Flashlight assembly

By using a plastic film and wave spring design, the sealing problem of the flashlight assembly was solved, resulting in cost reduction and improved operational feedback, providing a more reliable liquid seal and a compact structure.

CN121383149APending Publication Date: 2026-01-23STREAMLIGHT INC
View PDF 0 Cites 0 Cited by

Patent Information

Application Number
CN202511012355.7
Authority / Receiving Office
CN · China
Patent Type
Applications(China)
Current Assignee / Owner
Priority Date
2024-07-23
Filing Date
2025-07-22
Publication Date
2026-01-23

AI Technical Summary

Technical Problem

Existing flashlight components suffer from problems such as large sealing components, high production costs, and unreliability, while the tail switch design lacks sufficient operational feedback.

Method used

A plastic film is used as a sealant, attached to the subframe by heat welding or removable tape, forming a fluid-impermeable barrier. Wave springs and sealing sleeves are used to cover the end openings of the switch assembly, providing a liquid seal and improved operational feedback.

Benefits of technology

It simplifies the construction, reduces costs, saves space, and provides a better operating feel and seal through an improved switch design.

✦ Generated by Eureka AI based on patent content.

Smart Images

  • Figure CN121383149A_ABST
    Figure CN121383149A_ABST
Patent Text Reader

Abstract

A lighting device having a body includes a light assembly, an electronics subassembly, and a switch assembly. The light assembly is secured to the electronics subassembly at a front end of the body, while the switch assembly is secured to the electronics subassembly at a rear end of the body. The electronics subassembly accommodates a battery and a circuit board within a sealed interior volume. The switch assembly comprises a switch button, a sealing sleeve and a wave spring.
Need to check novelty before this filing date? Find Prior Art

Description

Technical Field

[0001] This disclosure relates to the field of portable lighting devices, and more specifically, to a handheld flashlight assembly having a sealed electronic device compartment and an improved tail cap switch. Background Technology

[0002] Flashlight assemblies with sealed electronic component compartments are known in the art. Such flashlight assemblies typically have high-profile sealed electronic component compartments comprising adhesive or compression seals that span the gap between housing members and / or fasteners. These seals can be bulky, expensive to manufacture, and / or unreliable.

[0003] Existing flashlight components also include a switch located on its tail side (i.e., opposite the lens). Some existing tail switch designs—when the switch is pressed—do not provide sufficient operational feedback to the user.

[0004] Therefore, there is a need for improved portable lighting devices to overcome these and other shortcomings of existing technology devices. Summary of the Invention

[0005] In one aspect, the concept of the present invention is: a lighting device comprising: a body having a front end and a rear end, the rear end being opposite to the front end; a light source having a first operating state and a second operating state, the light source extending through the front end of the body; an electronic device subassembly including power supply and switching components; a subframe having an internal volume, end openings, and a sealing surface, wherein the sealing surface surrounds the openings in the subframe, the power supply and switching components are located within the internal volume, and the light source, power supply, and switching components are electrically coupled together; and a seal having a periphery attached to the sealing surface, such that the subframe... The opening is impermeable to liquid; and a switch assembly extending through the rear end of the body, the switch assembly including a switch button, a sealing sleeve, and a wave spring, the switch button having an actuator, the wave spring being compressed between the switch button and the sealing sleeve such that the sealing sleeve covers the end opening and makes it impermeable to liquid, the actuator extending through the wave spring, the switch assembly being pressable such that the actuator engages the sealing sleeve and applies pressure to the switch member; wherein, when the switch member is fully depressed, the light source changes between its first operating state and its second operating state.

