Headlamp assembly

Abstract

Headlamp assembly comprising: a strap configured to be worn by a user; a headlamp comprising: a battery compartment configured to receive a battery, and a light assembly with a light element configured to be powered by the battery and a housing holding the light element; and a mounting bracket coupled to the headlamp and the strap, the mounting bracket comprising a rigid frame and a flexible support, the flexible support being coupled to the rigid frame and configured to engage with the user's head or helmet.

Description

Cross-reference to related registrations This application claims priority over preliminary US application No. 63 / 796,814 filed on April 29, 2025, the entire contents of which are incorporated herein by reference. Field of invention The present disclosure relates to lighting systems, in particular headlamps and headlamp assemblies. background Headlamps are typically designed to be attached to a user's head or a helmet via a mounting mechanism. Headlamps include a light source, which may be a single LED or multiple LEDs. The light source is designed to illuminate an area in front of the user. Some headlamps may include a battery attached to the headlamp and electrically connected to the light source to power it. Overview of the invention The present disclosure specifies in one aspect a headlamp assembly comprising: a strap configured to be worn by a user; a headlamp comprising a battery compartment configured to receive a battery, and a lighting assembly comprising an output element configured to be powered by the battery and a housing holding the output element; and an attachment bracket coupled to the headlamp and the strap, wherein the attachment bracket comprises a rigid frame and a flexible support, and the flexible support is coupled to the rigid frame and configured to engage with the user's head or helmet. The present disclosure further specifies a headlamp comprising a battery compartment configured to receive a battery; a lighting assembly attachable at an interface to the battery compartment, the lighting assembly comprising an output element configured to receive power from the battery, and a housing holding the output element; and a seal arranged at the interface between the battery compartment and the housing of the lighting assembly, the seal forming a light guide for at least one section of a user interface. The present disclosure further specifies a headlamp assembly comprising a strap designed to be worn by a user; a headlamp including a battery compartment capable of holding a battery; a lighting assembly with an output element designed to be powered by the battery; and a housing that holds the output element.and a mounting bracket coupled to the headlamp and the strap, the mounting bracket comprising: a frame comprising a first edge and a second edge opposite the first edge, a first arm extending from adjacent to the first edge of the frame towards the second edge of the frame, the first arm comprising a first cantilever finger engaging with the headlamp to control the rotation of the headlamp relative to the mounting bracket, and a second arm extending from adjacent to the second edge of the frame towards the first edge of the frame, the second arm comprising a second cantilever finger engaging with the headlamp to control the rotation of the headlamp relative to the mounting bracket. Further aspects of the invention will become clear from the following detailed description and the accompanying drawings. Brief description of the drawingsFig. 1A is a front perspective top view of a headlamp assembly according to an embodiment of the present disclosure, wherein the headlamp assembly comprises a headlamp and a mounting bracket. Fig. 1B is a front perspective bottom view of the headlamp assembly from Fig. 1A. Fig. 2 is a perspective view of the headlamp assembly from Fig. 1A, which is coupled to a protective helmet by means of a strap of the headlamp assembly. Fig. 3A is a top view of the headlamp assembly from Fig. 1A. Fig. 3B is a bottom view of the headlamp assembly from Fig. 1A. Fig. 4A is a perspective view of a battery compartment of the headlamp from Fig. 1A. Fig. 4B is an enlarged perspective view of a section of the headlamp from which a lamp assembly has been removed to show a light guide. Fig. 4C is an enlarged cross-sectional view of a section of the headlamp from Fig. 1A, along section line 5-5 from Fig. 1A.Figure 5 is a cross-sectional view of the headlamp assembly from Figure 1A, along section line 5-5 in Figure 1A. Figure 6 is a front view of the headlamp assembly from Figure 1A, representing an end cap. Figure 7 is a perspective view of a lighting assembly of the headlamp from Figure 1A. Figure 8 is a rear view of the mounting bracket of the headlamp assembly from Figure 1A. Figure 9 is a perspective front view of the mounting bracket from Figure 8. Figure 10 is a perspective rear view of the mounting bracket from Figure 8. Figure 11 is an enlarged cross-sectional view of the mounting bracket from Figure 8, viewed from a first end of the headlamp, representing the mounting bracket engaging in the rail of the headlamp from Figure 1A and being rotated in a first direction. Fig. 12 is a further enlarged cross-sectional view of the mounting bracket from Fig.Fig. 8, viewed from a second end of the headlamp, which represents the mounting bracket engaging in the rail of the headlamp from Fig. 1A and rotating in the first direction. Fig. 13 is a rear view of the mounting bracket from Fig. 8, which represents a flexible support. Fig. 14 is a top view of the headlamp assembly from Fig. 1A engaging with the head or a protective helmet of a user. Fig. 15 is a side view of the headlamp assembly from Fig. 1A engaging with the head or a protective helmet of a user. Fig. 16 is another top view of the headlamp assembly from Fig. 1A engaging with the head or a protective helmet of a user and representing a flexible support, according to a further embodiment. Fig. 17 is another top view of the headlamp assembly from Fig. 1A engaging with the head or a protective helmet and representing the flexible support from Fig.Figure 16 is shown. Figure 18 is a perspective rear view of another mounting bracket for use with the headlamp from Figure 1A. Figure 19 is an enlarged cross-sectional view of the mounting bracket from Figure 18, showing the mounting bracket engaging in the rail of the headlamp from Figure 1A and rotating in one direction. Figure 20 is a rear view of another mounting bracket for use with the headlamp from Figure 1A. Figure 21 is a rear view of the mounting bracket from Figure 20. Detailed description Before embodiments of the disclosure are explained in detail, it should be noted that the application of the disclosure is not limited to the design details and arrangements of components set forth in the following description or illustrated in