that define a common detection region of interest. The common detection region of interest at least partially overlaps with a target region of interest that is illuminated by the light source.

Each of the distance sensors may have a tilted orientation. For example, in a surgical light head, the distance sensor may be tilted relative to a center line of focus of the light head rather than facing in a straight downward direction, i.e. in a direction parallel to the center line of focus, such as in conventional light heads in which the FOVs of the sensors are non-overlapping and thus susceptible to blockage that impedes accurate distance measurements. In an exemplary embodiment, the housing cover may be formed to have an integral tilted seat for supporting the distance sensor in the tilted orientation such that the precise positioning of the distance sensors is accommodated by the shape of the light head itself. In an exemplary embodiment, the distance sensors may also be integrated into the light head using optical components that are sealed relative to the light head.

Using the proximity detection system and method described herein is advantageous in that the system is configured for aiming each distance sensor at a light focal point to ensure the measured distance represents the distance to the target of illumination. Arranging the distance sensors to be separated and in spaced locations along the light head, such as along the periphery of the light head, ensures that the detected distance to the target is not sensitive to blockage of one or several sensors due to the arrangement of all of the sensors. Integrating the distance sensors into the light head is further advantageous in providing ingress protection for the light head without sacrificing accuracy of the distance sensors.

<FIG> and <FIG> show an exemplary medical device support system <NUM> in which the proximity detection system may be implemented. The medical device support system <NUM> includes two light heads <NUM> in accordance with an embodiment of the invention. As shown in <FIG>, each light head <NUM> of the system <NUM> includes a housing base <NUM> and a housing cover <NUM> that together define an overall form and structure of the light head <NUM>. Each light head <NUM> includes an annular shape outer portion <NUM>, an inner round portion <NUM>, and a radially protruding arm <NUM> that connects the annular shape outer portion <NUM> to the inner round portion <NUM>. The housing base <NUM> and the housing cover <NUM> may be formed of metal, thermoplastic, or thermoset materials, or combinations of these materials. Other materials may be suitable.

The light head <NUM> may be configured to be repositioned using a load balancing arm and yoke assembly. In an exemplary embodiment, a bushing or other coupling member <NUM> is provided on each light head <NUM> for rotatably connecting the respective light head <NUM> to a distal arm <NUM> of a yoke assembly <NUM>. The yoke assembly <NUM> is arranged on a distal end of a load balancing arm <NUM> and is configured to support the respective light head <NUM> for multi-axis movement relative to the load balancing arm <NUM>. The medical device support system <NUM> may include two load balancing arms <NUM>, one for each light head <NUM>, and each load balancing arm <NUM> may be pivotably mounted to a distal end of an extension arm <NUM>. The extension arm <NUM> is mounted to a central shaft or support column <NUM> that is suspended from the ceiling, or mounted to a wall or stand. The extension arm <NUM> is configured for rotational movement about the shaft <NUM>. Using the load balancing arms <NUM> and the yoke assemblies <NUM> is advantageous in enabling positioning of the light heads <NUM> to a proper orientation relative to, for example, a patient operating table and healthcare professionals in the operating room.

Referring in addition to <FIG>, the housing cover <NUM> includes a housing lens <NUM> and each light head <NUM> further includes an annular shape lens <NUM>, a plurality of light emitting elements <NUM>, and a motion transfer member <NUM>. The housing lens <NUM> and the annular shape lens <NUM> are arranged in a light emitting path LP of the plurality of light emitting elements <NUM>. The motion transfer member <NUM> may include a lever, gear arrangement, or articulating assembly and is configured to movably interact with a boss <NUM> of the annular shape lens <NUM> to rotate the annular shape lens <NUM> about a rotational axis R within an interior cavity <NUM> of the housing cover <NUM>.

As shown in <FIG>, a driving source <NUM>, such as a handle of the light head <NUM> may be movably coupled with the motion transfer member <NUM>, such that motion from the driving source <NUM> translates into rotation of the annular shape lens <NUM> about the rotational axis R. For example, the annular shape lens <NUM> may be rotated to adjust the distribution of light from the light head <NUM>. As shown in <FIG>, movement of the driving source <NUM> is transferred to the annular shape lens <NUM> via a lever <NUM> and a motion transfer assembly <NUM>. The motion occurs within a low overall height structure which is advantageous for maneuverability of the light head <NUM> and enabling a structure that has improved laminar flow conditions.

As shown in <FIG>, an inside surface <NUM> of the housing base <NUM> supports the plurality of light emitting elements <NUM>, which may be for example light emitting diodes (LEDs) or any other suitable light source. In the illustrative embodiment, a plurality of collimators <NUM> are also mounted to the inside surface <NUM> of the housing base <NUM> and in the light emitting paths LP of the respective plurality of light emitting elements <NUM>. The collimators <NUM> collect and direct, and/or collimate, the light into narrow beams. In one form, the collimators <NUM> may comprise total internal reflection (TIR) lenses. The light emitting elements <NUM>, the collimators <NUM>, the annular shape lens <NUM>, and the housing lens <NUM> may have an axial arrangement where axial refers to the direction of emission of light from the light heads <NUM>, or downward in <FIG>.

Referring in addition to <FIG>, the light emitting elements <NUM> and the collimators <NUM> may be grouped together in modules <NUM>, <NUM>. The modules <NUM>, <NUM> may be mounted to the inside surface <NUM> of the housing base <NUM>. Some of the modules <NUM> may be arc shape and mounted to the inside surface <NUM> of an annular shape outer base portion <NUM> of the housing base <NUM> that corresponds to the annular shape outer portion <NUM> of the light head <NUM>. One round module <NUM> may be mounted to the inside surface <NUM> of an inner round base portion <NUM> of the housing base <NUM> that corresponds to the inner round portion <NUM> of the light head <NUM>.

