Flashlight

The present invention relates to a flexible core (16) for a portable device, such as a flashlight (10), which includes a pair of conductor wires (54, 56) for connecting a hosted power source (78, 80). inside a housing (12) to an energy user accessory (92) housed in a housing (14). A flexible column (28) surrounds the pair of conductor wires (54, 56) and includes a plurality of universally rotatable (28A, 288). engages on the surface form the column (28). nickel wire and selectively the flashlight to an external electrical power source of the interconnected components and a resilient sleeve (18) rotatable components that

An adapter that includes a chromed conductor can be used to

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NATIONAL INSTITUTE OF INDUSTRIAL PROPERTY

PATENT SERVICES DIRECTORATE

SUMMARY SHEET (Continued)

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Summary (continued) (57) volt instead of two standard C batteries housed inside the flashlight.

The present invention is usable, for example, in the electrical appliance industry.

DO NOT FILL SHADOW ZONES

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DESCRIPTIVE MEMORY

Flashlight

This invention relates to a portable flashlight and in particular to a flexible core for connecting the power generating end of the flashlight to the power using end thereof.

The modern flashlight is one of the most useful appliances found at home, in the car, or in other places where a portable light source is desirable. Very often a flashlight is employed in situations where it is desirable for the user's hands to be free to hold or maneuver an object to be illuminated.

For example, when a person is servicing a car, there are many circumstances when it is desirable to use both hands to perform the maintenance task even though artificial lighting is still required. Other applications include reviewing documents, such as reading maps in a car, trying to find an object in a relatively dark place, and performing similar tasks. When the user has a normal flashlight, the user must appeal to various unorthodox means for holding the flashlight to free his or her hands. For example, the user may place the flashlight under the arms, in the mouth or place the flashlight in a nearby holder, which may not necessarily be close enough to the object to be viewed to provide the desired illumination.

So far, there have been a variety of lighting products, which have included flexible cores for the general purpose of manipulating a light source to a desired position. In some cases, the light source is on a base and a flexible core contains glass fibers to conduct light to the core tip. Some of these lighting products are powered by

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They are battery-powered, although most are AC powered to provide the high intensity light generally required for such applications as inspection work.

In other cases, the lamp may be constructed with a goose neck formed from a coiled, interlocked and flexible metal ribbon tube. Generally, such a lighting product is used with AC powered lamps, such as desk lamps, and includes two wires internally supported by the flexible metal tube.

In some battery powered applications, one of the conductive wires may be omitted and a second conductive circuit is provided by the flexible metal tube itself. There are some other lighting products, some of which are battery powered and some are AC powered, which use a flexible core constructed from a plastic jacket and coaxial cable. The center core is usually a solid wire. It is separated by an insulating plastic and enclosed by a twisted sheet of metal wire around it. The plastic jacket, typically a polyvinyl chloride, protects from the outside. Other lamps having a flexible core utilize a series of solid copper, charging or aluminum wire, which are either individually or together in cable, to provide physical support for the flexible core. In some cases, the wire or wires are used as conductors to provide one or more of the two electrical circuits required for a light source. In some applications the wires are bars and in others the wires may be individually or collectively insulated with some plastic sleeves. In addition, there are known AC-powered lamps that utilize a series of interlocking plastics elements to form a flexible core. This core is sold under brands such as LOCKWOOD and CEDERBURG. The flexible core is designed to support cutting / cooling fluid for metal cutting machine-supported workpieces such as lathes and milling machines. The flexible core is generally hollow and is leak proof. 0 core

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-3 is flexible to allow fluid to be directed into various workpieces as required. AC-powered lamps using this flexible core generally have two wires running into the central hole formed by the flexible plastic elements.

A major problem with cores utilizing the common, interlocked, flexible goosenecked metal ribbon tube is that the bend radius is too limited for a flexible lamp application. Although the gooseneck tube is reasonably durable, it also gradually reduces its ability to withstand bending force due to wear on interlocking surfaces. Interlocking surfaces provide the friction necessary to make the product retain the shape in which the user has placed the core.

The main problem associated with the types of wire and / or coaxial cable cores is that they have a very limited life span when flexed. Metal fatigue quickly and, if bent back and forth continuously at the same location, the core will tend to break at that point. In some cases this may occur after only 100 folding cycles.