the following drawings. The disclosure permits other embodiments and can be implemented or carried out in various ways. Furthermore, it should be noted that the language and terminology used here serve the purpose of the description and should not be considered restrictive. Features shown or described as part of one embodiment can be combined with another embodiment to produce a further embodiment. Thus, the present disclosure is intended to cover such modifications and variations that fall within the scope of the appended claims and their equivalents. In the detailed description, numerical and letter designations are used to refer to features in the drawings. Identical or similar designations in the drawings and the description have been used to refer to identical or similar parts of the disclosure. The terms "first," "second," and "third" may be used interchangeably to distinguish one component from another and are not intended to indicate the location or significance of any individual component. The singular forms "a," "an," and "the" encompass the multitude unless the context clearly indicates otherwise. The terms "coupled," "fixed," "attached to," and the like refer to both direct coupling, fixing, or attaching and indirect coupling, fixing, or attaching via one or more intermediate components or features, unless otherwise specified herein. The terms "includes," "comprehensive," "includes," "has," or other variations thereof, as used herein, are intended to include non-exclusive elements.For example, a process, procedure, object, or device that includes a list of characteristics is not necessarily limited to those characteristics but may also include other characteristics not expressly listed or inherent in such a process, procedure, object, or device. Unless expressly stated otherwise, "or" refers to an inclusive or and not an exclusive or. For example, condition A or B is satisfied if any of the following conditions is met: A is true (or present) and B is not true (or present), A is not true (or present) and B is true (or present), and both A and B are true (or present). Terms of approximation such as "about," "generally," "approximately," or "essentially" include values ​​that are within ten percent above or below the stated value. When used in conjunction with an angle or direction, these terms include values ​​within ten degrees greater or less than the stated angle or direction. For example, "essentially vertical" includes directions within ten degrees of the vertical in any direction, such as clockwise or counterclockwise. Advantages, other benefits, and problem solutions are described below with regard to specific embodiments. However, the benefits, advantages, problem solutions, and features that may lead to a benefit, advantage, or solution occurring or becoming more pronounced are not to be understood as significant, necessary, or essential features of one or all claims. Figures 1A to 3B depict a headlamp assembly 10. The headlamp assembly 10 selectively illuminates an area, such as a work area. The illustrated headlamp assembly 10 includes a strap 15 that adapts to the head of a user, a safety helmet, or another similar surface. The headlamp assembly 10 also includes a headlamp 20 and a mounting bracket 30 coupled to the headlamp 20. The mounting bracket 30 receives the strap to secure the headlamp 20 to the user's head or safety helmet. In the illustrated embodiment, the strap 15 is made of an elastic material that can be stretched to encircle a user's head or a protective helmet. In some embodiments, the strap 15 may be made of a semi-rigid, flexible material. Referring to Fig. 2, the strap 15 is secured to a protective helmet by a plurality of attachment clips 35 evenly distributed around a rear brim of the helmet. In some cases, the strap 15 may be worn directly on the user's head without the protective helmet or the attachment clips 35. As shown in Figs. 1A and 1B, the headlamp 20 comprises a battery compartment 21, a light assembly 25, and a user interface 26. In the illustrated embodiment, the light assembly 25 and the user interface 26 are separate from the battery compartment 21. In other embodiments, the battery compartment 21 and the light assembly 25 are formed as a single part. The user interface 26 is arranged on the light assembly 25. In the illustrated embodiment, the headlamp 20 is oriented towards the front of the helmet or the user's head. In other embodiments, the headlamp 20 may be arranged in a different location. In some embodiments, the headlamp assembly 20 may include a second strap that is coupled to the headlamp 20 and rests against the top of the user's head or the helmet to improve the stability of the headlamp assembly 20. Referring to Fig. 4A and Fig. 5, the battery compartment 21 forms a body of the headlamp 20. The battery compartment 21 extends from a first end 40a to a second end 40b along a central axis A. The central axis A is also a longitudinal axis of the headlamp 20. In the illustrated embodiment, the battery compartment 21 is a substantially cylindrical shell. The battery compartment 21 has a cylindrical cross-section corresponding to the cylindrical cross-section of a battery 44, such as a rechargeable lithium-ion battery. The battery 44 can be inserted into the battery compartment 21 along the central axis A. In particular, the battery compartment 21 includes a compartment 45 that receives the battery 44. In other embodiments, the battery compartment 21 can instead receive disposable alkaline batteries (for example, AA batteries or the like).In other embodiments, the battery compartment 21 may have a prismatic cross-section or a different shape to accommodate other battery types. Referring to Figs. 1A, 1B, 3A, 3B, 4A, and 4C, the battery compartment 21 accommodates a pair of end caps 50a, 50b. The end caps 50a, 50b are secured to the ends 40a, 40b of the battery compartment 21 to secure the battery 44 within the battery compartment 21. An annular surface seal 52 is arranged between the first end cap 50a and the first end 40a. The surface seal 52 can be, for example, an O-ring, an X-ring, or another suitable annular element. The surface seal 52 exerts a compressive force on the first end cap 50a, which biases the first end cap 50a away from the first end 40a. In some embodiments, the first end cap 50a can be firmly secured to the first end 40a and thus not designed to be removable from the battery compartment 21. Once secured to the first end 40a, the first end cap 50a protects the battery compartment 21 and the battery 44 from external influences that could cause structural or electrical damage, such as water. In other embodiments, the first end cap 50a can be fixed by a fastening element, a radial seal, or by another similar component or manufacturing process to protect the battery 44 and the battery compartment 45 from damage caused by external