Interchangeable Hat Light Assembly with Conductive Prongs
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Solution Overview
Problem
Existing illuminated hat designs lack the ability to change designs efficiently, as they often require manufacturing different static light assemblies for various designs, which is inefficient and limits user customization.
Innovation Solution
A light assembly for hats featuring a changeable display element with conductive prongs and prong receptacles that allow for easy alignment and electrical contact, enabling the use of interchangeable translucent covers with different designs, along with a driver circuit and switch for activation and deactivation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different static light assemblies are manufactured for various designs, then design variety is achieved, but manufacturing efficiency deteriorates
Solution Approach 1:
The light assembly is divided into separate functional modules: a reusable base assembly containing the light source, battery, and control circuitry, and interchangeable cover elements containing different designs. This segmentation allows the base assembly to be manufactured once and reused, while only the cover elements need to be varied for different designs, significantly improving manufacturing efficiency while maintaining design variety.
Solution Approach 2:
The base assembly is designed as a universal platform that can accommodate multiple different cover elements through standardized mounting mechanisms. The conductive prongs and receptacles create a universal electrical connection system that works with any cover element, allowing a single base assembly to serve multiple design configurations without requiring separate manufacturing for each design variant.
2Adaptability or versatility
If multiple different light assemblies are produced for customization, then user preference satisfaction improves, but device complexity increases
Solution Approach 1:
By segmenting the light assembly into a permanent base and interchangeable covers, the system reduces complexity. Users only need to swap simple cover elements rather than dealing with complex assembly disassembly. The standardized interface (conductive prongs and receptacles) simplifies the customization process while enabling diverse design options.
Solution Approach 2:
The cover elements are designed as simplified copies or representations of different designs that can be easily interchanged. Each cover contains only the essential design elements (logos, patterns, colors) printed or molded onto the translucent material, allowing users to change designs without complex mechanisms. The base assembly remains identical across all configurations, reducing the number of unique components users must manage.
3Reliability
If conductive prongs extend beyond receptacle exits requiring bending for contact, then electrical connection reliability improves, but assembly precision requirements increase
Solution Approach 1:
The conductive prongs are designed with flexibility to bend during the assembly process. When the cover element is placed onto the base assembly, the prongs naturally bend to make contact with the conductive receptacles. This dynamic bending action compensates for minor misalignments and ensures reliable electrical connection without requiring extremely precise manufacturing tolerances for the positioning of prongs and receptacles.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables users to easily change and customize the design on their illuminated hats by using interchangeable covers, reducing manufacturing inefficiencies and enhancing user preference through customizable lighting displays.
Implementation Method 1
A light circuit board is disposed in the interior space adjacent the back wall and has a light emitting element disposed thereon
Data Source
AI summary
A lighting system for a hat includes a front housing containing lighting elements that mates with a back plate positioned on the inside of the hat. Driver circuitry controls operation of the LEDs for various lighting modes, and a cover for the front housing is translucent and designed in the shape of a recognizable logo or other design. Electric power comes from a battery located on the back plate, and is provided through the hate using prongs or projections that pass through the hat, from the back plate to a circuit connector in the front housing. The circuit connector is electrically coupled to circuitry on a circuit board in the front housing.