THE

The core formed of a plurality of interlocking plastics elements offers the advantage of long duration while bending forward and backward. The core is not prone to fatigue, and due to the use of low coefficient of friction materials such as acetal plastic, the core elements tend to have relatively little wear. However, the prior art plastic interlocking element cores tend to suffer from some problems. Since each element is free to rotate relative to the next interlocking element, the entire chain of plastics elements can be bent and twisted and thus come out of alignment. This gives a very unattractive core. In addition, the elements are joined together.

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By snapping together each element as a ball joint and snapping to the next successive element. While the foregoing allows for a relatively large range of free movement and easy assembly / disassembly, such a structure also allows the elements to separate from each other if the interlocking chain is bent to too tight a radius by relatively strong applied force. Modifications to the socket design will increase the ability of the core to withstand forces that will tend to cause the socket to separate. One of the usual situations involving the need for a hands-free flashlight involves reading a map or similar document in a car. It is desirable to have a flashlight capable of being powered by a few standard AA, C or D batteries, while also having the ability to be powered by a much higher level of DC voltage available from a standard car battery. . For this application the relatively few batteries are preferably two which will provide an average DC voltage of 2.4 volts. The higher voltage generated by the car battery should be converted to a lower working voltage level usable by the lantern lamp, without generating excessive heat. Such voltage conversions may be performed with a DC converter or pulse width modulation circuit or by the use of passive means such as a drop resistor.

The circuit approach has several basic drawbacks. The first is the relatively expensive cost associated with the components and the manufacture and the second is the problem of having to close the circuit board having control within the flashlight. A third drawback is safety due to the growing number of components and the relatively aggressive operating environment.

Drop resistance, on the other hand, is inexpensive and safe but causes excessive heat when it dissipates the energy produced by dropping the 12 volt DC voltage to approximately 2.4 volts.

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This heat generated poses a packaging problem due to temperature limitations of the normal plastic materials employed in the manufacture of lantern housings.

Accordingly, it is an object of this invention to provide a flexible core for a flashlight or similar device that is capable of maintaining a user-defined shape, permits repetitive bending and allows energy conducting means to pass through the core, so that energy provided to one end of the core may be provided to the other end, which includes an energy user element. It is a further object of the invention to provide an adapter for a flashlight or other similar device which will allow the device to be powered by standard dry batteries or a 12 volt car battery. The foregoing and other objects are achieved in a flexible core for a flashlight or similar device.

In a first aspect the present invention provides a flashlight comprising:

a base forming a power supply end for said flashlight;

at least one battery housed in said base;

a working end housing spaced from said base and supporting a reflector, lens and lamp; and a flexible core assembly connecting said base to said working end housing and comprising a pair of conductive wires electrically connecting said battery to said lamp, a flexible column surrounding said pair of conductive wires and includes a plurality of interconnected and universally rotatable components, and a resilient sleeve member engaging an outer surface of each of the rotatable components forming said column.

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In a preferred embodiment the device may alternatively be connected to a 12 volt DC voltage source or to a normal dry battery battery such as a C battery. One of the conductors that connects the device to the 12 volt DC voltage source is formed. of nickel and chromium wire. 0 Nickel and chromium wire acts as a drop resistor to reduce the voltage level provided by the 12 volt DC voltage source to the level that can be used by the lantern lamp or other power user element of the device.

According to a second aspect of the invention a flexible core for connecting a first housing having at least one battery supported therein to a second housing, said battery serving as a power source and including said A second housing means connected to the power source for utilizing said power to be operated by it comprises:

a pair of electrically conductive wires connecting said battery to said energy user means;

a flexible column surrounding said pair of conductive wires including a plurality of interconnected and universally rotatable components; and a resilient sleeve member engaging an outer surface of each of the rotatable members forming said column.

The present invention further provides a flexible core assembly for connecting a first housing to a second housing and comprising a pair of lead wires electrically connecting said power supply end to said light source, wherein a flexible column surrounds said pair of conductive wires and including a plurality of interconnected and universally rotatable components, and a resilient sleeve member engaging an outer surface of each of the rotatable members forming said column.

