Fan-based cooler for head-protection gear
A cooler accessory for use with a hard hat or other head-protecting gear having a protective shell with a rim, the accessory including a housing that is attachable to the protective shell, flexible and pliable tubing that extends from the rigid housing in a manner that allows for user control over position and orientation of the tubing, and airflow supply means (e.g., an electric fan assembly) for supplying a flow of air that passes through the tubing and exits therefrom. During use, a portion of the tubing is disposed below the rim of the protective shell for directing the flow of air supplied by the airflow supply means under the rim for injection toward space adjacent the user's body, thereby cooling the user's body. Preferably, the tubing is positioned such that airflow is injected into an air gap between the user's head and the protective shell and over the user's head, thereby actively cooling the user's head. In another aspect, parts of the active cooling device (e.g., the housing or portions thereof) can be integrally formed with the protective shell and rim of the hard hat or other type of head-protection gear.
1. Field of the Invention
This invention relates broadly to hard hats for protecting the heads of users in dangerous environments, such as construction sites, mines, industrial environments (e.g., chemical plants, assembly plants, steel mills, lumber mills), forestry and other tree cutting and pruning environments, military helmets, motorcycle helmets, helmets for alpine skiing and/or snowboarding, and other head-protection gear that employ a rigid head-protecting shell. More particularly, the invention relates to mechanisms that are secured to (or part of) the protective shell of a hard hat and operate to cool the user.
2. State of the Art
Environments involving high temperatures, radiant heat sources, high humidity, direct physical contact with hot objects, or strenuous physical activities have a high potential for inducing heat stress in individuals that work in such environments. Such environments include iron and steel foundries, brick-firing and ceramic plants, glass products facilities, rubber products facilities, electrical utilities (particularly boiler rooms), bakeries, confectioneries, commercial kitchens, laundries, food canneries, chemical plants, mining sites, smelters and steam tunnels.
Outdoor operations conducted in hot weather, such as construction, forestry and lumber mills, refining, asbestos removal, and hazardous waste site activities, especially those that require workers to wear semi-permeable or impermeable clothing are also likely to cause heat stress among exposed workers.
In many of these environments, workers wear hard hats that protect the users' heads from falling debris and other potential hazards. However, in hot weather, hard hats provide a “greenhouse” effect where the humidity caused by body perspiration about the head and neck builds up under the hard hat, thereby thwarting the body's own evaporative cooling system. Some leading hard hat manufactures have introduced small air vents similar to the concept disclosed in U.S. Pat. No. 6,170,090 to Minor. However, these small vents provide minimal to no cooling effect. There have been many hard hat designs that actively cool the user by blowing air over the head. Such a design takes advantage of the body's own evaporative cooling system and enhances it with the cooling properties of wind chill. See U.S. Pat. No. Re. 36,242 to Apisdorf, U.S. Pat. No. 3,813,696 to Yeager, U.S. Pat. No. 3,881,198 to Waters, U.S. Pat. No. 3,881,478 to Rosendahl et al., U.S. Pat. No. 4,680,815 to Hirsch et al., U.S. Pat. No. 4,893,356 to Waters, U.S. Pat. No. 5,561,862 to Flores, Sr., U.S. Pat. No. 6,122,773 to Katz, and U.S. Pat. No. 6,760,925 to Maxwell. However, these designs are disadvantageous in that they require modification (e.g., thru-holes) to the protective shell of the hard hat and thus risk compromising the structural integrity of the protective shell. Some standards bodies such as the American National Standards Institute (ANSI) also forbid modification of the hard hat by drilling holes. Moreover, the designs suffer from other limitations including high costs, the inability to remove the active cooling mechanism from the hard hat, the inability to secure the active cooling mechanism to hard hats of varying size, the use of materials that are unsuitable for rugged high-impact environments, and the lack of effective user control over the active cooling function.