influences. Referring to Fig. 4A and Fig. 6, the second end cap 50b and the second end 40b comprise interacting geometric features 47 (Fig. 4A). The interacting geometric features 47 allow the second end cap 50b to be detachably coupled to the second end 40b. For example, the second end cap 50b can be rotatably attached to the second end 40b in a first direction 55, as shown in Fig. 6, to secure the second end cap 50b in place. Conversely, the second end cap 50b can be rotated in a second direction 59 opposite to the first direction 55 to remove the second end cap 50b from the battery compartment 21. When the second end cap 50b is removed from the battery compartment 21, the battery 44 can be removed and replaced.In the illustrated embodiment, the second end cap 50b has a plurality of notches 51 machined into it to facilitate rotation of the second end cap 50b by a user either in the first direction 55 or in the second direction 59. In some embodiments, the interacting geometric features 47 include threaded ends or rotary locking geometries. With reference to Fig. 4A, Fig. 4B, and Fig. 5, the battery receptacle 21 further comprises an outer housing 60 and an inner housing 62. The outer housing 60 and the inner housing 62 extend from the battery receptacle 21. In the illustrated embodiment, the outer housing 60 and the inner housing 62 extend longitudinally along the central axis A. The circumference of the inner housing 62 is smaller than the circumference of the outer housing 60. As shown in Fig. 4A, the circumference of the inner housing 62 is arranged within the circumference of the outer housing 60. The outer housing 60 and the inner housing 62 are complementary to each other, such that the circumferences of the housings 60 and 62 have the same shape. For example, in the illustrated embodiment, the circumference of the outer housing 60 has a substantially rectangular shape. Consequently, the circumference of the inner housing 62 also has a substantially rectangular shape to complement the shape of the circumference.In other embodiments, the circumferences of the housings 60, 62 are square. The inner housing 62 also includes an opening 62b formed therein. Referring to Figs. 4A and 4B, a seal 68 is arranged between the outer housing 60 and the inner housing 62. The seal 68 includes a light guide 69 (Fig. 4B). In the illustrated embodiment, the light guide 69 is formed integrally with the remainder of the seal 68. In other embodiments, the seal 68 and the light guide 69 are formed as a single part. The seal 68 is partially received in a plurality of anchoring points 62c formed in the inner housing 62. The anchoring points 62c help to secure the seal 68 in place relative to the outer housing 60 and the inner housing 62. In the illustrated embodiment, the light guide 69 is aligned with a section of the user interface 26. For example, the light guide 69 can be aligned with a charging indicator 72 (Fig. 4B).1B) of the user interface 26 to direct light from indicator lights inside the battery compartment 21 to outside the battery compartment 21, as explained below. In some embodiments, the seal 68 is made of a transparent material. In other embodiments, the seal 68 may be made of an elastomeric polymer material such as rubber. The battery compartment 21 also includes a plurality of sockets 77 extending from the battery compartment 21. In the illustrated embodiment, the battery compartment 21 includes four sockets 77 arranged at the corners of the inner housing 62. In other embodiments, the battery compartment 21 may include fewer or more sockets 77 and / or the sockets 77 may be arranged at a different location on the battery compartment 21. The sockets 77 serve to couple the lighting assembly 25 to the battery compartment 21. The seal 68 defines a perimeter of the interface (i.e., the sockets 77 and other structures that accommodate the lighting assembly 25) to which the lighting assembly 25 is attached. Referring to Figs. 4A, 4C, and 7, the charging indicator 72 is arranged within the opening 62b of the inner housing 62. The charging indicator 72 comprises a plurality of indicator lights 74. In the illustrated embodiment, the indicator lights 74 are arranged adjacent to the light guide 69 and within a circumference defined by the seal 68. The charging indicator 72 also comprises a partition 76, which is arranged within the opening 62b. The partition 76 comprises a plurality of legs 76a. Each indicator light 74 is arranged between a pair of legs 76a, so that the indicator lights 74 are separated from one another. The indicator lights 74 may be arranged differently in other embodiments. In some embodiments, each indicator light 74 is assigned to a corresponding component of the user interface 26 and fulfills a specific function.For example, an indicator light 74 can be assigned to a power switch, a mode selector switch or another user input to indicate the battery charge status, operating mode, charging status or another operating condition of the headlamp assembly 10. The charge indicator 72 serves to display the remaining charge of the battery 44 housed in the battery compartment 21. In the illustrated embodiment, the charge indicator 72 comprises four indicator lights 74 (for example, LEDs), which generally correspond to the remaining charge of the battery 44. For example, the illumination of all four indicator lights 74 means that the battery 44 is fully or almost fully charged, while the illumination of only one indicator light 74 means that the battery 44 has a low charge (for example, less than 25%). In other embodiments, the charge indicator 72 may comprise fewer or more indicator lights 74. The charge indicator 72 can switch on automatically when the headlamp 20 is switched on by actuating the actuator 70 and then switch off automatically after a short period of time (for example, 5 seconds).In other embodiments, the charging indicator 72 can remain switched on as long as the headlamp 20 remains switched on. Fig. 7 shows the lighting assembly 25 of the headlamp assembly 10. The lighting assembly 25 receives power from the battery 44. In the illustrated embodiment, the lighting assembly 25 comprises a circuit board 43 (Fig. 5), one or more LEDs 67 (Fig. 5) held by the circuit board 43, and a housing 85. The circuit board 43 and the LEDs 67 are arranged inside the housing 85. In the illustrated embodiment, the lighting assembly 25 comprises two LEDs 67. For example, the lighting assembly 25 can comprise a point LED and a floodlight LED. In other embodiments, the lighting assembly 25 can comprise fewer or more LEDs 67. Additionally, the lighting assembly 25 can comprise other types of LEDs 67. The housing 85 comprises a top 85a, a bottom 85b, and a side 85c.In the illustrated embodiment, the housing 85 is attached to the battery compartment 21 by means of four fastening elements 80 (for example, screws or the like) which are