[0006] In another aspect, the concept of the present invention is: a lighting device comprising: a light source; a power source electrically coupled to the light source; a sub-frame having an internal volume, end openings, and a sealing surface, wherein the sealing surface surrounds an opening in the sub-frame, the opening being sized to allow the power source to pass through the opening and be inserted into the internal volume of the sub-frame, the power source being entirely located within the internal volume; and a switch assembly engageable by a user from the outside of the lighting device, the switch assembly comprising a switch button, a sealing sleeve, and a wave spring, the switch button having an actuator, the wave spring being compressed between the switch button and the sealing sleeve. The actuator extends through the wave spring, such that the sealing sleeve covers the end opening of the subframe and makes it liquid-impermeable; a seal with a periphery attached to the sealing surface, such that the opening in the subframe is fluid-impermeable; and a body with a front end and a rear end opposite to the front end, the body surrounding at least a portion of the subframe and the light source, the light source extending through the front end of the body; wherein the subframe and the seal are made of plastic material, and the periphery of the seal is removably attachable and reattachable to the sealing surface of the subframe using an adhesive material. Attached Figure Description

[0007] The lighting device according to the present disclosure is further described with reference to the accompanying drawings, wherein:

[0008] Figure 1 This is a right front isometric view of a flashlight assembly according to an embodiment of the present disclosure;

[0009] Figure 2 yes Figure 1 Isometric view of the lower rear left of the flashlight assembly;

[0010] Figure 3 yes Figure 1 An exploded isometric view of the right rear of the main body of the flashlight assembly;

[0011] Figure 4 yes Figure 1 right rear exploded isometric view of the flashlight assembly;

[0012] Figure 5 yes Figure 1 Left-view exploded isometric view of the flashlight assembly;

[0013] Figure 6 yes Figure 1 Right-view exploded isometric view of the lamp component of the flashlight assembly;

[0014] Figure 7 It is along Figure 1 The right-side view of the cross-section of the lamp assembly, taken from line 7-7;

[0015] Figure 8 It is along Figure 1 The rear view of the lamp assembly section taken by line 8-8; and

[0016] Figure 9 yes Figure 1 An isometric view of the switch button of a flashlight assembly. Detailed Implementation

[0017] The following detailed description provides exemplary embodiments only and is not intended to limit the scope, applicability, or configuration of the embodiments disclosed herein. Rather, the following detailed description of exemplary embodiments will provide an enabling description for implementing the exemplary embodiments according to this disclosure to those skilled in the art. It should be understood that various changes may be made to the function and arrangement of the elements without departing from the spirit and scope of the invention as set forth in the appended claims.

[0018] To aid in describing the claimed disclosure and / or invention, directional terms (e.g., up, down, left, right, etc.) may be used in the specification and claims to describe portions of the disclosure and / or invention. These directional definitions are intended only to aid in describing embodiments and claiming the invention, and are not intended to limit the disclosure or the claimed invention in any way. Additionally, reference numerals introduced in connection with the drawings in the specification may be repeated in one or more subsequent drawings without additional description in the specification, in order to provide context for other features.

[0019] It should be understood that when an element is referred to as "connected" or "coupled" to another element, it can be integrated with the other element, directly connected or coupled to the other element, or there may be an intermediary element. Conversely, when an element is referred to as "directly connected" or "directly coupled" to another element, it should be understood that there is no intermediary element. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" vs. "directly between", "adjacent" vs. "directly adjacent", etc.).

[0020] In the embodiments described herein or shown in the accompanying drawings, any direct electrical connection or coupling (i.e., any connection or coupling without additional intermediary elements) may also be achieved by indirect connection or coupling (i.e., connection or coupling with one or more additional intermediary elements), and vice versa, as long as the overall purpose of the connection or coupling is substantially maintained, for example, for transmitting some signal or transmitting some information. Features from different embodiments may be combined to form other embodiments. For example, unless indicated to the contrary, variations or modifications to one description of an embodiment may also apply to other embodiments.

[0021] Figures 1-8 A flashlight assembly 100 according to an embodiment of the present disclosure is shown. Typically, the flashlight assembly 100 can be configured as a portable lighting device. (Refer to...) Figure 1 The flashlight assembly 100 includes a main body assembly 102 and a lamp assembly 104. The main body assembly 102 includes a first main body member 108 and a second main body member 110. As shown, the first and second main body members 108 and 110 can be secured together by fasteners 112; however, other configurations are also possible. For example, in some embodiments, the components of the main body assembly 102 can be secured together via one or more of various fastening mechanisms, including mechanical fasteners (pins, screws, bolts, plugs, rivets, etc.), adhesives, or welding.

