ELECTRICAL SWITCH, AS FOR CONTROLLING A FLASHLIGHT

• US 20090152081A1
• Filed: 12/18/2007
• Published: 06/18/2009
• Est. Priority Date: 12/18/2007
• Status: Active Grant

• Current Assignee: Streamlight, Inc.
• Original Assignee: Streamlight, Inc.
• Inventors: Ziegenfuss, Peter J., Snyder, Mark W., SHARRAH, Raymond L.
• Granted Patent: US 7,652,216 B2
• Time in Patent Office: Days
• US Class Current: 200/1.B
• CPC Class Codes: F21V 23/0414 specially adapted to be used with portable lighting devices
• CPC Class Codes: H01H 1/18 with subsequent sliding
• CPC Class Codes: H01H 13/48 using buckling of disc springs
• CPC Class Codes: H01H 13/64 wherein the switch has more than two electrically distinguishable positions, e.g. multi-position push-button switches
• CPC Class Codes: H01H 2227/028 Key stroke
• CPC Class Codes: H01H 2227/032 Operating force

Abstract

An electrical switch may comprise a base having three electrical conductors thereon and an electrically conductive flexible dome adjacent the base. The flexible dome has plural longer legs extending from its dome and in electrical contact with a first conductor, has a shorter leg extending from its dome and overlying a second conductor, and has its dome overlying a third conductor. A pushbutton must be moved over a distance substantially greater than an actuation distance of the flexible dome to apply sufficient force to cause the shorter leg to contact the second conductor and the dome to contact the third conductor. A spring between the pushbutton and the flexible dome couples force to the flexible dome.

Claims

1. An electrical switch comprising:

a base having at least first and second peripheral electrical conductors and a central electrical conductor thereon;

an electrically conductive flexible dome disposed on said base, said flexible dome having a plurality of relatively longer legs extending from a dome portion thereof and being in electrical contact with the first peripheral electrical conductor of said base, said flexible dome having a relatively shorter leg extending from the dome portion thereof and overlying the second peripheral electrical conductor of said base, and the dome portion of said flexible dome overlying the central electrical conductor of said base, said flexible dome having an actuation distance;

wherein the relatively shorter leg of said flexible dome comes into electrical contact with the second electrical conductor of said base when said flexible dome is pressed towards said base with a first actuation force, and wherein the dome portion of said flexible dome comes into electrical contact with the central electrical conductor of said base when said flexible dome is pressed towards said base with a second actuation force that is greater than the first actuation force;

a spring having a first end bearing against said flexible dome and having a second end;

an actuation pushbutton disposed at the second end of said spring, wherein said actuation pushbutton is urged away from said flexible dome by said spring,

wherein said actuation pushbutton is movable for applying force to said flexible dome via said spring, and

wherein said spring has a spring rate selected so that said actuation pushbutton must be moved over a distance that is substantially greater than the actuation distance of said flexible dome in order to produce the second actuation force on said flexible dome.

2. The electrical switch of claim 1 wherein the spring has a length that is substantially longer than the actuation distance of said flexible dome.

3. The electrical switch of claim 1 further comprising:

a housing cover disposed adjacent said base, said housing cover having walls defining a central cavity, and having an opening therethrough in which said actuation pushbutton is movable,

wherein said flexible dome and said spring are disposed in the cavity of said housing cover, and

wherein electrical connections to the central and peripheral electrical conductors of said base are made by electrical conductors on said base, by electrical conductors extending from said base, or by electrical conductors on and extending from said base.

4. The electrical switch of claim 3 wherein at least one spring extends from said base for providing an electrical connection to at least one of the central electrical conductor, the first peripheral electrical conductor, and the second peripheral electrical conductor of said base.

5. The electrical switch of claim 4 wherein said at least one spring includes two concentric springs extending in a direction generally parallel to a plane defined by said base.

6. The electrical switch of claim 1 further comprising first and second housing parts defining a generally cylindrical module, wherein said base of said electrical switch is disposed between said first and second housing parts with two concentric springs extending axially from the generally cylindrical module and with said actuation pushbutton actuatable through an opening in said first housing part.

