Safety helmet system

Abstract

The present invention relates to a safety helmet system. A light assembly is provided that is supported by a safety helmet. In various embodiments, the light assembly includes a headlamp, a bracket configured to couple to the safety helmet and support the headlamp at a front portion of the safety helmet, a battery pack, and a mounting bracket configured to couple to the safety helmet and support the battery pack at a rear portion of the safety helmet. In particular embodiments, the headlamp includes a red light. In particular embodiments, the battery pack includes one or more red lights.

Description

Cross-referencing of related patent applications

[0001] This application claims the benefits and priority of U.S. Provisional Application No. 63 / 814,789, filed May 30, 2025, and U.S. Provisional Application No. 63 / 788,920, filed April 15, 2025, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure generally relates to the field of safety helmets. Specifically, this disclosure relates to safety helmet lighting systems. Background Technology

[0003] Safety helmets are frequently used in low-light conditions. Wearing a safety helmet in high-risk environments can provide additional protection against head injuries. Light-emitting systems can assist vision in low-light or low-visibility environments. Summary of the Invention

[0004] One embodiment of the present invention relates to a helmet system including a helmet and a light-emitting system. The helmet includes a shell, the shell including an outer surface and an inner surface defining a cavity. The helmet includes a front mounting ridge extending outward from a front portion of the outer surface of the shell and a rear mounting ridge extending outward from a rear portion of the outer surface of the shell. The light-emitting system includes a first bracket and a headlamp supported by the first bracket, the first bracket being configured to removably engage the front mounting ridge. The headlamp includes a first light-emitting element configured to emit red light forward in a first direction. The light-emitting system also includes a second bracket and a power source supported by the second bracket, the second bracket being configured to removably engage the rear mounting ridge. The power source includes a second light-emitting element configured to emit red light rearward in a second direction opposite to the first direction.

[0005] Another embodiment of the invention relates to a helmet system including a helmet. The helmet includes a shell comprising an outer surface and an inner surface. The helmet system includes a first mounting ridge extending outward from the outer surface of the shell and a second mounting ridge positioned on a portion of the shell opposite to the first mounting ridge. A second mounting member extends outward from the outer surface of the shell. The helmet system includes a headlamp supported relative to the first mounting ridge via a first mounting bracket and a battery pack supported relative to the second mounting ridge via a second mounting bracket. The headlamp includes a plurality of light-emitting elements. At least one of the plurality of light-emitting elements is configured to emit red light along a first direction. The battery pack includes a battery-powered light-emitting element configured to emit red light along a second direction opposite to the first direction.

[0006] Another embodiment of the invention relates to a helmet system including a helmet. The helmet includes a shell, the shell having an outer surface and an inner surface defining a cavity. The helmet includes a mounting ridge extending outward from the outer surface of the shell. The mounting ridge includes opposing edges projecting away from opposite sides of the mounting ridge. The helmet system includes a mounting bracket coupled to the mounting ridge and a power source supported by the mounting bracket. The mounting bracket includes opposing arms engaging between opposite edges of the shell and the mounting ridge. The power source is configured to supply power to an accessory coupled to the helmet. The power source includes a housing and a pair of light-emitting elements positioned on a rear surface of the housing, the housing having a rear surface facing away from the helmet. Each of the pair of light-emitting elements is configured to emit red light.

[0007] Additional features and advantages will be set forth in the following detailed description and will be readily understood by those skilled in the art based on the description or by practice of the embodiments as described in the written description and / or illustrated in the accompanying drawings. It should be understood that both the preceding general description and the following detailed description are exemplary.

[0008] The accompanying drawings are included to provide a further understanding and are incorporated in and form a part of this specification. The drawings illustrate one or more embodiments and, together with the description, serve to explain the principles and operation of various embodiments. Attached Figure Description

[0009] This application will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which the same reference numerals refer to the same elements:

[0010] Figure 1 This is a frontal perspective view of a safety helmet according to an exemplary embodiment.

[0011] Figure 2 According to an exemplary implementation Figure 1 A rear-view 3D view of a safety helmet.

[0012] Figure 3 This is a frontal perspective view of a light-emitting component attached to a safety helmet according to an exemplary embodiment.

[0013] Figure 4 According to an exemplary implementation Figure 3 Rear-view stereoscopic view of the light-emitting components connected to the safety helmet.

[0014] Figure 5 According to an exemplary implementation Figure 3 A 3D view of the light-emitting components connected to the safety helmet.

[0015] Figure 6 According to an exemplary implementation Figure 3 A rear-view stereoscopic view of the light-emitting components connected to the safety helmet, viewed from below.

[0016] Figure 7 According to an exemplary implementation Figure 3 Rear-view stereoscopic view of the light-emitting components connected to the safety helmet.

[0017] Figure 8 According to an exemplary implementation Figure 3 A top-down view of the light-emitting components connected to the safety helmet.

[0018] Figure 9 According to an exemplary implementation Figure 3 A downward-viewing plan view of the light-emitting components connected to the safety helmet.

[0019] Figure 10 According to an exemplary implementation Figure 3 Front view of the light-emitting component connected to the safety helmet.

[0020] Figure 11 This is a perspective view of the first part of a light-emitting component attached to a safety helmet according to an exemplary embodiment.

[0021] Figure 12 According to an exemplary implementation Figure 11 The connection to the safety helmet Figure 11 A detailed front view of the first part of the light-emitting component.

[0022] Figure 13 According to an exemplary implementation Figure 11 A three-dimensional view of the first part of the light-emitting component.

[0023] Figure 14 According to an exemplary implementation Figure 11 A three-dimensional view of the first part of the light-emitting component.

[0024] Figure 15 According to an exemplary implementation Figure 11 An exploded view of the first part of the light-emitting component.

[0025] Figure 16 This is a perspective view of the second part of a light-emitting component attached to a safety helmet according to an exemplary embodiment.

