Recessed Light Unit Lens for Focused Headwear Beam
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Solution Overview
Problem
Current lighted headwear, such as hats with LEDs, fail to provide sufficient illumination at a distance and lack a focused beam of light, making them inadequate for tasks that require directed lighting like flashlights.
Innovation Solution
Incorporating a light unit within the brim of the hat, featuring a holder and a lens that converges light from a light source to produce a narrower beam, utilizing LEDs and potentially additional lenses like Fresnel or rectangular lenses to maximize light output and direct it effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple LEDs are used to illuminate an area in front of the wearer, then the illumination coverage area is improved, but the beam focus and distance illumination capability deteriorates
Solution Approach 1:
The illumination system is segmented into multiple functional zones: a first light source (LED array) provides wide-area diffuse illumination for general visibility, while a second light source (high-intensity LED or laser diode) with a lens provides a focused narrow beam for distance illumination. This segmentation allows each light source to optimize for its specific function without compromising the other.
Solution Approach 2:
A lens system acts as an intermediary between the second light source and the target area, concentrating and directing the light into a narrow beam. The lens mediates the transformation from point-source light to a focused directional beam, enabling distance illumination while maintaining energy efficiency.
2Illumination intensity
If incandescent bulbs or other traditional light sources are used, then the light output brightness is improved, but the power consumption and battery size requirements worsen
Solution Approach 1:
The patent transitions from traditional incandescent light sources to LED technology, changing the fundamental operating parameters of the light source. LEDs operate at significantly lower voltages and currents, consuming less power while delivering comparable or superior light output. This parameter change enables the use of smaller, lighter batteries that can be integrated into the headwear without compromising illumination performance.
3Ease of operation
If conventional light sources are used without directional control, then the ease of operation is improved, but the need for additional directional control devices increases device complexity
Solution Approach 1:
The patent merges the light source and directional control (lens) into a single integrated assembly. The second light source is positioned within or near the brim, with its lens system built-in, eliminating the need for separate directional control devices. This integration maintains ease of operation while reducing overall device complexity.
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
The solution enhances illumination range and focus, allowing lighted headwear to provide a bright, directed beam of light up to 60 feet, surpassing the limited diffuse illumination of existing designs.
Implementation Method 1
at least one lens located within the holder at the front end of the holder; and at least one light source located within the holder and axially spaced from the at least one lens such that light produced by the light source projects along the holder, through the lens, and out the front end of the holder
Data Source
AI summary
Lighted headwear having a brim and a light unit located within the brim. The light unit includes: a holder with a front end and a back end; at least one lens located within the holder at the front end of the holder; and at least one light source located within the holder and axially spaced from the at least one lens such that light produced by the light source projects along the holder, through the lens, and out the front end of the holder. The lighted headwear produces a narrower, longer-distance beam of light than typical lighted headwear, more akin to the light produced by a flashlight or torch, while maintaining the look of a normal hat or cap.