WO2014186347A1 - Ensemble de lampe frontale médicale - Google Patents

Ensemble de lampe frontale médicale Download PDF

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Publication number
WO2014186347A1
WO2014186347A1 PCT/US2014/037813 US2014037813W WO2014186347A1 WO 2014186347 A1 WO2014186347 A1 WO 2014186347A1 US 2014037813 W US2014037813 W US 2014037813W WO 2014186347 A1 WO2014186347 A1 WO 2014186347A1
Authority
WO
WIPO (PCT)
Prior art keywords
assembly
headlamp
light
electrical
lamp
Prior art date
Application number
PCT/US2014/037813
Other languages
English (en)
Inventor
John Thomas FERGUSON
Original Assignee
River Point, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US13/972,489 external-priority patent/US20140334132A1/en
Priority claimed from US14/162,244 external-priority patent/US9091428B2/en
Priority claimed from US14/243,263 external-priority patent/US9234653B2/en
Application filed by River Point, Llc filed Critical River Point, Llc
Priority to EP14797604.7A priority Critical patent/EP2997297A4/fr
Priority to GB1521926.4A priority patent/GB2529365B/en
Publication of WO2014186347A1 publication Critical patent/WO2014186347A1/fr

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Classifications

    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61BDIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B90/00Instruments, implements or accessories specially adapted for surgery or diagnosis and not covered by any of the groups A61B1/00 - A61B50/00, e.g. for luxation treatment or for protecting wound edges
    • A61B90/30Devices for illuminating a surgical field, the devices having an interrelation with other surgical devices or with a surgical procedure
    • A61B90/35Supports therefor
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21LLIGHTING DEVICES OR SYSTEMS THEREOF, BEING PORTABLE OR SPECIALLY ADAPTED FOR TRANSPORTATION
    • F21L4/00Electric lighting devices with self-contained electric batteries or cells
    • F21L4/04Electric lighting devices with self-contained electric batteries or cells characterised by the provision of a light source housing portion adjustably fixed to the remainder of the device
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61BDIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B90/00Instruments, implements or accessories specially adapted for surgery or diagnosis and not covered by any of the groups A61B1/00 - A61B50/00, e.g. for luxation treatment or for protecting wound edges
    • A61B90/30Devices for illuminating a surgical field, the devices having an interrelation with other surgical devices or with a surgical procedure
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V21/00Supporting, suspending, or attaching arrangements for lighting devices; Hand grips
    • F21V21/08Devices for easy attachment to any desired place, e.g. clip, clamp, magnet
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V21/00Supporting, suspending, or attaching arrangements for lighting devices; Hand grips
    • F21V21/08Devices for easy attachment to any desired place, e.g. clip, clamp, magnet
    • F21V21/084Head fittings
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61BDIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B90/00Instruments, implements or accessories specially adapted for surgery or diagnosis and not covered by any of the groups A61B1/00 - A61B50/00, e.g. for luxation treatment or for protecting wound edges
    • A61B90/30Devices for illuminating a surgical field, the devices having an interrelation with other surgical devices or with a surgical procedure
    • A61B2090/309Devices for illuminating a surgical field, the devices having an interrelation with other surgical devices or with a surgical procedure using white LEDs
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61BDIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B90/00Instruments, implements or accessories specially adapted for surgery or diagnosis and not covered by any of the groups A61B1/00 - A61B50/00, e.g. for luxation treatment or for protecting wound edges
    • A61B90/50Supports for surgical instruments, e.g. articulated arms
    • A61B2090/502Headgear, e.g. helmet, spectacles

