ELECTRICAL SWITCH HAVING STACKED SWITCHING ELEMENTS, AS FOR CONTROLLING A FLASHLIGHT

• US 20070246335A1
• Filed: 04/12/2007
• Published: 10/25/2007
• Est. Priority Date: 04/20/2006
• Status: Active Grant

• Current Assignee: Streamlight, Inc.
• Original Assignee: Streamlight, Inc.
• Inventors: Ziegenfuss, Peter J., Snyder, Mark W., Sharrah, Raymond L.
• Granted Patent: US 7,674,003 B2
• Time in Patent Office: Days
• US Class Current: 200/1.B
• CPC Class Codes: F21L 4/00 Electric lighting devices with self-contained electric batteries or cells
• CPC Class Codes: H01H 13/48 using buckling of disc springs
• CPC Class Codes: H01H 13/503 Stacked switches
• CPC Class Codes: H01H 2225/002 superimposed
• CPC Class Codes: H05B 39/041 the light-intensity of the source H05B39/08 takes precedence
• CPC Class Codes: H05B 41/30 in which the lamp is fed by pulses, e.g. flash lamp
• CPC Class Codes: H05B 45/00 Circuit arrangements for operating light-emitting diodes [LED]
• CPC Class Codes: H05B 45/325 Pulse-width modulation [PWM]
• CPC Class Codes: H05B 45/345 Current stabilisation; Maintaining constant current
• CPC Class Codes: H05B 47/10 Controlling the light source

Abstract

An electrical switch comprises first and second switch elements including respective first and second electrically conductive flexible domes for selectively making electrical connections. The second switch element is disposed adjacent the first switch element with an electrical conductor therebetween. An actuator is movable for exerting force on the second switch element via a spring, and for exerting force on the first switch element via the spring and the second switch element. The second flexible dome may have an actuating force that is less than the actuating force of said first flexible dome.

Claims

1. An electrical switch comprising:

a first switch element including;

a first substrate having at least a central electrical conductor and a peripheral electrical conductor thereon;

an electrically conductive first flexible dome disposed on said first substrate in electrical contact with the peripheral electrical conductor thereof and overlying the central conductor thereof, said first flexible dome having a given actuating force,

wherein said first flexible dome comes into electrical contact with the central electrical conductor of said first substrate when pressed towards said first substrate with the given actuating force;

a second switch element disposed adjacent the first switch element, said second switch element including;

a flexible second substrate having at least a central electrical conductor and a peripheral electrical conductor thereon;

an electrically conductive second flexible dome disposed on said flexible second substrate in electrical contact with the peripheral electrical conductor thereof and overlying the central conductor thereof, said second flexible dome having an actuating force that is less than the given actuating force of said first flexible dome,

wherein said second flexible dome comes into electrical contact with the central electrical conductor of said flexible second substrate when pressed towards said flexible second substrate with a force less than the given actuating force; and

an actuator disposed adjacent said second switch element and urged away therefrom by a spring therebetween,

wherein said actuator is movable for exerting force on said second switch element via said spring, and for exerting force on said first switch element via said spring said second switch element.

2. The electrical switch of claim 1 wherein the spring has a length that is substantially longer than an actuating distance of said first and second flexible domes.

3. The electrical switch of claim 1 further comprising:

a housing base having walls defining a central cavity and defining at least two races through the walls; and

a housing cover disposed adjacent said housing base for enclosing said first and second switch elements therebetween, said housing cover having an opening therethrough in which said actuator is movable, said housing cover including respective race covers for the at least two races,

wherein the respective races and race covers define at least two passages through which electrical connection to the respective central and peripheral electrical conductors of said first and second switch elements may respectively be made.

4. The electrical switch of claim 1 further comprising:

a housing base providing said first substrate on which the central and peripheral electrical conductors of said first switch element are disposed; and

a housing cover disposed adjacent said housing base, said housing cover having walls defining a central cavity and a passage through the wall, and having an opening therethrough in which said actuator is movable,

wherein said first and second switch elements are enclosed in the cavity between said housing base and said housing cover, and

wherein electrical connection to the central and peripheral electrical conductors of said second switch element may be made through the passage.