inserted into blind holes 77a in the base 77. In other embodiments, the housing 85 and the battery compartment 21 can be coupled to each other by means of snap-fit ​​geometries, magnetic closures, rivets, and the like. When attached to the battery compartment 21, the housing 85 engages in the seal 68 and encloses the internal electronic components between the housing 85 and the battery compartment 21. The luminaire assembly 25 also includes a lens 90. The lens 90 is received by the side surface 85c of the housing 85 to cover and protect the LEDs 67. The lens 90 acts as a light guide, so that the light emitted by the LEDs 67 can be directed through the lens 90 to illuminate a work area. In the illustrated embodiment, the lens 90 is transparent. In other embodiments, the lens 90 can have a different color, such as blue, green, yellow, and any other desired color along the light spectrum. The LEDs 67 are configured to operate in a variety of lighting modes, as described in more detail below.In some embodiments, the LEDs 67 themselves are configured to emit colored light (for example, the LEDs 67 are configured to emit red light, blue light, green light, and any other desired color along the light spectrum when excited by an electric current). The LEDs 67 may optionally be configured to emit yellow or white light in some cases when a colored lens is present. Figures 3A and 3B depict the user interface 26. The illustrated user interface 26 is located on the top 85a and bottom 85b of the housing 85. The user interface 26 is configured to control the operation of the headlamp 20. In the illustrated embodiment, the user interface 26 comprises a power switch 70, a mode selector switch 95, a charging port 100, and the light guide 69. In other embodiments, the user interface 26 may have different configurations or include additional features and components. The power switch 70 is used to activate the headlamp 20 and, in particular, the LEDs 67 (for example, to switch it on and off). The mode selector switch 95 is used to switch the headlamp 20 and, in particular, the LEDs 67 between a variety of lighting modes. The power switch 70 and the mode selector switch 95 are both located on the top 85a of the housing 85.In the illustrated embodiment, the power switch 70 and the mode selector switch 95 are pushbuttons. In other embodiments, the power switch 70 and the mode selector switch 95 can comprise other suitable actuators, such as rotary controls, slide switches, and the like. Referring to Fig. 3A and Fig. 7, the power switch 70 can be actuated (for example, pressed) to activate an ON mode in which light is emitted by the LED, and an OFF mode in which the LEDs 67 do not emit light. The operating modes of the headlamp 20 include the multiple lighting modes of the LEDs 67. The mode selector switch 95 allows a user, when actuated, to control the intensity of the light emitted by the LEDs 67 in ON mode. The multiple lighting modes include a high-intensity ON mode ("HIGH mode"), a medium-intensity ON mode ("MEDIUM mode"), and a low-intensity ON mode ("LOW mode"). The multiple lighting modes may also include a floodlight mode in which only the floodlight LED is illuminated, a spot mode in which only the spot LED is illuminated, or a full mode in which both the floodlight LED and the spot LED are illuminated.In some embodiments, the array of lighting modes may include a power burst mode (“BOOST mode”). In the power boost mode, some or all of the LEDs 67 emit an increased light output that is greater than the high light output of the HIGH mode. After a predetermined time period, the LEDs 67 may return to the previous mode (for example, HIGH, MEDIUM, or LOW) or to a specified mode (for example, HIGH). For example, the LEDs 67 may emit 1000 lumens in the BOOST mode for a period of 60 seconds. In other embodiments, the LEDs 67 may emit a higher or lower lumen output in the BOOST mode for a shorter or longer period. In other embodiments, the array of lighting modes may include a non-flashing ON mode (“standby mode”), a fast-flashing ON mode (“FAST FLASH mode”), and a slow-flashing ON mode (“SLOW FLASH mode”).In other embodiments, the headlamp assembly 10 may include fewer or more modes. Additionally or alternatively, the headlamp assembly 10 may include different types of modes. During operation of the Headlamp Assembly 10, the user expects each mode to emit a brightness / light type suitable for a desired application or scenario. The numerous modes of the Headlamp Assembly 10 allow the user to conveniently switch between output modes without having to change the headlamp. In other words, the Headlamp Assembly 10 is designed to perform the functions of a variety of headlamps, so the user can rely on a single headlamp instead of needing multiple headlamps depending on the desired application (for example, a first high-lumen headlamp for area illumination, a second medium-lumen headlamp for recreational activities, a separate flashing safety light, etc.). As shown in Fig. 1B and Fig. 3B, the connector 100 is located on the underside 85b of the housing 85. In the illustrated embodiment, the connector 100 is a USB connector. The connector 100 allows the battery 44 in the battery compartment 21 to be charged via an external device. In some embodiments, the connector 100 can be a bidirectional connector, which also allows an external device (for example, a mobile phone, a power tool, etc.) to receive power from the battery 44 housed in the battery compartment 21. In other embodiments, the user interface 26 can include multiple connectors 100. For example, the user interface 26 can include a first connector for charging the battery 44 and a second connector for receiving power from the battery 44.In other embodiments, the terminal 100 can be a different type of terminal, located at a different position on the housing 85, or omitted. The charge indicator 72 is located on the battery compartment 21 of the headlamp 20 next to the terminal 100. In other embodiments, the charge indicator 72 can be located at a different position on the battery compartment 21. Referring again to Fig. 4B, the light guide 69 directs the light from the indicator lights 74 (Fig. 4A) inside the battery compartment 21 to the outer surface of the battery compartment 21. As mentioned above, the charging indicator 72 is aligned with the light guide 69 (Fig. 4A). The light guide 69 shown is at least partially subdivided by a plurality of ribs 78 to reduce the flow of light between the indicator lights 74. In the illustrated embodiment, the light guide 69 is subdivided into four segments by three ribs 78. In other embodiments, the light guide 69 may be subdivided into fewer or more segments depending on the number of indicator lights. In some embodiments, the light guide 69 may also or alternatively be aligned with another component of the user interface 26. For example, the light