Definitions

  • This application relates to medical headlamps. More specifically, this application relates to medical headlamps employing a high efficiency light source, and which includes batteries mounted on the headband that supports the headlamp.
  • a medical headlamp assembly is a critical part of the surgeon's suite of tools, as it is of great importance that a surgeon can clearly see in the operating theater.
  • the ideal headlamp would be easily portable, light and comfortable to wear for at least four hours. Further, it would have battery power, mounted on the headstrap, sufficient to last four hours from one charge, thereby eliminating the necessity of waist mounted battery pack and cables connecting this pack to the lamp, which are uncomfortable and complicate antiseptic protocol. Further the ideal headlamp assembly would create a bright beam of light that was homogenous and uniform in brightness and color, from edge-to-edge, directly along the surgeon's line of sight, without obscuring his or her line of sight. Also, it would be entirely silent, easily adjustable in position and would not be susceptible to infection by mold or any other sort of organism.
  • the batteries could be placed in a waist pack, but doing so requires an electrical line extending from an aseptic area, about the waist underneath the scrubs (anything under the neck is a "sterile" area), to a non-sterile area, on the surgeon's head.
  • This arrangement complicates aseptic protocol.
  • There is a currently available headlamp assembly that mounts batteries on the headband and that has batteries that can be swapped out, one at a time, for extended surgical periods.
  • the light produced by this headlamp is on the order of 166 lumens in intensity. For many types of surgery, for example where a deep cavity that has been opened up inside a patient requires illumination, a higher intensity lamp is desirable.
  • the present invention may take the form of a battery headlamp assembly that includes a light engine bezel, and adjustable linkage supporting the bezel and including an electrically conductive system terminating at the bezel.
  • a headband assembly supports the adjustable linkage and includes inner assembly.
  • the inner assembly has a strip of flex circuit having two longitudinally opposed ends and defining a set of conductive traces.
  • the conductive traces connect both the networks to each other to permit communications between the networks.
  • a further electrically conductive element electrically connects at least one conductive trace of the flex circuit to the electrically conductive system of the adjustable linkage, to permit the bezel to be powered from the battery contacts.
  • a housing of flexible material substantially encloses the inner assembly and the further electrically conductive element and supports the linkage.
  • the flex circuit and circuit boards are integrated together into one continuous piece of rigid-flex circuit.
  • the housing of flexible material defines a battery slot on each end of the rigid-flex circuit.
  • the flexible material is unitary and homogeneous.
  • the flexible material ensheathes at least a portion of the inner assembly, directly touching it.
  • the battery contacts are a component of both circuit boards and are at the end of each circuit board farthest from the linkage.
  • the inner assem bly further includes a set of cans covering the electrical networks and the flexible material substantially ensheathes the inner assemble, except the battery contacts and a conductive portion of the further electrically conductive element, to permit it ito be electrically connected to the electrically conductive system.
  • the D Shore durometer rating of the flexible material is between 45D and 70D. In a particular embodiment, the D Shore durometer rating of the flexible material is between 50D and 60D. In a particular embodiment, the D Shore durometer rating of the flexible material is between 55D and 60D.
  • the band extends past the inner assembly, thereby forming side-extension located behind and above the batteries, that may be joined together to form a portion extending around the back of a user's head.
  • the side extensions have a shore durometer rating that is different from the shore durometer rating of the flexible material covering the rigid-flex circuit.
  • the band includes two portions extending perpendicularly from the portions sheathing the inner assembly, these extensions being joinable to form a portion extending around the top of a user's head.
  • the further electrically conductive element includes a jack connected to at least one of the traces, and the electrically conductive system includes a mating plug.
  • the further electrically conductive element includes an additional jack connected to at least one of the traces and a permitting mating plug for transmitting electricity to the battery contacts, for recharging batteries connected to the contacts.
  • the jacks are positions side by side about the linkage and are ensheathed by the polymer material to create a pair of forward protrusions, which resist vertical flexure of the headband assembly during linkage adjustment.
  • the flexible material is a polymer material.
  • the electrically conductive system and the further electrically conductive element comprise an insulated wire, connected to a rigid-flex circuit trace and to the bezel, where the wire in the headband assembly constitutes the further electrically conductive element and where the linkage constitutes the electrically conductive system.
  • the present invention may take the form of a method of making a headband for an electrical device to be supported and supplied with electricity by the headband, that utilized an inner assembly, including an electrically conductive assembly, including a terminal to permit connection to the electrical device and two networks of electrical components each supported by and electrically connected together, to one of the battery contacts and to the electrical terminal by the electrically conductive assembly, and protective cans placed over the networks.
  • the rigid-flex circuit assembly is suspended inside a mold, which is filled with a curable resin, thereby substantially covering the inner assembly with the resin and the resin is permitted to cure.
  • the electrical terminal is at the center of the inner assembly.
  • the electrically conductive assembly includes a longitudinal extent of flex circuit that supports as well as electrically connects the networks.
  • the terminal is a jack supported by the flex circuit.
  • the curable resin is a polymer resin.
  • the curable resin is a styrene-ethylene/butylene-styrene block copolymer.
  • the present invention may take the form of a battery headlamp assembly that includes a light engine bezel and an adjustable linkage supporting the bezel, and including an electrically conductive system terminating at the bezel.
  • a headband assembly supports and provides an electrical connection to the adjustable linkage and includes battery contacts and battery slots extending rearwardly from the adjustable linkage, for accepting batteries having electrical contacts matching the headband battery contacts and positioning the batteries so that the electrical contacts mate to the battery contacts.
  • the battery contacts are positioned at least a 14 cm distance from the adjustable linkage, so that on a user of average head size the batteries are positioned mostly behind the user's ears.
  • the batteries are at least 14 cm from the linkage, as measured from the closest portion of each battery to the linkage, along the headband as it curves about a user's head. In a particular embodiment, the batteries are at least 14.5 cm from the linkage, as measured from the closest portion of each battery to the linkage, along the headband as it curves about a user's head.
  • the present invention takes the form of a lamp having a front surface from which light is emitted and that includes a high efficiency light source assembly producing a beam having a 3 dB beamwidth of greater than 100°, and which includes a substrate, a high efficiency light source supported by the substrate; and a dome-lens that contains the high efficiency light source.