5. The electrical switch of claim 1 in combination with a controller and a load, wherein said controller is responsive to said first flexible dome making contact between the central and peripheral electrical conductors of said first switch element, to said second flexible dome making contact between the central and peripheral electrical conductors of said second switch element, to said first flexible dome breaking contact between the central and peripheral electrical conductors of said first switch element, to said second flexible dome breaking contact between the central and peripheral electrical conductors of said second switch element, and to any combination of the foregoing, for controlling the load.

6. The electrical switch of claim 5 wherein the controlling the load includes energizing the load momentarily, energizing the load continuously, de-energizing the load, causing the load to alternate repetitively between energized and de-energized conditions, causing the load to change from a more energized condition to a less energized condition, causing the load to change from a less energized condition to a more energized condition, and any combination of the foregoing.

7. The electrical switch of claim 5 wherein the load is an electrical light source, and wherein said controller controls the light source to momentary ON, continuous ON, OFF, flashing, and dimming conditions, and optionally to an un-dimming operating condition.

8. An electrical switch comprising:

a first switch element including an electrically conductive first flexible dome, said first flexible dome being flexible for selectively making electrical connection between a first pair of electrical conductors, said first flexible dome having a given actuating force,

a second switch element disposed adjacent the first switch element, said second switch element including an electrically conductive second flexible dome, said second flexible dome being flexible for selectively making an electrical connection between a second pair of electrical conductors, wherein said second pair of electrical conductors are flexible and are between said second flexible dome and said first switch element, said second flexible dome having an actuating force that is less than the given actuating force of said first flexible dome,

an actuator disposed adjacent said second switch element and urged away therefrom by a spring therebetween,

wherein said actuator is movable for exerting force on said second switch element via said spring, and for exerting force on said first switch element via said spring and said second switch element.

9. The electrical switch of claim 8 wherein the second pair of electrical conductors are disposed on a flexible insulating substrate that is disposed between said first and second flexible domes.

10. The electrical switch of claim 8 wherein the spring has a length that is substantially longer than an actuating distance of said first and second flexible domes.

11. The electrical switch of claim 8 further comprising:

a housing base having walls defining a central cavity and defining at least two races through the walls; and

a housing cover disposed adjacent said housing base for enclosing said first and second switch elements therebetween, said housing cover having an opening therethrough in which said actuator is movable, said housing cover including respective covers for the at least two races,

wherein the respective races and covers define at least two passages through which said first and second pairs of electrical conductors pass.

12. The electrical switch of claim 8 further comprising:

a housing base providing a first substrate on which said first pair of electrical conductors are disposed; and

a housing cover disposed adjacent said housing base, said housing cover having walls defining a central cavity and a passage through the wall, and having an opening therethrough in which said actuator is movable,

wherein said first and second switch elements are enclosed in the cavity between said housing base and said housing cover, and

wherein the second pair of electrical conductors pass through the passage through the wall of said housing cover.

13. The electrical switch of claim 8 in combination with a controller and a load, wherein said controller is responsive to said first flexible dome making contact with said first pair of electrical conductors, to said second flexible dome making contact with said second pair of electrical conductors, to said first flexible dome breaking contact with said first pair of electrical conductors, to said second flexible dome breaking contact with said second pair of electrical conductors, and to any combination of the foregoing, for controlling the load.

14. The electrical switch of claim 13 wherein the controlling the load includes energizing the load momentarily, energizing the load continuously, de-energizing the load, causing the load to alternate repetitively between energized and de-energized conditions, causing the load to change from a more energized condition to a less energized condition, causing the load to change from a less energized condition to a more energized condition, and any combination of the foregoing.

15. The electrical switch of claim 13 wherein the load is an electrical light source, and wherein said controller controls the light source to momentary ON, continuous ON, OFF, flashing, and dimming conditions, and optionally to an un-dimming operating condition.