Thus, there remains a need in the art to provide an active cooling device for use with a hard hat that does not require modification to the protective shell of the hard hat (and thus does not risk compromising the structural integrity of the hard hat). Moreover, there remains a need in the art for such an active cooling device that is inexpensive, preferably removable from the hard hat, capable of being added to hard hats of varying size, uses materials that are suitable for rugged high-impact environments, and affords effective user control over the active cooling function.
SUMMARY OF THE INVENTIONIt is therefore an object of the invention to provide an active cooling device for use with a hard hat that does not require modification to the protective shell of the hard hat (and thus does not risk compromising the structural integrity of the hard hat).
It is another object of the invention to provide such an active cooling device that is inexpensive.
It is a further object of the invention to provide such an active cooling device that is removable from the hard hat.
It is also an object of the invention to provide such an active cooling device that is capable of being added to hard hats of varying size.
It is an additional object of the invention to provide such an active cooling device that is realized from materials that are suitable for rugged high-impact environments.
It is still another object of the invention to provide such an active cooling device that affords effective user control over the cool function of the device.
In accord with these objects, which will be discussed in detail below, an active cooler accessory is provided for use with a hard hat or other head-protecting gear having a protective shell with a rim. The accessory includes a housing that is attachable to the protective shell, flexible and pliable tubing that extends from the housing in a manner that allows for user control over position and orientation of the tubing, and airflow supply means (e.g., an electric fan assembly) for supplying a flow of air that passes through the tubing and exits therefrom. During use, a portion of the tubing is disposed below the rim of the protective shell for directing the flow of air supplied by the airflow supply means under the rim for injection toward space adjacent the user's body, thereby cooling the user's body. Preferably, the tubing is positioned such that airflow is injected into an air gap between the user's head and the protective shell and over the user's head, thereby actively cooling the user's head. Preferably, the housing supports a battery compartment and at least one user-manipulated switch and associated control circuitry that operate to selectively couple at least one battery held within the battery compartment to the electric fan assembly in response to user manipulation of the at least one switch.
It will be appreciated that the cooling airflow provided by the accessory device can be directed such that it flows over the user's head, which works in conjunction with the body's own evaporative cooling system to significantly reduce the heat and humidity experienced by the user and thus results in a significant increase in the comfort of the user. Such cooling also reduces the exposure to work related heat exhaustion, potential serious heatstroke and reduced productivity.
According to one embodiment of the invention, a first switch (e.g., 3-position switch) cooperates with control circuitry to operate in each one of the following modes: i) a first mode wherein airflow supply means is powered off; ii) a second mode wherein the airflow supply means is automatically cycled on/off for predetermined on/off time periods; and iii) a third mode wherein the airflow supply means is continuously powered on. A second switch (e.g., larger size push button switch) cooperates with the control circuitry to operate in a fourth mode wherein the airflow supply means is automatically powered on for a predetermined time period, with the fourth mode overriding the operations of the first and second modes.
According to another embodiment of the invention, the housing supports one or more connectors that connect to external power source(s) (e.g., external AC/DC power converter (outlet charger), external DC/DC power converter (automobile cigarette lighter charger), external solar-cell power converter) for charging the battery(ies) that are held in the battery compartment of the housing, and possibly for powering the airflow supply means of the device for use.
According to yet another embodiment of the invention, the housing includes a curved base that generally follows the contour of an exterior portion of the protective shell with a flexible insert cushion fixed thereto. The tubing is extendible along its length. These features allow the accessory to be secured to hard hats of varying size and shape.
In another aspect of the present invention, parts of the active cooling device (e.g., the housing or portions thereof can be integrally formed with the protective shell and rim of the hard hat.
Additional objects and advantages of the invention will become apparent to those skilled in the art upon reference to the detailed description taken in conjunction with the provided figures.
