Headlight Conductor Integration in Non-Elastic Headband

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Solution Overview

Problem

Existing headlamps face issues with power cable durability and wearing comfort due to external mechanical damage and entanglement risks, particularly when the elastic band stretches or relaxes, leading to frictional forces and potential injury.

Innovation Solution

Integrating the conductor into a non-elastic part of the headband, which is co-extruded with plastic for protection, allowing for adjustable length and reduced friction, and incorporating foam padding and eyelets for comfort and easy detachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the power line is attached to the headband by retaining clips or metal strands, then the headlamp can be assembled, but there is a risk of line break under tensile stress

Engineering Contradiction:

Improveconductor durabilityVSAvoidmechanical damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The conductor is integrated into the headband structure by co-extrusion, merging the electrical conductor with the structural component. This eliminates separate attachment points that could fail, as the conductor becomes an inherent part of the headband rather than a separate element subject to mechanical stress at connection points.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conductor is enclosed within the headband material through co-extrusion, nesting the electrical component inside the protective structural element. This protects the conductor from external mechanical damage while maintaining electrical functionality.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Object-affected harmful factors

If the band is formed as a hose band with the power line in the inner cavity, then the power cable is protected against external mechanical damage, but the conductor must assume a meandering position under tensile stress

Engineering Contradiction:

Improvemechanical protectionVSAvoidfrictional forces and wear

Core Design Contradiction:

Object-affected harmful factorsVSObject-generated harmful factors

Solution Approach 1:

The conductor and headband are merged into a single co-extruded structure, eliminating the meandering configuration. The conductor runs straight through the headband without bending or looping, preventing frictional forces and wear that would result from repeated flexing of a meandering conductor.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If the conductor protrudes beyond the headband in a spiral shape, then friction-free changes in length are possible, but the conductor can easily get caught in other objects

Engineering Contradiction:

Improvelength adjustment freedomVSAvoidentanglement risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The conductor is integrated within the headband structure, eliminating the protruding spiral shape. The headband itself provides the necessary flexibility and length adjustment through its elastic properties, while the conductor remains protected and retracted within the headband, preventing entanglement with external objects.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If the conductor is integrated in the non-elastic part of the strap, then the conductor is protected from tensile loads, but the manufacturing complexity increases

Engineering Contradiction:

Improveconductor protectionVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The headband and conductor are manufactured as a single integrated component through co-extrusion technology. This merging of components achieves conductor protection while actually simplifying manufacturing by eliminating separate assembly steps for attaching conductors to the headband.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The headband is manufactured as a composite structure with the conductor embedded within the non-elastic material matrix. This composite approach allows the conductor to be protected by the rigid non-elastic material while maintaining structural integrity and electrical functionality.

Inventive Principle:

Principle #40Composite materials

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

Enhances durability and comfort by shielding the conductor from mechanical stress and preventing entanglement, while maintaining adjustability and ease of use, with improved visibility through reflectors.

Implementation Method 1

the band has an elastic and a non-elastic part

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

the conductor can be enclosed in the non-elastic part, for example by co-extrusion of a plastic

Methodology Applied

Scientific EffectCo-extrusion: Extrusion

Implementation Method 3

incorporating foam padding and eyelets for comfort

Methodology Applied

Scientific EffectFoam cushioning: Foam

Data Source

PatentUS11781741B2Headlight

Publication Date: 2023.10.10 LEDLENSER GMBH & CO KG

AI summary

A headlight (forehead light) includes a housing (10) for accommodating a light-emitting device, in particular at least one LED, and a further housing (11) for accommodating at least one battery or rechargeable battery (15). The housings (10, 11) are connected to one another by a conductor (16) suitable for voltage and current supply and are secured to a strap. The strap has an elastic and a non-elastic part (12, 13). The conductor (16) is integrated into the non-elastic part (12).