Dual mode switch mechanism for flashlights

• US 20030147239A1
• Filed: 01/31/2003
• Published: 08/07/2003
• Est. Priority Date: 02/01/2002
• Status: Active Grant

• Current Assignee: Nite Ize Incorporated
• Original Assignee: Dr Robert Galli
• Inventors: Galli, Robert
• Granted Patent: US 6,971,762 B2
• Time in Patent Office: Days
• US Class Current: 362/205
• CPC Class Codes: F21L 4/027 the light sources being a LED
• CPC Class Codes: F21V 23/0414 specially adapted to be used with portable lighting devices
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

The present invention provides a unique dual mode, inline switch mechanism that is fully integrated into the rear cap of a flashlight assembly to provide a completely self contained and waterproof switching mechanism. The switch assembly further provides dual mode functionality including an ON position and a momentary ON position while also including a reliable OFF position that prevents the accidental activation of the light when the user desires that it remain off. The entire mechanism resides in the end cap of the flashlight assembly and includes an end cap structure that is designed to be rotatably attached to the end of a flashlight housing, a contact plate, a plunger, an insulator disk and an elastomeric cover. The switch mechanism is fully integrated on the interior of the flashlight providing the highly desirable, fully contained, in line functionality.

Claims

1. A switch device for use in a flashlight comprising:

a housing having an electrical contact on a first end thereof and an outer wall defining an interior cavity;

at least one battery in said interior cavity, said battery being spring biased in a first linear direction towards said first end of said housing; and

a switch assembly having a slidable actuator therein, said switch assembly threadedly received on said first end of said housing, said actuator being in electrical communication with said battery,

said switch device having a fully closed position wherein said switch assembly is fully threaded onto said housing and said actuator is in electrical communication with said electrical contact, said switch device having a selectibly closed position wherein rotation of said switch assembly relative to said housing creates a space between said actuator and said electrical contact, said actuator being depressible in a second linear direction opposite said first causing said actuator to move into electrical communication with said electrical contact and said switch device having a fully open position wherein further rotation of said switch assembly relative to said housing causes said space between said actuator and said electrical contact to be greater than the allowable linear travel of said actuator preventing said actuator from contacting said electrical contact.

2. The switch device of claim 1, wherein said housing is electrically conductive.

3. The switch device of claim 1, said switch assembly further comprising:

an end cap threadedly received on said first end of said housing, said end cap having an annular opening therein;

an insulative disk having a first side, a second side and a central opening in the center thereof, said disk being received in said annular opening in said end cap;

an actuator having a head portion and a post extending from said head portion, said head portion further including a shoulder area adjacent to said post, said post of said actuator being slidably received in said central opening of said insulative disk, said post having a terminal end; and

a contact plate, said contact plate being electrically conductive and having a first contact surface and a second surface opposite said first surface, said second surface being attached to said terminal end of said post, said contact plate in electrical communication with one terminal of said battery,

said switch device having a fully closed position wherein said switch assembly is fully threaded onto said housing and said contact plate is in electrical communication with said electrical contact, said switch device having a selectibly closed position wherein rotation of said switch assembly relative to said housing creates a space between said contact plate and said electrical contact, said actuator being depressible in a second linear direction opposite said first, causing said switch actuator to move said contact plate into electrical communication with said electrical contact and said switch device having a fully open position wherein further rotation of said end cap relative to said housing causes said space between said electrical contact and said contact surface to be greater than the space between said shoulder area of said actuator and said first side of said insulative disk, contact of said shoulder with said disk preventing said contact surface from contacting said electrical contact.

4. The switch device of claim 3, said switch assembly further comprising:

an elastomeric cover disposed in said end cap covering said actuator.

6. The switch device of claim 4, said switch assembly further comprising:

an elastomeric cover disposed in said annular opening of said end cap, said elastomeric cover covering said actuator.