[0026] Figure 17 This is a perspective view of the second part of a light-emitting component according to an exemplary embodiment.

[0027] Figure 18 This is an exploded view of the second part of a light-emitting component according to an exemplary embodiment.

[0028] Figure 19 According to an exemplary implementation Figure 16 A detailed view of the second part of the light-emitting component.

[0029] Figure 20 This is a left-side view of the second part of a light-emitting assembly attached to a safety helmet according to an exemplary embodiment.

[0030] Figure 21 This is a right-side view of the second part of a light-emitting assembly attached to a safety helmet according to an exemplary embodiment.

[0031] Figure 22 This is a detailed view of the connector of the light-emitting component in the first, closed position according to an exemplary embodiment.

[0032] Figure 23 This is a detailed view of the connector of the light-emitting component in the second, open position according to an exemplary embodiment.

[0033] Figure 24 This is a front perspective view of a light-emitting component according to an exemplary embodiment.

[0034] Figure 25 According to an exemplary implementation Figure 24 Rear-view perspective of the light-emitting components.

[0035] Figure 26 According to an exemplary implementation Figure 24 A top view of the light-emitting components.

[0036] Figure 27 This is a perspective view of a light-emitting component attached to a safety helmet according to an exemplary embodiment, wherein a first portion of the light-emitting component is in a pivot position. Detailed Implementation

[0037] Referring generally to the accompanying drawings, various embodiments of a safety helmet illumination system are illustrated. Safety helmets, such as hard hats and protective helmets, are used in various construction work or other construction, residential, or commercial settings. Hard hats are often used in dim or poorly lit environments. In conventional lamp attachment systems, the operator attaches a lamp that emits white light to the hard hat. However, as will generally be understood, white light can be particularly difficult to see in dim or dark environments due to its brightness (e.g., it has a blinding effect, impairs night vision, etc.). In contrast, the various embodiments of the safety helmet illumination system discussed herein include a headlamp supported by a mounting bracket, wherein the headlamp emits red light for forward illumination. Therefore, the illumination of the wearer's path for the headlamp discussed herein uses red light instead of conventional white light. The applicant believes that the use of red light allows for increased protection of the wearer's night vision. In a specific embodiment, the headlamp includes a red LED as the light source.

[0038] In various embodiments, the helmet lighting system discussed herein also includes a power source, such as a battery pack supported by a bracket mounted to the helmet. In such embodiments, the headlamp is mounted on the front portion of the helmet, while the power source is mounted on the opposite rear portion of the helmet. In various embodiments, the power source includes one or more rearward-facing light-emitting elements. In a specific embodiment, the battery pack includes two light-emitting elements emitting red light. In other words, the rear light-emitting elements act as a taillight for the wearer. In a specific embodiment, the battery pack housing includes two red LEDs. The applicant believes that using a rear red light on the power source of the lighting system, as discussed herein, provides improved visibility of the user from behind in working line-of-sight and / or dimly lit environments.

[0039] In various embodiments, the helmet lighting system discussed herein includes a circuit board, such as a printed circuit board assembly (PCBA) within a headlamp. In specific embodiments, the circuit board controls at least some of the light-emitting elements in the headlamp and battery pack. In specific embodiments, a first circuit board in the headlamp controls the light-emitting elements in the headlamp, and a second circuit board in the battery pack controls the light-emitting elements in the battery pack. In specific embodiments, the circuit board controls all the light-emitting elements in the headlamp and battery pack. The applicant believes that the location of the circuit board within the headlamp provides improved weight balance for the helmet lighting system.

[0040] In various embodiments, the safety helmet lighting system discussed herein includes a quick-disconnect cable. In such embodiments, the quick-disconnect cable extends between the headlamp and the battery pack and connects the headlamp to the battery pack. In a specific embodiment, the quick-disconnect cable includes a quick-disconnect connector along the length of the cable. In such embodiments, if the cable connecting the headlamp and the battery pack becomes stuck on an object, the quick-disconnect connector will disengage, thereby turning off the headlamp and preventing further pulling on the lighting components. The applicant believes that the use of a quick-disconnect cable provides improved safety in the event of cable jamming and reduces the likelihood of damage to the cable and / or other lighting component parts.

[0041] Reference Figures 1 to 2 The image shows a perspective view of a safety helmet, illustrated as a safety helmet 10, according to an exemplary embodiment. The safety helmet 10 includes an outer shell 12. In a specific embodiment, the outer shell 12 is formed of a rigid material, such as a rigid polymer material. The outer shell 12 includes an outer surface 14 and an inner surface 16 (see, for example...). Figures 2 to 3 The inner surface 16 defines the cavity 18 (see example). Figures 5 to 6 as well as Figure 9 The cavity is 18mm in size to accommodate the head of the user and / or wearer.

[0042] The outer shell 12 includes a crown portion 22 and a bottom section 24 defining the lower circumference of the helmet 10. In various embodiments, a brim 26 extends radially outward from a portion of the lower circumference. In a specific embodiment, the brim 26 extends radially outward from the helmet 10 and specifically from the front portion 28 of the outer shell 12. The outer shell 12 also includes a plurality of openings or vents 34. The vents 34 extend through the outer shell 12 to provide fluid communication between the cavity 18 and ambient air adjacent to the outer surface 14 of the outer shell 12.

[0043] As will be discussed in more detail below, various embodiments of the helmet 10 include one or more mounting ridges configured to connect to and / or support accessories. Side accessory support ridges or auxiliary mounting ridges 36 are positioned along the bottom section 24 on the lateral side of the housing 12. The auxiliary mounting ridge 36 includes a first end and a second end opposite the first end. A plurality of openings or slots 38 are positioned along the auxiliary mounting ridge 36 between the first and second ends. The slots 38 are configured to receive a coupling mechanism, such as a clip, or part of a helmet accessory to connect the accessory to the housing 12. The auxiliary mounting ridge 36 supports accessories for the helmet 10, such as earmuffs, tool or eyeglass holders, lamp supports, face shields, and / or reflectors.