  • an optical assembly is positioned to receive light from the light emitting diode assembly and produce a headlamp light beam emitted from the front surface of the lamp.
  • an annular light block defines an annulus and is placed about the lens, so that the lens protrudes through the annulus, thereby creating a sharp boundary for the output light beam.
  • the high efficiency light source is a light emitting diode.
  • the lens is made of silicone.
  • the annular light block is supported by the lens.
  • the optical assembly includes a lens having a rear surface defining a concavity into which the light emitting diode assembly protrudes.
  • the headlamp light beam has a circular edge wherein light intensity decreased by 20 dB over 0.5° from a position inside the headlamp light beam to a position outside the headlamp light beam.
  • the lamp has a mass of less than 30 grams.
  • the electrical conductor is connected to a one amp current source, uses about 3.15 Watts of electricity and produces a beam of greater than 300 lumens from the front surface.
  • the present invention takes the form of a lamp having a light source and an annular light block positioned to block an annulus of the light produced by the light source, the annular light block being thinner than 75 ⁇ .
  • the annular light block is thinner than 40 ⁇ .
  • the light source is an LED assembly.
  • the LED assembly includes a dome lens encasing an LED.
  • the annular light block is located within 1 cm of the light source.
  • the lamp produces a light beam having an edge wherein the light intensity diminishes by 20 dB over 0.5 degrees from inside the edge to outside the edge.
  • the present invention takes the form of a lamp having a front surface from which a beam of light is emitted and that includes a housing, and a high efficiency light source assembly, having a high efficiency light source covered by a lens, supported within the housing, an optical assembly, supported by the housing and having a front surface that is coincident with the front surface of the lamp and positioned to accept light from the high efficiency light source assembly and to emit the light from the front surface, and having a rear surface that defines a concavity; and wherein the high efficiency light source lens protrudes into the concavity.
  • most of the light produced by the high efficiency light source assembly is emitted from the front surface of the lamp.
  • the high efficiency light source is a light emitting diode (LED).
  • the optical assembly includes a prime lens, which defines the concavity and accepts light from the high efficiency light source, and an exit lens, which accepts light from the prime lends and define the front surface of the optical assembly and the lamp.
  • the lamp further has an annular light block placed about the light source assembly at the concavity.
  • the present invention may take the form of a medical headlamp having a front surface from which a lamp light beam is emitted.
  • the headlamp has a high efficiency light source producing a beam having a 3 dB beam width of greater than 100° and an annular light block, defining an annulus and placed immediately in front of the high efficiency light source, a light beam extending from the light block.
  • an optical assembly is positioned to receive light from the high efficiency light source assembly and produce a lamp light beam emitted from the front surface of the lamp.
  • a housing supports the light source and the optical assembly and an electrical conductor connects to the light source, for supplying electricity to the light source.
  • the optical assembly includes an adjustable iris assembly including a user accessible actuator and an iris that is adjustable by the actuator, to be retracted away, thus leaving unaffected the light beam from the light block, or to be tightened to block a portion of the light beam from the annular light block, thus producing a thinner lamp light beam.
  • the high efficiency light source is a light emitting diode.
  • the optical assembly includes a prime lens and an exit lens. In a particular embodiment, the exit lens is moved backward or forward in response to the user accessible actuator, over at least a portion of the actuator's range.
  • a portion of the actuator's range moves the iris to block a variable portion of the light beam from the light block, and over that portion of the actuator's range the exit lens is not moved.
  • a portion of the actuator's range moves the iris over a range that does not block the light beam from the light block, and over that portion of the actuator's range the exit lens is moved forward or backward by the actuator.
  • the light beam when the iris is expanded to leave the light beam unaffected, the light beam has a circular edge wherein light intensity decreases by 20 dB over 0.5° from a position inside the light beam to a position outside the light beam.
  • the present invention may take the form of a medical headlamp having a front from which light is selectively emitted.
  • the headlamp includes a beam origination portion that produces a light beam and an iris assembly, positioned in front of the beam origination portion, having a user accessible actuator and an iris, responsive to the actuator to block a user selectable portion of the light beam.
  • the iris is also responsive to the actuator to block none of the light beam, for maximum efficiency, when a user so selects.
  • the headlamp further includes an exit lens that can be controlled to move forward or backward.
  • the exit lens is greater than 20 mm in diameter and the beam spreads out from it in greater than 3 degrees in all directions as the beam advances, when the exit lens is focused and the iris is actuated to block none of the light beam.
  • the iris and the exit lens are controlled in tandem, by a single manual actuator.
  • the beam origination portion includes a light source and an annular light block that is thinner than 100 ⁇ .
  • the headlamp when the iris blocks none of the light, the headlamp emits a beam of greater than 90 lumens, per watt of power consumed.
  • the headlamp emits a beam of greater than 100 lumens, per watt of power consumed.
  • the beam has a light intensity of more than 110 lumens per watt of power consumed.
  • the beam of light has a color rendering index of greater than 60.
  • the present invention may take the form of a lamp having a front from which light is selectively emitted.
  • the lamp includes a beam origination portion, which produces a light beam and a beam modification portion, which can be controlled to block a selectable portion of the light beam and can also be controlled to block none of the light beam, for maximum efficiency.
  • the beam modification portion when the beam modification portion is controlled to block none of the light beam, the lamp produces a beam of more than 90 lumens per watt of electrical power delivered to the lamp.
  • the headlamp emits a beam of greater than 100 lumens, per watt of power consumed.
  • the beam has a light intensity of more than 110 lumens per watt of power delivered to the lamp.
  • the beam of light has a color-rendering index of greater than 60.
  • the present invention may take the form of a medical headlamp assembly has a headband subassembly, including an electrical network, including a battery and an electrical jack and a headlamp mount.
  • An electrical headlamp subassembly has a mounting element that is matingly and removably engaged to the headlamp mount, and an electrical plug that is matingly and removably engaged to the jack and an electrical headlamp, electrically connected to the plug.
  • the electrical headlamp subassembly also includes a second electrical headlamp subassembly, having a mounting element capable of removably mating to the headlamp mount and an electrical plug capable of removably mating to the jack and and electrical headlamp, electrically connected to the plug.