[0022] Still refer to Figure 1 The flashlight assembly 100 includes a charging port 116. The charging port 116 is accessible through an opening 118 formed in a first body member 108 of the body assembly 102. The opening 118 is generally configured as a lateral port. The charging port 116 connects to the battery 120 (e.g., see...). Figure 4 and 5 The flashlight assembly 100 is electrically connected and configured to receive an external power source (e.g., USB power). Battery 120 can be configured as a rechargeable battery and used as a power source to power the light in the light assembly 104. Therefore, an external power source can charge the battery 120 of the flashlight assembly 100. In some embodiments, the charging port 116 may also allow data transfer to the flashlight assembly 100 (e.g., firmware updates) and / or provide the ability to charge another external device using the energy stored in the battery 120.

[0023] Figure 2 A rear view of the flashlight assembly 100 is shown. (As shown) Figure 2 As shown, the flashlight assembly 100 may further include a clip body 122 fixed to the second body member 110 and a switch assembly 126 disposed at the rear end 128 of the body assembly 102—in a configuration commonly referred to in the art as a tail switch configuration. In this embodiment, the switch assembly 126 includes a switch button 130 that partially extends outside the body assembly 102. In use, the user can press (or otherwise engage) the switch button 130 and... Figure 2 Direction D shown x Pressing (or otherwise pushing) the switch button 130 actuates the switch assembly 126 and turns on, off, or otherwise adjusts the light source 134 of the lamp assembly 104 (see [link]). Figure 6(In this embodiment, the light source 134 is an LED). The switch button 130 translates a predetermined distance before reaching its designed travel limit and stops against the subframe 146. At the full length of its travel, the internal central post of the switch button 130 (i.e., the actuator 230) does not fully depress the switch member 198 (in this embodiment, the switch member is an electronic tactile switch). In fact, in this embodiment, even at the full length of its travel, the actuator 230 does not fully reach the switch member 198, and actuation of the switch member 198 is achieved by compressing the seal 192 between the switch button 130 (i.e., the actuator 230) and the switch member 198. This design prevents the switch member 198 from being crushed if the lamp falls from its end (i.e., from the switch button 130). This arrangement also prevents the spring 190 from being over-compressed and collapsing. In some embodiments, when the switch button 130 is at its full travel, the measured value of the gap between the end of the actuator 230 and the switch member 198 is a fraction of the measured value of the thickness of the seal 192, for example, a fraction between 1 / 8 and 3 / 8, more preferably a fraction between 3 / 16 and 5 / 16, and most preferably a fraction of 1 / 4 (e.g., a gap of 0.010 inches and a seal thickness of 0.040 inches).

[0024] like Figure 2 As shown, the switch button 130 may include ridges 138. In the illustrated embodiment, the ridges 138 include multiple lines (e.g., according to...). Figure 1 The xyz axis frame shown and constructed extends in the y direction. The raised texture 138 can provide a tactile reference for a user searching for the location of the switch button 130. The switch button 130 can comprise one or more materials, including polymers or other composites. For example, the switch button 130 can comprise or be composed of polycarbonate.

[0025] Now for reference Figure 3 An exploded view of the main body assembly 102 is shown. The main body assembly 102 generally provides a housing for the electronics subassembly 144. The electronics subassembly 144 houses the electronics of the flashlight assembly 100, which includes a battery 120, as will be described in more detail below. Each of the lamp assembly 104 and the switch assembly 126 is electrically coupled to the electronics subassembly 144. As shown, the switch assembly 126 is coupled to the rear end 128 of the electronics subassembly 144, and the lamp assembly 104 is positioned at the opposite end of the electronics subassembly (e.g., the front end of the electronics subassembly 144).

[0026] like Figure 4 and 5As shown, the electronic device subassembly 144 includes a subframe 146 and a seal 148. The seal 148 includes a mating surface 150 arranged around the outer periphery of the seal 148. The dimensions of the mating surface 150 of the seal 148 are designed to engage the sealing surface 152 of the subframe 146 (see Figure 148). Figure 5 During assembly, the mating surface 150 of the seal 148 may be heat-welded to or alternatively attached to the sealing surface 152 of the subframe 146 by adhesive. The material seal between the periphery of the subframe 146 and the seal 148 can provide a fluid-impermeable (e.g., waterproof) barrier—at the sealing surface 152 between the external and internal volumes of the subframe 146.

