Flashlights Utilizing Unique LED Light Sources

• US 20070109775A1
• Filed: 04/17/2006
• Published: 05/17/2007
• Est. Priority Date: 11/15/2005
• Status: Active Grant

• Current Assignee: Sunlite Science & Technology, Inc.
• Original Assignee: Jeff Chen, Xiaofang Suo
• Inventors: Chen, Jeff
• Granted Patent: US 7,618,155 B2
• Time in Patent Office: Days
• US Class Current: 362/187
• 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 23/0421 the switch being part of, or disposed on the tail cap portion thereof
• CPC Class Codes: F21V 29/80 with pins or wires
• CPC Class Codes: F21V 31/005 Sealing arrangements therefor
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/45144 Gold (Au) as principal constituent
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/73265 Layer and wire connectors
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/00012 Relevant to the scope of the group, the symbol of which is combined with the symbol of this group
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/181 Encapsulation

Abstract

Seven thermally and optically efficient LED units and two control units are disclosed. Flashlights utilizing these LED units and control units are also disclosed. Such a flashlight mainly includes a cylindrical housing, a cylindrical rear cap, one of the seven LED units, one of the two control units. Each LED units are interchangeable between different emitting colors. Each LED unit mainly comprises a metal base, a reflector if the metal base is not a reflector itself, a leadframe formed attaching one or more metal pins to a printed circuit board, one or more LED dies mounted on the metal base, optical material disposed over the LED dies, and an optional lens to further focus the light.

Claims

1. A flashlight comprising a LED unit, a cylindrical housing, a copper ring optionally embedded at the end of the said cylindrical housing where the said LED unit is to be connected, batteries, a cylindrical rear cap, a control unit. The said cylindrical housing and said cylindrical rear cap is preferably aluminum with anodized finish. The anodized finish is removed at locations where electrical connection is to be made.

2. The flashlight of claim 1 wherein the said LED unit has the smallest outer diameter of 0.96 cm, and can be any sizes depending on the sizes of the flashlight.

3. The flashlight of claim 1 wherein the said LED unit is interchangeable between seven different emitting colors of UV, blue, green, white, yellow, red, IR, etc.

4. The flashlight of claim 1 wherein the said LED unit comprising a metal base that also functions as a reflector, one or more metal pins connected on a printed circuit board to provide electrical contacts, one or more LED dies mounted on the said metal base, and wire-bonded to the said metal pins, an optical material disposed over the said LED dies, and a lens coupled with a lens frame connected to the said metal base.

5. The LED unit of claim 4 wherein said lens is optionally adjustable for focusing and dispersing the LED beam as desired.

6. The flashlight of claim 1 wherein the said LED unit comprising a metal base that also functions as a reflector, one or more metal pins connected on a printed circuit board to provide electrical contacts, one or more LED dies mounted on the said metal base, and wire-bonded to the said metal pins, an optical material disposed over the said LED dies, and an optional lens fixed to the said metal base.

7. The flashlight of claim 1 wherein the said LED unit comprising a reflective metal ring, one or more metal pins connected on a printed circuit board to provide electrical contacts, one or more LED dies mounted on the said metal ring, and wire-bonded to the said metal pins, an optical material disposed over the said LED dies, a reflector connected to the metal ring, and an optional lens fixed to the said reflector.

8. The flashlight of claim 1 wherein the said LED unit comprising a metal base, a reflector adhered to the said metal base, a metal frame connected to the metal base, one or more metal pins connected on a printed circuit board to provide electrical contacts, one or more LED dies mounted on the said metal base, and wire-bonded to the said metal pins, an optical material disposed over the said LED dies, and an optional lens fixed to the said metal frame.

9. The flashlight of claim 1 wherein the said LED unit comprising a metal bar or a metal core PCB, a reflector connected to the metal bar or the metal core PCB, one or more LED dies symmetrically located in the center of the edge on both sides of the said metal bar or metal core PCB, an optical material disposed over the said LED dies, and an optional lens fixed to the said reflector.

10. The flashlight of claim 1 wherein the said LED unit comprising a metal bar or a metal core PCB, a reflector connected to the metal bar or the metal core PCB, two or more LED dies evenly mounted along the edge on both sides of the metal bar or the metal core PCB, an optical material disposed over the said LED dies, and an optional lens fixed to the said reflector.

11. The flashlight of claim 1 wherein the said LED unit comprising a metal base, one or more metal pins connected on a printed circuit board to provide electrical contacts, one or more LED dies mounted on the said metal base, and wire-bonded to the said metal pins, a dome-shaped optical lens encapsulating the said LED dies, a metal frame connected to the said metal base, and an optional lens fixed to the said metal frame.

12. The flashlight of claim 1 wherein the said control unit comprising a spring, a resistor, a switch mounted on a printed circuit board, a washer and a rubber cap.

13. The control unit of claim 12 wherein the said printed circuit board electrically contacts the cylindrical housing and the batteries of claim 1 to establish the electrical connection between the said batteries and the said LED unit of claim 1. The said switch of claim 12 completes and breaks the electrical connection.

14. The flashlight of claim 1 wherein the said control unit comprising a printed circuit board, an inductor mounted on the said printed circuit board and two springs attached to both sides of said printed circuit board.

15. The control unit of claim 14 wherein the said printed circuit board is connected or disconnected from the said cylindrical housing of claim 1, completing or breaking the electrical connection between the batteries and the LED unit of claim 1.

16. The flashlight of claim 1 wherein the said cylindrical housing and the said LED unit can be connected through a flexible metal tube.