[0044] Additional side accessory support ridges or auxiliary mounting ridges 36 are positioned along the bottom section 24 on the lateral side of the housing 12. The helmet 10 also includes a first mounting ridge, shown as a front mounting ridge 20 positioned on the front 28 of the housing 12. The front mounting ridge 20 includes a first edge and a second edge, the first edge shown as a right edge 42 projecting outward from the front mounting ridge 20, and the second edge shown as a left edge 44 projecting outward from the front mounting ridge 20 opposite to the right edge 42. In a specific embodiment, the right edge 42 and the left edge 44 extend outward from opposite flat surfaces 40 positioned on each side of the front mounting ridge 20.

[0045] In a specific embodiment, the front mounting ridge 20 includes a stop 46 positioned on the outer surface 14 between the right edge 42 and the left edge 42 and configured to engage with a mounting bracket, such as mounting bracket 64 (see example...). Figure 3 (and / or accessories) engagement. In a specific embodiment, the stop 46 is centered on the front mounting ridge 20. The right edge 42 and left edge 44 of the front mounting ridge 20 each extend toward the bottom section 24 of the housing 12. The right edge 42 and left edge 44 each include a portion that increases in width as the right edge 42 and left edge 44 approach the bottom section 24 and / or the visor 26.

[0046] In various embodiments, the helmet 10 includes a second mounting ridge, shown as a rear mounting ridge 32 located at the rear 30 of the helmet 10. This allows the user to attach accessories and / or accessory mounting brackets to both the front 28 and rear 30 of the helmet 10, in addition to the lateral portion of the helmet 10 including the auxiliary mounting ridge 36. The rear mounting ridge 32 is substantially the same as the front mounting ridge 20.

[0047] The rear mounting ridge 32 includes a first edge 50 projecting outward from the rear mounting ridge 32 and a second edge 52 projecting outward from the rear mounting ridge 32 opposite to the first edge 50. In a specific embodiment, the first edge 50 and the second edge 52 extend outward from opposite flat surfaces 48 positioned on each side of the rear mounting ridge 32. In a specific embodiment, the rear mounting ridge 32 includes a stop 54 positioned on the outer surface 14 between the first edge 50 and the second edge 52 and configured to engage with a mounting bracket, such as a mounting bracket 66 (see example...). Figure 4 (and / or attachments)

[0048] Reference Figures 3 to 10Various aspects of a helmet system 8 are illustrated according to exemplary embodiments. In various embodiments, the helmet system 8 includes a helmet 10 and a light-emitting component 60. As will generally be understood, the light-emitting component 60 can be used with other safety helmets, protective caps, etc. In various embodiments, the light-emitting component 60 includes a bracket 64 supporting a light-emitting unit shown as a headlamp 62 and a mounting bracket 66 for a power source shown as a battery pack 68. The light-emitting component 60 is coupled to and supported by the helmet 10.

[0049] The bracket 64 is connected to the helmet 10, for example, via a direct connection to the front mounting spine 20. The headlamp 62 receives power from a power source, shown as a battery pack 68, via a wire 70. In other words, in various embodiments, the battery pack 68 is configured to supply power to an accessory (e.g., the headlamp 62) connected to the helmet 10. In various embodiments, the battery pack 68 includes a housing 67. In a specific embodiment, the battery pack 68 includes a lithium-USB battery. In various embodiments, the headlamp 62 is connected to the front 28 of the helmet 10, while the battery pack 68 is connected to the rear 30 of the helmet 10. As will be discussed in more detail below, the headlamp 62 is configured to provide external visibility to the wearer and also to make the wearer visible to others in the environment.

[0050] In one embodiment, battery pack 68 includes a removable and rechargeable battery for emitting light. In another embodiment, battery pack 68 includes a built-in rechargeable (non-removable) battery. In yet another embodiment, battery pack 68 includes a single-cell lithium-ion battery. In other embodiments, battery pack 68 includes multiple batteries, such as pouch cells.

[0051] In various embodiments, in addition to the light-emitting system 60, the helmet system 8 also includes accessories supported by and / or removably coupled to the helmet 10. The accessory shown as a face shield 72 is supported by one or more auxiliary mounting ridges 36. Specifically, one or more mounting clips 74 can be positioned within slots 38 of the auxiliary mounting ridges 36 such that the face shield 72 is supported by the helmet 10.

[0052] In various embodiments, the cable 70 extends circumferentially around at least a portion of the outer surface 14 of the helmet shell 12. In various embodiments, the cable 70 includes an expandable cable segment, shown as an accordion segment 86. The accordion segment 86 is configured to allow the cable 70 to extend to a greater length. The accordion segment 86 is actuated between a retracted configuration and an extended configuration and is biased towards the retracted configuration. The accordion segment 86 also keeps the cable taut when no additional length is needed to connect the headlamp 62 to the battery pack 68. The cable 70 and specifically, a plug 84, are connected to an interface of the battery pack 68. In a specific embodiment, the plug 84 has an end with a 90-degree angle that connects to the top surface 102 of the battery pack 68. With this configuration, the cable 70 remains tightly pressed against the outer surface 14 of the helmet 10 to avoid jamming and sticking.

[0053] like Figures 7 to 8 As shown, in a specific embodiment, the cable 70 is a quick-disconnect cable. As will be discussed in more detail below, in such an embodiment, the cable 70 includes a quick-disconnect connector 82 positioned along the length of the cable 70. Specifically, the connector 82 is positioned between the plug 84 and the opposite end 88 of the cable 70 connected to the headlamp 62.