In the illustrative embodiment, five arc shape modules <NUM> are mounted to the inside surface <NUM> of the annular shape outer base portion <NUM> and one round module <NUM> is mounted to the inside surface <NUM> of the inner round base portion <NUM>. Each of the five arc shape modules <NUM> may have six light emitting elements <NUM> (shown in <FIG>) and collimators <NUM>, and the round inner module <NUM> may have <NUM> light emitting elements <NUM> and collimators <NUM>. The light emitting elements <NUM> and the collimators <NUM> in the five arc shape modules <NUM> may be evenly distributed about the annular shape outer base portion <NUM>. The round inner module <NUM> may include an outer ring of nine light emitting elements <NUM> and collimators <NUM> and a triangle of three within the outer ring. Any suitable fasteners, risers, and bosses may be used to secure the modules <NUM>, <NUM> to the inside surface <NUM> of the housing base <NUM>.

Further details of an exemplary surgical light system suitable for the present application are described in <CIT>, and titled "Lighthead with Rotating Lens Assembly and Method of Operating Same".

Referring in addition to <FIG>, each light head <NUM> is communicatively coupled with a control system <NUM> which includes control elements integrated into the light head housing, handle, or support structure. The control system <NUM> may include a main processor 66a including any suitable microprocessor, control processing unit (CPU), control circuitry, or the like. A controller 66b may be communicatively coupled between the processor 66a and components in the light head <NUM> for adjusting the components based on instructions received from the processor 66a. For example, the controller 66b may be configured to adjust an intensity of the light emitting elements <NUM>. Further details of an exemplary surgical light with power balancing system suitable for the present application are described in <CIT>, and titled "Surgical Light Head with Beam Spreading and Adjustable Power Balancing".

A memory 66c may also be provided as part of the control system <NUM>. The memory 66c may contain stored data pertaining to operation of the light head <NUM> that is used by the processor 66a in providing instructions to the controller 66b. For example, the memory 66c may be configured to store data pertaining to a default light intensity for the light emitting elements <NUM> or a look-up table having data pertaining to position or light intensity adjustments that correspond to particular blockages. Further details of an exemplary surgical light and system for identification of illumination abnormalities and automatic compensation suitable for the present application are described in <CIT>, and titled "System and Method for Identification of Illumination Abnormalities and Automatic Compensation Therefor," which is attached herewith, and which is incorporated by reference for all purposes as if fully set forth herein.

The control system <NUM> further includes a plurality of proximity or distance sensors or detectors <NUM>, <NUM>, which may also be referred to as sensors, proximity sensors, optical transceivers, or optical emitters, that are integrated into the light head <NUM> (shown in <FIG> and <FIG>). The plurality of distance sensors <NUM>, <NUM> are in communication with the processor 66a (shown in <FIG>) and are configured to provide readings representing the distance between the distance sensors <NUM>, <NUM> and incident light on an object such as a patient, surgical equipment, or a physician's head or hand, to the processor 66a. The plurality of distance sensors <NUM>, <NUM> are arranged in the housing cover <NUM> of the light head <NUM> and are configured to detect the distance to the object, where the distance sensor <NUM>, <NUM> has within a field of view (FOV) of the distance sensor <NUM>, <NUM> a target region of interest <NUM> that is a distance D from the distance sensors <NUM>, <NUM>. The control system <NUM> is configured to control the lighting of the light head <NUM> based on at least in part the detected data received from the distance sensors <NUM>, <NUM>. In exemplary applications, the processor 66a may be configured to determine an average of all of the measurements received from the distance sensors <NUM>, <NUM>.

The target region of interest <NUM> may include a specific target, such as a patient on a surgical table. A target may be defined as an area which the user intends to illuminate by aiming the light <NUM> produced by the surgical light. The target region of interest <NUM> may be defined as the area that is illuminated by the light head <NUM> which is typically at a distance of one meter from the light head <NUM>. "Target" "region of interest," "target region", and "target region of interest," etc. may be used with reference to the same area. The target region of interest <NUM> is formed by the light emitting elements <NUM> that emit light and the lenses <NUM>, <NUM>, <NUM> that aim, redirect, spread, converge, and or focus the light. A center line of focus F of the light head <NUM> is defined by a central axis of the target region of interest <NUM> that is formed by the illumination, i.e. an axis extending through the point at which the light beam converges or focuses. The center line of focus F may be the same as or proximate the rotational axis R of the annular shape lens <NUM> (shown in <FIG>) and the center line of focus F may be directly centered in the light head <NUM> or slightly offset depending on the geometry of the light head <NUM> and the positioning and aiming of the light emitting elements <NUM> and the positioning and adjusting capabilities of the lenses <NUM>, <NUM>, <NUM>.

The distance sensors <NUM>, <NUM> may include any suitable sensor type. For example, the distance sensors <NUM>, <NUM> may use visible light, infrared light, ultrasonic waves or any other known output for measuring the distance D from the light head <NUM> to the target. In an exemplary embodiment, the distance D may be approximately one meter. Each distance sensor <NUM>, <NUM> has a field of view (FOV) <NUM> that extends outwardly from the corresponding distance sensor <NUM>, <NUM> and defines a detection region of interest <NUM> for the corresponding distance sensor <NUM>, <NUM>. The FOV <NUM> may be defined as the area that is seen when looking outwardly from the point along the light head <NUM> where the distance sensor <NUM>, <NUM> is located, whereas the detection region of interest <NUM> for the distance sensor <NUM>, <NUM> may be defined as the area from which the distance sensor makes measurements. Each distance sensor <NUM>, <NUM> may be oriented such that the corresponding detection region of interest <NUM> is aimed at the focal point of the light emitted from the light head <NUM>.

While the individual surgical light beams are converging, the FOV <NUM> of each distance sensor <NUM>, <NUM> is increasing. Each distance sensor <NUM>, <NUM> is oriented at an oblique angle relative to the center line of focus F such that each FOV <NUM> is slanted or tilted relative to the center line of focus F. The FOV <NUM> of each distance sensor <NUM>, <NUM> may define a cone of sensitivity or a frustoconical shape that is radially increasing starting from where the corresponding distance sensor <NUM>, <NUM> is mounted to the light head <NUM>. The frustoconical shape may define a central axis C<NUM>, C<NUM> and have an opening angle A that is between <NUM> and <NUM> degrees. The opening angle A may be approximately <NUM> degrees. Each FOV <NUM> may have the same opening angle or a different opening angle.

