Flashlights utilizing unique LED light sources

• US 7,618,155 B2
• Filed: 04/17/2006
• Issued: 11/17/2009
• Est. Priority Date: 11/15/2005
• Status: Active Grant

• Current Assignee: Sunlite Science & Technology, Inc.
• Original Assignee: Jeff Jianhua Chen
• Inventors: Chen, Jeff Jianhua
• Primary Examiner(s): Choi; Jacob Y
• Assistant Examiner(s): Shallenberger; Julie A
• Application Number:
  US11/279,929
• Publication Number:
  US 20070109775A1
• Time in Patent Office: 1,310 Days
• Field of Search: 362202-206, 362/189
• US Class Current: 362/206
• 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 light emitting diode (LED) unit, comprising;

a metal base having a first end and a second end, wherein said first end internally tapers towards bottom of said metal base to form a reflective inner surface comprising a flat portion;

a metal core printed circuit board (PCB) mounted on said flat portion of the metal base, wherein one or more LED dies are conductively mounted on both sides of said metal core PCB by one of welding and adhering, and wherein the one or more LED dies are interconnected using one or more wires;

one or more metal screws inserted through one or more recesses around outer periphery of the metal base for establishing a contact between the metal core PCB and the metal base, wherein the metal base absorbs and dissipates heat produced by the LED dies;

a lens mounted on the first end of the metal base in front of the reflective inner surface; and

a printed circuit board (PCB) attached to said second end of the metal base for providing a first electrical connection to the one or more LED dies through said one or more wires, wherein the one or more wires are connected to one or more metal pins inserted through one or more insulated openings in the metal base, and wherein said metal pins form a leadframe on top of said PCB;

a cylindrical housing for accommodating one or more batteries, wherein said cylindrical housing comprises a first opening and a second opening, and wherein the cylindrical housing is attached to the second end of the metal base through said first opening;

said batteries for providing electrical power to the one or more LED dies, wherein said batteries are in electrical communication to provide a first terminal and a second terminal, and wherein said first terminal is connected to said first electrical connection of the PCB; and

an end cap attached to the cylindrical housing through said second opening for holding a control unit, wherein said control unit establishes a second electrical connection between the one or more LED dies and said second terminal through the cylindrical housing, the metal base, the one or more metal screws, and the metal core PCB.

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

3. The flashlight of claim 2, wherein said second printed circuit board electrically contacts the cylindrical housing and the second terminal of the batteries to establish said second electrical connection.

4. The flashlight of claim 1, wherein said control unit comprises a second printed circuit board, an inductor mounted on said second printed circuit board, and one or more springs attached to both sides of said second printed circuit board, wherein said springs are in contact with said end cap.

5. The flashlight of claim 4, wherein said second electrical connection is established between the cylindrical housing and the second terminal through said springs by twisting the end cap in a first direction, wherein twisting the end cap in a direction opposite to said first direction disconnects said established connection.

6. The flashlight of claim 1, wherein the lens is coupled to a lens frame connected to the metal base.

7. The flashlight of claim 1, wherein the lens is adhesively affixed to the metal base.

8. The flashlight of claim 1, wherein an optical material is disposed over the LED dies and the wires, and wherein said optical material protects the LED dies and the wires.

9. The flashlight of claim 1, wherein the cylindrical housing is attached to the metal base through a flexible metal tube.