[0054] Reference Figure 9 A detailed bottom view of the helmet system 8 is shown according to an exemplary embodiment. The outer shell 12 and / or auxiliary ridge 36 include a bottom edge 78 of each groove 38. The bottom edge 78 is opposite to the top edge 76 of the auxiliary ridge 36. The depth of the groove 38 is defined between the bottom edge 78 and the top edge 76. The engaging portion 80 of the mounting clip 74 abuts and / or engages the bottom edge 78 to secure an accessory such as a face shield 72 to the helmet 10.

[0055] Reference Figures 10 to 15 Details of the light-emitting component 60, and more specifically the headlamp 62 and mounting bracket 64, are shown according to an exemplary embodiment. Figures 10 to 12 As shown, the mounting bracket 64 and / or headlamp 62 can be removably attached to a safety helmet, such as helmet 10 or helmet 210. Except for the differences discussed herein, helmet 210 is substantially the same as helmet 10.

[0056] In various embodiments, the mounting bracket 64 is removably coupled to the housings 12, 212, and more specifically to the front mounting ridges 20, 220 of the helmets 10, 210. As will generally be understood, in other embodiments, the mounting bracket 64 and the headlamp 62 may be similarly mounted on different surfaces of the helmets 10, 210. The mounting bracket 64 includes a body 91 extending along its longitudinal axis or long axis. The body 91 extends between a first arm 90 and a second arm 92. The first arm 90 and the second arm 92 are configured to receive and engage a first edge (see, for example, 42) and a second edge (see, for example, 44) of the front mounting ridges 20, 220 to secure the mounting bracket 64 and / or the headlamp 62 to the helmets 10, 210.

[0057] In various embodiments, the headlamp 62 includes a housing 63. The housing 63 is defined by a front surface 106 facing away from the front mounting ridge 20 and a rear surface 120 facing the front mounting ridge. The housing 63 also includes a top surface 98. In various embodiments, the top surface 98 is opposite to the engagement portion 110. In various embodiments, the housing 63 includes a pair of opposite side surfaces 122 extending between and connecting the front surface 106 and the rear surface 120. In various embodiments, the end 88 of the wire 70 is coupled to the side surfaces 122 of the housing 63 and / or the headlamp 62. The engagement portion 110 and the top portion 112 of the bracket 64 together form a hinge. The top portion 112 of the bracket 64 defines a gap 124 configured to receive the engagement portion 110 of the headlamp 62. In other words, in various embodiments, the headlamp 62 is pivotally coupled to the mounting bracket 64 and is pivotable about a pin 126 (see example...). Figure 15 ).

[0058] The headlamp 62, and more specifically, the front surface 106, includes a lens 108. As previously described, in various embodiments, the headlamp 62 includes a light-emitting element 114 that emits red light for forward illumination. In this embodiment, the light-emitting element 114 is a red LED. Therefore, the path ahead is illuminated with red light instead of conventional white light. The applicant believes that the use of red light allows for increased protection of the wearer's night vision capabilities, thereby improving the wearer's ability to observe details (e.g., reading instructions, diagrams, etc.).

[0059] In various embodiments, the headlamp 62 includes a plurality of light-emitting elements 114, 116, and 118. In various specific embodiments, the headlamp 62 includes a second light-emitting element shown as a floodlight LED 116. As will generally be understood, the second light-emitting element 116 is a wide-angle light. In various specific embodiments, the headlamp 62 includes a third light-emitting element shown as a spotlight LED 118. As will generally be understood, the spotlight LED 118 is a narrower beam of light. In a specific embodiment, the headlamp 62 includes a floodlight element 116, a spotlight element 118, and a red-light-emitting element 114. In a specific embodiment, the floodlight element 116 and the spotlight element 118 emit white light. In a specific embodiment, the headlamp 62 includes a pair of floodlight elements 116, a pair of spotlight elements 118, and a red-light-emitting element 114. In such an embodiment, the light-emitting element 114 is positioned above the floodlight element 116 and between the floodlight element 116 and the top surface 98 of the housing 63.

[0060] Various light-emitting elements of the headlamp 62 (e.g., red light 114, floodlight 116, and / or spotlight 118) are controlled by one or more actuators 94, 96. In a specific embodiment, the headlamp 62 includes an actuator shown as a power button 94. In a specific embodiment, the power button 94 is located on the top surface 98 of the housing 63 of the headlamp 62. In various embodiments, the headlamp 62 includes a second actuator shown as a mode button 96. In such an embodiment, the mode button 96 controls which of the light-emitting elements 114, 116, 118 is activated. In a specific embodiment, the mode button 96 is located on the top surface 98 of the housing 63 of the headlamp 62. In a specific embodiment, a lens 108 protects one or more LEDs 114, 116, 118 and / or converges or diverges the emitted light.

[0061] Reference Figure 15 An exploded view of a headlamp 62 and mounting bracket 64 according to an exemplary embodiment is shown. The housing 63 of the headlamp 62 also includes a hinge hole 128 extending through the engagement portion 110 and configured to receive a pin 126. A clip, shown as a C-shaped clip 130, is configured to secure the end 88 of the wire 70 within a cord hole 129 in the side surface 122 of the housing 63.

[0062] The headlamp 62 also includes a light source housing 132. The light source housing 132 includes one or more recessed segments 134 defined in a front surface. The recessed segments 134 are configured to receive one or more light-emitting elements 114, 116, 118. A rear surface 136 of the light source housing 132 is coupled to a rear surface opposite to the recessed segments 134. In a specific embodiment, actuators 94, 96 provide input to a circuit board, shown as a printed circuit board assembly (PCBA) 140. When the headlamp 62 is assembled, the PCBA is positioned in housing 63 between the light source housing 132 and the rear surface 120. A plurality of fasteners of various sizes, shown as screws 142, are used to join the light source housing 132, support 138, PCBA 140, and / or rear surface 120 together to form the assembled headlamp 62.