The distance sensors <NUM>, <NUM> have slanted or tilted orientation such that the FOVs <NUM> of at least two of the distance sensors <NUM>, <NUM> overlap at the detection region of interest <NUM> to define a common FOV area and thus a common detection region of interest <NUM>. The common detection region of interest <NUM> of the distance sensors <NUM>, <NUM> at least partially overlaps with the target region of interest <NUM>. The distance sensors <NUM>, <NUM> may include at least one inner distance sensor <NUM> that is arranged proximate the center line of focus F and a plurality of outer distance sensors <NUM> that are radially spaced relative to the inner distance sensor <NUM>. The plurality of distance sensors <NUM>, <NUM> may be obliquely angled relative to the center line of focus F. In an exemplary embodiment, an angle B<NUM> between the central axis C<NUM> of the FOV <NUM> of the outer distance sensor <NUM> and the center line of focus F may be between <NUM> and <NUM> degrees. In the illustrative embodiment, the angle B<NUM> is approximately <NUM> degrees. The other outer distance sensors <NUM> may have the same angle B<NUM> or different angles. The angle B<NUM> between the central axis C<NUM> of the FOV <NUM> of the inner distance sensor <NUM> and the center line of focus F may be less than the angle B<NUM>, such as between <NUM> degrees and <NUM> degrees. In the illustrative embodiment, the angle B<NUM> is approximately three degrees. Accordingly, the FOV <NUM> of the inner distance sensor <NUM> extends more nearly parallel relative to the center line of focus F as compared with the FOV <NUM> of the outer distance sensor <NUM>.

As shown in <FIG>, the plurality of distance sensors <NUM>, <NUM> may include only a single inner distance sensor <NUM> and a plurality of outer distance sensors <NUM> that are spaced radially outwardly relative to the single distance sensor <NUM>. The distance sensors <NUM>, <NUM> may be integrated into the housing cover <NUM> (shown in <FIG>). The plurality of outer distance sensors <NUM> are arranged along a periphery, in the illustrative embodiment a circumference, of the housing cover <NUM> in a spaced relationship relative to each other such that all of the distance sensors <NUM>, <NUM> are spaced and separated relative to each other. The single inner distance sensor <NUM> may be arranged radially offset relative to the center line of focus F. The plurality of outer distance sensors <NUM> may be radially spaced from the center line of focus F by a same distance, and spaced relative to each other by a same distance. The outer distance sensors <NUM> may be arranged radially outwardly relative to the light emitting elements <NUM> and the collimators <NUM> when the housing cover <NUM> is engaged with the housing base <NUM>. Further, the outer distance sensors <NUM> may be arranged radially outwardly relative to the housing lens <NUM> and the annular shape lens <NUM>.

Any number of distance sensors <NUM>, <NUM> may be used. Between five and ten distance sensors <NUM>, <NUM> may be used. The distance sensors <NUM>, <NUM> may be separate and spaced about the housing <NUM>, <NUM>. For example, as shown in <FIG>, six distance sensors <NUM>, <NUM> may be used including five outer distance sensors <NUM> that are evenly spaced by approximately <NUM> degrees. Using six distance sensors <NUM>, <NUM> is advantageous in that blockage of between one and three detectors, for example by a surgeon's body or surgical tools, does not adversely impact the readings of the remaining detectors. For example, the processor 66a may use a voting algorithm that ignores the blocked detection measurement and the resulting averaged distance is unaffected. Other arrangements of the distance sensors <NUM>, <NUM> may be suitable. For example, the distance sensors <NUM> may have a non-uniform or uneven distribution about the housing cover <NUM> of the light head <NUM>.

<FIG> show a detection region pattern 80a, 80b, 80c provided by the arrangement of the distance sensors <NUM>, <NUM> of <FIG> relative to a surgical table <NUM>. <FIG> shows the detection region pattern 80a when the distance sensors <NUM>, <NUM> are oriented such that the distance D between the distance sensors <NUM>, <NUM> and the target is approximately one meter. The light head <NUM> is configured to provide the converging light that defines the target region of interest <NUM> for illumination and each distance sensor <NUM>, <NUM> is configured to have a corresponding detection region of interest <NUM>, as defined by the FOV <NUM> (shown in <FIG>), that overlaps with the target region of interest <NUM> of illumination. More than two detection regions of interest <NUM> may overlap with each other and the detection region of interest <NUM> (shown as 75a in <FIG>) of the single inner distance sensor <NUM> arranged proximate the center line of focus F may overlap with all of the detection regions of interest <NUM> of the outer distance sensors <NUM>.

<FIG> shows the detection region pattern 80b when the distance sensors <NUM>, <NUM> are arranged at a distance D that is less than one meter relative to the target. As shown in <FIG>, the region of interest 75a of the single inner distance sensor <NUM> still overlaps with each of the detection regions of interest <NUM> of the outer distance sensors <NUM> such that the target region of interest <NUM> is overlapped by at least two detection regions of interest <NUM>, 75a. <FIG> shows the detection region pattern 80c when the distance sensors <NUM>, <NUM> are arranged at a distance D that is greater than one meter relative to the target. <FIG> shows the regions of interest <NUM>, 75a overlapping with the target region of interest <NUM>.

As shown in <FIG>, the target region of interest <NUM> and the detection regions of interest <NUM> may have different shapes and the shapes may be dependent on the distance D between the light head <NUM> and the target. For example, the target region of interest <NUM> for illumination may be circular and the detection regions of interest <NUM> for the distance sensors <NUM>, <NUM>, as defined by the FOVs, may be elliptical as illustrated or oval or circular in shape. The detection region of interest <NUM> (shown as 75a in <FIG>) for the inner distance sensor <NUM> may be circular as illustrated or elliptical or oval in shape. The distance sensors <NUM>, <NUM> may be oriented such that the detection regions of interest <NUM> converge at approximately one meter from the light head (for example perpendicularly downward in <FIG>), such that all the regions maximally overlap at the region of interest <NUM>, for example, at a one meter distance. Other patterns may be provided and the patterns may be altered by altering the orientation and spacing of the distance sensors <NUM>, <NUM>. In exemplary embodiments, the distance sensors <NUM>, <NUM> may be co-located with, or located proximate to the modules <NUM>, <NUM> of the light emitting elements <NUM> at predetermined locations along the periphery of the housing cover <NUM> to further ensure maximum overlap and that readings are received from the target. The distance sensors <NUM>, <NUM> may be located in the middle of the modules <NUM>, <NUM>. For example, as illustrated, the distance sensor <NUM> may be arranged between two sets of three light emitting elements <NUM>. Arranging the distance sensors <NUM>, <NUM> proximate the modules <NUM>, <NUM> enables control of the modules <NUM>, <NUM> in a one to one ratio with the detected blockage.