BRIEF DESCRIPTION OF THE DRAWINGS
The term “hard hat” as used herein is meant to include not only the specific designs shown, but also include other types of head-protecting safety hats for dangerous environments such as construction sites, mines, industrial environments (e.g., chemical plants, assembly plants, steel mills, lumber mills), forestry and other tree cutting and pruning environments, miner's hats, protective hats for industrial applications, protective hats for lumbering and tree pruning applications, military helmets, motorcycle helmets, helmets for alpine skiing and/or snowboarding, and other head-protection gear that employ a rigid head-protecting shell.
Turning now to
As best shown in
As best shown in the exploded view of
As best shown in
During use, the air duct 31 is positioned substantially orthogonal relative to the plane defined by the rim 14 as best shown in
The housing 23 includes a battery compartment 38 (not shown) that holds one or more batteries that supply electrical power to the electric motor 39 of the fan assembly 35. The housing part 23C also supports a printed circuit board (
In the preferred embodiment, two switches 45A and 45B are used. As best shown in
As shown in the schematic diagram of
The first switch 45A cooperates with the microcontroller 51 to carry out three different operations modes as follows:
-
- i) “∘” position—Off Mode: the switching circuitry 53 is controlled so that electric motor 39 is powered off—the transistor Q1 is switched OFF so that the ground current path is inactive);
- ii) “A” position—Intermittent Mode: the switching circuitry 53 is controlled so that the electric motor is automatically cycled on/off for predetermined on/off time periods (e.g., on for one minute and then off for four minutes)—the transistor Q1 is automatically cycled on/off for predetermined on/off time periods so that the ground current path is cycled on/off;
- iii) “●” position—Continuous Mode: the switching circuitry 53 is controlled so that electric motor 39 is continuously powered ON—the transistor Q1 is switched ON so that the ground current path is continuously active.
Preferably, the power capacity of the battery(ies) held in the battery compartment, the power consumption characteristics of the electric motor 39 and the associated control circuitry, and the predetermined ON/OFF time periods of the Intermittent mode are adapted such that the electric motor 39 can operate in the Intermittent mode for an 8 to 10 hour time period. In this configuration, the Intermittent mode is advantageous because the device can be used to cool the user for an entire work day (or a substantial part of a long work day) on a single battery charge. The Intermittent mode has other advantages. More particularly, during the OFF time periods, heat and moisture will typically build up under the protective shell 12 and cause the user to perspire. In the ON mode, the air blown over the head will enhance the evaporative-based cooling provided by such perspiration for an improved cooling effect.
The second switch 45B cooperates with the microcontroller 51 to carry out a “Fast-Blast” mode wherein the switching circuitry 53 is controlled to power ON the electric motor 39 for a predetermined time period (e.g., two minutes)—the transistor Q1 is automatically cycled on for the predetermined time period so that the ground current path is activated for the predetermined time period. In such operations, the “Fast-Blast” mode overrides the “OFF” and “Intermittent” modes such that the “Fast-Blast” mode takes precedence over the control of the switching circuitry 53 (e.g., transistor Q1) and governs the operation of the electric motor 39. In the preferred embodiment, the “Fast-Blast” switch 45B
Referring back to
The dimensions of an exemplary embodiment of the cooling accessory of the present invention is shown in
In an alternate embodiment shown in
In yet another alternate embodiment shown in
Advantageously, the cooling airflow provided by the active cooling device of the present invention can be directed such that it flows over the user's head, which significantly reduces the heat and humidity experienced by the user and greatly enhances the body's evaporative cooling mechanism (perspiration) and thus results in a significant increase in the comfort of the user. Such cooling also reduces the exposure to work related heat exhaustion, potential serious heatstroke while improving worker concentration and productivity. Moreover, such cooling is consistent with the Occupational Safety & Health Administration's guidelines for methods for controlling and preventing heat related illness. The housing also provides crush absorption to absorb shock. Finally, the device's low cost and durable construction affords exceptional return on investment.
In alternate embodiments, the housing of the device may be realized from a lightweight, low-cost foam material (or possibly some other material). Such foam material provides additional crush absorption to absorb shock beyond that provided by a rigid plastic housing.