[0027] In one embodiment, the seal 148 is configured as a plastic film, which may be made of, for example, PET material. Using a plastic film as the seal 148, which is thermally welded to the subframe 146, eliminates the need for adhesives or compression seals on the electronic device subassembly 144, thus simplifying construction and reducing costs. Alternatively, the plastic film forming the seal 148 may be adhered to the periphery of the subframe 146 via removable tape or other adhesives (e.g., tape manufactured by tesa tape inc., Charlotte, North Carolina, USA). Using removable tape to form a bond between the seal 148 and the subframe 146 makes it easier to repair or replace components located inside the subframe 146, such as the battery 120, for example by allowing the seal 148 to be removed and then reattached to the periphery of the subframe 146. Furthermore, using a plastic film for the seal 148 allows the seal 148 to have a very low profile, thus saving space within the main assembly 102. Furthermore, the seal 148 is flexible, which allows the battery 120 to expand and grow during its lifespan without damaging or reducing the effectiveness of the impermeable barrier formed by the seal 148.

[0028] like Figure 4 As shown, the seal 148 includes a mating surface 150 and a recessed body portion 154 (i.e., from...). Figure 4 (The perspective view shows it is recessed). The seal 148 also includes a protruding planar member 156 extending from the recessed body portion 154 toward the battery 120, such as... Figure 4 As shown. Typically, seal 148 includes a varying cross-sectional thickness—across its mating surface 150, a recessed body portion 154, and a protruding planar member 156. These features of seal 148 allow for a tight and secure fit with battery 120. When flashlight assembly 100 or at least electronic device subassembly 144 is assembled, the protruding planar member 156 can contact the side surface 158 of battery 120 (see Figure 158). Figure 5), to buffer and fix the battery 120 relative to the subframe 146.

[0029] like Figure 4 As further shown, the sub-frame 146 includes a sub-port 160. The sub-port 160 includes a sealing plate and an opening extending from the outside of the sub-frame 146 into its internal volume. The sub-port 160 is configured to align with the charging port 116 and the opening 118 of the body assembly 102, such that an external charger can extend through each of the opening 118 and the sub-port 160. The charging port 116 and the opening 118 of the body assembly 102 mate together to form a liquid-resistant seal, preventing any liquid or debris from entering the internal volume of the sub-frame 146.

[0030] Continue to refer to Figure 4 and 5 The electronic component sub-assembly 144 also includes a main printed circuit board (PCB) 164, a PCB holder 166, and a USB component 168. Each of the PCB 164, PCB holder 166, and USB component 168 can be housed within the sub-frame 146 and sealed within the sub-frame 146 by a seal 148. The USB component 168 includes a charging port 116 and is configured to align with the sub-port 160 and electrically couple an external charger to the battery 120 to charge the battery 120. Additionally or alternatively, in other embodiments, an external device can be electrically coupled to the battery 120 via the USB component 168 to draw power from the battery 120 and charge the external device.

[0031] PCB retainer 166 is configured to fix the main PCB 164 relative to the battery 120. For example... Figure 5 As shown, the PCB retainer 166 can be secured to the sub-frame 146 at the sub-frame bracket 170 using fasteners 172 (e.g., screws). However, other fastening configurations are also possible, including pins, tabs, snap-fit ​​connections, adhesives, etc. In the illustrated embodiment, the sub-frame bracket 170 and the sub-frame 146 are integrally (i.e., monolithically) formed. When assembled, the main PCB 164 is configured to extend along the narrow side 174 (e.g., the top side) of the battery 120. This orientation of the main PCB 164 allows for a narrower, more compact PCB than conventional components, thus allowing for a more compact flashlight assembly 100.

[0032] like Figure 4As shown, the USB component 168 also includes a printed circuit board 176 (e.g., a secondary circuit board) electrically coupled to the main PCB 164 and configured to receive signals from the switch assembly 126 to turn the light source 134 of the flashlight assembly 100 on or off, or otherwise change its mode or intensity. Thus, the USB component 168 is electrically connected to the main PCB 164 and the charging port 116. The printed circuit board 176 of the USB component 168 is configured to be held within a sub-frame 146 and aligned with an end opening 180. The end opening 180 of the sub-frame 146 is an opening in the sub-frame 146 that extends between the outer surface of the sub-frame 146 and the internal volume of the sub-frame 146. On the outer surface of the sub-frame 146, the end opening 180 is at least partially framed by a retainer 182.