guide 69 may be aligned with the power switch 70, the mode selector switch 95, and / or the charging port 100.In such embodiments, the light guide 69 can form a ring or other pattern around the power switch 70, the mode selector switch 95 and / or the charging port 100 to illuminate the edges of the power switch 70, the mode selector switch 95 and / or the charging port 100. Figures 8, 9 to 10 depict the mounting bracket 30. The mounting bracket 30 comprises a rigid frame 105, prongs 110, and claws 115. In the illustrated embodiment, the rigid frame 105 is generally rectangular. In other embodiments, the rigid frame 105 may have other shapes. The rigid frame 105 comprises a first edge 105a, a second edge 105b, a third edge 105c, and a fourth edge 105d. The second edge 105b is opposite the first edge 105a. The third edge 105c extends between the first and second edges 105a, 105b. The fourth edge 105d is opposite the third edge 105c and also extends between the first and second edges 105a, 105b. Together, the edges 105a to 105d define a perimeter of the rigid frame 105. In the illustrated embodiment, the rigid frame 105 comprises a plate-like area formed within the perimeter defined by the first, second, third, and fourth edges 105a to 105d. The plate-like area has a substantially I-shaped profile comprising opposing longitudinal rail sections extending along the rigid frame 105 and a central web section extending between the rail sections. The central web section connects the opposing rail sections such that the plate-like area ensures structural continuity across the rigid frame 105 while allowing controlled flexibility. The central web section defines a recessed section 106 of the rigid frame 105. The recessed section 106 is configured to receive a flexible support 140, as described below.In the illustrated embodiment, the recessed section 106 is formed within the central web section of the I-shaped plate-like area, so that sections of the rail sections on opposite sides of the recessed section remain structurally continuous. The prongs 110 extend outwards from the rigid frame 105. One of the prongs 110 (for example, a first prong) abuts the third edge 105c of the rigid frame 105. Another of the prongs 110 (for example, a second prong 110) abuts the fourth edge 105d of the rigid frame 105. The prongs 110 extend in a direction perpendicular to the central support axis B of the rigid frame 105. The central support axis B is a longitudinal axis that passes through the center of the rigid frame 105. The prongs 110 are designed to engage with the headlamp 20 and, in particular, with the battery holder 21, as shown in Fig. 3A and Fig. 3B. In particular, the outline of each prong 110 is designed to be complementary to the shape of the battery compartment 21, so that the prongs 110 can be clamped onto the battery compartment 21. Once the prongs 110 are clamped onto the battery compartment 21, the headlamp 20 is rotatably coupled to the mounting bracket 30.To couple the mounting bracket 30 with the battery compartment 21, the prongs 110 are aligned with the slots 120 (Fig. 3A and Fig. 3B) located between the end caps 50a, 50b and the housing 85. The headlamp 20 can be detached from the mounting bracket 30, allowing a user to operate the headlamp 20 independently of the mounting bracket 30 and the strap 15. The mounting bracket 30 includes a retaining device designed to secure the strap 15 to the headlamp assembly 10. In the illustrated example, the retaining devices are the claws 115. One of the claws 115 (for example, a first claw) extends outward from the third edge 105c of the rigid frame 105. Another of the claws 115 (for example, a second claw) extends outward from the fourth edge 105d of the rigid frame 105. The claws 115 extend in a direction parallel to the retaining centerline axis B of the mounting bracket and perpendicular to the prongs 110. The claws 115 receive the ends of the strap 15 to secure the strap 15 to the mounting bracket 30. Each claw 115 comprises a first claw half 115a and a second claw half 115b. Each respective claw 115 defines an opening 123 that can receive one end of the strap 15.In other embodiments, the retaining device is a socket end of a buckle designed to receive a plug end of a buckle formed at the end of the belt. With further reference to Figs. 8, 9 to 10, the mounting bracket 30 also comprises a first arm 125 and a second arm 126. In other embodiments, the mounting bracket 30 may have a smaller or larger number of arms. The first arm 125 extends from adjacent to the first edge 105a of the rigid frame 105 towards the second edge 105b of the rigid frame 105. The second arm 126 extends from adjacent to the second edge 105b of the rigid frame 105 towards the first edge 105a of the rigid frame 105. In other words, the arms 125, 126 extend from opposite edges of the rigid frame 105 towards each other. The arms 125, 126 shown extend over sufficient distances so that the arms 125, 126 overlap in a lateral direction parallel to the centerline axis B of the holder.For example, each arm 125 extends over more than half a distance from its respective edge 105a, 105b towards the other edge 105a, 105b. In the illustrated embodiment, the support centerline axis B intersects both arms 125, 126. The arms 125, 126 are spaced apart laterally along the support centerline axis B. Furthermore, the arms 125, 126 are located between the prongs 110. In other embodiments, the arms 125, 126 can be arranged laterally outside the prongs 110 (for example, the prongs 110 can be arranged between the arms 125, 126). Each arm 125, 126 is cantilevered. Each arm 125, 126 also includes a cantilever finger 125a, 126a at a distal or free end of the respective arm 125, 126. The cantilever fingers 125a, 126a are oriented laterally to each other and are intersected by the midline B of the mounting bracket. The cantilever fingers 125a, 126a can be inserted into corresponding rails 130 (Fig. 3A and Fig. 3B).3B) engage, which are formed on the battery compartment 21 of the headlamp assembly 10. In the illustrated embodiment, a first guide 130 is formed adjacent to the first end 40a of the battery compartment 21 and a second guide 130 is formed adjacent to the second end 40b of the battery compartment 21. Referring to Figures 11 and 12, each rail 130 comprises a plurality of teeth 130a. The teeth 130a are arranged circumferentially around the rail 130. A plurality of channels 135 are formed between adjacent teeth 130a. The cantilever fingers 125a, 126a are selectively received in the channels 135 to temporarily hold or secure the headlamp 20 in a fixed rotational position relative to the mounting bracket 30. Thus, the cantilever fingers 125a, 126a can control (for example, limit or restrict) the rotation of the headlamp 20 relative to the mounting bracket 30 by releasably holding the headlamp 20 in various rotational positions. The