According to a third aspect of the invention a flashlight

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-7 comprises:

a first housing forming a power supply end for said flashlight;

at least one battery housed in said first housing;

a second housing spaced from said first housing and supporting a reflector, lens and lamp;

a flexible mounting assembly connecting said first housing to said second housing and comprising a pair of electrically conductive wires, electrically connecting said battery to said lamp, a flexible column surrounding said pair of conductive wires and including a plurality of interconnected and universally rotatable components; and a resilient sleeve member engaging an outer surface of each of the rotatable members forming said column; and including one of said first and second housings having a longitudinally extending rib surface, and including the other of said housings having a longitudinally extending groove surface, said rib surface being substantially opposite to one another.

said groove surface for insertion therein, when said flexible mounting assembly is folded to provide a compact configuration.

According to a fourth aspect of the invention a flashlight comprises:

a first housing forming a power supply end for said flashlight;

at least one battery housed in said first housing;

a second spaced housing from said first housing

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Supporting a reflector, lens and lamp;

a flexible mounting assembly connecting said first housing to said second housing and including a pair of electrically conductive wires electrically connecting said battery to said lamp, said folding mounting assembly being in a U-shaped configuration ; and including one of said first and second housings a first component and the other of said housings including a second component, for engaging said first component to retain said mounting assembly in the U-shape configuration, said configuration forming. U-shaped handle for said flashlight.

According to a fifth aspect of the invention a flashlight comprises:

a first housing forming a power supply end for said flashlight;

a second housing spaced from said first housing and including a light source; and a flexible mounting assembly connecting said first housing to said second housing and including a pair of electrically conductive wires electrically connecting said power supply end to said light source, characterized in that said mounting assembly be foldable in a U-shape configuration, and one of said first and second housings includes a first component and the other of said housings include a second component, for engaging said first component so as to retain said mounting assembly in the U-shape configuration.

According to a sixth aspect of the invention a flashlight comprises:

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9th first housing forming a power supply end for said flashlight;

a second housing spaced from said first housing and supporting a light source; and a flexible mounting assembly having a first end connected to a first end of said first housing and a second end connected to a first end of said second housing, said mounting assembly including a pair of electrically conductive wires which electrically connect said power supply end to said light source; a flexible column; and a flexible sleeve circumferentially surrounding the outer surface of said column; the width of said sleeve being substantially equal to the width of each of said first ends of said first and second housings.

According to a seventh aspect of the invention a flashlight comprises:

a first housing forming a power supply end for said flashlight;

a second housing spaced from said first housing and including a light source; and a flexible mounting assembly having a first end connected to a first end of said first housing and a second end connected to a first end of said second housing, said mounting assembly including a pair of electrically conductive wires which electrically connect said power supply end to said light source; a flexible column circumferentially surrounding said pair of conductive wires and including a plurality of interconnected and universally rotatable components; and a sleeve member circumferentially surrounding the other surface of said column.

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According to another aspect of the invention a flashlight comprises:

a first housing forming a power supply end for said flashlight;

a second housing spaced from said first housing and including a light source; and a flexible mounting assembly having a first end connected to a first end of said first housing and a second end connected to a first end of said second housing, said mounting assembly including a pair of electrically conductive wires which electrically connect said power supply end to said light source; a flexible column; and a flexible sleeve circumferentially surrounding the outer surface of said column; the width of said sleeve being substantially equal to the width of each of said first ends of said first and second housings.

According to an eighth aspect of the invention a flashlight comprises:

a housing base forming a power supply end for said flashlight and having a longitudinally extending perforation including at least one battery housed therein;

a working end housing spaced from said base housing and supporting a reflector, lens and lamp including said working end housing means defining a longitudinally extending perforation;

a flexible core assembly connecting said base housing to said working end housing and comprising a pair of electrically conductive wires electrically connecting said battery to said lamp, a column

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Flexible surrounding said pair of conductive wires and including a plurality of interconnected and universally rotatable members, and a flexible sleeve member engaging an outer surface of each of the rotatable members forming said column;

a first anchor, connected to a first end of said flexible core and having a portion extending into the perforation of said base housing, said first anchor including anchoring means underlying the resilient sleeve member of said flexible core, and including said base housing drilling second clamping means overlying the sleeve of said flexible core and sandwiching said sleeve between said first and second clamping means; and a second anchor connected to a second end of said flexible core and having a portion extending into the perforation of said working end housing, said second anchor including third clamping means underlying the sleeve of said flexible core, and including said working end housing drilling fourth clamping means overlying the sleeve of said flexible core and sandwiching said sleeve between said third and fourth clamping means.

