Explosion proof lantern

• US 7,641,358 B1
• Filed: 06/13/2007
• Issued: 01/05/2010
• Est. Priority Date: 06/13/2007
• Status: Expired due to Fees

• Current Assignee: Sunlite Safety Products, LLC
• Original Assignee: Sunlite Safety Products, LLC
• Inventors: Kelly, Kevin, Smith, Mike, Kline, Bret, Goodman, Randy, Brundage, Marty
• Primary Examiner(s): Philogene; Haissa
• Application Number:
  US11/808,788
• Time in Patent Office: 937 Days
• Field of Search: 362/183, 362/184, 362/157, 362/161, 362/192, 362/227, 362/800, 320/114, 320/107, 320/112, 320/123, 315/86, 315/276, 315/307, 315/312, 307/64, 307/66
• US Class Current: 362/183
• CPC Class Codes: F21L 2/00 Systems of electric lighting devices systems employing both electric and non-electric light sources or exchangeable light sources F21L27/00
• CPC Class Codes: F21L 4/08 characterised by means for in situ recharging of the batteries or cells
• CPC Class Codes: F21V 23/00 Arrangement of electric circuit elements in or on lighting devices characterised by cooling arrangements F21V29/508
• CPC Class Codes: F21V 25/12 Flameproof or explosion-proof arrangements
• CPC Class Codes: F21V 29/77 with essentially identical diverging planar fins or blades, e.g. with fan-like or star-like cross-section
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05B 45/30 Driver circuits
• CPC Class Codes: H05B 45/345 Current stabilisation; Maintaining constant current
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

A portable rechargeable lantern capable of use in an explosive environment includes light emitting diode light source, fault tolerant circuitry, a rechargeable battery and a charging circuit that receives power from an external charger via an induction coil. Formed within a sealed housing, the induction coil charging system eliminates external metal contacts, thereby eliminating a potential ignition source during charging operations. Fault tolerant circuitry and a cool-running light emitting diode light source eliminate potential ignition sources due to breakage or fault conditions. Mating surfaces between the lantern and its charger cradle facilitate aligning the charging induction coils.

Claims

1. A portable lantern, comprising:

at least one light emitting diode;

a rechargeable battery;

a secondary induction coil connected to the rechargeable battery and configured to provide charging current to the rechargeable battery;

at least three fault diodes connected between the rechargeable battery and ground; and

at least one fuse and resistor array connected between the rechargeable battery and the light emitting diode.

2. The portable lantern of claim 1, comprising three light emitting diodes.

3. The portable lantern of claim 1, wherein the rechargeable battery comprises a nickel metal hydride (NiMH) cell.

4. The portable lantern of claim 3, wherein the rechargeable battery comprises five NiMH battery cells electrically connected in series.

5. The portable lantern of claim 1, further comprising a fuse and a resistor array connected between the rechargeable battery and one of the at least one light emitting diodes.

6. The portable lantern of claim 5, wherein each resistor array is configured to limit current flow to the one of the at least one light emitting diodes in the event of a fault condition.

7. The portable lantern of claim 5, further comprising a closed loop current control circuit coupled to one resistor array and to one light emitting diode, wherein the resistor array is configured and connected so that a voltage across the resistor array is provided as an input to the closed loop current control circuit, and the closed loop current control circuit is configured to regulate current flowing to the one light emitting diode.

8. The portable lantern of claim 1, further comprising

a first thermistor disposed to sense a temperature of the battery;

a second thermistor disposed to sense an ambient temperature; and

a microcontroller coupled to the first and second thermistor and to a transistor coupled between the second induction coil and the battery, wherein the microcontroller is adapted and configured to regulate battery charging based in part upon signals received from the first and second thermistor by turning the transistor on or off.

9. The portable lantern of claim 8, wherein the microcontroller is further adapted and configured to regulate battery charging based upon a measured rate of temperature increase as indicated in the signal received from the first thermistor.