plurality of teeth 130a of each rail 130 is uniformly arranged on each rail 130. The uniform arrangement of the teeth 130a on each rail 130 allows the cantilever fingers 125a, 126a of each arm 125, 126 to engage in the same, corresponding channels 135 of each rail 130.Each arm 125, 126 is sufficiently flexible to allow minor adjustments of the arms 125, 126 so that the cantilever fingers 125a, 126a can engage seamlessly with the multitude of teeth 130a without compromising the structural integrity of the arms 125, 126. Referring to Figures 8, 9 to 10, the arms 125, 126 interact with the rails 130 to fix the headlamp 20 relative to the mounting bracket 30 in a variety of rotational positions. The flexibility of the arms 125, 126 allows the headlamp 20 to be rotated about the central axis A relative to the mounting bracket 30. Each channel 135 corresponds to an angle at which the headlamp 20 can be positioned relative to the mounting bracket 30 along an angular range of 180 degrees. In the illustrated embodiment, the cantilever fingers 125a, 126a are simultaneously received in corresponding channels 135 of the rail 130 to prevent rotation of the headlamp 20 relative to the mounting bracket 30.The headlamp 20 can be adjusted at regular angular intervals of 2 degrees, 5 degrees, 10 degrees, or any other desired angular interval along the angular range by rotating the headlamp 20 until the projecting fingers 125a, 126a engage in a selected channel 135. In some embodiments, the numerous teeth 130a are arranged at irregular intervals around the rail 130, so that the channels 135 can be more densely spaced in areas corresponding to the more desirable fixed angular positions of the headlamp 20. A moment 127a, 127b is exerted on each arm 125, 126 when the headlamp 20 is rotated about the central axis A. The first moment 127a is exerted on the first arm 125 when the headlamp 20 is rotated in a first direction. The second moment 127b is exerted on the first arm 125 when the headlamp 20 is rotated in a second direction. Since the second arm 126 is aligned opposite to the first arm 125, the moments acting on the second arm 126 when the headlamp 20 is rotated are opposite to the moments 127a and 127b acting on the first arm 125. Thus, the same force is required to rotate the headlamp 20 in both directions. In other words, the rotation of the headlamp 20 relative to the mounting bracket 30 is directionally balanced when the arms 125 and 126 are arranged at opposite edges of the rigid frame 105.In some embodiments, the mounting bracket includes 30 additional offset arms to provide additional support to the battery compartment 21 while the headlamp 20 rotates about the axis of rotation A. With reference to Figures 8 and 9, the rigid frame 105 also defines a plurality of perforations 140a formed in the plate-like area. In the illustrated embodiment, the perforations 140a are formed in the central web section of the plate-like area, which adjoins the recessed section that receives the flexible support 140. The perforations 140a substantially fill a large part of the central web section. The perforations 140a are formed on a side of the rigid frame 105 opposite the support support 140. In the illustrated embodiment, the perforations 140a are formed on a first side of the rigid frame 105 facing the headlamp 20, and the support support 140 is arranged on a second side of the rigid frame 105 facing a user. The perforations 140a are uniformly dimensioned.In the illustrated embodiment, the perforations 140a are circular. In other embodiments, the perforations 140a may have other shapes and / or not be uniformly dimensioned or shaped. The illustrated perforations 140a are arranged in a series of rows extending substantially parallel to the centerline axis B of the mounting bracket 30. In the illustrated embodiment, the perforations 140a are arranged in three main rows, with some perforations 140a located outside the rows (for example, in a fourth and fifth row) to fill the plate-like area. In other embodiments, the perforations 140a may be arranged in fewer or more rows or in a random pattern. In the illustrated embodiment, adjacent rows of perforations 140a are offset relative to one another.The perforations 140a extend only partially through the rigid frame 105, so that the perforations 140a are visible from one side of the rigid frame 105, while an opposite side of the rigid frame 105 comprises a continuous solid wall that maintains the structural integrity of the rail sections. The perforations 140a reduce the bending stiffness of the central web section of the I-shaped plate-like area, while the rail sections remain essentially unperforated, allowing the rigid frame 105 to exhibit directional flexibility across the plate-like area. In some embodiments, the perforations 140a can extend completely through the rigid frame 105. In such embodiments, when the headlamp assembly 10 is secured to a user's head or to a protective helmet, air can flow through the perforations 140a in the rigid frame 105, thereby improving heat transfer at the interface between the user's head and the mounting bracket 30 and reducing heat generation and perspiration. Referring to Fig. 13, the mounting bracket 30 also includes the flexible support 140, which is coupled to the rigid frame 105. The flexible support 140 is arranged within the recessed section 106 and overlaps at least one section of the plate-like area, such that the flexible support 140 covers the central web section, while the rail sections define and support the flexible support 140. The flexible support 140 is made of an elastomeric polymer material such as rubber. The flexible support 140 comprises a first surface 141, which is configured to engage with the user's head or protective helmet, and a second surface 142 (Figs. 14 and 16), which faces the rigid frame 105. The second surface 142 engages in the rigid frame 105 within the recessed section 106.In the illustrated embodiment, the flexible support 140 is shaped to complement the recessed section and the underlying I-shaped plate-like area of ​​the rigid frame 105. The flexible support 140 can be secured to the rigid frame 105 by overmolding, adhesive, fasteners, or a combination thereof, so that the mounting bracket 30 forms a single, unified structure. The flexible support 140 can be curved (for example, concave) about the centerline axis B (Fig. 8) of the mounting bracket 30. The flexible support 140 can also be curved (for example, concave) about a second axis C (Fig. 8) of the mounting bracket 30, which is perpendicular to the centerline axis B. Alternatively, the flexible support 140 can be curved away from the headlamp 20 and towards the user's head or helmet. In other words, the flexible support 140 can be convex relative to the headlamp 20. The flexible support 140 can be curved (for example, convex) about the center line B (Fig. 