Referring now to <FIG>, each distance sensor may be integrated into the housing cover <NUM> of the light head via support features that are integrally formed in the housing cover <NUM>. In an exemplary embodiment of the housing cover <NUM>, the housing cover <NUM> may be formed as a single monolithic component and include an annular shape outer cover <NUM> and an inner round cover <NUM> that are connected by an arm cover <NUM> extending radially therebetween. The radially extending arm cover <NUM> may also arrange the annular shape outer cover <NUM> and the inner round cover <NUM> in concentric relation to one another, and/or in concentric relation to the rotational axis R of the annular shape lens <NUM> (shown in <FIG>). The housing cover <NUM> defines the interior cavity <NUM> which has three interconnected portions corresponding to the annular shape outer cover <NUM>, the inner round cover <NUM>, and the arm cover <NUM> extending radially therebetween.

The housing cover <NUM> also includes the housing lens <NUM> which includes an annular shape outer lens <NUM> and an inner round lens <NUM>. The annular shape outer lens <NUM> forms a bottom surface of the annular shape outer cover <NUM> and the inner round lens <NUM> forms a bottom surface of the inner round cover <NUM>. In an alternate form, the bottom wall of the annular shape outer cover <NUM> and/or the inner round cover <NUM> may be formed by a transparent non-lens material, i.e. a non-light bending material, and the annular shape outer lens <NUM> and/or the inner round lens <NUM> may be positioned, for example, above the transparent non-lens bottom walls and secured to surrounding structure of the housing cover <NUM>.

The annular shape outer lens <NUM> and the inner round lens <NUM> are arranged in the light emitting paths LP of the plurality of light emitting elements <NUM> (shown in <FIG>). The annular shape lens <NUM> (shown in <FIG>) is positioned between the annular shape outer lens <NUM> and the light emitting elements <NUM> in the light emitting path LP. The collimators <NUM> (shown in <FIG>) are also arranged in the light emitting paths LP of the plurality of light emitting elements <NUM> in the annular shape outer portion <NUM> (shown in <FIG>) of the light head <NUM> positioned between the light emitting elements <NUM> and the annular shape lens <NUM>, and in the inner round portion of the light head <NUM> positioned between the light emitting elements <NUM> and the inner round lens <NUM>. The annular shape lens <NUM> and the housing lens <NUM>, and the collimators <NUM> if provided, can take on any form for spreading and/or bending the light emitted by the light emitting elements <NUM>.

The distance sensors <NUM>, <NUM> operate in conjunction with the light emitting elements <NUM> and lenses <NUM>, <NUM>, <NUM> and are integrated into the housing cover <NUM> via tilted seats <NUM>, <NUM> that are slanted or tilted and formed in the housing cover <NUM>. The tilted seats <NUM>, <NUM> are configured to support the distance sensors <NUM>, <NUM> (shown in <FIG>) and position the distance sensors <NUM>, <NUM> relative to the light emitting elements <NUM> and lenses <NUM>, <NUM>, <NUM>. The distance sensors <NUM>, <NUM> may be obliquely angled toward the center line of focus F when seated in the tilted seats <NUM>, <NUM>, whereby at least two of the distance sensors <NUM>, <NUM> have field of views that overlap to define the common detection region of interest <NUM>. The tilted seats <NUM>, <NUM> may be formed by a planar surface that defines a through-going aperture <NUM>, such that a corresponding distance sensor <NUM>, <NUM> is engageable against the planar surface and faces outwardly through the aperture <NUM> for performing detection. The apertures <NUM> of the tilted seats <NUM>, <NUM> may have any suitable shape and the shape may correspond to a shape of the distance sensor. For example, the apertures <NUM> may be circular, elliptical, or oval in shape.

The tilted seats <NUM>, <NUM> are formed to be slanted or tilted relative to the center line of focus F of the light head <NUM> (shown in <FIG>), which may also be the center of the annular shape lens <NUM>. The outer tilted seats <NUM> may be arranged radially outwardly relative to the rotatable annular shape lens <NUM> and the housing cover annular shape outer lens <NUM>. The tilted seats <NUM>, <NUM> are tilted such that when the distance sensors <NUM>, <NUM> are seated against or in contacting engagement with the tilted seats <NUM>, <NUM>, the distance sensors <NUM>, <NUM> provide the desired overlapping FOVs <NUM> (shown in <FIG>). Each tilted seat <NUM>, <NUM> may be tilted radially inwardly toward the center line of focus F, for example, to be obliquely angled toward the center line of focus F. The tilted seats <NUM>, <NUM> may be obliquely angled relative to the center line of focus F by an angle that is between <NUM> and <NUM> degrees, for example. The pattern and number of tilted seats <NUM>, <NUM> corresponds to the pattern and number of distance sensors <NUM>, <NUM>. For example, one tilted inner seat <NUM> may be arranged proximate the center line of focus F for receiving the inner distance sensor <NUM> and a plurality of tilted outer seats <NUM> may be arranged to receive the plurality of outer distance sensors <NUM>. The tilted outer seats <NUM> may be equally spaced along the periphery of the housing cover <NUM>, and the tilted outer seats <NUM> may be radially spaced from the inner seat <NUM>. In exemplary embodiments, more tilted seats <NUM>, <NUM> may be provided than distance sensors <NUM>, <NUM> to provide flexibility in patterns and/or locations of the distance sensors <NUM>, <NUM>. Any empty seats <NUM>, <NUM> may be plugged to prevent contaminants from entering the housing of the light head <NUM>. The tilted seats <NUM>, <NUM> may be defined within a recessed portion <NUM> of the housing cover <NUM> that is recessed relative to an outer peripheral surface <NUM> formed in the housing cover <NUM>. Accordingly, the distance sensor <NUM>, <NUM> is accommodated against the tilted seat <NUM>, <NUM> within the recessed portion <NUM> without interfering with other components in the housing cover <NUM>.