There have been described and illustrated herein several embodiments of a fan-based cooler accessory for a hard hat and related methods of operation. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, while particular configurations and materials have been disclosed, it will be appreciated that other configurations and materials can be used as well. Moreover, while the device described above employs an electric fan assembly to actively generating a supply of airflow, other air moving mechanisms (such as an air blower, centrifuge fan or air pump) can also be used. Also, while particular mechanisms for securing the device to the hard hat have been disclosed, other fixation mechanisms that do not rely on drilling, such as suction cups, permanent adhesives, etc. can be used. In some applications, fixation means (e.g., screws, rivets) that employ holes drilled through the protective shell of the hard hat may be used. In addition, while particular control schemes and electronic control circuitry have been disclosed, it will be understood that other control schemes and other electronic control circuitry can be used. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed.
Claims
1. A device for use with head-protection gear that includes a protective shell with a rim, the device comprising:
- a housing that is attachable to the protective shell;
- flexible and pliable tubing that extends from the housing in a manner that enables a user to adjust position and orientation of the tubing in order to control the direction of the airflow that exits therefrom; and
- airflow supply means, supported by the housing, for supplying a flow of air that passes through the tubing and exits therefrom;
- wherein, during use, a portion of the tubing is disposed below the rim of the protective shell for directing the flow of air supplied by the airflow supply means under the rim for injection toward space adjacent the user's body, thereby cooling the user's body.
2. A device according to claim 1, wherein:
- the tubing is positioned such that flow of air supplied by the airflow supply means is injected into an air gap between the user's head and the protective shell and over the user's head.
3. A device according to claim 1, wherein:
- the length of the tubing is extendible.
4. A device according to claim 1, wherein:
- the housing defines an interior air duct that extends from an opening to the tubing, wherein the airflow supply means is mounted axially within the interior air duct.
5. A device according to claim 3, further comprising:
- a removable grill that covers the opening.
6. A device according to claim 1, further comprising:
- a battery compartment that is supported by the housing and holds at least one battery for powering the airflow supply means and
- at least one user-manipulated switch and associated control circuitry that are supported by the housing and operate to selectively couple the at least one battery to the airflow supply means in response to user manipulation of the at least one switch.
7. A device according to claim 6, further comprising:
- a first user-manipulated switch cooperates with associated control circuitry to operate in the following modes: i) a first mode wherein airflow supply means is powered off; and ii) a second mode wherein the airflow supply means is automatically cycled on/off for predetermined on/off time periods.
8. A device according to claim 7, wherein:
- the first user-manipulated switch cooperates with associated control circuitry to operate in a third mode wherein the airflow supply means is continuously powered on.
9. A device according to claim 8, wherein:
- the first user-manipulated switch comprises a 3-position switch that is disposed on a recessed surface of the housing and covered by a movable door.
10. A device according to claim 7, further comprising:
- a second user-manipulated switch cooperates with associated control circuitry to operate in a fourth mode wherein the airflow supply means is automatically powered on for a predetermined time period, said fourth mode overriding the operations of the first and second modes.
11. A device according to claim 10, wherein:
- the second user-manipulated switch comprises a button switch that is disposed on the exterior of the housing.
12. A device according to claim 11, wherein:
- the button switch provides an ergonomic design that facilitates finger manipulation by user's wearing gloves.
13. A device according to claim 6, wherein:
- the control circuitry comprises a microcontroller that interfaces to switching circuitry that selectively opens and closes a current path between the at least one battery held in the battery compartment and the airflow supply means, the operation of the microcontroller dictated by user manipulation of the at least one switch.
14. A device according to claim 6, further comprising:
- a connector that is supported by the housing and connects to an external power source, the external power source selected from the group including an AC/DC power converter, a DC/DC power converter, and a solar-cell power source.
15. A device according to claim 14, wherein:
- the connector interfaces to charging circuitry that charges the at least battery held in the battery compartment with electrical energy supplied by the external power source connected thereto.
