Hard Hat with Fan and Fan Control System

The present application claims the benefit of and priority to U.S. Provisional Application No. 63/646,208, filed on May 13, 2024, which is incorporated herein by reference in its entirety.

The present invention relates generally to the field of hard hats. The present invention relates specifically to a hard hat with fan and a fan control system.

One embodiment of the invention relates to a hard hat fan system including a shell, a fan, and a sensor. The shell includes an inner surface configured to receive a head of a user and an outer surface opposite the inner surface. The fan is coupled to the outer surface of the shell. The fan includes an inlet, an outlet, a processing unit, a motor configured to be turned on and off, a fan blade coupled to the motor, and a power supplied coupled to the fan and configured to provide power to the motor. When the motor is on, the motor rotates the fan blade and the fan blade draws air into the fan through the inlet and pushes air out through the outlet. The sensor is communicably coupled to the processing unit of the fan. The sensor is configured to detect environmental condition data and generate a data signal that is indicative of the environmental condition data. The sensor communicates the data signal to the processing unit. When the processing unit receives the data signal, the processing unit compares the environmental condition data to a threshold condition to determine if the environmental condition data is above the threshold condition. If the environmental condition data is above the threshold condition, the processing unit generates a control signal configured to change a first speed of the fan blade to a second speed different from the first speed.

Another embodiment of the invention relates to a hard hat fan system including a shell, a fan, and a power supply. The shell includes an inner surface configured to receive a head of a user and an outer surface opposite the inner surface. The fan is coupled to the outer surface of the shell. The fan includes a housing with an inlet and an outlet, a processing unit, a receiver communicably coupled to the processing unit, and a motor configured to be turned on and off. When the motor is on, air enters the fan through the inlet and exits through the outlet. The power supply is coupled to the fan and configured to provide power to the motor. The receiver of the fan is configured to receive environmental condition data from a personal electronic device and generate a data signal that is indicative of the environmental condition data. The receiver communicates the data signal to the processing unit. When the processing unit receives the data signal, the processing unit compares the environmental condition data to a threshold condition to determine if the environmental condition data is above the threshold condition. If the environmental condition data is above the threshold condition, then the processing unit generates a power control signal configured to change a first power level provided by the power supply to the motor to a second power level different from the first power level.

Another embodiment of the invention relates to a hard hat fan system. The hard hat fan system includes a shell, a fan coupled to an outer surface of the shell, and a battery cell coupled to the fan. The fan includes an inlet, an outlet, a processing unit, a motor configured to be turned on and off, and a fan blade coupled to the motor. When the motor is on, the motor rotates the fan blade and the fan blade draws air into the fan through the inlet and pushes air out through the outlet. The battery cell is configured to provide power to the motor. The processing unit is configured to detect a battery charge level of the battery cell. When the processing unit detects the battery charge level, the processing unit compares the battery charge level to a predetermined battery charge to determine if the battery charge level is below the predetermined battery charge. If the battery charge level is below the predetermined battery charge, then the processing unit generates a first control signal configured to change a first speed level of the fan to a second speed level different from the first speed level to provide a haptic indicator of the battery charge level to a user of the hard hat fan system.

Additional features and advantages will be set forth in the detailed description which follows and will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description and/or shown in the accompany drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary.

The accompanying drawings are included to provide further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments and, together with the description, serve to explain principles and operation of the various embodiments. In addition, alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims.

Referring generally to the figures, various embodiments of a hard hat fan system are shown. Hard hats may be used in a variety of construction jobs or other situations. Those wearing hard hats complete a wide range of tasks and physical labor. These tasks may be performed in confined spaces or outdoors, which include hot and unventilated environments. As such, there is a demand by hard hat users to keep the head comfortable in these environments.

Applicant has developed various hard hat fan systems that are believed to provide for various advantages over typical hard hats with fans. The hard hat fan systems discussed herein include a fan and a hard hat. The fan is coupled to the hard hat and may provide a cooling sensation to a user. The fan includes a control system which turns off the fan when environmental conditions are above a predetermined threshold condition.