[0063] Reference Figures 16 to 21 Details of the light-emitting assembly 60 according to an exemplary embodiment, and more specifically the battery pack 68 and mounting bracket 66, are shown. In various embodiments, the mounting bracket 66 is removably coupled to the housing 12, and more specifically to the rear mounting ridge 32 of the helmet 10. As will generally be understood, in other embodiments, the mounting bracket 66 and the battery pack 68 may be similarly mounted on different surfaces of the helmet 10. The mounting bracket 66 includes a body 178 extending along the longitudinal axis or long axis of the mounting bracket 66. The body 178 extends between a first end 180 and a second end 182. As will be discussed in more detail below, the first end 180 and the second end 182 are configured to engage a first edge of the rear mounting ridge 32 (see, for example...). Figure 2 50 in the middle) and the second edge (see example) Figure 2 (52) to secure the mounting bracket 66 and / or battery pack 68 to the safety helmet 10.

[0064] In various embodiments, the mounting bracket 66 includes a cam rod 150. In a specific embodiment, the mounting bracket 66 includes a first cam rod 150 and a second cam rod 152. In such an embodiment, the first cam rod 150 is positioned at a first end 180 of the mounting bracket 66 and is rotatably coupled to the mounting bracket 66. Similarly, the second cam rod 152 is positioned at a second end 182 of the mounting bracket 66 and is rotatably coupled to the mounting bracket 66. Each cam rod 150, 152 includes a body portion 160 and a rod portion 162. The rod portion 162 extends away from the body portion 160 along the longitudinal axis of the cam rods 150, 152.

[0065] When cam levers 150 and 152 are in the locked position, each lever portion 162 (see example) Figure 17The first cam rod 150 is rotatable about a first axis of rotation 154, and the second cam rod 152 is rotatable about a second axis of rotation 154. The first and second axes of rotation 154 extend outward and forward from the mounting bracket 6 (see, for example...). Figure 17 (or orientation in the context).

[0066] When the operator actuates the cam rods 150 and 152 in the first locking direction indicated by arrow 156, the cam rods 150 and 152 rotate about the rotation axis 154. As the cam rods 150 and 152 move in the locking direction 156, they move toward the body 178 of the mounting bracket 66. The rotation axis 154 extends in an orientation perpendicular to the longitudinal axis of the cam rods 150 and 152. When the cam rods 150 and 152 are in the locked position, the mounting bracket 66 clamps or compresses onto the edges 50 and 52 of the helmet 10 to securely attach the mounting bracket 66 to the rear mounting ridge 32 of the helmet 10.

[0067] Reference Figure 17 A perspective view of the mounting bracket 66 in a second unlocked position according to an exemplary embodiment is shown. When the operator actuates the cam rods 150, 152 in the second unlocking direction indicated by arrow 158, the cam rods 150, 152 rotate about the rotation axis 154. When the cam rods 150, 152 are in the unlocked position, the mounting bracket 66 is released and no longer compresses the edges 50, 52 of the safety helmet 10. When the cam rods 150, 152 are in the unlocked position, each rod portion 162 extends in a direction away from the opposite planar surface 48 located on each side of the rear mounting ridge 32 and / or away from the body 178 of the mounting bracket 66.

[0068] Mounting bracket 66 also includes a protrusion shown as a central protrusion 164 extending downward from body 178 toward bottom section 24 of helmet 10. The central protrusion 164 is configured to grip, retain, and / or engage retaining clips or stops of helmet 10 (see, for example...). Figure 2 (54). The central protrusion 164 is positioned between the cam rods 150 and 152.

[0069] The battery pack 68 housing 67 includes an outer surface 166 facing away from the mounting bracket 66, a first side surface 148, and a second side surface 170. The housing 67 also includes an upward-facing (e.g., in a direction opposite to the central protrusion 164) top surface 102 and a bottom surface 104 opposite to the top surface 102. In various embodiments, the first side surface 148 includes a port shown as a USB port 144. As will generally be understood, the USB port 144 allows charging of the battery pack 68.

[0070] In various embodiments, the first side surface 148 includes a lamp 146. In specific embodiments, the lamp 146 emits a color. For example, the lamp 146 may emit green. In various embodiments, the lamp 146 indicates the charging state of the battery pack 68. In such embodiments, when the battery pack 68 is discharging and has 50% to 100% charge, the lamp 146 emits green light. When the battery pack 68 has 10% to 49% charge, the lamp 146 emits yellow light. When the battery pack 68 has 3% to 9% charge, the lamp 146 emits red light. When the battery pack 68 has 0% to 3% charge, the lamp 146 will flash red until the power is completely depleted.

[0071] In various embodiments, the battery pack 68 and the lamp 146 emit different colors while the battery pack 68 is charging. When the battery pack 68 is charging and has 50% to 99% charge, the lamp 146 emits yellow light. When the battery pack 68 has 0% to 49% charge, the lamp 146 emits red light. When the battery pack 68 has 100% charge, the lamp 146 emits green light when connected to the charger. In such an embodiment, the lamp 146 will continue to emit green light for 3 seconds after being unplugged and / or disconnected.

[0072] In various embodiments, the battery pack 68 and / or housing 67 include an actuator shown as a power button 100. In a specific embodiment, the power button 100 is positioned on the top surface 102 of the battery pack 68. In a specific embodiment, the battery pack 68 includes a light-emitting element 168. In a specific embodiment, the battery pack 68 includes a pair of light-emitting elements 168. In a specific embodiment, the light-emitting elements 168 are positioned on an outer surface 166 facing rearward (e.g., away from the mounting bracket 66 and the helmet 10). In a specific embodiment, the light-emitting elements 168 emit red light. In other words, the rear light-emitting elements 168 serve as a taillight for the wearer. In a specific embodiment, the battery pack housing 67 includes two red LEDs. In such an embodiment, the battery pack 67 includes a first red LED and a second red LED spaced apart from the first red LED. As previously discussed, the applicant believes that using rear red light on the power supply of the light-emitting assembly 60, as discussed herein, provides the user with improved visibility from behind in working lines of sight and / or dimly lit environments. In addition, the applicant believes that the use of red light allows for increased protection of night vision for other people and / or workers in the environment.

