Waterproof head assembly for a flashlight

• US 20030156406A1
• Filed: 12/02/2002
• Published: 08/21/2003
• Est. Priority Date: 02/22/2001
• Status: Active Grant

• Current Assignee: Nite Ize Incorporated
• Original Assignee: Emissive Energy Corporation
• Inventors: Galli, Robert
• Granted Patent: US 6,769,786 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 novel waterproof head assembly specifically designed for LED light sources. The rounded end surfaces of the LED are exposed to the outside environment through apertures formed in a solid end wall of the head assembly. To prevent water from entering into the interior of the flashlight through the apertures, the present invention discloses filling the interior cavity of the head with a sealant which substantially entirely fills all of the gaps between the outside surfaces of the LED'"'"'s, the inside surfaces of the apertures, and the inside surfaces of the open end of the head assembly.

Claims

1. A sealed head assembly for an LED light comprising:

a tubular enclosure including

a tubular side wall, and

an end wall, wherein inner surfaces of said end wall and said side wall cooperate to define an open end of said enclosure, said end wall having at least one inwardly extending aperture;

a mounting board received in interfitting engagement within said inner side walls of said open end of said enclosure wherein an inner surface of said mounting board and said inner surfaces of said side wall and said end wall cooperate to define a substantially enclosed interior cavity within said tubular enclosure;

at least one LED mounted on said inner surface said mounting board, said at least one LED being slideably received within said at least one aperture in said end wall; and

a sealant substantially entirely filling said enclosed interior cavity, such that contaminants cannot enter into said enclosed interior cavity through said at least one aperture in said end wall.

2. The sealed head assembly of claim 1, further comprising:

a plurality of LED'"'"'s mounted on said mounting board, said end wall including a like plurality of inwardly extending apertures to slideably receive said plurality of LED'"'"'s.

3. The sealed head assembly of claim 1, wherein said mounting board comprises a circuit board having contact leads thereon, and further wherein said at least one LED includes spaced leads that are mounted on said circuit board in electrical communication with said contact leads.

4. The sealed head assembly of claim 1, wherein a gap is formed between an outer surface of said LED and said inner surface of said inwardly extending aperture when said LED is slideably received therein, said sealant filling at least a portion of said gap.

5. A flashlight assembly comprising:

a housing having a bottom wall and a side wall extending upwardly from said bottom wall, an electrically conductive path extending from said bottom wall upwardly along said side wall and a threaded opening opposite said bottom wall;

a battery having a first contact and a second contact said battery received within said housing wherein said first contact is in electrical communication with electrically conductive path;

a flashlight head, said flashlight head including,

a tubular enclosure having a side wall, and an end wall, wherein inner surfaces of said end wall and said side wall cooperate to define said tubular enclosure having an open end, said end wall having at least one inwardly extending aperture,

a mounting board received in interfitting engagement within said inner side walls of said open end of said enclosure wherein an inner surface of said mounting board and said inner surfaces of said side wall and said end wall cooperate to define a substantially enclosed interior cavity within said tubular enclosure,

at least one LED mounted on said inner surface said mounting board having first and second contact leads, said first contact lead in electrical communication with said first contact of said battery, said at least one LED being slideably received within said at least one aperture in said end wall, and

a sealant substantially entirely filling said enclosed interior cavity, such that fluid contaminants cannot enter into said enclosed interior cavity through said at least one aperture in said end wall.

said head being received in said opening in said housing; and

a switch assembly disposed between said second contact lead of said LED and said second contact of said battery, said switch assembly being operable to selectively energize said lighting element.

6. The flashlight assembly of claim 5, further comprising:

a plurality of LED'"'"'s mounted on said mounting board, said end wall including a like plurality of inwardly extending apertures to slideably receive said plurality of LED'"'"'s.

7. The flashlight assembly of claim 5, wherein said mounting board comprises a circuit board having contact leads thereon, and further wherein said first and second contact leads of said LED are mounted on said circuit board in electrical communication with said contact leads.

8. The flashlight assembly of claim 5, wherein a gap is formed between an outer surface of said LED and said inner surface of said inwardly extending aperture when said LED is slideably received therein, said sealant filling at least a portion of said gap.

9. An LED assembly comprising:

a housing;

a power source mounted within said housing; and

a sealed LED head assembly mounted to said housing, said sealed LED head assembly including,

a tubular enclosure including

a tubular side wall, and

an end wall, wherein inner surfaces of said end wall and said side wall cooperate to define an open end of said enclosure, said end wall having at least one inwardly extending aperture,

a mounting board received in interfitting engagement within said inner side walls of said open end of said enclosure wherein an inner surface of said mounting board and said inner surfaces of said side wall and said end wall cooperate to define a substantially enclosed interior cavity within said tubular enclosure,

at least one LED mounted on said inner surface said mounting board, said at least one LED being slideably received within said at least one aperture in said end wall, said at least one LED being in electrical communication with said power source, and

a sealant substantially entirely filling said enclosed interior cavity, such that contaminants cannot enter into said enclosed interior cavity through said at least one aperture in said end wall.