The housing cover <NUM> may further include threaded openings <NUM> that are formed in bosses <NUM> of the housing cover <NUM>. The bosses <NUM> are circumferentially arranged and spaced and are configured to receive fasteners for connecting the housing base <NUM> and the housing cover <NUM> (shown in <FIG>). A plurality of the bosses <NUM> are formed on the outer peripheral surface <NUM> in the annular shape outer cover <NUM> of the housing cover <NUM>. Some of the bosses <NUM> may be formed adjacent the recessed portions <NUM> and the tilted seats <NUM>, <NUM>. Both the tilted seats <NUM>, <NUM> and the bosses <NUM> may be molded or formed integrally with the housing cover <NUM> as a single monolithic component.

<FIG> and <FIG> show further details of the tilted seats <NUM>, <NUM> formed in the housing cover <NUM> with the distance sensors <NUM>, <NUM> being seated in the tilted seats <NUM>, <NUM>. <FIG> is a cross-sectional view of the light head <NUM> shown in <FIG> as cut along line A-A. The bottom of the recessed portions <NUM> that define the tilted seats <NUM>, <NUM> are formed by the bottom surfaces of the housing cover <NUM>. The annular shape outer lens <NUM> forms a bottom wall <NUM> of the annular shape outer cover <NUM> and the inner round lens <NUM> forms a bottom wall <NUM> of the inner round cover <NUM>. The bottom walls <NUM>, <NUM> define the tilted seats <NUM>, <NUM> and their respective apertures <NUM>. As shown in <FIG>, the tilted seats <NUM>, <NUM> may be positioned below the annular shape lens <NUM> which, in turn, is positioned below the collimators <NUM> and the light emitting elements <NUM> supported by the housing base <NUM>. The annular shape lens <NUM> is positioned between the collimators <NUM> and the bottom wall <NUM> in which the tilted seat <NUM> is formed. As also shown in <FIG>, the annular shape lens <NUM> may have a top surface that is formed as a stepped surface that bends individual portions of the light beams. For example, the annular shape lens <NUM> may have a plurality of Fresnel wedges.

With further reference to <FIG>, the tilted outer seats <NUM> are formed at a radially outer portion of the bottom wall <NUM>. The bottom wall <NUM> is continuous with a side wall <NUM> of the housing cover <NUM> that extends upright relative to the bottom wall <NUM> for engagement with the housing base <NUM>. The tilted seat <NUM> is arranged proximate a curved wall <NUM> connecting the bottom wall <NUM> and the side wall <NUM>. The bottom wall <NUM> and the side wall <NUM> may each be formed to have a non-uniform contour. For example, as shown in <FIG>, the bottom wall <NUM> may be formed to have a bottom surface <NUM> that extends radially outwardly and upwardly toward the tilted seat <NUM> to define a radially inner edge <NUM> of the tilted seat <NUM>. The curved wall <NUM> may curve radially inwardly and upwardly toward the tilted seat <NUM> to define a radially outer edge <NUM> of the tilted seat <NUM> that is lower relative to the radially inner edge <NUM>, but parallel with the radially inner edge <NUM>, thus forming the angle of the seat <NUM> for the distance sensor <NUM>. The inner and outer edges <NUM>, <NUM> are also shown in <FIG> and are formed in the recessed portion <NUM>.

The radially inner and outer edges <NUM>, <NUM> of the tilted seat <NUM> define the aperture <NUM> that receives the distance sensor <NUM> such that the distance sensor <NUM> includes an engaging surface that engages the perimeter of the aperture <NUM>. The aperture <NUM> may be formed to have a dimension suitable to receive different types of distance sensors. The tilted seat <NUM> is formed to define a seating plane S which is defined as a plane within which the detecting face of the distance sensor <NUM> extends or the plane along which the distance sensor <NUM> contacts the tilted seat <NUM>. The seating plane S is normal to the central axis C<NUM> of the distance sensor <NUM> (as also shown in <FIG>).

The seating plane S is tilted by an oblique angle E relative to a plane P in which the light head <NUM> extends, with the plane P being normal to the center line of focus F of the light head <NUM>. The angle E may be between <NUM> and <NUM> degrees, and in exemplary embodiments, the angle E may be approximately <NUM> degrees. Many different angles are suitable. When the distance sensor <NUM> is seated, meaning that the body of the distance sensor <NUM> rests against the tilted seat <NUM>, the distance sensor <NUM> is angled radially inwardly to ensure that the detection region of interest of the distance sensor <NUM> overlaps with the target region of interest (shown in <FIG>).

Each tilted seat <NUM> corresponding to the outer distance sensors <NUM> may have the same shape and may be angled radially inwardly at a same angle relative to the plane P of the light head <NUM> and the center line of focus F. In other exemplary embodiments, the tilted seats <NUM> may be formed to have different angles such that each outer distance sensor <NUM> is oriented differently. The tilted seat <NUM> corresponding to the inner distance sensor <NUM> may be formed to have an angle G relative to the plane P that is smaller than the angle E between the seating plane S of the tilted seat <NUM> and the plane P. The angle G of the tilted seat <NUM> may be less than <NUM> degrees such that the inner distance sensor <NUM> is arranged more nearly parallel with the plane P of the light head <NUM> as compared with the outer distance sensor <NUM>.

The bottom wall <NUM> of the inner round cover <NUM> is formed to define a bottom surface of the tilted seat <NUM> that receives the inner distance sensor <NUM>. The bottom wall <NUM> may have a planar bottom surface <NUM>. The angle of the tilted seat <NUM> may be formed by a tilted surface formed in the recessed portion <NUM> (shown in <FIG>) against which the distance sensor <NUM> is seated.

The tilted seats <NUM>, <NUM> may be formed to have many different angles and position the distance sensors <NUM>, <NUM> in different orientations. Forming the tilted seats <NUM>, <NUM> with the housing cover <NUM> as a monolithic component is advantageous in that the positioning of the distance sensors <NUM>, <NUM> is ensured in forming the housing cover <NUM> and the light head <NUM> is formed to arrange and aim the distance sensors <NUM>, <NUM> without impeding the emitted light. In other exemplary embodiments, the distance sensors <NUM>, <NUM> may be mounted and angled by brackets or other separate attachment mechanisms, including clamps, pins, screws, bolts, adhesives, or any other suitable device. Thus, the housing cover <NUM> may be formed without the tilted seats <NUM>, <NUM>.