[0073] Reference Figure 18An exploded view of a battery pack 68 and a mounting bracket 66 according to an exemplary embodiment is shown. The body 178 also includes a pair of locking portions 188 located on opposite sides of a front connecting portion 186. The front connecting portion 186 faces the housing 67 of the battery pack 68 and engages the housing 67 when the battery pack 68 is coupled to the mounting bracket 66. The locking portions 188 are positioned below opposite end protrusions 175. Cam rods 150, 152 are rotatably coupled to the mounting bracket 66 and specifically to the locking portions 188. The locking portions 188 have a shape corresponding to the cam rods 150, 152. Each locking portion 188 includes a hole 190 extending through the locking portion 188 along a rotation axis 154.

[0074] Mounting bracket 66 includes a pair of rear clamps 172. Each rear clamp 172 includes a clamping portion 173 and a clamping locking portion 171. Each clamping locking portion 171 includes a hole 174 extending through the clamping locking portion 171 along a rotation axis 154. When mounting bracket 66 is assembled, a connector shown as a screw 176 extends along the rotation axis 154 through the hole 174 of each clamping locking portion 171 and the hole 190 of the body 178.

[0075] When the mounting bracket 66 is connected to the rear mounting ridge 32, the clamping portion 173 of the rear clamp 172 and the rear surface 184 of the body 178 are positioned on opposite sides of the corresponding edges 50, 52 of the helmet 10. The rear clamp 172 and the body 178 together function as a vise to securely clamp onto the helmet 10. Each cam rod 150, 152 also includes a rearwardly extending protrusion 192. In other words, the protrusion 192 extends toward the body 178 of the mounting bracket 66.

[0076] When the battery pack 68 is coupled to the mounting bracket 66, the battery pack 68 also includes a cavity 200 defined by the housing 67 and the front connection portion 185 of the mounting bracket 66. In a specific embodiment, the battery pack 68 also includes a battery 194 and a battery housing 196 positioned within the cavity 200. In various embodiments, the battery pack 68 also includes one or more PCBAs 198 positioned within the housing 67 and / or the cavity 200. The battery pack 68 also includes a clip, shown as a C-shaped clip 202, for securing the plug 84 to the housing 67 and / or the battery pack 68.

[0077] In various embodiments, the light-emitting assembly 60 includes a circuit board, such as a printed circuit board assembly (PCBA) 140 within the headlamp 62. In a specific embodiment, the circuit board 140 controls at least some of the light-emitting elements 114, 116, 118, and 168 in the headlamp 62 and battery pack 68. In a specific embodiment, a first circuit board 140 supported within the headlamp 62 controls the light-emitting elements 114, 116, and 118 in the headlamp 62, and a second circuit board 198 supported within the battery pack 68 controls the light-emitting element 168 in the battery pack 68. In a specific embodiment, the circuit board 140 controls all the light-emitting elements 114, 116, 118, and 168 in the headlamp 62 and battery pack 68. The applicant believes that the position of the circuit board 140 within the headlamp 62 provides improved weight balance for the safety head-mounted light-emitting assembly 60. In a specific embodiment, the headlamp 62 and mounting bracket 64 have a weight less than the maximum weight.

[0078] The applicant has discovered that a better weight balance can be achieved instead of having a significant portion of the weight located at the rear (e.g., 75% rear weight and 25% front weight). The applicant considers a near 50 / 50 weight distribution to be ideal. Weight balance is considered to be headlamp weight / total weight = front weight percentage. Rear weight percentage = 100 - front weight percentage. The weight of the headlamp is defined as the weight of the headlamp 62 and all internal components, as well as the mounting bracket 64 and wiring 70. The rear weight is defined as the weight of the battery pack 68 (i.e., the battery housing and the battery itself) and the bracket 66.

[0079] In various embodiments, the front portion weighs 30% to 50% of the total weight, and the rear portion weighs 50% to 70% of the total weight. In a specific embodiment, the front portion weighs approximately 35% of the total weight, and the rear portion weighs approximately 65% ​​of the total weight. In a specific embodiment, the headlamp 62 weighs approximately 83.7 g, and the rear portion weighs approximately 148 g. In a specific embodiment, the headlamp 62 weighs approximately 77.7 g, and the rear portion weighs approximately 148.6 g. In such embodiments, the total weight is 226.3 g.

[0080] In another specific embodiment, the front portion accounts for approximately 34% of the weight, and the rear portion accounts for approximately 66% of the weight. In such an embodiment, the total weight is 222 g, the front portion weighs 75 g, and the rear portion weighs 147 g. In a specific embodiment, the rear portion weighs 148 g or less. In various embodiments, the front portion accounts for approximately 34% to approximately 35% of the total weight. In various embodiments, the maximum rear portion weight is 200 g or less.

[0081] Reference Figures 22 to 23Details of a quick-disconnect cable 70 according to an exemplary embodiment are shown. In a specific embodiment, cable 70 is a quick-disconnect cable. Cable 70 includes a quick-disconnect connector 82 positioned along the length of cable 70. Specifically, connector 82 includes a first portion or connector 204 positioned between a second portion or connector 206 and an accordion section 86 of cable 70. In other words, connector 82 is positioned between a plug 84 connected to battery pack 68 and the opposite end 88 of cable 70 connected to headlamp 62. First connector 204 and second connector 206 are configured to disconnect in the event of cable 70 being hooked or tangled, and thus prevent the light-emitting assembly 60 from detaching from helmet 10. In other words, when force is applied to cable 70, the first portion 204 and second portion 206 of connector 82 disconnect.