16. An electrical switch comprising:

a housing having walls defining a central cavity and defining at least two passages through the walls of said housing;

a first switch element disposed in the central cavity of said housing, said first switch element including;

a first substrate adjacent said housing, said first substrate having at least a central electrical conductor and a peripheral electrical conductor thereon, wherein the central electrical conductor and the peripheral electrical conductor extend into or through or into and through a first of said at least two passages;

an electrically conductive first flexible dome disposed on said first substrate in electrical contact with the peripheral electrical conductor thereof and overlying the central conductor thereof, said first flexible dome having a given actuating force,

wherein said first flexible dome comes into electrical contact with the central electrical conductor of said first substrate when pressed towards said first substrate with the given actuating force;

a second switch element disposed in the central cavity of said housing adjacent the first switch element, said second switch element including;

a flexible second substrate adjacent the first switch element, said flexible second substrate having at least a central electrical conductor and a peripheral electrical conductor thereon, wherein the central electrical conductor and the peripheral electrical conductor extend into or through or into and through a second of said at least two passages;

an electrically conductive second flexible dome disposed on said flexible second substrate in electrical contact with the peripheral electrical conductor thereof and overlying the central conductor thereof, said second flexible dome having an actuating force that is less than the given actuating force of said first flexible dome,

wherein said second flexible dome comes into electrical contact with the central electrical conductor of said flexible second substrate when pressed towards said flexible second substrate with a force less than the given actuating force;

an actuator button disposed in an opening of said housing adjacent said second switch element; and

a coil spring disposed between said actuator button and said second switch element for urging said actuator button away from said second switch element,

wherein said actuator button is movable in the opening of said housing for exerting force on said second switch element via said coil spring, and for exerting force on said first switch element via said coil spring and said second switch element.

17. The electrical switch of claim 16 wherein the coil spring has a length that is substantially longer than an actuating distance of said first and second flexible domes.

18. The electrical switch of claim 16 wherein said housing comprises:

a housing base having walls defining the central cavity and defining at least two races through the walls; and

a housing cover disposed adjacent said housing base for enclosing said first and second switch elements therebetween, said housing cover having an opening therethrough in which said actuator button is movable, said housing cover including respective race covers for the at least two races,

wherein the respective races and race covers define the at least two passages.

19. The electrical switch of claim 16 wherein said housing comprises:

a housing base providing said first substrate; and

a housing cover disposed adjacent said housing base, said housing cover having walls defining the central cavity and at least one of the at least two passages, and having an opening therethrough in which said actuator button is movable,

wherein said first and second switch elements are enclosed in the central cavity between said housing base and said housing cover, and

wherein either said housing cover provides a second of the at least two passages through the walls thereof or said housing base provides a second of the at least two passages through the first substrate thereof.

20. The electrical switch of claim 16 in combination with a controller and a load, wherein said controller is responsive to said first flexible dome making contact between the central and peripheral electrical conductors of said first switch element, to said second flexible dome making contact between the central and peripheral electrical conductors of said second switch element, to said first flexible dome breaking contact between the central and peripheral electrical conductors of said first switch element, to said second flexible dome breaking contact between the central and peripheral electrical conductors of said second switch element, and to any combination of the foregoing, for controlling the load.

21. The electrical switch of claim 20 wherein the controlling the load includes energizing the load momentarily, energizing the load continuously, de-energizing the load, causing the load to alternate repetitively between energized and de-energized conditions, causing the load to change from a more energized condition to a less energized condition, causing the load to change from a less energized condition to a more energized condition, and any combination of the foregoing.

22. The electrical switch of claim 20 wherein the load is an electrical light source, and wherein said controller controls the light source to momentary ON, continuous ON, OFF, flashing, and dimming conditions, and optionally to an un-dimming operating condition.

23. An electrical switch comprising:

a first switch element including an electrically conductive first flexible dome for selectively making electrical connection to a first electrical conductor and having a first given actuating force;

a second switch element adjacent the first switch element, the second switch element including an electrically conductive second flexible dome for selectively making an electrical connection to a second electrical conductor;

wherein the second electrical conductor is between the second flexible dome and the first switch element, the second flexible dome having a second given actuating force; and

an actuator movable for exerting force on the second switch element via a spring, and for exerting force on the first switch element via the spring and the second switch element.