In particular, the fan includes a processing unit configured to receive and process environmental condition data. Environmental condition data includes weather data from a personal electronic device, temperature data from a sensor, and humidity data from a sensor. When the processing unit receives environmental condition data, it determines if the environmental condition data is above a threshold condition, such as a high temperature or a high humidity. When the environmental condition data is above the predetermined threshold condition, the processing unit changes the speed of the motor, and in some embodiments turns off the motor of the fan. Applicant has found that, under certain environmental conditions (e.g., high temperature, high humidity, etc.), high fan speeds for fan-based cooling is undesirable or may be counterproductive to cooling a user. As such, Applicant believes that the hard hat fan systems including an environmental condition based control system discussed herein provide advantages over typical hard hats with fans.

Referring to, a protective helmet or hard hatis shown and described. As shown, hard hatincludes a shellwith an inner surfaceconfigured to receive the head of a user and an outer surfaceopposite inner surface. Outer surfaceof hard hatincludes a front surface, and a rear surfacethat opposes front surface. Front surfaceincludes a front mounting feature. Front mounting featureis the location at which an accessory (e.g., light sources, sensors, communications equipment, auditory equipment, fan systems, power sources, etc.) may be coupled to front side surface. Front mounting featureincludes a mounting ridgeconfigured to removably couple to an accessory.

Hard hatincludes a bill or brimthat extends outward from a lower circumference of hard hat. Brimextends around at least a portion of hard hatto shield the eyes of a user. Hard hatalso includes a side accessory ridgepositioned between front surfaceand rear surfacealong outer surfaceof hard hat. Specifically, hard hatincludes two side accessory ridgespositioned on opposite sides of outer surface.

Rear surfacehas a rear mounting feature. Rear mounting featureis the location at which an accessory may by coupled to rear surface. Rear mounting featureincludes a mounting ridge. Mounting ridgeis configured to removably couple to an accessory. Mounting ridgeincludes a pair of dovetail projections or wingsextending outward from opposing planar surfacesthat extend from rear mounting feature. Wingsdefine a first edgeand a second edgeopposite first edge. Additionally, mounting ridgeincludes a retention cleat. Retention cleatis centered on rear mounting featurebetween the pair of wings. Front mounting ridgeis generally the same as rear mounting ridge. As shown, the rear mounting featureis configured to receive a fan system.

Referring to, hard hat systemis shown. Hard hat systemis coupled to hard hat. Although discussed namely in the context of hard hat, the hard hat systems discussed herein are further applicable to other protective headwear, like a protective helmet. Hard hat systemincludes a mounting bracket, a fan system, and a power supply or power source, shown as a battery cell.

Fan systemis coupled to hard hatat rear mount featurethrough mounting bracket. Mounting bracketis configured to couple an accessory, such as a fan system, to outer surfaceof shellat front mounting featureor rear mounting feature. As shown, fan systemis coupled to rear mounting featurethrough mounting bracket.

Mounting bracketis securely and removably coupled to mounting ridgeand, more specifically, to first edgeand a second edgedefined by wings. Mounting bracketincludes a first cam lockand a second cam lock. Cam locks,are configured to actuate between a locked and unlocked position. When actuated into the locked position, first cam lockbiases first edgeof mounting ridgeand second cam lockbiases second edgeto retain mounting bracketon shellof hard hat.

Fan systemis coupled to a front surface of mounting bracket. Fan systemincludes a fan. Fanhas a fan housing, an inlet, an exhaust or outlet, a motor, and at least one fan bladecoupled to motor.

Inletis positioned along a front surface of fan housing. Inletfaces away from outer surfaceand, specifically, rear surfaceof shell. Outletis positioned along a bottom surface of fan housingbelow inlet. Fanis mounted above lower edgeof hard hatsuch that outletdoes not extend below lower edge. Additionally, outletdoes not extend below brim. Inletdefines an opening in fan housingsuch that ambient air may enter fanthrough inlet. Outletalso defines an opening such that air may exit fanthrough outlet.