Referring now to <FIG>, each distance sensor <NUM>, <NUM> may be arranged in a distance sensor assembly <NUM> such that any distance sensor <NUM>, <NUM> previously shown may be a distance sensor assembly <NUM>. For example, the light head may include six distance sensor assemblies <NUM> in place of the distance sensors <NUM>, <NUM> shown in <FIG>. <FIG> show exploded views of the distance sensor assembly <NUM>, <FIG> show the distance sensor assembly <NUM> as assembled, <FIG> shows a front view of the distance sensor assembly <NUM>, and <FIG> shows a cross-sectional view of the distance sensor assembly <NUM> as cut along line B-B in <FIG>. The distance sensor assembly <NUM> is configured to be implemented in the light head <NUM> (shown in <FIG> and <FIG>) and may be configured to be obliquely angled relative to the center line of focus F and obliquely angled relative to the plane P in which the light head <NUM> extends as previously described (shown in <FIG>). A plurality of distance sensor assemblies <NUM> may correspond to a same number of tilted seats <NUM>, <NUM>. Each distance sensor assembly <NUM> is arranged in a corresponding tilted seat <NUM>, <NUM>, or, in other embodiments, separately mounted to the light head.

The distance sensor assembly <NUM> includes a printed circuit board assembly (PCBA) <NUM> that has an electrical interface <NUM>, such as a plug, the distance sensor <NUM>, <NUM>, and associated electronics <NUM>. The electrical interface <NUM> is disposed on a first surface <NUM> of the PCBA <NUM> and extends outwardly from the first surface <NUM>. The distance sensor <NUM>, <NUM> is disposed on a second surface <NUM> of the PCBA <NUM> that opposes the first surface <NUM>. The electrical interface <NUM> is configured to provide power and communication to the distance sensor <NUM>, <NUM> from a power source and communication line of the medical device support system <NUM> (shown in <FIG>). In an exemplary embodiment, the distance sensor <NUM>, <NUM> may be an infrared distance sensor, but other sensors may be suitable.

The distance sensor assembly <NUM> may further include an optical component <NUM> that is configured for aiming, orienting, and protecting the distance sensor <NUM>, <NUM>. The optical component <NUM> may be configured to be matingly engageable against a corresponding one of the tilted seats <NUM>, <NUM> and coupled to the printed circuit board assembly <NUM>. The optical component <NUM> may be arranged to cover the distance sensor <NUM>, <NUM> adjacent the second surface <NUM> of the PCBA <NUM> and is also configured to be sealed relative to the light head housing, such as the housing cover. As best shown in <FIG>, a complementary recess <NUM> may be formed in the optical component <NUM> to receive and support the distance sensor <NUM>, <NUM>. As described in greater detail below, the distance sensor <NUM>, <NUM> of the distance sensor assembly <NUM> may be configured to transmit and receive distance sensing signals through the optical component <NUM>. The optical component <NUM> may be configured to enable passage of infrared light and block visible light. In other embodiments, the optical component <NUM> may enable passage and/or blockage of other electromagnetic or ultrasonic waves.

In addition to filtering out undesired light, such as visible light that may interfere with the detection capabilities of the distance sensor <NUM>, <NUM>, the optical component <NUM> is also advantageous in providing ingress protection for the housing cover <NUM> by preventing contaminants from entering into the housing cover <NUM>. The optical component <NUM> may be sealed relative to the light head <NUM>, such as relative to the housing cover <NUM> (shown in <FIG>), by any suitable adhesive layer <NUM>. The adhesive layer <NUM> may be disposed between the optical component <NUM> and the housing <NUM>, <NUM>. For example, the adhesive layer <NUM> may be disposed between the optical component <NUM> and a corresponding one of the tilted seats <NUM>, <NUM>. Thus, the adhesive layer <NUM> provides an interface between the distance sensor assembly <NUM> and the housing cover <NUM>. The adhesive layer <NUM> may be formed as a thin tape material and may have a thickness that is less than a thickness of the optical component <NUM>. An acrylic adhesive material may be suitable. Double-sided foam tapes formed of acrylic adhesive material may be suitable. Still other adhesives may be suitable.

An opening <NUM> is formed in the adhesive layer <NUM> to enable the optical component <NUM> to protrude through the adhesive layer <NUM>. In an exemplary embodiment, a protruding portion <NUM> of the optical component <NUM> may have a shape that is complimentary to the aperture <NUM> formed by the corresponding tilted seat <NUM>, <NUM> (shown in <FIG>) such that the optical component <NUM> is configured for matingly engaging with a perimeter of the aperture <NUM>. In some embodiments, the mating engagement between the optical component <NUM> and the perimeter of the aperture <NUM> may itself seal the aperture <NUM> and provide ingress protection, in addition to or as an alternative to the sealing provided by the adhesive layer <NUM>. The protruding portion <NUM> of the optical component <NUM> may be oval in shape as shown, or other shapes.

The adhesive layer <NUM> may have a shape that is complimentary to the shape of the optical component <NUM>. Each of the adhesive layer <NUM> and the optical component <NUM> may be elongated such that the elongate outer ends of the components engage the housing cover <NUM> and the portion in between, or inner portion, supports the distance sensor <NUM>, <NUM>. In an exemplary embodiment, the optical component <NUM> and the adhesive layer <NUM> may both be oval in shape and have a common outer perimeter. Opposite end portions <NUM>, <NUM> of the adhesive layer <NUM> are engageable against the housing cover <NUM> such that the adhesive layer <NUM> provides the sealing engagement between the housing cover <NUM> and the distance sensor assembly <NUM> when the distance sensor assembly <NUM> is seated in a corresponding tilted seat. For example, the adhesive layer <NUM> may engage against the surface defining the recessed portion <NUM> of the housing cover <NUM> (shown in <FIG>).