According to a final aspect of the invention a flashlight comprises:

a base housing forming a power supply end for said flashlight and having a longitudinally extending perforation including at least one battery housed therein;

a working end housing spaced from said base housing and supporting a reflector, lens and lamp, said working end housing including means defining a perforation extending

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Longitudinally;

A flexible core assembly connecting said base housing to said working end housing and comprising a pair of conductive wires electrically connecting said battery to said lamp; a flexible column surrounding said pair of conductor wires and including a plurality of interconnected and universally rotatable components, and a flexible sleeve member engaging an outer surface of each of the rotatable components forming said column including said component sleeve a first end, extending into the bore of the base housing and a second end extending into the bore of the working end housing, each of said bores including a plurality of inwardly extending ferrules for engaging the outer surface of said sleeve.

The invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

fig. 1 is an exploded perspective view showing the features of the flashlight of the invention;

fig. 2 is a side elevational view, partly in section, of the lantern of FIG. 1;

fig. 3 is a side elevational view with partially cut off portions to show further details of the lantern;

fig. 4 is an enlarged elevational view showing details of a portion of the lantern of the present invention;

fig. 5 is an enlarged elevational view of an additional portion of the lantern of the invention;

fig. 6 is a perspective view of the flashlight in a

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A somewhat bent position showing the manner in which the two lantern housings can be joined together;

fig. 7 is an exploded perspective view of a portion of the flashlight;

fig. 8 is a view similar to fig. 7, showing the parts in their assembled states;

fig. 9 is an exploded perspective view of an additional portion of the flashlight;

fig. 10 is an exploded perspective view of a subset of the lantern;

fig. 11 is an enlarged sectional view taken along line 11-11 of FIG. 12;

fig. 12 is a fragmentary sectional view of a portion of one of the lantern housings showing its details;

fig. 13 is an enlarged sectional view along line 13-13 of FIG. 12;

fig. 14 is a top view along line 14-14 of FIG. 1;

fig. 15 is a schematic diagram of the wiring harness showing the flashlight powered by a 12 volt car battery; and fig. 16 is an elevational view showing the adapter used to connect the flashlight to the 12 volt car battery.

Referring now to the various figures of the drawings, a preferred embodiment of the present invention is described. Referring to the various figures in the drawings, like numbers indicate like parts.

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Referring specifically to FIG. 1, a flashlight is described

10 having a first housing 12 and a second housing 14.

Housings 12 and 14 are spaced apart and are connected together by a flexible core 16. Housing 12 serves as a power supply end of the flashlight and contains batteries 78 and 80 (see Fig. 2). used as the primary source of electricity for the flashlight. Batteries 78 and 80 can be standard C batteries.

The housing 14 functions as the working end of the lantern 10 and includes a lens 50. As shown in fig. 2, housing 14 has also mounted within itself the reflector 90 and lamp 92. A switch 20 is provided for selectively connecting lamp 92 to the electrical power source such as batteries 78 and 80. 0 housing 14 is generally L-shaped and includes a generally cylindrical elongate branch 25 and a somewhat shorter rectangular-shaped branch 24 extending from branch 25. Branch 24 serves for mounting lens 50 of reflector 90 and lamp 92. Housing 12 includes a perforation 13 and branch 25 of housing 14 includes a similar perforation 15. One end of flexible core 16 is inserted into perforation 15 and the other end is inserted into perforation 13. Each end of core 16 has an anchor 22 to be more fully described hereinafter which is inserted into one of perforations 13 15 to attach flexible core 18 to housings 12 and 14.

Referring first to Figs. 2 to 10, the additional features of the flashlight will now be described in detail.