24. The electrical switch of claim 23 wherein the second given actuating force of the second flexible dome is less than the first given actuating force of the first flexible dome.

25. The electrical switch of claim 23 wherein the second electrical conductor is a flexible conductor.

26. The electrical switch of claim 23 wherein the first flexible dome and the second flexible dome electrically connect to the second electrical conductor.

27. An electrical switch comprising:

a first switch element including an electrically conductive first flexible dome for providing a first normally open switch contact and having a first given actuating force,

a second switch element adjacent the first switch element, the second switch element including an electrically conductive second flexible dome for providing a second normally open switch contact and having a second given actuating force, said second switch element including a flexible electrical conductor between said first switch element and the second flexible dome; and

an actuator movable for exerting force on the second switch element via a spring, and for exerting force on the first switch element via the spring and the second switch element,

wherein the actuator moves a distance for closing the first and second normally open contacts that is substantially longer than an actuating distance of said first and second flexible domes.

28. The electrical switch of claim 27 wherein the second given actuating force of the second flexible dome is less than the first given actuating force of the first flexible dome.

29. The electrical switch of claim 27 wherein the first flexible dome and the second flexible dome electrically connect to the flexible electrical conductor.

30. An electrical switch comprising:

a first switch element including an electrically conductive first flexible dome for providing a first normally open switch contact and having a first given actuating force,

a second switch element adjacent the first switch element, the second switch element including an electrically conductive second flexible dome for providing a second normally open switch contact and having a second given actuating force, said second switch element including a flexible electrical conductor between said first switch element and the second flexible dome;

a controller responsive to closure, or opening, or both, of the first normally open switch contact and of the second normally open switch contact for controlling electrical power to a load; and

an actuator movable for exerting force on the second switch element via a spring, and for exerting force on the first switch element via the spring and the second switch element,

wherein the actuator moves a distance for closing the first and second normally open contacts that is substantially longer than an actuating distance of said first and second flexible domes.

31. The electrical switch of claim 30 wherein the controlling electrical power to the load includes energizing the load momentarily, energizing the load continuously, de-energizing the load, causing the load to alternate repetitively between energized and de-energized conditions, causing the load to change from a more energized condition to a less energized condition, causing the load to change from a less energized condition to a more energized condition, and any combination of the foregoing.

32. The electrical switch of claim 30 wherein the load is an electrical light source, and wherein said controller controls the light source to momentary ON, continuous ON, OFF, flashing, and dimming conditions, and optionally to an un-dimming operating condition.

33. An electrical switch for a flashlight including a housing having a head end and a tail end and having a cavity for receiving a battery, and an electrical light source disposed proximate the head end of the housing, said electrical switch comprising:

a first pushbutton switch disposed proximate the head end of the housing for providing at least a first switch contact;

a second pushbutton switch disposed proximate the tail end of the housing for providing at least a second switch contact;

a controller disposed in the housing and electrically connected to the electrical light source and to the battery when a battery is provided in the cavity of the housing for selectively coupling electrical power from the battery to the electrical light source,

wherein said controller is electrically connected to said first pushbutton switch and is responsive to closure, or opening, or both, of the first switch contact for controlling electrical power to the electrical light source at least for selectively energizing and de-energizing the electrical light source when the battery is present in the cavity of the housing, and

wherein said controller is electrically connected to said second pushbutton switch and is responsive to closure, or opening, or both, of the second switch contact for controlling electrical power to the electrical light source at least for selectively energizing and de-energizing the electrical light source when the battery is present in the cavity of the housing,

whereby the electrical light source may be selectively energized and de-energized responsive to either or both of the first and second pushbutton switches without electrical power to energize the light source flowing through the first and second pushbutton switches.

34. The electrical switch of claim 33 wherein either or both of said first pushbutton switch and said second pushbutton switch comprises:

a first switch element including an electrically conductive first flexible dome for providing a first normally open switch contact and having a first given actuating force, and

a second switch element adjacent said first switch element, said second switch element including an electrically conductive second flexible dome for providing a second normally open switch contact and having a second given actuating force, said second switch element including a flexible electrical conductor between said first switch element and the second flexible dome;

wherein said controller is responsive to closure, or opening, or both, of the first and second normally open switch contacts for controlling the electrical power to the electrical light source.