5. A switch device for use in a flashlight comprising:

a tubular housing having an electrically conductive outer wall, a first end and a second end, said outer wall defining an interior cavity;

at least one battery received in said interior cavity, said battery being spring biased in a first linear direction towards said first end of said housing;

an end cap threadedly received on said first end of said housing, said end cap having an annular opening therein;

an insulative support disk having a first side, a second side and a central opening in the center thereof, said support disk being received in said annular opening in said end cap;

an actuator having a head portion and a post extending from said head portion, said head portion further including a shoulder area adjacent to said post, said post of said actuator being slideably received in said central opening of said insulative support disk, said post having a terminal end; and

a contact plate, said contact plate having a first contact surface and a second surface opposite said first surface, said second surface being attached to said terminal end of said post, said contact plate in electrical communication with one terminal of said battery,

said switch device having a fully closed position wherein said contact surface is in electrical communication with said first end of said housing when said end cap is fully threaded onto said housing, said switch device having a selectibly closed position wherein rotation of said end cap relative to said housing creates a space between said first end of said housing and said contact surface, said contact surface being urged into electrical communication with said first end of said housing by pressing said actuator in a second linear direction opposite said first and said switch device having a fully open position wherein further rotation of said end cap relative to said housing causes said space between said first end of said housing and said contact surface to be greater than the space between said shoulder area of said actuator and said first side of said insulative disk, contact of said shoulder with said disk preventing said contact surface from contacting said housing.

7. A flashlight assembly comprising:

a housing having an outer wall, a first end, a second end and an electrical contact on said first end thereof, said outer wall defining an interior cavity;

at least one battery in said interior cavity, said battery having a first contact and a second contact, said battery being spring biased in a first linear direction towards said first end of said housing;

a lighting element having first and second electrical contacts, said lighting element disposed in said second end of said housing, said first electrical contact in electrical communication with said electrical contact on said housing and said second electrical contact in electrical communication with said second contact of said battery; and

a switch assembly having a slidable actuator therein, said switch assembly threadedly received on said first end of said housing, said actuator being in electrical communication with said first contact of said battery,

said switch device having a fully closed position wherein said switch assembly is fully threaded onto said housing and said actuator is in electrical communication with said electrical contact thereby energizing said lighting element, said switch device having a selectibly closed position wherein rotation of said switch assembly relative to said housing creates a space between said actuator and said electrical contact, said actuator being depressible in a second linear direction opposite said first causing said actuator to move into electrical communication with said electrical contact selectively energizing said lighting element and said switch device having a fully open position wherein further rotation of said switch assembly relative to said housing causes said space between said actuator and said electrical contact to be greater than the allowable linear travel of said actuator preventing said actuator from contacting said electrical contact.

8. The flashlight assembly of claim 7, wherein said housing is electrically conductive.

9. The flashlight assembly of claim 7, said switch assembly further comprising:

an end cap threadedly received on said first end of said housing, said end cap having an annular opening therein;

an insulative disk having a first side, a second side and a central opening in the center thereof, said disk being received in said annular opening in said end cap;

an actuator having a head portion and a post extending from said head portion, said head portion further including a shoulder area adjacent to said post, said post of said actuator being slideably received in said central opening of said insulative disk, said post having a terminal end; and

a contact plate, said contact plate being electrically conductive and having a first contact surface and a second surface opposite said first surface, said second surface being attached to said terminal end of said post, said contact plate in electrical communication with one terminal of said battery,

said switch device having a fully closed position wherein said switch assembly is fully threaded onto said housing and said contact plate is in electrical communication with said electrical contact, said switch device having a selectibly closed position wherein rotation of said switch assembly relative to said housing creates a space between said contact plate and said electrical contact, said actuator being depressible in a second linear direction opposite said first, causing said switch actuator to move said contact plate into electrical communication with said electrical contact and said switch device having a fully open position wherein further rotation of said end cap relative to said housing causes said space between said electrical contact and said contact surface to be greater than the space between said shoulder area of said actuator and said first side of said insulative disk, contact of said shoulder with said disk preventing said contact surface from contacting said electrical contact.

10. The flashlight assembly of claim 9, said switch assembly further comprising:

an elastomeric cover disposed in said end cap covering said actuator.

11. The flashlight assembly of claim 7 wherein said lighting element is a light emitting diode.

12. The flashlight assembly of claim 7 wherein said lighting element is an array of light emitting diodes.