  • the second electrical headlamp subassembly is different in design from the first electrical headlamp subassembly.
  • both the first and second electrical headlamp subassemblies each require an electrical current source at the electrical plug, and the electrical current source required by the second electric headlamp subassembly is different from the electrical current source required by the first electrical headlamp subassem bly.
  • the electrical plug of the first and second electrical headlamp subassemblies are physically identical, each having a set of pin elements which are mutually electrically isolated from one another and the pin elements of the electrical plug for the first electrical headlamp subassembly are connected to the first electrical headlamp
  • the electrical plugs are audio plugs, each having a single longitudinal element which is divided into mutually electrically isolated pin elements.
  • the headlamp subassembly further includes an adjustable mechanical linkage, permitting adjustment of the elevation angle of the electrical headlamp.
  • the headlamp mount is a guide rod and the mounding element is a slider.
  • the headband subassembly is shaped to be worn on a human head in a predetermined manner, and when the head is vertically oriented, the guide rod is substantially vertical, thereby permitting adjustment of the vertical position of the electrical headlamp.
  • the present invention may take the form of a method of switching out a medical headlamp that makes use of a medical headlamp assembly having a headband assembly, including a mounting element, an electrical jack and a power supply assembly electrically connected to the electrical jack.
  • a first headlamp assembly is removably engaged to the mounting element and including a conductor terminating in a plug that is plugged into the jack; and a second headlamp assembly removeably engageable to the mounting element and including a conductor terminating in a plug that is engageable to the jack.
  • the method includes removing the first headlamp assembly from the mounting element and unplugging the first headlamp plug from the jack and mounting the second headlamp on the mounting element and plugging the second headlamp plug into the jack.
  • the second headlamp has different illumination characteristics from the first headlamp. In a particular embodiment, the second headlamp has different electrical power requirements from the first headlamp. In a particular embodiment, the second headlamp plug makes a different electrical connection to the jack, compared to the electrical connection formed by the first headlamp plug to the jack. In a particular embodiment, the electrical power supply supplies electrical power having different characteristics to the second headlamp, compared to the characteristics of the electrical power delivered to the first headlamp.
  • the power supply assembly includes a network of resisters that the return from the headlamp connects into at a different point, depending on the plug, and includes a power sense resister that drives a DC-to-DC converter, which is driven differently depending on the point in the resistive network where the return from the headlamp is connected.
  • the electrical plugs are audio plugs, each having a single longitudinal element which is divided into mutually electrically isolated pin elements.
  • the headlamp subassembly further includes an adjustable mechanical linkage, permitting adjustment of the elevation angle of the electrical headlamp.
  • the headlamp mount is a guide rod and the mounting element is a slider.
  • the headband subassembly is shaped to be worn on a human head in a predetermined manner, and when the head is vertically oriented the guide rod is substantially vertical, thereby permitting adjustment of vertical position of the electrical headlamp.
  • FIG. 1 is an isometric side-top view of a medical headlamp assembly according to the present invention, configured to be received onto a user's head.
  • FIG. 2 is an isometric side-top view of the assembly of FIG. 1, but without the tightness adjustment elements, and with elements extended outwardly, in a plane.
  • FIG. 3 is a front view of the assembly of FIG. 2.
  • FIG. 4 is an isometric side-top view of a rigid-flex circuit element of the assembly of FIG. 2.
  • FIG. 5 is a front view of the rigid-flex circuit element of FIG. 4.
  • FIG. 6 is a section view of the assembly of FIG. 3, taken along view line 6-6 of
  • FIG. 7 is a section view of the assembly of FIG. 3, taken along view line 7-7 of FIG. 3.
  • FIG. 8 is a cross-sectional view of a lamp for use in a medical headlamp assembly such as that of FIG. 1.
  • FIG. 9 is an exploded view of the lamp of FIG. 8.
  • FIG. 10 is a diagram of the lens system of a prior art headlamp, showing the outer light rays when the system is in operation.
  • FIG. 11 is a diagram of the lamp of FIG. 8, showing the outer light rays when the system is in operation.
  • FIG. 12 is a graph of light intensity values from a spot formed on a white background formed 45.7 cm (18 inches) in front of the front surface of the headlamp, according to a preferred embodiment, using 1 Amp of current and a 3.4 Volt, from battery, voltage drop. The intensity values are taken along a diameter of the light spot.
  • FIG. 13 shows an exploded view of a medical headlamp, according to an alternative preferred embodiment of the present invention.
  • FIG. 14 shows a sectional view of the medical headlamp of FIG. 13.
  • FIG. 15 is an illustration of the effect of the barrel adjustment on the light beam diameter, for the lamp of FIG. 13.
  • FIG. 16 shows an isometric view of a medical headlamp assembly, having an attached medical headlamp of a first type.
  • FIG. 17 shows an isometric view of a medical headlamp assembly, having a detached medical headlamp of the first type.
  • FIG. 18 shows an isometric view of a medical headlamp assembly, having an attached medical headlamp of a second type.
  • FIG. 19 shows an isometric view of a medical headlamp assembly, having a detached medical headlamp of the second type.
  • FIG. 20 shows an isometric view of a medical headlamp assembly, having an attached medical headlamp of a third type.
  • FIG. 21 shows an isometric view of a medical headlamp assembly, having a detached medical headlamp of the third type.
  • FIG. 22 shows an audio plug and the scheme of use of the poles of the audio plug that is used in a preferred embodiment of the present invention.
  • FIG. 23 shows a simplified schematic of the electrical network of the medical headlamp assembly of FIGS. 16-21.
  • a “high efficiency light source” is an electrically powered light source having a light emitting surface area of less than 50 mm 2 that produces light at a rate of greater than 50 lumens per watt of input power and at a rate greater than 30 lumens per square millimeter of light emitting area. This term does not include packaging or a lens. If these items are included the phrase used is "high efficiency light source assembly”.
  • a light emitting diode refers to a solid state electrical device and does not include any lens or packaging. This element is sometimes referred to as a "die,” by others.
  • a light emitting diode assembly includes packaging and a lens.
  • the term "light” as used in this application refers to visible light.
  • the "front” of the medical lamp is the side from which light is emitted.
  • headlamp and “light engine bezel” are used interchangeably and are synonymous.
  • a medical headlamp assembly 10 having a light engine bezel 12, an adjustable bezel support linkage 14 , a headband assembly 16, defining a pair of battery sockets 18, bearing batteries 20, each in contact to a rigid-flex circuit insert 30 (FIG. 4).
  • the charge remaining in batteries 20 is indicated by a set of battery charge indicator lights 21.
  • a head-top strap 22 and a head-back strap 23 form a part of headband assembly 16.
  • straps 22 and 23 are both formed from a pair of arms (26, 28) each having a serrated elongated opening 25.