[0033] The retainer 182 includes a pair of tabs extending along the X-axis from the rear end 128 of the subframe 146 (i.e., adjacent to the rear end 128 of the body assembly 102). Typically, the retainer 182 is configured to hold the switch assembly 126 relative to the electronics subassembly 144. The retainer 182 includes angled tabs 184 that substantially become points at their distal ends. The retainer 182 is arranged to engage the switch button 130 of the switch assembly 126, and each of the angled tabs 184 is arranged to extend at least partially through a corresponding pair of slits 188 formed in the body of the switch button 130. During assembly of the switch assembly 126 to the electronics subassembly 144, the switch button 130 can slide onto the retainer 182 until the angled tabs 184 slightly deform until they engage the slits 188 of the switch button 130, at which point they spring back and at least partially enter the slits 188. The angled geometry of the angled tab 184 allows the switch button 130 to slide onto the retainer 182 during assembly, but prevents the switch button 130 from accidentally detaching from the electronic component subassembly 144 once secured.

[0034] Still referencing Figure 4 and 5The switch assembly 126 may also include a wave spring 190 and a sealing sleeve 192. The sealing sleeve 192 is configured to provide a seal at the end opening 180 of the sub-frame 146 to prevent liquids and debris from entering the internal volume of the sub-frame 146. The wave spring 190 extends between the internal body 194 of the switch button 130 and the flange 191 of the sealing sleeve 192. As will be further described below, the wave spring 190—in all its possible compressed states when the switch assembly 126 is assembled—provides sufficient pressure against the flange 191 of the sealing sleeve 192 to achieve uniform compression of the sealing sleeve 192 against the end opening 180 in the sub-frame 146, thereby creating a liquid-resistant seal. When compared to a standard tail switch, the wave spring 190 also serves to increase the force required to press the switch button 130, thereby improving the user feel and increasing the necessary actuation travel distance to minimize accidental actuation of the light source 134. In this embodiment, the sealing sleeve 192 is configured as a flexible seal, which can translate the movement from the switch button 130. Therefore, in use, when the switch button 130 is fully pressed (i.e., along...), Figure 2 Direction D x The movement of the switch button 130 is translated to the sealing sleeve 192. The sealing sleeve 192 then connects with the USB component 168 (see also...). Figure 7 The switching member 198 (which may be, for example, a snap-on switch) interacts with the light source 134 (or battery 120) of the flashlight assembly 100 to control the light source 134 (or battery 120) of the flashlight assembly 100.

[0035] Figure 5 A front opening 202 of the subframe 146 is also shown. The front opening 202 extends from the outer surface of the subframe 146 to the internal volume of the subframe 146. The lamp assembly 104 can be fixed to the electronics subassembly 144 at the front opening 202 of the subframe 146, so that the lamp assembly 104 is electrically connected to the main PCB 164.

[0036] Now refer to Figure 6 The lamp assembly 104 includes a lens 206, a reflector 208, a locating pin 210, a light source 134, an LED PCB 212, a heat sink 214, and a seal 216. The lens 206 includes locators 218 extending radially from the lens 206. Each locator 218 is configured to engage a corresponding recess 222 in the body assembly 102 (see...). Figure 7The lamp assembly 104 is rotatably aligned with the main assembly 102. Similarly, the locating pin 210 may extend through the LED PCB 212 to rotatably align the LED PCB 212 with the main PCB 164 within the electronics subassembly 144 for assembly. The subframe pin 210 includes a flange and a rod. The flange is arranged to engage the LED PCB 212, and the rod is arranged to extend through the LED PCB 212. The subframe pin 210 serves as a centering device and is comprised of plastic in this embodiment. When the reflector 208 is screwed into the heat sink 214, the subframe pin 210 is used to: press the LED PCB 212 against the heat sink 214 to obtain good thermal conductivity; ensure the concentricity of the light source 134 and the reflector 208; limit the reflector 208 to the correct height of the focal point of the light source 134; and isolate the reflector 208 (which is metallic in this embodiment) from contact with the LED PCB 212.