[0082] Reference Figures 24 to 25 A perspective view of a light-emitting component 60 according to an exemplary embodiment is shown. Mounting brackets 66 and 64 can be removably attached to a safety helmet, such as helmet 10, 210. As will generally be understood, mounting bracket 66 and battery pack 68 and / or bracket 64 and headlamp can be removed separately from the safety helmet.

[0083] like Figure 24 As shown, the mounting bracket 66, and specifically the rear surface 184, includes a recess 308. The recess 308 is positioned above the central protrusion 164. In a specific embodiment, the recess 308 is positioned on the rear surface 184 between the central protrusion 164 and the top surface 102. The recess 308 is sized and / or configured to receive, grip, retain, and / or engage retaining clips or stops of the helmets 10, 210 (see, for example...). Figure 2 (54). Similar to the central protrusion 164, the recess 308 is positioned between the cam rods 150 and 152.

[0084] As previously discussed, the engaging portion 110 and the top portion 112 of the bracket 64 together form a hinge. The top portion 112 of the bracket 64 and the engaging portion 110 of the headlamp together define a pivot axis 314. In other words, in various embodiments, the headlamp 62 is pivotally connected to the mounting bracket 64 and is capable of pivoting about the pivot axis 314 (see, for example...). Figure 27 ).

[0085] Reference Figure 26The light-emitting assembly 60 according to an exemplary embodiment is shown from above. A first arm 90 and a second arm 92 are configured to receive and engage a first edge (see, for example, 42) and a second edge (see, for example, 44) of the front mounting ridges 20, 220 to secure the mounting bracket 64 and / or the headlamp 62 to the helmets 10, 210. In other words, the bracket 64, and particularly the first arm 90 and the second arm 92, engage the front mounting ridges 20, 220 such that the headlamp 62 is supported by the helmets 10, 210.

[0086] The first arm 90 also includes a rear protrusion 309 that defines a first space or gap 310 that receives and / or at least partially encloses a first edge on the helmet 10, 210, etc. Similarly, the second arm 92 includes a second rear protrusion 311 that defines a second space or gap 312 that receives and / or at least partially encloses a second edge on the helmet 10, 210, etc.

[0087] Reference Figure 27 This diagram shows a front perspective view of a helmet 410 supporting a light-emitting assembly 60 according to another exemplary embodiment. Except for the differences discussed herein, helmet 410 is substantially the same as helmets 10 and 210. The outer shell 412 includes a recess 425 positioned between a front portion 428 and a rear portion 430 of helmet 410. Recess 425 is positioned close to the wearer's ear. In a specific embodiment, recess 425 extends a height over a portion of the bottom section 424 near the front portion 428 and / or the rear portion 430 of helmet 410. In a specific embodiment, recess 425 is positioned along a portion of an auxiliary mounting ridge 436.

[0088] As previously discussed, the headlamp 62 can be positioned in an upright and / or generally vertical position (see example...). Figures 10 to 14 ) and like Figure 27 The headlamp 62 can move between the pivoting positions shown. The headlamp 62 is movable from a first position to a second position, in which the rear surface 120 is adjacent to the outer surface 414 and / or the front mounting ridge 420, and in the second position, the rear surface 120 is spaced apart from the outer surface 414 and / or the front mounting ridge 420. In other words, as the headlamp 62 pivots about the pivot axis 314 to the second position, the distance between the headlamp 62 and specifically the rear surface 120 increases. Therefore, in the second pivoting position, the headlamp 62 is positioned at an angle relative to the bracket 64. In a specific embodiment, the headlamp 62 is capable of pivoting from an upright position (i.e., a vertical position) to a second angular position at 70 degrees from the upright position. In other embodiments, the headlamp 62 is capable of pivoting within different angular ranges.

[0089] It should be understood that the accompanying drawings illustrate exemplary embodiments in detail, and it should be understood that this application is not limited to the details or methods set forth in the description or illustrated in the drawings. It should also be understood that the terminology is for descriptive purposes only and should not be considered limiting.

[0090] In view of this description, other modifications and alternative embodiments of various aspects of this disclosure will be apparent to those skilled in the art. Therefore, this description is to be interpreted as illustrative only. The constructions and arrangements shown in the various exemplary embodiments are merely illustrative. Although only a few embodiments are described in detail in this disclosure, many modifications (e.g., variations in the size, dimensions, structure, shape and proportion, parameter values, mounting arrangements, use of materials, color, orientation, etc.) are possible without substantially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed from multiple parts or elements, the positions of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be changed or varied. The order or sequence of any process, logical algorithm, or method steps may be changed or reordered according to alternative embodiments. Other substitutions, modifications, variations, and omissions may also be made in terms of the design, operating conditions, and arrangements of the various exemplary embodiments without departing from the scope of this disclosure.

[0091] Unless otherwise expressly stated, no method described herein is intended to be construed as requiring its steps to be performed in a particular order. Therefore, no particular order is intended to be inferred unless a method claim actually describes the order to be followed by its steps or unless the claims or description specifically state that the steps should be limited to a particular order. Furthermore, as used herein, the article “a” is intended to include one or more parts or elements and is not intended to be construed as meaning only one.

[0092] For the purposes of this disclosure, the term "connection" means that two components are directly or indirectly linked to each other. Such a connection may be inherently fixed or inherently movable. This connection can be achieved by the two components and any additional intermediate components forming a single unit, or by the attachment of two components or two components and any additional components to each other. Such a connection may be inherently permanent, or alternatively, it may be inherently removable or releasable. As used herein, a "rigid connection" refers to two components connected such that the components move together in a fixed positional relationship when subjected to forces.