7. The electrical switch of claim 1 in combination with a controller and a load, wherein said controller is responsive to the relatively shorter leg of said flexible dome making connection between the first and second peripheral electrical conductors of said base, to the dome portion of said flexible dome making connection between the central conductor and the first peripheral electrical conductor of said base, to the dome portion of said flexible dome breaking connection between the central conductor and the first peripheral electrical conductor of said base, to the relatively shorter leg of said flexible dome breaking connection between the first and second peripheral electrical conductors of said base, or to any combination of the foregoing, for controlling the load.

8. The electrical switch of claim 7 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, or any combination of the foregoing.

9. The electrical switch of claim 7 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 operating conditions, and optionally to an un-dimming operating condition.

10. An electrical switch comprising:

a base having at least first, second and third electrical conductors thereon;

a housing cover disposed adjacent said base, said housing cover having walls defining a central cavity, and having an opening therethrough;

an electrically conductive flexible dome disposed in the cavity of said housing cover, said flexible dome having a plurality of relatively longer legs extending from a dome portion thereof and being in electrical contact with the first electrical conductor of said base, said flexible dome having a relatively shorter leg extending from the dome portion thereof and overlying the second electrical conductor of said base, and the dome portion of said flexible dome overlying the third electrical conductor of said base, said flexible dome having an actuation distance,

wherein the relatively shorter leg of said flexible dome comes into electrical contact with the second electrical conductor when said flexible dome is pressed with a first actuation force, and wherein the dome portion of said flexible dome comes into electrical contact with the third electrical conductor when said flexible dome is pressed with a second actuation force;

a spring in the cavity between said base and said housing cover, said spring having a first end bearing against said flexible dome and having a second end;

a pushbutton disposed in the opening of said housing cover at the second end of said spring, wherein said pushbutton is movable in the opening of said housing cover for exerting force on said flexible dome via said spring and is urged away from said flexible dome by said spring,

wherein said spring has a spring rate selected so that said pushbutton must be moved over a distance that is substantially greater than the actuation distance of said flexible dome in order to produce the second actuation force on said flexible dome.

11. The electrical switch of claim 10 wherein the spring has a length that is substantially longer than the actuation distance of said flexible dome.

12. The electrical switch of claim 10 wherein said base is larger than said housing cover disposed thereon, and

wherein electrical connections to the first, second and third electrical conductors of said base are made by electrical conductors on said base, by electrical conductors extending from said base, or by electrical conductors on and extending from said base.

13. The electrical switch of claim 10 wherein at least one spring extends from said base for providing an electrical connection to at least one of the first, second and third electrical conductors of said base.

14. The electrical switch of claim 13 wherein said at least one spring includes two concentric springs extending in a direction generally parallel to a plane defined by said base.

15. The electrical switch of claim 10 further comprising first and second housing parts defining a generally cylindrical module, wherein said base is disposed between said first and second housing parts with two concentric springs extending axially from the generally cylindrical module and with said pushbutton actuatable through an opening in said first housing part.

16. The electrical switch of claim 10 in combination with a controller and a load, wherein said controller is responsive to the relatively shorter leg of said flexible dome making connection between the first and second peripheral electrical conductors of said base, to the dome portion of said flexible dome making connection between the central conductor and the first peripheral electrical conductor of said base, to the dome portion of said flexible dome breaking connection between the central conductor and the first peripheral electrical conductor of said base, to the relatively shorter leg of said flexible dome breaking connection between the first and second peripheral electrical conductors of said base, or to any combination of the foregoing, for controlling the load.

17. The electrical switch of claim 16 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, or any combination of the foregoing.

18. The electrical switch of claim 16 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 operating conditions, and optionally to an un-dimming operating condition.