10 The flexible core 16 includes a resilient outer sleeve 18 made of a resilient elastomeric material such as a thermoplastic rubber sold by Monsanto Corporation under the trademark SANTOPRENE. Referring in particular to FIG. 4 a flexible column 28 is contained within the sleeve 18. The column 28 comprises a plurality of interconnected and universally rotatable components. Each universally rotatable component comprises a male end portion 28A and a female end portion 28B. The male end portion 28A has a

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An anchor 22 is attached to each end of the flexible core 16. One of the anchors is inserted into the perforation 13 of housing 12 and the other of the anchors is inserted into perforation 15 of housing 14. Anchor 22 includes a ball portion 64, a main body portion 66 including a plurality of ribs 34 and a somewhat rectangularly shaped portion 30. The height of the central rib 34A is somewhat higher compared to the height of the other ribs 34 of each anchor 22. As will be more fully described hereinafter, portion 30 has an open end facing outwardly of body portion 66 for embossing. of pressure 32 within itself. Each rib 34 includes a ramp-like front surface 34B for expanding sleeve material 18 outwardly to

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Allow each end of the sleeve to be wrapped around an anchor.

pressure relief 32 includes a pair of longitudinally spaced slots 47. pressure relief 32 mounted within housing 14 receives contacts 36, 38 in slots 47, while pressure relief 32 mounted in housing 12 receives contacts 42, 46 47. The pressure relief electrically connects the conductors 54, 56 to the contacts in each housing 12, 14. 0 The contact 42 in the housing 12 is in turn connected to the negative tape conductor 45, while the contact 42 is connected to the positive conductor 44. (See Fig. 3). Leads 44 and 45 are in turn connected to batteries 78 and 80. Housing 12 includes a removable battery cover 40. Contacts 36, 38 are connected to leads 58, 60 in housing 14.

As shown, switch 20 is in series with conductor 58. As is known to those skilled in the art, switch 20 is normally open and is closed to connect lamp 92 to batteries 78, 80 through various electrical leads and contacts indicated above. .

Referring specifically to Figs. 1 and 6, one of the housings, for example, housing 12 includes a vertical rib 26. Rib 26 includes a thin elongated portion 27, connected to a relatively wide elongated portion 29. The other housing, for example, housing 14 includes a groove 68 whose length is generally the same length as the rib 26. The groove 68 is generally U-shaped and includes a pair of spring clips 52. The spring clips 52 are placed into the slot 68 in a portion overlapping the relatively narrow portion 27 of the rib 26. If it is desired to reduce the overall length of the lantern 10, for example for storage purposes, or to hold the lantern for For portable use, the core 16 is folded so that the core forms a general U shape so that the housing 12 is in the same vertical plane as the housing 14. As shown

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Specifically in fig. 6, when the core 16 is bent as described, the rib 26 underlies the U-shaped slot.

68 To assemble the two housings together, the rib 26 is snap-fitted into the groove 68. The relatively narrow portion 27 of the rib 26 is inserted between the opposite faces of the spring clips 52, which force the opposite faces outwards. When the rib is inserted into the grooves, opposite faces of the spring clip are forced inwardly to lock the rib into the groove 68 to positively join the two housings together.

As described above, each end of the flexible core 16 includes an anchor 22. One of the anchors is inserted into the bore 13 and the other of the anchors is inserted into the bore 15. During testing, it was found that twisting or rotating the flexible core to achieve a desired lantern configuration produced forces tending to push the sleeve of each or both housing perforations or to twist each end of the sleeve 18 relative to each other. perforations 13 or 15. In order to prevent the undesirable occurrence of sleeve separation 18 from one or both housings and unwanted twisting of the sleeve 10 relative to the housings, clamping means have been added, which will be described more fully below in both perforations 13, 15 and anchorages 22.

Referring specifically to Figs. 11 through 14, each perforation 13, 15 is provided with a plurality of circumferentially spaced inwardly extending ferrules 100 and 102 respectively. The ferrules 100 and 102 extend radially inwardly to the surface of the sleeve 18. In addition furthermore, each perforation includes a pair of 180-degree circumferentially spaced grooves 104 underlying the ribs 34A when each anchor 22 is placed in a respective perforation 13,15.

Housing 14 includes four circumferentially spaced ferrules 100, while housing 12 includes 12 circumferentially spaced ferrules 102.

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Each ferrule 100 is greater than the length of each ferrule 102. As shown in FIG. 13, the cross-sectional shape of each ferrule 100 (or 102) is similar to a shark tooth, so that the outer surface of the sleeve engaged by each ferrule 100, 102 is firmly tightened to sandwich the sleeve between the outer surface of the shark. anchor 22 and the outer surface of each ferrule. This arrangement prevents the sleeve from being twisted with respect to each perforation 13, 15 and prevents the sleeve from being separated from either of the housings 12, 14.