Referring to <FIG>, another adhesive material <NUM> may be provided between the PCBA <NUM> and the optical component <NUM>, such as between a PCBA-facing surface <NUM> of the optical component <NUM> and the second surface <NUM> of the PCBA <NUM>. The adhesive material <NUM> may be a cyanoacrylate material or other acrylate material. Other adhesive materials may be suitable.

As shown in <FIG>, when the distance sensor assembly <NUM> is assembled, an air gap <NUM> may be defined between the distance sensor <NUM>, <NUM> and the optical component <NUM>. The air gap <NUM> enables calibration of the distance sensor <NUM>, <NUM> according to manufacturer specifications. Providing the air gap <NUM> is also advantageous in providing a clearance for mounting the optical component <NUM> with the PCBA <NUM> and over the distance sensor <NUM>, <NUM> to enclose the distance sensor <NUM>, <NUM>.

In other exemplary embodiments, the distance sensor <NUM>, <NUM> may be positioned behind the housing cover without the optical component. In still other embodiments, the optical component may be integrally formed with the housing cover as a single monolithic component. The optical component <NUM> may be integrally formed with the housing base or the housing cover. Other arrangements of the optical component may also be suitable. For example, the optical component may be co-located or located proximate the light-emitting element.

Referring in addition to <FIG> and <FIG>, the distance sensor assembly <NUM> may be mounted to the housing cover <NUM> using features formed integrally with the housing cover <NUM>, separate attachment mechanisms, or a combination thereof. The bottom wall <NUM> of the annular shape outer cover <NUM> may be formed to have a plurality of locating posts <NUM>, <NUM> that protrude from the housing cover <NUM> to support the distance sensor assembly <NUM>. The locating posts <NUM>, <NUM> may be formed on the tilted seats <NUM>, <NUM> and engageable with a corresponding one of the distance sensor assemblies <NUM>. The locating posts <NUM>, <NUM> may be molded or formed integrally with the housing cover <NUM> as a single monolithic structure that extends from the tilted seat <NUM>, <NUM> of the housing cover <NUM>.

Each locating post <NUM>, <NUM> may extend upwardly from the bottom wall <NUM> into the interior cavity <NUM> of the housing cover <NUM> such that the locating posts <NUM>, <NUM> are accommodated inside the housing cover <NUM>. The interior cavity <NUM> may be formed by the side wall <NUM> and the bottom wall <NUM> of the housing cover <NUM>. The direction in which the locating posts <NUM>, <NUM> extend may be normal or obliquely angled relative to the tilted seat <NUM>, <NUM>. The locating post <NUM>, <NUM> may have any suitable shape such as a tapered and/or cylindrical shape. The locating posts <NUM>, <NUM> may be formed radially outwardly relative to the annular shape lens <NUM> such that the locating posts <NUM>, <NUM> do not interfere with a rotational path of the annular shape lens <NUM>.

Each distance sensor assembly <NUM> is formed to have a corresponding locating feature for mounting the distance sensor assembly <NUM> relative to the locating post <NUM>, <NUM> such that the locating post <NUM>, <NUM> limits axial movement of the distance sensor assembly <NUM> relative to the locating post <NUM>, <NUM>. The engaging portion may be formed as through-holes through which the locating posts <NUM>, <NUM> extend. Forming the locating posts <NUM>, <NUM> to be tapered enables the optical component <NUM> to slide down the locating post <NUM>, <NUM> thereby aligning the optical component <NUM>, and thus the distance sensor assembly <NUM>, in the x-y plane.

The locating posts <NUM>, <NUM> may protrude from a corresponding one of the tilted seats <NUM>, <NUM> and have a tapered shape that tapers in a protrusion direction away from the corresponding one of the tilted seats <NUM>, <NUM>. The locating posts <NUM>, <NUM> may be tapered radially inwardly in the protruding direction of the locating posts <NUM>, <NUM> relative to the tilted seat <NUM>. The shape of the locating posts <NUM>, <NUM> may enable the optical component <NUM> to have a rocking movement for adjusting the optical component <NUM> until the optical component <NUM> is engaged against the tilted seat <NUM>, <NUM>. When assembled, a thicker base portion <NUM> of the locating post <NUM> may limit lateral movement of the optical component <NUM>. The tilted seat <NUM> is formed as an alignment surface that captures the distance sensor assembly <NUM> in the z-direction and orients the distance sensor assembly <NUM> rotationally.

As shown in <FIG>, each end portion of the optical component <NUM> is formed with through-holes <NUM> that are configured to receive a corresponding locating post <NUM>, <NUM>. The locating posts <NUM>, <NUM> may be formed on the tilted seats <NUM>, <NUM> to be engageable with the optical component <NUM>, for example, by the locating posts <NUM>, <NUM> extending through the opposite end through-holes <NUM>. The number of apertures formed in the optical component <NUM> may correspond to the number of locating posts <NUM>, <NUM>. Two locating posts <NUM>, <NUM> may be suitable. In other embodiments, one or more than two locating posts <NUM>, <NUM> may be provided. Similarly, the adhesive layer <NUM> is formed with through-holes <NUM> that correspond to the through-holes <NUM> of the optical component <NUM> and are configured to receive the corresponding locating post <NUM>, <NUM>. Each through-hole <NUM>, <NUM> may be circular in shape or have a shape that is suitable for receiving the locating post <NUM>, <NUM>. As shown in <FIG>, the through-holes <NUM> of the adhesive layer <NUM> may be formed to have a larger diameter relative to the diameter of the through-holes <NUM> of the optical component <NUM> to provide clearance during assembly of the distance sensor assembly <NUM>.

When mounted to the light cover <NUM>, the adhesive layer <NUM> and the optical component <NUM> face or mate with the engaging surface of the tilted seat <NUM> defined by the bottom wall <NUM> of the annular shape outer cover <NUM>. As shown in <FIG>, both the adhesive layer <NUM> and the optical component <NUM> are retained via the through-holes <NUM>, <NUM> (shown in <FIG>) receiving the locating posts <NUM>, <NUM> therethrough. The PCBA <NUM> is positioned on the optical component <NUM> between the locating posts <NUM>, <NUM> and the electrical interface or plug <NUM> extends upwardly past the locating posts <NUM>, <NUM>.