8) of the mounting bracket 30. The flexible support 140 can also be curved (for example, convex) about the second axis C (Fig. 8) of the mounting bracket 30. In such an embodiment, the flexible support 140 can bulge outwards from the rigid frame 105. When pressed against the user's head or helmet, the flexible support 140 can flex like a leaf spring. When a load is exerted by the user's head or helmet, the flexible support 140 and the rigid frame 105 flex together. Thus, the mounting bracket 30 can flex to generally conform to the curvature of the user's head or helmet. The flexion of the mounting bracket 30 is primarily absorbed by the deformation of the central web section of the I-shaped plate-like area, while the rail sections provide structural support and distribute the load across the rigid frame 105. In some embodiments, the flexible support 140 can be concave or convex relative to the headlamp 20 to accommodate different head shapes. In some embodiments, perforations 140a can also extend through the flexible support 140. The mounting bracket 30 is designed to adapt to the curvature of the user's head or helmet.In the illustrated embodiment, the mounting bracket 30 is curved such that it generally corresponds to the curvature of the user's head or helmet. For example, the mounting bracket 30 is curved towards the headlamp 20 and away from the user's head or helmet. In other words, the mounting bracket 30 is concave relative to the headlamp 20. The mounting bracket 30 can be curved (for example, concave) about the center line B (Fig. 8). The mounting bracket 30 can also be curved (for example, concave) about a second axis C (Fig. 8) that is perpendicular to the center line B. Alternatively, as shown in Figs. 16 and 17, the mounting bracket 30 can be curved away from the headlamp 20 and towards the user's head or helmet. In other words, the mounting bracket 30 can be convex relative to the headlamp 20. The mounting bracket 30 can be curved (for example, convex) about the center line B (Fig. 8). The mounting bracket 30 can also be curved (for example, convex) about the second axis C (Fig. 8). When pressed against the user's head or helmet, the mounting bracket 30 can flex like a leaf spring. Figures 18 and 19 show another mounting bracket 230 for use with the headlamp 20. The mounting bracket 230 is similar to the mounting bracket 30 described above, with identical features indicated by the same reference numerals plus "200". The mounting bracket 230 comprises a rigid frame 305 designed to couple the headlamp 20 to the strap 15. The mounting bracket 230 includes a rigid frame 305, prongs 310, and claws 315. The prongs 310 extend from the rigid frame 305 and are shaped to be complementary to the battery compartment 21, so that the prongs 310 clamp the battery compartment 21 and allow the headlamp 20 to rotate about the central axis A. The mounting bracket 230 also includes a support 340. The mounting bracket 230 also includes a plurality of perforations 340a. In this embodiment, the perforations 340a extend completely through the frame 305.The perforations 340a can allow airflow through the mounting bracket 230. In this embodiment, the mounting bracket 230 also comprises a pair of arms 325 extending from the same edge of the rigid frame 305 of the mounting bracket 230. In particular, both arms 325 extend from the same edge 305b of the rigid frame 305. Each arm 325 is cantilevered and includes a cantilever finger 325a at its distal end. The cantilever fingers 325a can engage with the rails 130 formed on the battery receptacle 21 of the headlamp 20. The cantilever fingers 325a are optionally received in the channels 135 to secure the headlamp 20 against rotation relative to the mounting bracket 230. During the rotation of the headlamp 20 relative to the mounting bracket 230, a rotation in a first direction exerts a reaction force on the cantilever fingers 325a, which induces a moment 327, causing the arms 325 to bend outwards. A rotation of the headlamp 20 in a second, opposite direction exerts a reaction force that presses the cantilever fingers 325a into the channels 135. Consequently, a greater force is required to rotate the headlamp 20 in the second direction than in the first direction. Accordingly, the mounting bracket 230 of this embodiment exhibits a direction-dependent resistance to the rotation of the headlamp 20. When the headlamp 20 is rotated counterclockwise relative to the mounting bracket 230, the rotation of the headlamp 20 exerts a reaction force on the cantilever fingers 325a, which induces a moment 327 on the arms 325. The induced moment 327 forces the cantilever fingers 325a to move outwards out of the channel 135. When the headlamp 20 is rotated clockwise, the reaction force exerted on the cantilever fingers 325a forces them to remain in the channel 135. To overcome the tendency of the cantilever fingers 325a to remain in the channel 135, the user must apply a greater force clockwise to rotate the headlamp 20 than when rotating it counterclockwise. Since the arms 325 are aligned in the same direction, the force required to rotate the headlamp 20 clockwise is increased.In contrast to the mounting bracket 30, where the arms are arranged on opposite sides of the rigid frame 105 to provide a balanced rotational resistance in all directions, the rotation of the headlamp 20 relative to the mounting bracket 230 requires different forces from the user depending on the direction of rotation. Figures 20 and 21 show another mounting bracket 430 for use with the headlamp 20. The mounting bracket 430 is similar to the mounting bracket 30 described above, with identical features indicated by the same reference numerals plus "400". The mounting bracket 430 comprises a rigid frame 405 designed to couple the headlamp 20 to the strap 15. The rigid frame 405 includes a first rim 405a, a second rim 405b, a third rim 405c, and a fourth rim 405d, which define a perimeter of the rigid frame 405. Similar to the mounting bracket 30, the mounting bracket 430 comprises prongs 410, claws 415 and cantilever arms 425. The prongs 410 extend from the rigid frame 405 and are shaped complementarily to the battery receptacle 21, so that the prongs 410 clamp the battery receptacle 21 and allow the headlamp 20 to rotate about the central axis A. The mounting bracket 430 also includes a flexible support 540, which is coupled to the rigid frame 405. In the illustrated embodiment, the flexible support 540 is made of an elastomeric polymer material such as rubber. The flexible support 540 is arranged within an opening 406 of the rigid frame 405. In the illustrated embodiment, the flexible support 540 is injection-molded onto the rigid frame 405, so that the mounting bracket 430 forms a one-piece structure. In some embodiments, the flexible support 540 can be coupled by means of fastening elements to a plurality of projections 