Lighting head assembly with improved optical control

• US 6,994,451 B2
• Filed: 11/19/2003
• Issued: 02/07/2006
• Est. Priority Date: 01/03/2003
• Status: Active Grant

• Current Assignee: Nite Ize Incorporated
• Original Assignee: Robert D. Galli
• Inventors: Galli, Robert D.
• Primary Examiner(s): Cariaso, Alan
• Assistant Examiner(s): Rehm, Adam C.
• Application Number:
  US10/716,728
• Publication Number:
  US 20040130910A1
• Time in Patent Office: 811 Days
• Field of Search: 362/157, 362/189, 362196-208, 362/800, 362/257, 401/195
• US Class Current: 362/202
• 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: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 31/00 Gas-tight or water-tight arrangements
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01R 33/09 for baseless lamp bulb

Abstract

A novel lighting assembly that incorporates a high brightness light emitting diode (LED) in a compact assembly for further integration into a lighting device is provided. The lighting head assembly of the present invention provides several novel aspects that are all closely integrated to provide a unique assembly for incorporating a high brightness LED into a lighting device. In particular, the head assembly utilizes a receiver sleeve that includes a non reflective coating to provide a high level of contrast between the lighting element and the interior region surrounding the lighting element. Further, an optical element is coupled to the receiver to capture an image of the lighting element to provide a sharp, uniformly illuminated image in the far field of the device.

Claims

1. A lighting head assembly comprising:

a receiver sleeve having a first end and a second end, a tubular side wall having an interior surface, said tubular side wall extending between said first and second ends and a substantially planar end wall at said first end, said end wall having an interior surface, an exterior surface and an aperture in said end wall;

a non-reflective coating on said interior surfaces of said side wall and said end wall; and

a lighting element having an optical end, said optical end of said lighting element received on the exterior of said receiver sleeve in alignment with said aperture adjacent said exterior surface of said end wall, wherein said optical end of said lighting element is substantially entirely on the exterior side of the plane of said end wall, wherein light output from said lighting element is directed into said aperture.

2. The lighting head assembly of claim 1 wherein said aperture includes a central axis and said lighting element includes an optical axis, said optical axis of said lighting element being aligned with said central axis of said aperture.

3. The lighting head assembly of claim 2, wherein said optical end of said lighting element is substantially entirely on the exterior side of the plane of said end wall, wherein light output from said lighting element is directed into said aperture.

4. The lighting head assembly of claim 1, wherein said lighting element is a light emitting diode.

5. The lighting head assembly of claim 1, wherein said non-reflective coating is a flat black coating.

6. The lighting head assembly of claim 1, further comprising:

a lens adjacent said second end of said receiver sleeve, whereby said lens captures a circular image of the light output in said aperture and said interior surface of said end wall and projects said circular image into the far field of said lighting assembly thus providing a circular illuminated spot having a clearly defined edge.

7. The lighting head assembly of claim 6, wherein said lens has a focal length and is coupled to said second end of said receiver tube, said side wall of said receiver tube maintaining said lens at a fixed distance from said end wall, said fixed distance being approximately equal to said focal length of said lens.

8. The lighting head assembly of claim 1, further comprising:

a tubular tail portion extending from said exterior side of said end wall concentric to said aperture, said optical end of said lighting element received in said tail portion, wherein said output end of said lighting element is substantially entirely on the exterior side of the plane of said end wall, wherein light output from said lighting element is directed into said aperture.

9. The lighting head assembly of claim 8, further comprising:

a lens adjacent said second end of said receiver sleeve, whereby said lens captures a circular image of the light output in said aperture and said interior surface of said end wall and projects said circular image into the far field of said lighting assembly thus providing a circular illuminated spot having a clearly defined edge.

10. The lighting head assembly of claim 9, wherein said lens has a focal length and is coupled to said second end of said receiver tube, said side wall of said receiver tube maintaining said lens at a fixed distance from said end wall, said fixed distance being approximately equal to said focal length of said lens.

11. A lighting assembly comprising:

a receiver sleeve having a first end, a second end and an Interior surface,

an end wall at said first end of said receiver sleeve, said end wall having an interior surface, an exterior surface and an aperture therein;

a lighting element having an optical end, said optical end of said lighting element received on the exterior of said receiver sleeve in alignment with said aperture adjacent said exterior surface of said end wall, wherein light output from said lighting element passes through said aperture, illuminating said aperture such that the light entering the receiver sleeve through the illuminated aperture does not impInge on the interior surface of said end wall, said interior surface of said end wall remaining non-illuminated; and

a lens adjacent said second end of said receiver sleeve, wherein said lens captures and projects a circular image of the illuminated aperture and said non-illuminated end wall forming a clearly defined beam cut-off edge thus providing a circular illuminated spot having a clearly defined edge in the far field of said lighting assembly.

12. The lighting assembly of claim 11, further comprising:

a tubular tail portion extending from said exterior surface of said end wall concentric to said aperture, said optical end of said lighting element received in said tail portion, wherein said output end of said lighting element is substantially entirely on the exterior side of the plane of said end wall, wherein light output from said lighting element is directed into said aperture.

13. The lighting assembly of claim 11, further comprising:

a non-reflective coating on said interior surfaces of said receiver sleeve and said end wall.

14. The lighting assembly of claim 13, wherein said non-reflective coating is a fiat black coating.

15. The lighting assembly of claim 11 wherein said aperture includes a central axis and said lighting element includes an optical axis, said optical axis of said lighting element being aligned with said central axis of said aperture.

16. The lighting assembly of claim 11, wherein said lighting element is a light emitting diode.

17. A flashlight assembly comprising:

a housing having a first end and a second end;

a receiver sleeve received into said first end of said housing, said receiver sleeve having a first end, a second end, an interior surface and an end wall at said first end of said receiver sleeve, said end wall having an interior surface, an exterior surface and an aperture therein;

a mounting board adjacent said exterior surface of said end wall of said receiver sleeve, said mounting board having first and second electrical contacts thereon;

a power source received in said second end of said housing, said power source in electrical communication with said first and second electrical contacts on said mounting board;

a lighting element having an optical end and first and second contact leads extending therefrom, said lighting element mounted to said mounting board such that said first and second contact leads are in electrical communication with said first and second electrical contacts respectively, said optical end of said lighting element being on the exterior of said receiver sleeve in alignment with said aperture adjacent said exterior surface of said end wall, wherein light output from said lighting element passes through said aperture illuminating said aperture such that the light entering the receiver sleeve through the illuminated aperture does not impinge on the interior surface of said end wall, said interior surface of said end wall remaining non-illuminated;

switching means to selectively energize said lighting element; and

a lens adjacent said second end of said receiver sleeve, wherein said lens captures and projects a circular image of the illuminated aperture and said non-illuminated end wall forming a clearly defined beam cut-off edge thus providing a circular illuminated spot having a clearly defined edge in the far field of said flashlight.

18. The flashlight of claim 17, further comprising:

a tubular tail portion extending from said exterior surface of said end wall concentric to said aperture, said optical end of said lighting element received in said tail portion, wherein said output end of said lighting element is substantially entirely on the exterior side of the plane of said end wall, wherein light output from said lighting element is directed into said aperture.

19. The flashlight of claim 17, further comprising:

a non-reflective coating on said interior surfaces of said receiver sleeve and said end wall.

20. The flashlight of claim 19, wherein said non-reflective coating is a flat black coating.

21. The flashlight of claim 17 wherein said aperture includes a central axis and said lighting element includes an optical axis, said optical axis of said lighting element being aligned with said central axis of said aperture.

22. The flashlight of claim 17, wherein said lighting element is a light emitting diode.