Motorlocated within fan housing. Motoris configured to be turned on and off. When motoris on, ambient air enters fanthrough inletand exits through the outlet. In particular, motoris coupled to at least one fan blade. When motoris on, the fan bladerotates, which draws ambient air into fanthrough inletand pushes the air out through outlet. In certain embodiments, motoris configured to rotate the fan bladeat different speed levels.

Fan systemfurther includes a duct. Ductis removably coupled to outletof fan. Ductmay be coupled to outletthrough a friction fit arrangement, such as through an interference fit, snap fit, or press-fit arrangement. As shown, a first endof ductis received in outlet. Ductis configured to direct air from outlettowards inner surfaceof hard hat. In particular, a second endof ductopposite first endis angled to direct air under lower edgeof hard hat. Ductmay direct air at a user's neck or a user's head. The angle of second endmay vary depending on the hard hat. In certain embodiments, ductabuts brim. In other certain embodiments, ductmay be spaced from brimsuch that it does not abut brimas it extends around lower edge.

As shown in, fanincludes a filter assembly. Filter assemblyincludes a filterand a frame. Filteris coupled to frame. Filteris configured to allow ambient air to pass through filterand into inlet. Frameis removably coupled to inlet. In particular, framemay be coupled to inletthrough a friction fit arrangement, such as through an interference fit, snap fit, or press-fit arrangement. As shown, frameincludes a quarter-turn lock used to secure filter assemblyto inlet.

A power source, shown as battery cell, is configured to provide power to fan systemand, more specifically, to motor. Battery cellis coupled to fan. Specifically, battery cellis mounted on an outer surface of fan housing. Battery cellis configured to slidably engage with fansuch that battery cellis received within a portion of fan housing. Fan housingincludes a supportconfigured to receive and retain battery cell. Supportmay be coupled to fan housingor made from a single unitary piece of material with fan housing. As shown, supportextends from a top surface of fan housingand battery cellis positioned within support. Battery cellis oriented in a horizontal direction, such that battery cellextends substantially perpendicular to the top surface of fan housing.

Battery cellis a rechargeable battery cell, such as a lithium-ion battery. Fanmay include one or more ports used to electrically coupled to battery cell. As shown, portis configured to receive a USB-C cable which is used to charge battery cell, and portis configured to receive a barrel jack to couple battery cellto an additional accessory.

Battery cellhas a battery charge level which can be measured by the percentage of available capacity of battery cell with respect to the total capacity. Additionally, battery cellhas a battery life which can be measured by the amount of time the battery charge has until it reaches 0% battery charge. In this way, 100% battery charge level means that battery cellhas a full battery life, and 0% means no battery life.

In certain embodiments, hard hat systemincludes an additional accessorymounted on hard hat. Additional accessorymay be a light source, sensor, communication equipment, auditory equipment, power source, etc. Additional accessorymay be coupled to shellat front surface. Additional accessorymay be powered by the same power source as fan systemor have its own power source.

Referring to, fan systemfurther includes a processing unit, a user interface (such as a button), an environmental data device, shown as sensor, and an LED display. Processing unitis integrated with fan system. Processing unitis configured to send and receive signals throughout fan system, including signals to and from battery cell, signals to and from motor, and signals to and from LED display. In a certain embodiment, processing unitis integrated with fan. In another embodiment, processing unitis integrated with sensor.

Buttonis communicably coupled to processing unitand generates a signal, which is sent to processing unit, when a user presses and releases button. Sensoris communicably coupled to processing unit. Sensordetects and/or measures a condition, and then generates a signal, which is sent to processing unit, in response to the measured condition. LED displayis communicably coupled to processing unit and is configured to emit a colored light based on signals from processing unit. The various communication signals, sensor signals, and control signals communicated within systemmay be wired, wireless, or various combinations of wired and wireless signals.

