Compact LED work light

• US 8,789,963 B2
• Filed: 10/31/2011
• Issued: 07/29/2014
• Est. Priority Date: 03/18/2004
• Status: Expired due to Fees

• Current Assignee: Alltemp Products Company Limited (DiversiTech Holdings, Inc.)
• Original Assignee: Brasscorp Limited
• Inventors: Whitfield, Robert Tod, Klipstein, Donald L., Brass, Jack
• Primary Examiner(s): Truong, Bao Q
• Application Number:
  US13/285,604
• Publication Number:
  US 20120212944A1
• Time in Patent Office: 1,002 Days
• Field of Search: 362/184, 362/109, 362/120, 362/249.02, 362/249.05, 362/294, 362/373
• US Class Current: 362/184
• CPC Class Codes: F21L 14/023 having two or more, or different light sources
• CPC Class Codes: F21L 4/00 Electric lighting devices with self-contained electric batteries or cells
• CPC Class Codes: F21L 4/08 characterised by means for in situ recharging of the batteries or cells
• CPC Class Codes: F21S 4/20 with light sources held by or within elongate supports
• CPC Class Codes: F21V 15/04 Resilient mountings, e.g. shock absorbers shock absorbing devices of vehicle headlamp housings B60Q1/0491; in general F16F15/04
• CPC Class Codes: F21V 17/12 by screwing
• CPC Class Codes: F21V 21/06 Bases for movable standing lamps; Fixing standards to the bases F21V21/08 takes precedence
• CPC Class Codes: F21V 21/08 Devices for easy attachment to any desired place, e.g. clip, clamp, magnet
• CPC Class Codes: F21V 21/32 Flexible tubes
• CPC Class Codes: F21V 21/406 for portable lighting devices
• CPC Class Codes: F21V 23/005 the substrate is supporting also the light source
• CPC Class Codes: F21V 23/02 the elements being transformers, impedances or power supply units, e.g. a transformer with a rectifier
• CPC Class Codes: F21V 23/0435 activated by remote control means
• CPC Class Codes: F21V 27/005 for portable lighting devices
• CPC Class Codes: F21V 29/507 of means for protecting lighting devices from damage, e.g. housings
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/75 with fins or blades having different shapes, thicknesses or spacing
• CPC Class Codes: F21V 29/763 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21V 7/0091 : using total internal reflection
• CPC Class Codes: F21Y 2115/10 : Light-emitting diodes [LED]
• CPC Class Codes: H05B 45/30 : Driver circuits
• CPC Class Codes: H05B 45/37 : Converter circuits
• CPC Class Codes: H05B 45/3725 : Switched mode power supply [SMPS]
• CPC Class Codes: H05K 1/0209 : External configuration of printed circuit board adapted for heat dissipation, e.g. lay-out of conductors, coatings

Abstract

A work light having a work light body including handle section and light head section, an elongate housing, a battery compartment and a component chamber longitudinally aligned within the housing, a battery, an LED circuit board assembly extending longitudinally within the housing and having a substrate layer, an external component layer on a first side of the substrate layer, and a driving component layer on an opposing second side of the substrate layer. Overlapping portion of the LED circuit board assembly in close proximity to the battery. Also, at least one LED on the external component layer, the external component layer facing transaxially outwardly from the housing such that light emitting from the LED emits from the light head section. At least one driving component on the driving component layer, all driving components placed on an extending portion of the LED circuit board assembly over the component chamber.

Claims

1. A work light comprising:

a work light body including,

a handle section and a light head section,

an elongate housing extending through the handle section and the light head section,

a battery compartment and a component chamber longitudinally aligned within the housing,

a battery within the battery compartment,

an LED circuit board assembly extending longitudinally within the housing and having a substrate layer, an external component layer on a first side of the substrate layer, and a driving component layer on an opposing second side of the substrate layer, wherein an overlapping portion of the LED circuit board assembly is placed in close proximity to the battery over the battery compartment,

at least one LED on the external component layer, the external component layer facing transaxially outwardly from the housing such that light emitting from the LED emits from the light head section, and

at least one driving component on the driving component layer, all driving components on the driving components layer placed on an extending portion of the LED circuit board assembly that extends from the overlapping portion over the component chamber.

2. The work light of claim 1 wherein close proximity is less than depth of at least one driving circuit component in the driving circuit layer.

3. The work light of claim 1 wherein close proximity is less than depth of all driving circuit components in the driving circuit layer.

4. The work light of claim 1 further comprising a lens assembly over the LED circuit board assembly, the lens assembly including a lens over each LED.

5. The work light of claim 1 wherein:

the substrate layer is formed of a thermally conductive material, and the substrate is in thermal contact with the housing, and the housing is a heatsink formed of thermally conductive material.

6. The work light of claim 1 wherein:

the work light body further comprises;

a charging port for receiving external power to the work light body,

dual mode circuitry within the external component layer and driving circuit layer to charge the battery from the charging port when receiving external power through the charging port, and to power the at least one LED when the work light is receiving power from the charging port and when the work light is not receiving power from the charging port,

and

a tether port about the charging port,

and,

the work light further comprises;

a power cable assembly comprising,

a power cable,

a charging port connector at a first end of the power cable, the charging port connector compatible with the charging port to provide power through the power cable to the work light body, and

a tether port connector about the charging port connector at the first end of the power cable, the tether port connector compatible with the tether port to provide a manually operable tether connection between the power cable assembly and the work light body, the tether connection such that the work light body is mechanically restrained by the power cable assembly when tether connected, and the charging port and charging port connector are maintained connected when the work light body and power cable assembly are tether connected.

7. A work light comprising:

a work light body including,

a handle section and a light head section,

an elongate housing extending through the handle section and the light head section,

an LED circuit board assembly having a substrate layer and an external component layer on a side of the substrate layer, the substrate layer formed of a thermally conductive material, the substrate layer is in thermal contact with the housing, and the housing is a heatsink formed of thermally conductive material, and

at least one LED on the external component layer, the external component layer facing transaxially outwardly from the housing such that light emitting from the LED emits from the light head section,

wherein the housing comprises longitudinal grooves trapping longitudinal edges of the substrate layer to hold the substrate layer in thermal contact with the housing.

8. The work light of claim 7 wherein a layer of the LED circuit board assembly other than the substrate layer is between the substrate layer and the housing, such layer is electrically resistive with low thermal resistance.

9. The work light of claim 7 wherein the substrate is formed of metal and the LED circuit board assembly is a metal core LED circuit board assembly.

10. The work light of claim 9 wherein the housing is a single-piece unit.

12. The work light of claim 7 wherein a layer of the LED circuit board assembly other than the substrate layer is between the substrate layer and the housing, such other layer is electrically resistive with low thermal resistance.

13. The work light of claim 12 further comprising a driving component layer on an opposing side of the substrate layer, and at least one driving component on the driving component layer.

11. A work light comprising:

a work light body including,

a handle section and a light head section,

an elongate housing extending through the handle section and the light head section,

an LED circuit board assembly having a substrate layer and an external component layer on a side of the substrate layer, the substrate layer formed of a thermally conductive material, the substrate layer is in thermal contact with the housing, and the housing is a heatsink formed of thermally conductive material, and

at least one LED on the external component layer, the external component layer facing transaxially outwardly from the housing such that light emitting from the LED emits from the light head section,

wherein a layer of the LED circuit board assembly other than the substrate layer is between the substrate layer and the housing, such layer is electrically resistive with low thermal resistance.