  • the two arms of the head-top band are drawn together by tightness adjust 27 which engages the serrations to adjust the length of the coupled arms, and the two arms of the head-back strap 23 are drawn together by tightness adjust 29.
  • a brightness control knob 24 is also supported by headband assembly 16.
  • Rigid-flex circuit is an industry term that describes a structure having both rigid and flexible portions, constructed by laminating together rigid and flexible layers and then removing the rigid layers in areas where flexibility is desired.
  • the term "flex circuit” encompasses rigid-flex circuit, so that rigid-flex circuit is a type of flex circuit.
  • Rigid-flex circuit 30 includes right and left-side rigid portions that support a right hand electrical network 32, and a left hand electrical network 34, respectfully. The electrical components of network 32 and 34 are connected together by a first set of conductive traces (not shown) that are internal to rigid-flex circuit 30. These traces are configured in a pattern designed to effect a predetermined scheme of connection.
  • Rigid-flex circuit includes an additional rigid portion, right at the location where the linkage 14 connects to headband assembly 16.
  • the right hand network 32 is kept in an air pocket, protected by a right hand top can 35 (FIG. 6) and a right hand bottom can 37 (FIG. 6), both made of stainless steel that is .15 mm thick.
  • the top can 35 is 4.5 mm high, whereas can 37 is 1.5 mm high.
  • these cans 35 and 37 prevent the polymer material from contacting the components of network 32.
  • bottom can 37 does create an area of some rigidity to the outside of strap assembly 16, it is covered by a 0.3 mm thick covering of relatively soft polymeric material 36, which greatly ameliorates this condition.
  • a round indent (not shown) in can 37 which defines a hole (not shown) at its center, provides a seat for the head of a shaft (not shown) for the brightness control knob 24.
  • a top can 41 (FIG. 6), having similar dimensions to and made of the same material as the top right hand top can 35, is required, due to a smaller component set, confined to the top of rigid-flex circuit 30.
  • Electrical networks 32 and 34 are electrically connected together and to bezel 12 by a second set of conductive traces 40, each of which extends either across the center of rigid-flex circuit 30 or from one of the electrical networks 32 and 34 to either a first jack 42 or a second jack 44.
  • first jack 42 accepts a plug 46 that supplies bezel 12
  • second jack 44 accepts a plug (not shown) from a voltage source, for recharging batteries 20.
  • Plug 46 and the wire attached to it may be considered an electrically conductive system of linkage 14, whereas first jack 42 may be considered a further electrically conductive element of headband assembly 16.
  • Bezel 12 could be electrically connected to headband assembly 16 by a simple wire, in which case the portion of the wire in the linkage could still be considered an electrically conductive system and the portion in the headband could be considered a further electrically conductive element.
  • rigid-flex circuit 30 is replaced by a longitudinal flex circuit or a longitudinal rigid-flex circuit having a circuit board electrically and physically connected to either end, a right hand circuit board supporting and electrically connecting network 32 and a left had circuit board supporting and electrically conecting network 34.
  • the pair of circuit boards are connected by a cable harness or a ribbon cable.
  • rigid-flex circuit 30 (together with jacks 42 and 44 and networks 32 and 34) is encased in a sheathing of polymer material 36 that also forms the top arms 26 and side arms 28.
  • rigid-flex circuit 30 is suspended in a mold by shafts that extend through apertures for battery charge indicator lights 21. Polymer material in liquid phase is forced into the mold and after it has been allowed to cure, the shafts are withdrawn and the headband assembly 16 is ejected.
  • sheathing polymer material 36 may be Styrene-
  • Ethylene/Butylene-Styrene Block Copolymer or similar material preferably having a shore durometer rating of between 50 and 60 in its cured state. In one preferred embodiment, the shore durometer rating is 55.
  • the 100% modulus is preferably between 1800 and 2500 psi.
  • the mold injection temperature is between 180°C and 240°C. These materials are available from United Soft Plastics of Lawrenceville, Georgia.
  • the battery sockets have been separated from the material contacting the user's head by a space for circuitry, whereas in the preferred embodiment, the circuitry has been placed in front of the battery, as opposed to a position interposed between the battery and the head. Also, the battery sockets 18 have been moved farther back on the head, relative to prior art headbands, so that the closest portion of the batteries 20 to the linkage is 153 mm from the linkage as measured along the headband as it curves about the head, or stated in a slightly different but equivalent manner, measured as it would be if the headband assembly were laid out flat.
  • the resulting headband there are a number of advantages to the resulting headband.
  • the two pieces that were joined to form the band for the back of the head also formed the panels separating the batteries from the head.
  • This piece was made of a harder polymer material than other portions of the headband, in part to resist the tendency of the batteries, which extended further from the head because of the interposed electrical network, to torque with the top being pulled by gravity downwardly, which could easily translate to away from the head.
  • the use of a harder polymer can result in discomfort over the hours required to complete some surgeries.
  • the use over the entire assembly of polymer material 36 which in a preferred embodiment has a shore durometer reading of 55 is more comfortable, even over long periods of time.
  • the traces 40 that link networks 32 and 34 permit communication that permits these networks to cooperate.
  • the battery delivering power to the bezel 12 shifts periodically, for example as the voltage of the active battery passes below a threshold, the load of the optical assembly is shifted to the other battery 20, so that the batteries drain at the same rate, over time.
  • those traces leading from networks 32 and 34 to the jack for supplying bezel 12 make external wires unnecessary. Such wires can present a snagging hazard.
  • a pair of parallel front-center vertical ridges 50 are created by the encasement of jacks 42 and 44.
  • the valley 52 between these ridges form an elongated seat for post 54, which is part of support linkage 14.
  • post 54 is torqued and in turn torques headband assembly 16.
  • the structure of post 54 and ridges 50 help to diffuse this torque and material 36 helps to cushion the forehead from the torque, so that the operation of rotating arms 56 is not as uncomfortable to the wearer of headlamp assembly 10 as it would otherwise be.
  • an LED assembly 212 including a domed silicone lens 214, and producing a light beam having a 3dB beamwidth of 120°
  • an LED assembly 212 has a 25 ⁇ (1 mil) thick annular light block 220 fitted around LED assembly 212, with the domed silicone lens 214 extending through the annulus of the light block 220.
  • the beam exiting light block 220 has a beamwidth of 120° but with a much sharper edge then the beam from LED assembly 212. This contrasts with prior art systems in which an adjustable iris light block is placed entirely in front of the light source, resulting in a greater portion of the light being blocked and lost to beneficial use.
  • this assembly permits a larger spot of light for the surgeon using the optical assembly 12.
  • the placement of the light block 220 together with its 25 ⁇ thickness, creates a sharp boundary about the light, and ultimately creating a sharp spot of light, at the typical 80-100 mm (16- 18 in) working distance.
  • Lens 214 is fit into a concavity 216 formed in the back of an aspheric prime optic lens 218.