In order to avoid any twisting or longitudinal movement of the sleeve, the ribs 34A act to force the z '·' ·&gt;.

vb resilient material from sleeve 18 to underlying grooves

104. The combination of ribs 34A and grooves 104 further prevent twisting of sleeve 18.

A further feature of the lantern relates to pressure relief 32. Pressure relief 32 includes a hub portion 48 having a relatively enlarged boss 48A formed at one end of the hub. The other end of the hub does not have an enlarged boss similar to boss 48A and the end of the hub rests in the same vertical plane relative to the vertical plane of the end face of the body portion 30 of the anchor 22.

Each housing 12, 14 includes a relatively large inwardly extending boss 69 and a relatively small circumferentially spaced second boss 69A. When each anchor 22 and its associated pressure relief 32 is inserted into one of the perforations 13, 15, the enlarged boss 48A of the pressure relief 32 aligns with the relatively small boss 69A of the housing and the flat surface 48B of the hub aligns with. the relatively large boss 69 of the housing. Indeed, the pressure relief can only be inserted into the perforation in one position due to the relationships established by the bosses 48A, 69A and 69B and the flat surface 48B of the hub 48. The aforementioned allows anchor 22 and pressure relief 32 to be used with a colored plug. One screw 67 or

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A similar means is inserted through boss 69, hub 48 and boss 69A to secure each anchor 22 to its respective housing.

Referring now to Figs 15 and 16, the flashlight 10 will be shown when connected to an external power source, such as a 12 volt car battery. When connected to an external power source, batteries 78 and 80 will be disconnected.

There are many uses for flashlight 10 inside or near a car. Accordingly, to conserve the energy of the batteries mounted within the housing 12 it is desirable to connect the flashlight 10 to the car battery 82. The flashlight 10 is designed to be powered by relatively few standard batteries, such as type C batteries. Specifically, in the embodiment Preferred two C batteries are used to provide an average DC voltage of 2.4 volts. Since the car battery voltage (typically 12 volt) is much higher than that required to power the flashlight 10, the voltage should be reduced to approximately 2.4 volts without excessive heat generation which is usable by 92 lantern lamp. Voltage conversion can be achieved with a DC voltage converter or pulse width modulation circuit or by the use of passive means such as a drop resistor. Each of the above means has problems associated with them, in particular when it is desired to use such means with a flashlight.

An adapter 70 is provided for connection to a 12 volt battery and flashlight. Adapter 70 includes a plug 71 for insertion into the 12 volt battery terminal provided within the passenger compartment of the car. Adapter 70 includes conductors 72 and 74. One conductor, for example conductor 74 is formed of nickel and chromium wire for the reasons to be described more fully below. Leads 72 and 74 terminate in a second plug 76 which may be inserted into an opening provided in the housing 12 of the lantern 10. When inserted into the housing 12 the plug 76

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-20 activates the off switch 84 so that batteries 78 and 80 are disconnected from the flashlight electrical circuits. When plug 76 is removed from housing 12, switch 84 closes to reconnect the batteries to the lantern circuits. When the flashlight switch 10 is closed, the battery 82 supplies the electrical power through the conductors 72, 74 of the adapter 70, conductors 45 and 58 representative of the conductors within the lantern, to the lantern lamp 92.

The nickel and chromium wire resistance 74 is relatively high and therefore conductor 74 acts as a drop resistance to reduce the voltage level supplied from the 12 volt DC voltage source to the 2.4 volt voltage level. required to power the lantern lamp. The total conductor length is 3.6576 m (12 ft), and its linear resistance coefficient is 2.428 ohm per meter (0.74 ohm per foot). By forming one of the adapter wires 70 with nickel and chromium wire, the applied voltage is reduced to the desired level without significantly increasing the cost of the flashlight or generating a significant level of unwanted heat. In a preferred embodiment nickel and chromium wire 74 is manufactured by Hoskins Manufacturing sold under the trademark CROMEL A.

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Although a preferred embodiment of the present invention has been described and represented, the invention is not limited thereto but may be embodied differently within the scope of the following claims.