16. A device according to claim 14, wherein:
- the connector interfaces to control circuitry for selectively powering on the airflow supply means with electrical energy supplied by the external power source applied thereto.
17. A device according to claim 14, further comprising:
- means for mounting the solar-cell power source on the housing.
18. A device according to claim 1, wherein:
- the housing includes a curved base that generally follows the contour of a portion of the exterior surface of the protective shell.
19. A device according to claim 18, further comprising:
- an insert of flexible elastomeric material fixed to the curved base, wherein the insert provides a cushion for mounting the housing onto the exterior surface of the protective shell in a manner that accommodates protective shells with varying shapes and sizes.
20. A device according to claim 19, further comprising:
- means for detachably securing the curved base to the exterior surface of the protective shell.
21. A device according to claim 1, wherein:
- said housing is realized from a rigid plastic material.
22. A device according to claim 1, wherein:
- the airflow supply means comprises one of an electric fan assembly, an air blower, a centrifuge fan, and an air pump.
23. A device according to claim 1, wherein:
- the head-protection gear is a hard hat.
24. A device according to claim 1, wherein:
- the head-protection gear is one of a military helmet, motorcycle helmet, a helmet for alpine skiing and/or snowboarding.
25. A method of cooling a user wearing head-protection gear that has a protective shell with a rim, the method comprising:
- attaching a device to the protective shell, the device including a housing, flexible and pliable tubing that extends from the housing in a manner that enables a user to adjust position and orientation of the tubing in order to control the direction of the airflow that exits therefrom, and airflow supply means supported by the housing for supplying a flow of air that passes through the tubing and exits therefrom;
- adjusting the position of the tubing such that a portion of the tubing is disposed below the rim of the protective shell for directing the flow of air supplied by the airflow supply means under the rim for injection towards space adjacent the user's head, thereby cooling the user's body; and
- activating the airflow supply means to produce a flow of air that is directed under the rim and injected toward space adjacent the user's head, thereby cooling the user's body the user's head.
26. A method according to claim 25, further comprising:
- manipulating the tubing to adjust its length.
27. A method according to claim 25, further comprising:
- providing the device with a battery compartment; and
- loading the battery compartment with at least one battery for powering the airflow supply means.
28. A method according to claim 27, further comprising:
- providing the device with at least one user-manipulated switch and associated control circuitry that operate to selectively couple the at least one battery to the airflow supply means in response to user manipulation of the at least one switch;
- manipulating the at least one switch for activation of the electric fan assembly.
29. A method according to claim 28, further comprising:
- providing the device with a first user-manipulated switch that cooperates with associated control circuitry to operate in the following modes: i) a first mode wherein the airflow supply means is powered off; and ii) a second mode wherein the airflow supply means is automatically cycled on/off for predetermined on/off time periods.
30. A method according to claim 29, wherein:
- the first user-manipulated switch cooperates with associated control circuitry to operate in a third mode wherein the airflow supply means is continuously powered on.
31. A method according to claim 29, wherein:
- the first user-manipulated switch comprises a 3-position switch that is disposed on a recessed surface of the housing and covered by a movable door.
32. A method according to claim 29, further comprising:
- providing the device with a second user-manipulated switch that cooperates with associated control circuitry to operate in a fourth mode wherein the airflow supply means is automatically powered on for a predetermined time period, said fourth mode overriding the operations of the first and second modes.
33. A method according to claim 32, wherein:
- the second user-manipulated switch comprises a button switch that is disposed on the exterior of the housing.
34. A method according to claim 28, wherein:
- the control circuitry comprises a microcontroller that interfaces to switching circuitry that selectively opens and closes a current path between the at least one battery held in the battery compartment and the airflow supply means, the operation of the microcontroller dictated by user manipulation of the at least one switch.