  • Table 1 shows the LED assembly 212 characteristics for four differing embodiments. In an alternative preferred embodiment an LED assembly is used that is similar to the Oslon Square LED assembly, but includes more than one LED die, and in another preferred embodiment more than one LED assembly is used.
  • an exit lens 222 In front of prime optic lens 218, an exit lens 222 has a convex rear surface 224, thereby better directing the captured light back to create a beam of constant illumination over area.
  • Z is the distance of the surface away from the apex of the rear surface 224 of the exit lens 222, in the longitudinal dimension, toward plane 226 (see FIG. 11), where:
  • the curve described by the above equation has the characteristic that for every 0.5 mm chord connecting two points along the curve the perpendicular distance (“sagitta” or “sag”) from the chord to the curve, at the chord midpoint, is at least .025 mm.
  • prior art systems included an adjustable iris aperture in front of the light source to permit adjustment of light spot size and create a sharply defined edge and homogeneous brightness and color from edge to edge. Although this permitted flexibility with respect to spot size, the movable elements of the iris required the iris aperture to be positioned further in front, the light source resulting in more light being blocked. Also, the need to have moveable leaf elements that fit together could impart a noncircular shape to the beam and the spot of light produced by the beam. Even when an iris was not used, as illustrated by FIG. 10, prior art systems, such as optical arrangement 300, would lose light by placement of the prime lens 310 far ahead of the light source 312.
  • a preferred embodiment has a set aperture size created by the 25 micron - 100 micron (1 to 4 mils) thick annular light block 220.
  • This novel arrangement creates a far sharper light-spot boundary, due to the extremely thin circular aperture wall, resulting in virtually no light reflecting from the inner surface of annulus.
  • This light block 220 is positioned around dome 214 of LED assembly 212, thereby blocking a smaller portion of the light produced by assembly 212.
  • the LED assembly 212 is driven by a 750 milliamp or greater current.
  • a one (1) amp current at a typical battery voltage of 3.45 Volts results in a voltage drop through the LED assembly of about 3.15 Volts, due to some voltage drop through a rheostat, which is used to adjust light intensity, in the headstrap 16. This creates about 3.15 Watts of power that must be dissipated as heat from the LED assembly 212.
  • the LED assembly 212 is driven by traces 242 that extend through a sheet of flex circuit 240 that is mounted behind prime lens holder 250 (FIGS. 8 and 9). Annular light block 220 fits into a round recess 260 in the center of holder 250.
  • a layer of the flex circuit 240 is made of copper (except for channels where the copper has been removed to separate the traces 242 from the rest of the copper covering), which efficiently conducts heat away from assembly 212. Light is reflected from this conductive layer, which is close to the front, and at most covered with a transparent coating. This light is re-reflected back by the annular light block, preventing this yellowish light from entering the beam of light produced by assembly 10.
  • the exit lens 222 is held in a lens holder 270 that has a slot-follower 272 which is fitted into a curved slot 282 in an aft barrel 280.
  • An outer ring 290 includes a straight internal longitudinal slot 292, and is mounted about aft barrel 280, so that when outer ring 290 is rotated, lens holder 270 is also rotated as slot- follower 272 is forced to stay in straight slot 292. This rotation forces slot-follower 272 to rotate within curved slot 282, which in turn causes slot-follower 272 and lens holder 270 to be moved either forward or backward in aft barrel 280. This either focuses or defocuses the light beam, creating a larger or smaller spot of light.
  • the aft barrel 280 is made of aluminum and has a high thermal conductivity, whereas lens holder 270 and outer tube 290 are made of hard, black acrylonitrile butadiene styrene (ABS) polymer.
  • Aft barrel 280 has a length 300 of 49.36 mm, and a height 320 of 38.61 mm.
  • the front of aft barrel 280 has an outer diameter 330 of 27.26 mm._The other parts shown in FIGS. 8 and 9 are shown at the same scale as the aft barrel.
  • the optical assembly 12 has a mass of 43 grams.
  • the entire assembly 10, including batteries 18, has a mass of 340 grams. Table 1: LED Assemblies Used in Various Embodiments
  • the effect of the above detailed design is a medical headlamp assembly 10 with batteries 18 mounted on the headstrap assembly 16, and without a fan to provide forced air cooling, but which produces a brighter beam than previously available headlamp assemblies of this sort.
  • the beam produced in one preferred embodiment, has a light volume of 413 lumens with a color rendering index of at least 65.
  • the beam is emitted relatively evenly from the 23 mm diameter front surfaces of the exit lens 222, and spreads out by 4.19 degrees in all directions as the beam advances.
  • a one (1) Amp lamp as described above, where the voltage drop from the batteries is 3.4 Volts, produces a spot of light at 45.7 cm (18 inches) as shown.
  • the lamp is operable in an ambient temperature of up to 30° Celsius, with no fan to cool the lamp.
  • This brightness is achieved by two improvements, with respect to prior art assemblies.
  • the electric power applied to the LED assembly 212 is greater than in the prior art.
  • the proportion of light produced by the LED that is emitted in the beam is greater.
  • the greater electric power of 2.5875 Watts creates a problem of successfully expressing the heat produced. It is highly advantageous to do this without the use of a fan, which would drive up electric power usage and create an unwanted noise. Accordingly, no fan is used in the preferred embodiment.
  • the need to express the heat produced is addressed by a longer aft barrel 280 which is made of aluminum and acts as a heat radiator, without blocking the surgeon's view.
  • the copper surface of flex circuit 240 conducts heat away from the LED assembly 212 and toward the bezel housing.
  • a greater proportion of light produced by the LED is emitted in the light beam because: 1) the distance between the LED assembly 212 and the prime lens is shortened to virtually nothing, as the LED assembly 212 protrudes into a concavity 216 in the prime lens 218; 2) the adjustable iris, present in many prior art systems has been eliminated; 3) the annular light block 220 sits on the lens of the LED assembly 212, so that it is so far back that it blocks only a small proportion of the light.
  • 70% of the light produced by LED assembly 212 is emitted from the exit lens 222 as a light beam.
  • Alternative preferred embodiments emit anywhere from 50% to 70% of the light produced by the led assembly 212 out of exit lens 222.
  • the light beam produced from exit lens 222 has a volume of 114 to 161 lumens for every watt of power applied to LED assembly 212. In one alternative preferred embodiment this figure ranges from 90 lumens of output light per watt to 161 lumens of output light per watt. This device greatly eases the task of the surgeon, who may now have an adequately bright and wide spot for deep cavity surgery, without the need for the distracting noise and cumbersome extra weight of a fan and without the need of any power cable traversing from a sterile to a nonsterile zone.
  • a high-efficiency medical headlamp 310 is shown, of the type that could be attached to a head strap assembly and used by a surgeon to light the surgical theater, or by a medical professional, in general, to illuminate an area of interest.
  • This headlamp 310 is very efficient, producing a relatively high volume of light for the amount of electrical power consumed, thereby permitting the use of batteries mounted on the headband assembly, as opposed to mounted on a waist pack, with electrical cabling connecting the battery to the lights.
