LED Headlamp

Overview

The headlamp is a rechargeable head-worn lamp delivering up to 450 lumens from a multi-emitter optic on a tilting, weather-sealed head. A single 18650 cell drives spot, flood and red beams selected by a tactile button or a wave of the hand. The product combines a sealed Lamp Housing, an Optics Module module, a Control Board, a protected Battery and an adjustable Headband.

How it works

The optics module carries the LED Board, a metal-core PCB mounting a high-output spot LED, a wide flood LED and a low-output red LED for preserving night vision. A total-internal-reflection lens collimates the white emitters into a focused throw and a near-field flood, and an impact-resistant clear cover seals the front. Beam choice and brightness are set on the control board, where a microcontroller runs the mode logic and a constant-current buck driver regulates emitter current so output stays flat as the cell discharges.

User input arrives two ways: a rubber-capped tactile dome switch cycles power and modes, while an IR proximity sensor toggles the light on a hand wave, useful when gloved or hands-dirty. The same board holds a single-cell Li-ion charge controller fed from a USB-C port, and an Indicator LED LED reports charge state and battery level.

Power comes from the battery assembly: an 18650 lithium-ion cell guarded by a BMS protection board against overcharge, over-discharge and short circuit, with spring contact plates carrying current to the boards. The lamp head sits in the housing, whose two shells close on an O-ring seal for IPX4 splash resistance and mount to a ratcheting Tilt Bracket. A sprung pawl seats the toothed ratchet at each detent so the beam holds its downward angle. The elastic main strap and over-the-crown top strap distribute weight, while a mount bracket cradles the head and accepts the tilt pivot.