35. The electrical switch of claim 34 wherein either or both of said first pushbutton switch and said second pushbutton switch further comprises:

an actuator movable for exerting force on said second switch element via a spring, and for exerting force on said first switch element via the spring and said second switch element,

wherein the actuator moves a distance for closing the first and second normally open contacts that is substantially longer than an actuating distance of the first and second flexible domes.

36. The electrical switch of claim 34 wherein the second given actuating force of the second switch element is less than the first given actuating force of the first switch element.

37. The electrical switch of claim 33 wherein said controller controls electrical power to the electrical light source for energizing the electrical light source momentarily, for energizing the electrical light source continuously, for de-energizing the electrical light source, for causing the electrical light source to alternate repetitively between energized and de-energized conditions, for causing the electrical light source to change from a more energized condition to a less energized condition, for causing the electrical light source to change from a less energized condition to a more energized condition, and for any combination of the foregoing.

38. The electrical switch of claim 33 wherein said controller controls the electrical light source to momentary ON, to continuous ON, to OFF, to flashing, and to dimming conditions, and optionally to an un-dimming operating condition.

39. An electrical flashlight comprising:

a housing having a head end and a tail end and having a cavity for receiving a battery;

an electrical light source disposed proximate the head end of said housing; and

a first pushbutton switch disposed proximate the head end of said housing for providing at least a first switch contact;

a second pushbutton switch disposed proximate the tail end of said housing for providing at least a second switch contact;

a controller disposed in said housing and electrically connected to said electrical light source and to the battery when a battery is provided in the cavity of said housing for selectively coupling electrical power from the battery to said electrical light source,

wherein said controller is electrically connected to said first pushbutton switch and is responsive to closure, or opening, or both, of the first switch contact for controlling electrical power to said electrical light source at least for selectively energizing and de-energizing said electrical light source when the battery is present in the cavity of said housing, and

wherein said controller is electrically connected to said second pushbutton switch and is responsive to closure, or opening, or both, of the second switch contact for controlling electrical power to said electrical light source at least for selectively energizing and de-energizing said electrical light source when the battery is present in the cavity of said housing,

whereby said electrical light source of said flashlight may be selectively energized and de-energized responsive to either or both of said first and second pushbutton switches without electrical power to energize the light source flowing through the first and second pushbutton switches.

40. The electrical flashlight of claim 39 wherein either or both of said first pushbutton switch and said second pushbutton switch comprises:

a first switch element including an electrically conductive first flexible dome for providing a first normally open switch contact and having a first given actuating force, and

a second switch element adjacent said first switch element, said second switch element including an electrically conductive second flexible dome for providing a second normally open switch contact and having a second given actuating force, said second switch element including a flexible electrical conductor between said first switch element and the second flexible dome;

wherein said controller is responsive to closure, or opening, or both, of the first and second normally open switch contacts for controlling the electrical power to said electrical light source.

41. The electrical flashlight of claim 40 wherein either or both of said first pushbutton switch and said second pushbutton switch further comprises:

an actuator movable for exerting force on said second switch element via a spring, and for exerting force on said first switch element via the spring and said second switch element,

wherein the actuator moves a distance for closing the first and second normally open contacts that is substantially longer than an actuating distance of the first and second flexible domes.

42. The electrical flashlight of claim 40 wherein the second given actuating force of the second switch element is less than the first given actuating force of the first switch element.

43. The electrical flashlight of claim 39 wherein said controller controls electrical power to said electrical light source for energizing said electrical light source momentarily, for energizing said electrical light source continuously, for de-energizing said electrical light source, for causing said electrical light source to alternate repetitively between energized and de-energized conditions, for causing said electrical light source to change from a more energized condition to a less energized condition, for causing said electrical light source to change from a less energized condition to a more energized condition, and for any combination of the foregoing.

44. The electrical flashlight of claim 39 wherein said controller controls said electrical light source to momentary ON, to continuous ON, to OFF, to flashing, and to dimming conditions, and optionally to an un-dimming operating condition.