545, which extend from the rigid frame 405 in the direction of the center line B. In contrast to the flexible pad 140, the flexible pad 540 defines a plurality of perforations 540a. The perforations 540a are uniformly dimensioned. Furthermore, the perforations 540a shown are circular. In the illustrated embodiment, the perforations 540a are arranged linearly in a series of rows. The rows run parallel to the centerline axis B. The rows shown are staggered, such that the perforations 540a in one row are offset from the perforations 540a in adjacent rows in directions perpendicular to the centerline axis B. In other embodiments, the perforations 540a can have a variety of sizes, shapes, and arrangements to provide alternative configurations. The perforations 540a improve the flexibility properties of the flexible pad 540. In addition, the perforations 540a allow airflow through the flexible pad 540.When the headlamp assembly 10 is secured to a user's head, the perforations 540a increase airflow through the mounting bracket 430 and act as a cooling function. The increased airflow improves the heat transfer rate between the area where the user's head contacts the flexible pad 540 and the surrounding air, thus dissipating heat from the area of ​​the head in direct contact with the flexible pad 540 and reducing perspiration. Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist in the scope and concept of one or more independent aspects of the described invention. Various features of the invention are set out in the following claims. QUOTES INCLUDED IN THE DESCRIPTION This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature US 63 / 796,814

[0001]

Claims

Headlamp assembly comprising: a strap configured to be worn by a user; a headlamp comprising: a battery compartment configured to receive a battery, and a light assembly with a light element configured to be powered by the battery and a housing holding the light element; and a mounting bracket coupled to the headlamp and the strap, the mounting bracket comprising a rigid frame and a flexible support, the flexible support being coupled to the rigid frame and configured to engage with the user's head or helmet. Headlamp assembly according to claim 1, wherein the flexible support covers at least a section of the rigid frame. Headlamp assembly according to claim 2, wherein the flexible support is arranged in a recessed section of the rigid frame. Headlamp assembly according to claim 2, wherein the flexible support is arranged within a circumference of the rigid frame. Headlamp assembly according to claim 1, wherein the rigid frame comprises a plurality of perforations. Headlamp assembly according to claim 5, wherein the plurality of perforations extends only partially through the rigid frame. Headlamp assembly according to claim 5, wherein the plurality of perforations is formed on a first side of the rigid frame and the flexible support is coupled to a second side of the rigid frame opposite the first side. Headlamp assembly according to claim 1, wherein the mounting bracket is bent towards the headlamp. Headlamp assembly according to claim 1, wherein the mounting bracket comprises a prong that engages in the headlamp to detachably couple the headlamp to the mounting bracket. Headlamp comprising: a battery compartment configured to receive a battery; a lighting assembly attached at an interface to the battery compartment, the lighting assembly comprising an output element configured to be powered by the battery and a housing holding the output element; and a seal arranged between the interface between the battery compartment and the housing of the lighting assembly, the seal forming a light guide for at least one section of a user interface. Headlamp according to claim 10, wherein the seal is made of a transparent material. Headlamp according to claim 10, wherein the seal defines a circumference of the interface to which the lighting assembly is attached. Headlamp according to claim 10, wherein the light guide directs light from an indicator light inside the headlamp to an outer surface of the headlamp. Headlamp according to claim 13, wherein the indicator light is one of a plurality of indicator lights within the headlamp, wherein the light guide directs light from each of the plurality of indicator lights to the outer surface of the headlamp, and furthermore comprises a partition arranged between each of the plurality of indicator lights to separate the plurality of indicator lights from one another. Headlamp assembly comprising: a strap designed to be worn by a user; a headlamp comprising a battery compartment designed to receive a battery and a light assembly with an output element designed to be powered by the battery and a housing that holds the output element;and a mounting bracket coupled to the headlamp and the strap, the mounting bracket comprising: a frame comprising a first edge and a second edge opposite the first edge, a first arm extending from adjacent to the first edge of the frame towards the second edge of the frame, the first arm comprising a first cantilever finger engaging with the headlamp to control the rotation of the headlamp relative to the mounting bracket, and a second arm extending from adjacent to the second edge of the frame towards the first edge of the frame, the second arm comprising a second cantilever finger engaging with the headlamp to control the rotation of the headlamp relative to the mounting bracket. Headlamp assembly according to claim 15, wherein the headlamp further comprises a first rail and a second rail spaced apart from the first rail, the first cantilever finger cooperating with the first rail and the second cantilever finger cooperating with the second rail to control the rotation of the headlamp relative to the mounting bracket. Headlamp assembly according to claim 16, wherein the first rail and the second rail comprise a plurality of channels defining a plurality of rotational positions for the headlamp relative to the mounting bracket. Headlamp assembly according to claim 15, wherein the mounting bracket further comprises a first prong extending outwards from the frame and a second prong extending outwards from the frame to couple the mounting bracket to the headlamp. Headlamp assembly according to claim 18, wherein the first and second arms are arranged between the first and second prongs. Headlamp assembly according to claim 15, wherein the frame further comprises a third rim extending between the first and the second rim, and a fourth rim opposite the third rim extending between the first and the second rim, wherein the mounting bracket further comprises a first claw adjacent to the third rim and a second claw adjacent to the fourth rim, and the first and the second claw are configured to receive the strap in order to secure the mounting bracket to the strap.

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