Generally, when processing unitreceives certain inputs, such as a signal from buttonor a signal from sensor, processing unitsends a signal to LED displayand/or motor. When processing unitsends signals to motor, processing unitsends signals to components/switching circuits that provide power to motor. When processing unitsends signals to LED display, processing unitsends out a signal to have a specific electrical current transmitted to LED display. Based on the electrical current, LED displayilluminates certain light emitting diodes.

As shown, buttonis positioned along the front surface of fan housing. Buttonis located below sensorand adjacent to inlet. Buttonis electrically coupled to processing unitand configured send signals to processing unit. In particular, buttonsends signals to processing unitin response to a user pressing button. When buttonis pressed, processing unitreceives a signal from buttonand processing unitwill send a signal to motorbased on the current level of operation of motor. When buttonis pressed, processing unitmay send a signal to adjust the speed of motoror send a signal to provide or inhibit power to motor.

In a certain embodiment, motorhas three levels of operation: High Mode, Low Mode, and Off Mode. In High Mode, motorrotates the fan bladeat maximum speed. In Low Mode, motorrotates the fan bladeat a lower speed level than High Mode. And, in Off mode, motordoes not rotate the fan blade. In a certain embodiment, when in Off Mode, motoris inhibited from receiving power from battery cell. A user may “power cycle” fan systemby pressing buttonand turning motorto Off Mode and then pressing buttonagain to turn motorback on (e.g., to High Mode).

If motoris in Off Mode and a user presses button, then motorturns on in High Mode. In particular, when user presses button, a signal is sent to processing unit. Processing unitdetermines what operation level motoris in. If processing unitdetermines that motor is in Off Mode, then processing unitturns motoron and, specifically, turns motoron in High Mode. In a certain embodiment, processing unitwill only turn motor on in High Mode if buttonis pressed for one second or less. In such an embodiment, if motoris in Off Mode and buttonis pressed longer than one second, then processing unitwill not send a signal to motorand motorwill remain in Off Mode.

If motoris in High Mode and a user presses button, then motorchanges to Low Mode. In particular, when user presses button, a signal is sent to processing unit. Processing unitdetermines what operation level motoris in. If processing unitdetermines that motor is in High Mode, then processing unitsends a signal to motorto reduce speed and change to Low Mode. When adjusting from High Mode to Low Mode, a press and release of buttonof any duration will transition motorfrom High Mode to Low Mode.

If motoris in Low Mode and a user presses button, then motorchanges from Low Mode to Off Mode. In particular, when user presses button, a signal is sent to processing unit. Processing unitdetermines what operation level motoris in. If processing unitdetermines that motor is in Low Mode, then processing unitsends a signal to motorto reduce speed and turn to Off Mode. Processing unitmay also send a signal to inhibit power to motorfrom battery cell. Processing unitmay inhibit power to motorby sending signals to turn off components/switching circuits providing power to motor. When adjusting from Low Mode to Off Mode, a press and release of buttonof any duration will transition motorfrom Low Mode to Off Mode.

Additionally, when buttonis pressed, processing unitmay send a signal to LED display. Processing unitwill send signals to LED displayto display a specific colored light based on the signal. For instance, when buttonis pressed and motor transitions from Off Mode to High Mode, processing unitwill send a signal to LED displayto display a color corresponding to the current battery charge (Green, Yellow, or Red). LED displaywill display the color for three seconds and then LED displaywill turn off.

Similarly, when transitioning from Low Mode to Off Mode, processing unitwill send a signal to LED displayto display a color corresponding to the current battery charge. LED displaywill display the color for three seconds and then LED displaywill turn off.

As shown, LED displayis positioned such that it surrounds button. LED displayis used to indicate to a user the battery charge of battery cell. Specifically, LED displaydisplays a specific color corresponding to the battery charge. In a specific embodiment, the color green corresponds to 100% to 50% battery charge; the color yellow corresponds to 49% to 11% battery charge; and the color red corresponds to 10% or less. When at 3% battery charge or less, battery cellis in Low Power Mode. In a certain embodiment, when battery cellenters Low Power Mode, battery cellhas approximately 5 minutes of battery life remaining if motoris operating in High Mode.