19. An electrical switch comprising:

a housing cover having walls defining a central cavity and a non-circular base end, and having an opening to the central cavity for receiving a pushbutton;

a generally planar base having a size and shape at least as large as the base end of said housing cover and having at least first, second and third electrical conductors thereon,

wherein the base end of said housing cover is affixed to said base, and wherein the first, second and third electrical conductors are at least in part within a region defined by the non-circular base end of said housing cover;

an electrically conductive flexible dome disposed in the central cavity of said housing cover at the non-circular base end thereof and abutting said base, said flexible dome having a plurality of relatively longer legs extending from a dome portion thereof to electrically contact the first electrical conductor of said base, said flexible dome having a relatively shorter leg extending from the dome portion thereof and overlying the second electrical conductor of said base, the dome portion of said flexible dome overlying the third electrical conductor of said base,

wherein said flexible dome engages the non-circular base end of said housing cover for fixing its position relative to said housing cover and said base, and wherein said flexible dome has an actuation distance,

wherein the relatively shorter leg of said flexible dome comes into electrical contact with the second electrical conductor when said flexible dome is pressed with a first actuation force, and wherein the dome portion of said flexible dome comes into electrical contact with the third electrical conductor when said flexible dome is pressed with a second actuation force;

a pushbutton disposed in the opening of said housing cover and movable therein;

a coil spring in the cavity of said housing cover having a first end bearing against said flexible dome and having a second end bearing against said pushbutton;

wherein said pushbutton is movable in the opening of said housing cover for applying force to said flexible dome via said coil spring and is urged away from said flexible dome by said coil spring,

wherein said coil spring has a spring rate selected so that said pushbutton must be moved over a distance that is substantially greater than the actuation distance of said flexible dome in order to produce the second actuation force on said flexible dome.

20. The electrical switch of claim 19 wherein the spring rate of said coil spring is such that said pushbutton must be moved in the opening of said housing cover over a distance that is at least the actuation distance of said flexible dome for producing the first actuation force on said flexible dome.

21. The electrical switch of claim 19 in combination with a controller and a load, wherein said controller is responsive to the relatively shorter leg of said flexible dome making connection between the first and second peripheral electrical conductors of said base, to the dome portion of said flexible dome making connection between the central conductor and the first peripheral electrical conductor of said base, to the dome portion of said flexible dome breaking connection between the central conductor and the first peripheral electrical conductor of said base, to the relatively shorter leg of said flexible dome breaking connection between the first and second peripheral electrical conductors of said base, or to any combination of the foregoing, for controlling the load.

22. The electrical switch of claim 21 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, or any combination of the foregoing.

23. The electrical switch of claim 21 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 operating conditions, and optionally to an un-dimming operating condition.

24. 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 first switch contacts, wherein said first pushbutton switch includes a first electrically conductive flexible dome having a plurality of relatively longer legs extending from a dome portion thereof, a relatively shorter leg extending from the dome portion thereof, wherein the relatively shorter leg of said second flexible dome closes a first normally open switch contact of the first switch contacts when said second flexible dome is pressed with a first actuation force, and wherein the dome portion of said second flexible dome closes a second normally open switch contact of the first switch contacts when said second flexible dome is pressed with a second actuation force;

a second pushbutton switch disposed proximate the tail end of said housing for providing second switch contacts, wherein said second pushbutton switch includes a second electrically conductive flexible dome having a plurality of relatively longer legs extending from a dome portion thereof, a relatively shorter leg extending from the dome portion thereof, wherein the relatively shorter leg of said second flexible dome closes a first normally open switch contact of the second switch contacts when said second flexible dome is pressed with a first actuation force, and wherein the dome portion of said second flexible dome closes a second normally open switch contact of the second switch contacts when said second flexible dome is pressed with a second actuation force;

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 contacts thereof 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 contacts thereof 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.

25. The electrical flashlight of claim 24 wherein either or both of said first pushbutton switch and said second pushbutton switch further comprises:

an actuator movable for exerting force on the flexible dome thereof via a spring, and for exerting force on the flexible dome thereof via the spring,

wherein the actuator moves a distance for closing the normally open contacts of the flexible dome thereof that is substantially longer than an actuating distance of the flexible dome thereof.

26. The electrical flashlight of claim 24 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, or for any combination of the foregoing.

27. The electrical flashlight of claim 24 wherein said controller controls said electrical light source to momentary ON, to continuous ON, to OFF, to flashing, and to dimming operating conditions, and optionally to an un-dimming operating condition.