LED flashlight

• US 20050007768A1
• Filed: 06/10/2004
• Published: 01/13/2005
• Est. Priority Date: 06/10/2003
• Status: Active Grant

• Current Assignee: Signify Holding B.V. (Signify N.V.)
• Original Assignee: Illumination Management Solutions Incorporated (Eaton Corporation PLC.)
• Inventors: Rhoads, Greg, Holder, Ronald Garrison
• Granted Patent: US 7,001,047 B2
• Time in Patent Office: Days
• US Class Current: 362/157
• CPC Class Codes: F21L 4/005 the device being a pocket lamp F21L4/022, F21L4/045, F21L4/085 take precedence
• CPC Class Codes: F21L 4/027 the light sources being a LED
• CPC Class Codes: F21V 14/025 in portable lighting devices
• CPC Class Codes: F21V 29/773 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 7/0008 providing for indirect lighting
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

A module, or collection of discreet components, for an LED flashlight is coupled to a conventional flashlight body which includes a conventional power source. The module comprise a housing adapted to be coupled to the flashlight body; an LED light source coupled to the power source; a heat sink heat sink coupled to the housing, which heat sink is thermally and mechanically coupled to the LED light source; and a reflector coupled to the housing and having an optical axis. The LED light source is positioned by the heat sink on or near the optical axis and is optically coupled to the reflector. The reflector reflects light from the LED light source in a forward direction. The surface(s) of the reflector may be designed to create a beam of almost any distribution desired. The module, and/or components, is arranged and configured to be operatively coupled as a unit to the flashlight body and power source.

Claims

1. A module for an LED flashlight having a flashlight body including a power source comprising:

a housing adapted to be coupled to the flashlight body;

an LED light source coupled to the power source;

a heat sink coupled to the housing and thermally and mechanically coupled to the LED light source; and

a reflector coupled to the housing and having an optical axis, the LED light source being positioned by the heat sink on or near the optical axis and being optically coupled to the reflector, the reflector reflecting light from the LED light source in a forward direction,

wherein the module is arranged and configured to be operatively coupled as a unit to the flashlight body and power source.

2. The module of claim 1 further comprising a circuit disposed in the housing for providing power from the power source to the LED light source.

3. The module of claim 2 further comprising a circuit board disposed in the housing on which the circuit is mounted.

4. The module of claim 3 where the circuit board is coupled to the reflector.

5. The module of claim 3 where the circuit board is coupled to the housing.

6. The module of claim 1 wherein the module is arranged and configured to be operatively coupled as a unit into a conventional incandescent flashlight body and power source.

7. The module of claim 1 where the LED light source is position by the heat sink forward of the reflector as defined by the forward direction.

8. The module of claim 1 where the heat sink provides an electrical coupling from the power source to the LED light source.

9. The module of claim 1 where the heat sink comprises at least one heat fin for dissipating heat and for positioning the LED light source with respect to the reflector.

10. The module of claim 1 where the heat sink is thermally coupled to the reflector and/or housing.

11. The module of claim 1 where the LED light source is axially movable along the optical axis.

12. The module of claim 11 where the heat sink carries the LED light source and is axially movable along the optical axis.

13. The module of claim 1 further comprising an insulated electrical coupling between the LED light source and the power source.

14. The module of claim 13 where the insulated electrical coupling between the LED light source and the power source comprises a flex circuit.

15. The module of claim 2 where the circuit comprises an LED driver circuit which controls the current to the LED light source to prevent over driving the LED light source.

22. The module or components of claims 1 further comprising a single switch to power on/off the device.

23. The module or components of claims 1 further comprising a first switch to power on/off the device and a second switch located in the tail cap or section of the flashlight that may also control the on/off condition of the flashlight.

24. The module or components of claims 1 where the reflector surface is shaped to other than a conic profile to provide a reflected beam of a custom distribution pattern of energy from the LED.

16. A module for an LED flashlight having a flashlight body including a power source comprising:

a housing adapted to be coupled to the flashlight body;

an LED light source coupled to the power source;

a heat sink coupled to the housing and thermally and mechanically coupled to the LED light source;

a reflector coupled to the housing and having an optical axis, the LED light source being positioned by the heat sink on or near the optical axis and being optically coupled to the reflector, the reflector reflecting light from the LED light source in a forward direction,

a circuit disposed in the housing for providing power from the power source to the LED light source;

a circuit board disposed in the housing on which the circuit is mounted; and

wherein the module is arranged and configured to be operatively coupled as a unit to the flashlight body and power source.

17. The module of claim 16 wherein the module is arranged and configured to be operatively coupled as a unit into a conventional incandescent flashlight body and power source.

18. The module of claim 16 where the heat sink comprises at least one heat fin for dissipating heat and for positioning the LED light source with respect to the reflector.

19. The module of claim 16 where the LED light source is position by the heat sink forward of the reflector as defined by the forward direction.

20. An integrated module for an LED flashlight having a conventional incandescent flashlight body including a conventional power source comprising:

a housing adapted to be coupled to the conventional incandescent flashlight body;

an LED light source coupled to the power source;

a heat sink heat sink coupled to the housing and thermally and mechanically coupled to the LED light source, the heat sink having at least one heat fin for dissipating heat;

a reflector coupled to the housing and having an optical axis, the LED light source being positioned by the heat sink on or near the optical axis and being optically coupled to the reflector, the reflector reflecting light from the LED light source in a forward direction, the heat fin of the heat sink for positioning the LED light source forward of the reflector as defined by a forward direction;

a circuit disposed in the housing for providing power from the power source to the LED light source;

a circuit board disposed in the housing on which the circuit is mounted; and

wherein the module is arranged and configured to be operatively coupled as a unit to the flashlight body and power source.

21. An integrated system of components for an LED flashlight having a flashlight body including a conventional power source comprising:

an LED light source coupled to the power source;

a heat sink coupled to the body and thermally and mechanically coupled to the LED light source, the heat sink having at least one heat fin for dissipating heat;

a reflector coupled to the housing and having an optical axis, the LED light source being positioned by the heat sink on or near the optical axis and being optically coupled to the reflector, the reflector reflecting light from the LED light source in a forward direction, the heat fin of the heat sink for positioning the LED light source forward of the reflector as defined by a forward direction; and

a circuit disposed in the body for providing power from the power source to the LED light source;

wherein the components are arranged and configured to be operatively coupled as a unit to the flashlight body and power source.