When battery charge is 100% to 50%, and motorturns on (i.e., transitions from Off Mode to High Mode) LED displaywill display a solid green color for three seconds. When battery charge is 100% to 50%, and motoris in use (e.g., High Mode or Low Mode), then the LED displaywill not display anything. When battery charge is 100% to 50%, and motorturns off (i.e., transitions from Low Mode to Off Mode), LED displaywill display a solid green color for three seconds.

When battery charge is 49% to 11%, and motorturns on (i.e., transitions from Off Mode to High Mode) LED displaywill display a solid yellow color for three seconds. When battery charge is 49% to 11%, and motoris in use (e.g., High Mode or Low Mode), then the LED displaywill not display anything. When battery charge is 49% to 11%, and motorturns off (i.e., transitions from Low Mode to Off Mode), LED displaywill display a solid yellow color for three seconds.

When battery charge is 10% to 3%, and motorturns on (i.e., transitions from Off Mode to High Mode) LED displaywill display a solid red color for three seconds. When battery charge is 10% to 3%, and motoris in use (e.g., High Mode or Low Mode), then the LED displaywill not display anything. When battery charge is 10% to 3%, and motorturns off (i.e., transitions from Low Mode to Off Mode), LED displaywill display a solid red color for three seconds.

When battery cellis in Low Power Mode (i.e., 3% battery charge or less), and motorturns on (i.e., transitions from Off Mode to High Mode), LED displaywill flash a red color for three seconds. When battery cellis in Low Power Mode, and motoris in use (e.g., High Mode or Low Mode), then the LED displaywill flash a red color for three seconds. When battery cellis in Low Power Mode, and motorturns off (i.e., transitions from Low Mode to Off Mode), LED displaywill flash a red color for three seconds. This status indicator will only occur once during Low Power Mode unless fan systemhas been power cycled. In certain embodiments, hard hat systemwill indicate to a user that battery cellis in Low Power Mode by vibrating, or pulsating, motora predetermined number of times or for a predetermined period of time. In a certain embodiment, motorpulsates three times in a rhythmic pattern.

When battery cellis in Low Power Mode and is at a battery charge where motorwould be inoperable such that there is not enough power to rotate the fan blade, then, upon a user pressing buttonto turn motoron (i.e., from Off Mode to High Mode), LED displaywill flash a red color for three seconds, and motorwill stay in Off Mode. When battery cellis in Low Power Mode and is at a battery charge where motor would be inoperable, then, if motoris on (i.e., High Mode or Low Mode), LED displaywill flash a red color for three seconds, and motorwill turn to Off Mode.

Battery cellmay be charged while mounted on fanthrough port. While charging, if battery charge is 0% to 49%, then LED displaywill slowly flash the color red. “Slowly flash” means LED displaytransitions between being on and off over a period of time greater than one second. In a specific embodiment, the transition between on and off takes place over a three second period. If battery charge is 50% to 99%, LED displaywill slowly flash the color yellow. The LED displaywill slowly flash continuously while battery cellis charging, until battery charge is 100%. When battery charge is 100%, LED display will display a solid green color until battery cellis disconnected from the charger. That is, until a charging cable is disconnected from port. Once disconnected, LED displaywill display a solid green color for 3 seconds and then turn off.

In certain embodiments, fan systemis configured to provide indication to a user when battery cellis under atypical conditions. Atypical conditions include battery cellbeing over a threshold internal temperature, battery cellbeing under a threshold internal temperature, a fault in battery cell, battery cellnot charging, a fault with the charging of battery cell, or other errors.

If battery cellhas an internal temperature above a threshold temperature, then battery cellis considered to be in an “over-temp” condition. When in an over-temp condition, battery cellsends a signal to processing unit. If motoris on, then processing unitsends a signal to motorto turn to Off Mode. If motoris in Off Mode, then motorwill not turn on (e.g., High Mode or Low Mode) while battery cellis in the over-temp condition. When in an over-temp condition, LED displayis a solid red color for an hour, or until the internal temperature of battery cellis below the threshold temperature. When the internal temperature of battery cellis below the threshold temperature, LED displayturns off and normal operation of fan systemcan resume after fan systemis power cycled.