  • the headlamp 310 includes an aft barrel 312, which houses a round piece of flex circuit 314, upon which are defined conductive traces 316, adapted to drive a light emitting diode (LED) assembly 318, more generally termed "a high efficiency light assembly.”
  • Aft barrel 312 defines a channel 20 (FIG. 14) for an electrical wire to pass through, to connect a supply of electricity to traces 316.
  • a portion of LED assembly 318 extends through an aperture 322 in a prime lens holder 30, and also extends through an aperture 324 in an annular light block 32, which has a thickness on the order of 25 ⁇ and which blocks the peripheral light produced by assembly 318, thereby creating a crisp outline for the spot of light produced by headlamp 310.
  • a prime lens 334 having a convex rear surface (FIG. 14).
  • an iris 336 acts to permit an adjustment by actuator 338, to create a thinner light beam, which will be described in more depth, below.
  • An outer ring 354 surrounds exit lens holder 350.
  • the iris actuator 338 fits through a circumferential groove 360 defined in aft barrel 312 and further extends into straight forward and backward groove 362, defined in outer ring 354.
  • a groove follower 364 on exit lens holder 350 protrudes through a groove 366 on aft barrel, and also extends into groove 362 in outer ring 354.
  • the result of this arrangement is that as outer ring 354 is rotated, both actuator 338 and groove follower 364 are moved circumferentially.
  • groove follower 364 is moved forward or backward, as slot 366 is diagonal. This changes the focus of the light beam produced by headlamp 310. Over the remainder of the travel of outer ring 354, groove follower 364 is only moved circumferentially, which has no effect on the optical characteristics of headlamp 310.
  • outer ring is at the clockwise end of its travel, which causes actuator 338 to be at the extreme right end of groove 360 (from the perspective of an observer looking at groove 360).
  • This causes iris 336 to be in its narrowest aperture state, creating a very thin light beam 380.
  • Groove follower 364 is also at the extreme right hand side of groove 366, causing exit lens 352 to be at the extreme far forward extent of its range of motion. This option is sometimes required, particularly by ear, nose and throat specialists.
  • both actuator 338 and follower 364 are at the mid-range of their circumferential motion. This increases the aperture defined by iris 336 enough so that the beam width is defined by annular light block 324.
  • exit lens is maintained in its far forward position, defocusing the beam to create a wider, although less well focused light spot 382.
  • the actuator 338 and follower 364 are at the extreme left hand extent of their travel, causing iris to be definitively not affecting the beam 384, which is shaped entirely by annular light block 324.
  • the exit lens 352 is brought back in to create a tight, well-focused beam with sharp boundaries. Accordingly, a full range of beam widths are permitted, while removing the iris entirely from engagement with the light beam for the wide beam geometries, thereby resulting in a more efficient system, when it is needed most, for the illumination of deep cavity surgery.
  • the effect of the above detailed design is a medical headlamp 310, that can be incorporated into an assembly with batteries mounted on the head strap assembly, and without a fan to provide forced air cooling, but which produces a brighter beam than previously available headlamp assemblies of this sort, and is also adjustable.
  • iris 336 When iris 336 is opened up so that it does not block any of the light from LED 318, the proportion of this light that is emitted in the light beam from the exit lens 352 is greater than in prior art systems. This is because: 1) the distance between the LED assembly 318 and the prime lens 334 is shortened to virtually nothing, as the LED assembly 318 protrudes into a concavity in the prime lens 334; 2) the annular light block 332 sits on the lens of the LED assembly 318, sufficiently far back that it blocks only a small proportion of the light. In one preferred embodiment, 70% of the light produced by LED assembly 318 is emitted from the exit lens 352 as a light beam. Alternative preferred embodiments emit anywhere from 50% to 70% of the light produced by the LED assembly 318 out of exit lens 352.
  • the light beam produced from exit lens 352 has a volume of 114 to 161 lumens for every watt of power applied to LED assembly 318. In one alternative preferred embodiment this figure ranges from 90 lumens of output light per watt to 161 lumens of output light per watt.
  • Many prior art systems include an iris but do not include any part analogous to light block 332, so that the iris is always blocking a portion of the light beam produced by the light source.
  • the same lamp described above may, in its narrow beam state of adjustment, be used by an ear, nose and throat specialist.
  • a medical headlamp assembly 410 includes a headband 412, supporting a mounting column 414.
  • a low intensity headlamp assembly 416 includes a low intensity headlamp 418, a linkage 420, a slider 422. Also included is an electrical conductor 426 terminating in a four pole audio plug 428, which plugs into a four pole audio jack 430.
  • assembly 416 As shown in FIG. 17, when a user decides that he would like to remove assembly 416 from mounting column 414, he pulls assembly 416 upwardly to disengage slider 422 from column 414 and unplugs plug 428 from jack 430. He may do this simply to replace a worn out assembly 416, or (referring to FIG. 18) to install an assembly having different characteristics, such as medium intensity assembly 416', having medium intensity light 418' and plug 428' which is plugged into jack 430. Referring to FIGS. 20 and 21, in like manner assembly 416' can be switched out and assembly 416" having high intensity light 418" and plug 428", can be installed onto with slider 422 on column 414, and with plug 428" plugged into jack 430.
  • plugs 428, 428' and 428" appear identical, each one has a different active pin (longitudinally arranged electrical contact) that is electrically connected to the light emitting diode (not shown) of lamp 418, 418' or 418", respectively, and serving as the return, with the current being delivered into lamp 418, 418' and 418" in all cases through the ground.
  • Pin 1 of plug 428 serves as the LED return for lamp 418
  • pin 2 serves as the LED return for lamp 418'
  • pin 3 serves as the LED return for lamp 418".
  • Pin 1 pin 2 and pin 3 of plug 428 connects to pin 2, pin 3 and pin 4 of jack 430, respectively.
  • Pin 1 of jack 430 connects to the ground of pl ug 428.
  • a DC-to-DC converter 450 acts as a power supply to whichever one of lamps 418, 418' or 418" is connected to jack 430.
  • a feedback loop is formed by the output of converter 450 powering the LED line, all of the current in which flows to the LED return line, and at least a portion of which pass through a current sense resister Rl, which in turn drives the feed back pin FB of converter 450.
  • the voltage output of the brightness adjust rheostat 440 is fed into a pin of a microprocessor 456, resulting in a periodic waveform having a duty factor that is related to the rheostat output voltage, appearing on an output pin of the microprocessor 456.
  • this causes microprocessor 456 to produce a waveform that causes voltage increase circuitry 454 to amplify the voltage at its input, thereby reducing the current (and voltage) out of the DC-to-DC converter 450, and reducing the current through resister R5.
  • voltage increase circuitry is set to always amplify its input signal, thereby permitting a lower value for the voltage drop across Ri, when the lamp 418, 418' or 418" is not being dimmed. This permits a lower value of resistance for Ri, and lower power loss through Ri and through the entire resistance network Ri, R 2 , R3 and R 4 . For dimming positions of rheostat 440, this
  • the present invention finds industrial applicability in the manufacture of headlamp assemblies, and more particularly in the manufacture of medical headlamp assemblies.