[0037] like Figure 7 As shown, the heat sink 214 houses the light source 134 and the LED PCB 212. A seal 216 provides a seal between the heat sink 214 and the sub-frame 146 (at the front opening 202). The reflector 208 may also include one or more seals (e.g., O-rings 209, 211) that help form a waterproof seal with the heat sink 214. Figure 7 As further shown, as described above, the positioner 218 can be received within the recess 222, which helps to rotatably position the lamp assembly 114 relative to the main PCB 164 for easy assembly. The positioner 218 may also include a step in the axial direction. The heat sink 214 abuts this step to provide axial stop between the lens 206 and the heat sink 214.

[0038] Typically, the electronic component subassembly 144 provides a complete seal (e.g., a waterproof seal) between the exterior and interior volume of the subframe 146, which houses, for example, a battery 120 and a main PCB 164. The overall seal is provided through the following sealing contacts: the subframe 146 seals against a seal 148—at the mating surface 150 of the seal and the sealing surface 152 of the subframe; the subframe 146 seals against a first main body member 108—near the opening 118 via a sealing plate of the sub-port 160; the subframe 146 seals against a switch assembly 126—at the end opening 180 via a sealing sleeve 192; and the subframe 146 seals against a lamp assembly 104—at the front opening 202 using a seal 216 and a heat sink 214.

[0039] like Figure 7As further shown, the switch assembly 126 is aligned with the printed circuit board 176 of the USB assembly 168 in the x-axis direction, such that actuating the switch button 130 in the x-axis direction actuates the switch member 198 of the printed circuit board 176 to control the flashlight assembly 100. Figure 7 As further shown, the main PCB 164 extends along the narrow top side 174 of the battery 120. The main PCB 164 is also generally perpendicular to the seal 148. Figure 8 (Not shown in the figure) That is, the largest planar surface of each of the main PCB 164 and the seal 148 is perpendicular. Therefore, during assembly, the main PCB 164 does not engage with the seal 148. The PCB 164 is rigidly attached to the body assembly 102 via the main PCB retainer 166. Thus, advantageously, in use, if the battery 120 swells or the seal 148 bends, the main PCB 164 remains unaffected, which improves the durability and lifespan of the flashlight assembly 100 compared to conventional flashlights. The USB component 168 (at least its printed control board 176, and optionally a charging port 116) may also be arranged perpendicular to each of the main PCB 164 and the seal 148.

[0040] Still refer to Figure 7 As described above, a wave spring 190 extends between the inner body 194 of the switch button 130 and the sealing sleeve 192. The use of a wave spring instead of a conventional circular wire spring in this embodiment offers the benefit of providing virtually seamless “wafer” ends (i.e., the last coil of the material of the wave spring 190 is flat at each end), and also allows for higher force over a shorter compression distance (thus improving the user feel, as noted above), which helps to apply a uniform compressive force to the flange 191 of the sealing sleeve 192. When the switch button 130 at the rear end 128 of the flashlight assembly 100 is actuated, the user experiences the same or similar compression of the switch button 130 as with a conventional compression spring, while the switch assembly 126 occupies a smaller axial distance than when using a conventional compression spring.

[0041] Continue to refer to Figure 7 The flashlight assembly 100 defines a length L in the x-direction. x and the height H in the z direction z In some embodiments, the length L of the flashlight assembly 100 x With height H z The ratio between them is approximately 3.82. That is, the ratio L x H z Approximately 3.82:1. In other embodiments, the length L of the flashlight assembly 100 is... x With height H zThe ratio between them is between 3.5 and 4.1. In other embodiments, the length L of the flashlight assembly 100 is... x With height H z The ratio between them is between 3.6 and 4.

[0042] Now for reference Figure 8 The flashlight assembly 100 defines a width W measured along the y-axis. y As shown in the figure, the width is defined by the main body component 102 and does not include the clip body 122. Figure 8 (Not shown in the image). In some embodiments, the height H of the flashlight assembly 100 is... z and width W y The ratio between them is 1.8. That is, the ratio H z :W y The ratio is 1.8:1. In other embodiments, the height H of the flashlight assembly 100 is... z and width W y The ratio between them is between 1.4 and 2.2. In other embodiments, the height H of the flashlight assembly 100 is... z and width W y The ratio between them is between 1.6 and 2.