[0093] Although the present application describes specific combinations of features in the appended claims, various embodiments of the invention relate to any combination of any features described herein, whether or not such combinations are currently claimed, and any such combination of features may be claimed in this or a future application. Any feature, element, or component of any exemplary embodiment discussed above may be used alone or in combination with any feature, element, or component of any other embodiment discussed above.

[0094] In various exemplary embodiments, the relative dimensions, including angles, lengths, and radii, as shown in the accompanying drawings, are drawn to scale. Actual measurements of the drawings will reveal the relative dimensions, angles, and scales of the various exemplary embodiments. The various exemplary embodiments extend to a wide range around the absolute and relative dimensions, angles, and scales that can be determined from the drawings. The various exemplary embodiments include any combination of one or more relative dimensions or angles that can be determined from the drawings. Furthermore, actual dimensions not explicitly stated in this description can be determined by combining the ratios of the dimensions measured in the drawings with the explicit dimensions stated in this description.

Claims

1. A helmet system, comprising: Safety helmet, the safety helmet comprising: A shell, the shell comprising: outer surface; and Inner surface, the inner surface defining a cavity; A front mounting ridge that extends outward from the front portion of the outer surface of the housing; A rear mounting ridge extends outward from the rear portion of the outer surface of the housing; A light-emitting system, the light-emitting system comprising: A first bracket, configured to removably engage the front mounting ridge; A headlamp, the headlamp being supported by the first bracket, the headlamp including a first light-emitting element configured to emit red light forward in a first direction; A second bracket, configured to removably engage the post-mounted ridge; A power source, supported by a second bracket, includes a second light-emitting element configured to emit red light rearward in a second direction opposite to the first direction.

2. The helmet system according to claim 1, wherein, The second light-emitting element is positioned on the outer surface of the power supply, the outer surface of the power supply being away from the safety helmet.

3. The helmet system according to claim 1, wherein, The second light-emitting element includes a first red LED and a second red LED spaced apart from the first red LED.

4. The helmet system according to claim 1, wherein, The headlamp also includes a floodlight element and a spotlight element, wherein the floodlight element and the spotlight element are configured to emit white light along the first direction.

5. The helmet system according to claim 1, further comprising a circuit board supported within the headlamp, wherein, The circuit board is configured to control the first light-emitting element.

6. The helmet system according to claim 5, wherein, The circuit board is configured to control the second light-emitting element.

7. The helmet system of claim 5 further includes a second circuit board supported within the power supply, the second circuit board being configured to control the second light-emitting element.

8. The helmet system according to claim 1, wherein, The power source is a battery pack.

9. A helmet system, comprising: Safety helmet, the safety helmet comprising: A shell, the shell comprising: outer surface; and Inner surface; A first mounting ridge extends outward from the outer surface of the shell; A second mounting ridge is positioned on the portion of the shell opposite to the first mounting ridge, and the second mounting ridge extends outward from the outer surface of the shell; A headlamp, the headlamp being supported relative to a first mounting ridge via a first mounting bracket, the headlamp including a plurality of light-emitting elements, wherein at least one of the plurality of light-emitting elements is configured to emit red light along a first direction; A battery pack, which is supported relative to a second mounting ridge via a second mounting bracket, includes a battery light-emitting element configured to emit red light in a second direction opposite to the first direction.

10. The helmet system of claim 9, further comprising a wire connecting the battery pack and the headlamp, wherein, The headlamp receives power from the battery pack via the wire.

11. The helmet system according to claim 10, wherein, The wire includes an extendable segment that is actuated between a retracted position having a first length and an extended position having a second length, wherein the second length is greater than the first length.

12. The helmet system according to claim 10, wherein, The front weight includes the weight of the headlamp, the first mounting bracket, and the wiring, and the rear weight includes the weight of the battery pack and the second mounting bracket, wherein the front weight and the rear weight together define the total weight.

13. The helmet system according to claim 12, wherein, The front portion accounts for approximately 34% to approximately 35% of the total weight.

14. The helmet system according to claim 12, wherein, The rear part weighs 148 grams or less.

15. The helmet system according to claim 10, wherein, The wire includes a connector positioned between a first end of the wire that engages with the headlamp and a second end of the wire that engages with the battery pack.

16. The helmet system according to claim 15, wherein, The connector includes a first portion and a second portion removably coupled to the first portion, wherein the first portion and the second portion disconnect when force is applied to the wire.

17. A helmet system, comprising: Safety helmet, the safety helmet comprising: A shell, the shell comprising: outer surface; and Inner surface, the inner surface defining a cavity; Mounting ridge, the mounting ridge extending outward from the outer surface of the shell, the mounting ridge comprising: Opposite edges, which protrude from opposite sides away from the mounting ridge; Mounting bracket, the mounting bracket being coupled to the mounting ridge, the mounting bracket including opposing arms that engage between opposing edges of the housing and the mounting ridge; and A power source, supported by the mounting bracket, configured to supply power to accessories coupled to the helmet, the power source comprising: A housing, the housing including a rear surface opposite to the helmet; and A pair of light-emitting elements, the pair of light-emitting elements being positioned on the rear surface of the housing, wherein each of the pair of light-emitting elements is configured to emit red light.

18. The helmet system according to claim 17, wherein, The pair of light-emitting elements is a pair of red LEDs.

19. The helmet system of claim 17, further comprising: A second mounting bracket is configured to removably engage the helmet; as well as A headlamp supported by a second mounting bracket, the headlamp including a forward-emitting element configured to emit red light in a direction opposite to that of a pair of light-emitting elements of the power source.

20. The helmet system of claim 19, the helmet further comprising a second mounting ridge configured to support the second mounting bracket, the second mounting ridge being positioned opposite to the mounting ridge on the outer surface of the shell, the second mounting ridge extending outward from the outer surface of the shell, and including an opposite edge projecting away from the opposite side of the second mounting ridge.

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