Landscapes

  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Surgery (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Biomedical Technology (AREA)
  • Pathology (AREA)
  • Oral & Maxillofacial Surgery (AREA)
  • Nuclear Medicine, Radiotherapy & Molecular Imaging (AREA)
  • Heart & Thoracic Surgery (AREA)
  • Medical Informatics (AREA)
  • Molecular Biology (AREA)
  • Animal Behavior & Ethology (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Veterinary Medicine (AREA)
  • Arrangement Of Elements, Cooling, Sealing, Or The Like Of Lighting Devices (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Abstract

La présente invention concerne une lampe (12) possédant une surface avant (222) à partir de laquelle de la lumière est émise et qui comprend un ensemble formant source lumineuse à rendement élevé (212) produisant un faisceau ayant une largeur de faisceau à 3 dB supérieure à 100°, et qui comprend un substrat, une source lumineuse à rendement élevé supportée par le substrat ; et une lentille en dôme (214) qui contient la source lumineuse à rendement élevé. L'invention concerne également un ensemble optique positionné pour recevoir la lumière de l'ensemble formant source lumineuse à rendement élevé (212) et pour produire un faisceau lumineux de lampe frontale émise à partir de la surface avant (222) de la lampe (12). En outre, un bloc lumineux annulaire (220) définit un anneau et est placé autour de la lentille (214), de façon à ce que la lentille (214) fasse saillie à travers le bloc lumineux (220), créant ainsi une frontière nette pour le faisceau lumineux produit.
PCT/US2014/037813 2013-05-13 2014-05-13 Ensemble de lampe frontale médicale WO2014186347A1 (fr)

Priority Applications (2)

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EP14797604.7A EP2997297A4 (fr) 2013-05-13 2014-05-13 Ensemble de lampe frontale médicale
GB1521926.4A GB2529365B (en) 2013-05-13 2014-05-13 Medical headlamp assembly

Applications Claiming Priority (12)

Application Number Priority Date Filing Date Title
US201361822493P 2013-05-13 2013-05-13
US61/822,493 2013-05-13
US13/972,489 2013-08-21
US13/972,489 US20140334132A1 (en) 2013-05-13 2013-08-21 Medical Headlamp Optics
US13/972,446 2013-08-21
US13/972,446 US9687314B2 (en) 2013-05-13 2013-08-21 Medical headlamp optical arrangement
US14/057,351 2013-10-18
US14/057,351 US9351799B2 (en) 2013-05-13 2013-10-18 Comfortable medical headlamp assembly
US14/162,244 US9091428B2 (en) 2013-05-13 2014-01-23 Medical headlamp assembly having interchangeable headlamp types
US14/162,244 2014-01-23
US14/243,263 2014-04-02
US14/243,263 US9234653B2 (en) 2013-05-13 2014-04-02 Medical headlamp optical arrangement permitting variable beam width

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WO (1) WO2014186347A1 (fr)

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CN106778641A (zh) * 2016-12-23 2017-05-31 北京七鑫易维信息技术有限公司 视线估计方法及装置
CN106778641B (zh) * 2016-12-23 2020-07-03 北京七鑫易维信息技术有限公司 视线估计方法及装置
CN112262283A (zh) * 2018-05-10 2021-01-22 克诺格股份有限公司 头灯
CN112262283B (zh) * 2018-05-10 2024-01-09 克诺格股份有限公司 头灯

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GB2529365B (en) 2020-10-14
GB2529365A (en) 2016-02-17
EP2997297A4 (fr) 2016-05-25
GB201521926D0 (en) 2016-01-27

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