35. A method according to claim 27, further comprising:
- providing the device with a connector that is supported by the housing and connects to an external power source, the external power source selected from the group including an AC/DC power converter, a DC/DC power converter, and a solar-cell power source.
36. A method according to claim 35, wherein:
- the connector interfaces to charging circuitry that charges the at least battery held in the battery compartment with electrical energy supplied by the external power source connected thereto.
37. A method according to claim 35, wherein:
- the connector interfaces to control circuitry for selectively powering on the airflow supply means with electrical energy supplied by the external power source applied thereto.
38. A method according to claim 35, further comprising:
- connecting the solar-cell power source to the connector.
39. A method according to claim 35, further comprising:
- mounting the solar-cell power source onto the housing of the device.
40. A method according to claim 25, further comprising:
- providing the housing of the device with a curved base that generally follows the contour of a portion of the exterior surface of the protective shell; and
- detachably mounting the curved base to an exterior surface of the protective shell.
41. A method according to claim 40, further comprising:
- providing the housing of the device with an insert of flexible elastomeric material fixed to the curved base, wherein the insert provides a cushion for mounting the housing onto the exterior surface of the protective shell in a manner that accommodates protective shells with varying shapes and sizes.
42. A method according to claim 40, wherein:
- the device is detachably mounted on the rear portion of the protective shell.
43. A method according to claim 42, wherein:
- the tubing of the device is positioned such that airflow is injected into an air gap between the user's head and the protective shell and over the user's head, thereby cooling the user's head.
44. A method according to claim 25, wherein:
- the airflow supply means comprises one of an electric fan assembly, an air blower, a centrifuge fan, and an air pump.
45. A method according to claim 25, wherein:
- the head-protection gear is a hard hat.
46. A method according to claim 25, wherein:
- the head-protection gear is one of a military helmet, motorcycle helmet, a helmet for alpine skiing and/or snowboarding.
47. A head-protection apparatus comprising:
- a protective shell with a rim;
- a housing with portions that are attachable to, or integrally formed with, the protective shell;
- flexible and pliable tubing that extends from the rigid housing in a manner that enables a user to adjust position and orientation of the tubing in order to control the direction of the airflow that exits therefrom; and
- airflow supply means supported by the housing for supplying a flow of air that passes through the tubing and exits therefrom;
- wherein, during use, a portion of the tubing is disposed below the rim of the protective shell for directing the flow of air supplied by the electric fan assembly under the rim for injection toward space adjacent the user's body, thereby cooling the user's body.
48. A head-protection apparatus according to claim 47, wherein:
- the tubing is positioned such that flow of air supplied by the airflow supply means is injected into an air gap between the user's head and the protective shell and over the user's head.
49. A head-protection apparatus according to claim 47, wherein:
- the length of the tubing is extendible.
50. A head-protection apparatus according to claim 47, wherein:
- the housing defines an interior air duct that extends from an opening to the tubing, wherein the airflow supply means is mounted axially within the interior air duct.
51. A head-protection apparatus according to claim 47, further comprising:
- a battery compartment that is supported by the housing and holds at least one battery for powering the airflow supply means; and
- at least one user-manipulated switch and associated control circuitry that are supported by the housing and operate to selectively couple the at least one battery to the airflow supply means in response to user manipulation of the at least one switch.
52. A head-protection apparatus according to claim 47, wherein:
- said housing is realized from a rigid plastic material.
53. A head-protection apparatus according to claim 47, wherein:
- the airflow supply means comprises one of an electric fan assembly, an air blower, a centrifuge fan, and an air pump.
54. A head-protection apparatus according to claim 47, which is realized as a hard hat.
55. A head-protection apparatus according to claim 47, which is realized as one of a military helmet, motorcycle helmet, a helmet for alpine skiing and/or snowboarding.
Type: Application
Filed: Sep 21, 2005
Publication Date: Mar 22, 2007
Inventor: Nicholas Webb (Redding, CA)
Application Number: 11/232,283
International Classification: A42B 1/06 (20060101);