10. The portable lantern of claim 9, wherein the microcontroller is further adapted and configured to terminate battery charging if the signal from the first thermistor has a value indicating the battery is near a predetermined temperature.

11. The portable lantern of claim 9, wherein the microcontroller is further adapted and configured to terminate battery charging after a predetermined time has elapsed.

12. A portable rechargeable lantern system, comprising:

a lantern comprising;

at least one light emitting diode;

a rechargeable battery;

a secondary induction coil connected to the rechargeable battery to provide charging current to the rechargeable battery;

at least three fault diodes connected between the rechargeable battery and ground; and

at least one fuse and resistor array connected between the rechargeable battery and the at least one light emitting diode; and

a charging cradle comprising;

a power source;

a charging post; and

a primary induction coil disposed within the charging post and electrically connected to the power source.

13. The portable rechargeable lantern system of claim 12 wherein:

the portable lantern further comprises a lantern light head assembly and a lantern main body assembly, said lantern main body assembly having cavities and collar feet molded into the main body assembly, and

the charging cradle further comprises protrusions integrally molded within the charging cradle configured to mate with the cavities molded into the lantern main body assembly.

14. The portable rechargeable lantern system claim 13 wherein the charging cradle further comprises a charging cradle base having holes disposed in the charging cradle base to allow discharge of water and circulation of air to cool the lantern during charging.

15. The portable rechargeable lantern system claim 14 wherein the charging cradle further comprises a gutter configured to allow water to enter the charging cradle and drain out away from the lantern.

16. The portable rechargeable lantern system claim 13 wherein the charging cradle further comprises standing ribs integrally formed to mate with the collar feet molded into the lantern main body assembly.

17. The portable rechargeable lantern system claim 12 wherein the lantern further comprising a squeeze trigger which when engaged retracts a spring loaded trigger locking tab.

18. The portable rechargeable lantern system claim 17 where the charging cradle further comprises trigger locking slots adapted to mate with the trigger locking tab to secure the lantern in the charging cradle.

19. The portable rechargeable lantern system claim 18, comprising three light emitting diodes.

20. The portable rechargeable lantern system claim 18, wherein the rechargeable battery comprises a nickel metal hydride (NiMH) cell.

21. The portable rechargeable lantern system claim 20, wherein the rechargeable battery comprises five NiMH battery cells electrically connected in series.

22. The portable rechargeable lantern system claim 18, further comprising a fuse and a resistor array connected between the rechargeable battery and one of the at least one light emitting diodes.

23. The portable rechargeable lantern system claim 22, wherein each resistor array is configured to limit current flow to the on of the at least one light emitting diodes in the event of a fault condition.

24. The portable rechargeable lantern system claim 22, further comprising a closed loop current control circuit coupled to one resistor array and to one light emitting diode, wherein resistor array is configured and connected so that a voltage across the resistor array is provided as an input to the closed loop current control circuit, and the closed loop current control circuit is configured to regulate current flowing to the one light emitting diode.

25. The portable rechargeable lantern system claim 18, further comprising

a first thermistor disposed to sense a temperature of the battery;

a second thermistor disposed to sense an ambient temperature; and

a microcontroller coupled to the first and second thermistor and to a transistor coupled between the second induction coil and the battery, wherein the microcontroller is adapted and configured to regulate battery charging based in part upon signals received from the first and second thermistor by turning the transistor on or off.

26. The portable rechargeable lantern system claim 25, wherein the microcontroller is further adapted and configured to regulate battery charging based upon a measured rate of temperature increase as indicated in the signal received from the first thermistor.

27. The portable rechargeable lantern system claim 26, wherein the microcontroller is further adapted and configured to terminate battery charging if the signal from the first thermistor has a value indicating the battery is near a predetermined temperature.

28. The portable rechargeable lantern system claim 26, wherein the microcontroller is further adapted and configured to terminate battery charging after a predetermined time has elapsed.