As shown in <FIG>, the locating posts <NUM>, <NUM> may be formed in the recessed portion <NUM> of the housing cover <NUM> that is adjacent the boss <NUM>. The recessed portion <NUM> may be defined between sidewalls <NUM>, <NUM> of the outer peripheral surface <NUM>. The sidewalls <NUM>, <NUM> extend normal to the surface that defines the tilted seat <NUM> (shown in <FIG>). A back wall <NUM> extends axially between the sidewalls <NUM>, <NUM> and is formed to have a curvature such that the locating posts <NUM>, <NUM> and the distance sensor assembly <NUM> are fully accommodated within the recessed portion <NUM> and do not protrude past a height of the sidewalls <NUM>, <NUM>. The height of the sidewalls <NUM>, <NUM> may be formed to be lower relative to a bottom <NUM> of the boss <NUM> that includes the threaded openings <NUM> for securing the housing cover <NUM> and the housing base.

When the distance sensor assemblies <NUM> are posited relative to the housing cover <NUM> by the locating posts <NUM>, <NUM>, the locating posts <NUM>, <NUM> may undergo an ultrasonic heat staking process, whereby the locating posts <NUM>, <NUM> are deformed to form an interference fit with the distance sensor assembly <NUM>. In this regard, it will be appreciated that the heat staking of the locating posts <NUM>, <NUM> may be used as an added or alternative means to the adhesive layer <NUM> for sealing the optical component <NUM> to the housing cover <NUM>. Other securing methods and devices may be used to mount the distance sensor assembly <NUM> to the housing cover <NUM>. For example, the distance sensor assembly <NUM> may be integrated in the housing cover <NUM> via ultrasonic welding, a threaded connection, or a press-fit connection.

Any suitable manufacturing method may be used to form a light head having any of the features aforementioned. For example, processes such as injection molding, blow molding, thermoforming, transfer molding, reaction injection molding, compression molding, and extrusion, or any combination thereof may be suitable.

Referring now to <FIG>, a flowchart for a method <NUM> of proximity detecting for a surgical light head is shown. The method <NUM> may be implemented in a surgical light head, such as the surgical light head <NUM> of <FIG>. A first step <NUM> of the method <NUM> may include arranging a plurality of light emitting elements <NUM> in a housing <NUM> (shown in <FIG>) to direct light at a target region of interest <NUM> (shown in <FIG>). A step <NUM> of the method <NUM> may include arranging at least two distance sensors <NUM>, <NUM> to have field of views <NUM> that overlap to define a common detection region of interest <NUM> (shown in <FIG>). The common detection region of interest <NUM> at least partially overlaps with the target region of interest <NUM>. A step <NUM> of the method <NUM> includes arranging the at least two distance sensors <NUM>, <NUM> to be obliquely angled toward a center line of focus F of the surgical light head <NUM> (shown in <FIG>).

Referring now to <FIG>, a flowchart for a method <NUM> of forming a surgical light head, such as the surgical light head <NUM>, is shown. Step <NUM> of the method <NUM> includes molding the housing <NUM> to have a plurality of tilted seats <NUM>, <NUM> (shown in <FIG>) as a single monolithic component. Step <NUM> may include molding locating posts <NUM>, <NUM> (shown in <FIG> and <FIG>) with the housing <NUM>. Step <NUM> may include arranging the plurality of light emitting elements <NUM> in the housing <NUM> and step <NUM> of the method <NUM> includes spacing the plurality of distance sensors <NUM>, <NUM> along a periphery of the housing <NUM>. Step <NUM> of the method <NUM> includes orienting the plurality of distance sensors <NUM>, <NUM> to be obliquely angled toward the center line of focus F of the surgical light head <NUM>. Step <NUM> may include arranging the plurality of distance sensors <NUM>, <NUM> against the plurality of tilted seats <NUM>, <NUM> to position the plurality of distance sensors <NUM>, <NUM>.

Step <NUM> of the method <NUM> includes forming a distance sensor assembly <NUM> (shown in <FIG>). Step <NUM> may include communicatively coupling the housing <NUM> and one of the plurality of distance sensors <NUM>, <NUM> with a PCBA <NUM> and mounting the PCBA <NUM> to an optical component <NUM>. Mounting the PCBA <NUM> to the optical component <NUM> may include covering the distance sensor <NUM>, <NUM> with the optical component <NUM> such that the distance sensor <NUM>, <NUM> is configured to transmit and receive distance sensing signals through the optical component <NUM>. An air gap <NUM> may be defined between the distance sensor <NUM>, <NUM> and the optical component <NUM>.

The method <NUM> may further include a step <NUM> of sealing the optical component <NUM> relative to the housing <NUM>. Step <NUM> may include engaging the optical component <NUM> with the locating posts <NUM>, <NUM> to position the distance sensor assembly <NUM>. A heat staking process may be used to secure the optical component <NUM> and the locating posts <NUM>, <NUM>.

The surgical light head having any combination of the features described herein is advantageous in that the surgical light head has improved proximity detection. Forming the distance sensors to be spaced about the light head and obliquely angled toward the center line of focus ensures accuracy in the detected distance measurements, such that blockage of one sensor will not significantly impede the measurements, such as the voted output measurements, from the other sensors. Integrating the sensors into the light head via the tilted seats and/or the optical component ensures proper aiming of the distance sensors and provides ingress protection for the light head without sacrificing accuracy of the distance sensors.

Claim 1:
A surgical light head (<NUM>), comprising:
a housing (<NUM>, <NUM>);
a plurality of light emitting elements (<NUM>) arranged in the housing (<NUM>, <NUM>) and configured to direct light at a target region of interest (<NUM>); and
a plurality of sensors (<NUM>, <NUM>) arranged in the housing (<NUM>, <NUM>) wherein at least two of the sensors (<NUM>, <NUM>) have field of views that overlap to define a common detection region of interest (<NUM>), wherein the common detection region of interest (<NUM>) at least partially overlaps with the target region of interest (<NUM>)
characterised in that
the plurality of sensors are a plurality of distance sensors (<NUM>, <NUM>), wherein the distance sensors (<NUM>, <NUM>) are configured to measure a distance to an object.