If battery cell, is under an atypical condition, other than the over-temp condition, then LED displaywill flash between the red color and the green color. While battery cellunder an atypical condition, other than the over-temp condition, motorwill operate normally. That is, motorwill transition between Off Mode, High Mode, and Low Mode when buttonis pressed, as long as motorhas power.

Hard hat systemincludes a control system which controls fan systemin response to environmental condition data, such data from a localized sensor (like sensor) or other source (such as weather data from the internet, etc.). When processing unitreceives environmental condition data, it determines if the environmental condition data is above a threshold condition. If the environmental condition data is above the predetermined threshold condition, processing unitchanges the speed that motorrotates fan blade. In a specific embodiment, motorwill change between modes when the environmental condition is above the predetermined threshold condition (e.g., from High Mode to Low Mode, from High Mode to Off Mode, from Low Mode to High Mode, etc.). In a specific embodiment, processing unitturns off the motor of the fan when the environmental condition data is above the predetermined threshold condition. Applicant has found that certain environmental conditions (e.g., high temperature, high humidity, etc.) may result in fan-based cooling being undesirable or counterproductive to cooling a user.

Sensoris communicably or electrically coupled to processing unitand is configured to generate data that is communicated to processing unit. Sensorgenerates a data signalin response to a measured environmental condition (e.g., the weather, temperature, humidity, air quality, etc.) and sends data signalto processing unitbased on the measured environmental condition. In various embodiments, sensoris a temperature sensor and the environmental condition data is temperature data. In a specific embodiment, the temperature data is representative of ambient temperature of the air surrounding hard hat. In another embodiment, the temperature data is representative of ambient temperature of the air within hard hat. In another embodiment, the temperature data is representative of body temperature of the wearer of hard hat. In various embodiments, sensoris a humidity sensor and the environmental condition data is humidity data. In a specific embodiment, the humidity data is representative of humidity of the air surrounding hard hat. In a specific embodiment, the humidity data is representative of humidity of the air within hard hat.

As shown, sensoris physically coupled to a front surface of fan housing. In a certain embodiment, sensoris embedded in fan housing. In other various embodiments, sensoris physically coupled to hard hat. In a specific embodiment, sensoris embedded in hard hat. In another specific embodiment, sensoris physically coupled to outer surfaceof hard hat. In another embodiment, sensoris mounted on hard hatat one of the mounting features,. In other embodiments, sensoris coupled to bracket. In other embodiments, sensoris coupled to duct.

Sensortransmits data signal, which is representative of environmental condition data, to processing unit. Processing unitthen analyzes the environmental condition data and sends out one or more control signals to various components of hard hat systembased on the received environment condition data. When processing unitdetermines that the environmental condition data is above a threshold condition (such as above a predetermined temperature or above a predetermined humidity level), then processing unitsends a signalto fanto change a first speed of fan bladeto a second speed different from the first speed. In various embodiments, when the environmental condition data is above a threshold condition (such as above a predetermined temperature or above a predetermined humidity level), then processing unitsends a signalto fanto change a first power level provided by battery cellto a second power level different from the first power level. The change in power level changes the level of the fan (e.g., from High Mode to Low Mode, from High Mode to Off Mode, from Low Mode to High Mode, etc.) and adjusts the speed that motorrotates fan blade. In a certain embodiment, the second power level is less than the first power level.

In a certain embodiment, signalturns the motor of the fan off. More specifically, processing unitturns off motorby inhibiting power from being delivered to motorfrom battery cell. In such an embodiment, when the environmental condition data is above a threshold condition and motoris on (e.g., High Mode or Low Mode), then processing unitsends signalto motorto turn to Off Mode. When the environmental condition data is above a threshold condition and motoris in Off Mode, then motorwill not turn on until processing unitreceives a signal from sensorand determines that the environmental condition data is below the threshold condition.