[0043] Figure 9 An isometric view of a switch button 130 and its internal body 194 is shown. The internal body 194 includes four ribs that converge at a centrally located actuator 230 that extends beyond the open end of the switch button 130. The four angled ribs provide a rigid internal structure for the switch button 130, and the actuator 230 provides engagement points for the switch button 130 to engage a sealing sleeve 192 (which then engages the switch member 198 of the USB assembly 168) when the switch button 130 is actuated (i.e., fully pressed). Each of the four angled ribs of the internal body 194 is interrupted by a mounting surface 228 in which the end of a wave spring 190 is housed.

[0044] Although exemplary embodiments of the systems and methods described herein have been described in detail above, those skilled in the art will readily understand that many other modifications can be made to the exemplary embodiments without substantially departing from the novel teachings and advantages of the systems and methods described herein. Therefore, these and all such modifications are intended to be included within the scope of the systems and methods described herein. The systems and methods described herein may be better defined by the accompanying exemplary claims.

Claims

1. A lighting device comprising: A main body having a front-end and a back-end, wherein the back-end is opposite to the front-end; A light source having a first operating state and a second operating state, the light source extending through the front end of the body; Electronic device sub-assemblies, including power supply and switching components; A subframe having an internal volume, end openings, and a sealing surface, wherein the sealing surface surrounds the opening in the subframe, the power supply and the switching component are located within the internal volume, wherein the light source, the power supply, and the switching component are electrically coupled together; A seal with a periphery attached to the sealing surface, such that the opening in the subframe is liquid-impermeable; as well as A switch assembly extending through the rear end of the body includes a switch button, a sealing sleeve, and a wave spring. The switch button has an actuator. The wave spring is compressed between the switch button and the sealing sleeve such that the sealing sleeve covers the end opening and makes it liquid-impermeable. The actuator extends through the wave spring. The switch assembly is pressable such that the actuator engages the sealing sleeve and applies pressure to the switch member. When the switch member is actuated, the light source changes between its first operating state and its second operating state.

2. The lighting device according to claim 1, wherein, The wave spring is arranged and compressed between the inner body of the switch button and the flange of the sealing sleeve.

3. The lighting device according to claim 2, wherein, The internal body of the switch button includes a plurality of ribs that intersect to form the actuator.

4. The lighting device according to claim 1, wherein, The electronic device sub-assembly also includes a main printed circuit board and a USB component, the main printed circuit board and the USB component being electrically coupled to each other and electrically coupled to each of the light source and the power supply.

5. The lighting device according to claim 4, wherein, The switch component is located on the USB component.

6. The lighting device according to claim 4, wherein, The main printed circuit board, the USB component, and the seal are all perpendicular to each other.

7. The lighting device according to claim 4, wherein, The USB component includes a charging port, the body includes an opening, and the subframe includes a subport allowing access to its internal volume, wherein the charging port, the opening, and the subport are aligned when the lighting device is assembled.

8. The lighting device according to claim 7, wherein, The charging port is accessible from the outside of the main body, and the charging port is liquid-impermeable, so that liquid is prevented from entering the internal volume of the subframe through the opening in the main body.

9. The lighting device according to claim 1, wherein, The subframe includes a first retainer and a second retainer adjacent to the rear end of the main body, and The first retainer and the second retainer engage the switch button to secure the switch assembly to the subframe.

10. The lighting device according to claim 1, wherein, The light source is part of a lamp assembly, which also includes a lens. The lens includes at least one locator that extends radially from the lens and is sized to engage at least one recess in the front end of the body to rotatably align the lamp assembly with the body.

11. The lighting device according to claim 10, wherein the lamp assembly further includes a heat sink, wherein, The at least one locator defines a step in the axial direction, the step being sized to engage the radiator so that the lens is axially aligned with the radiator.

12. The lighting device of claim 11, wherein the lamp assembly further comprises a lamp printed circuit board and one or more locating pins extending in an axial direction and passing through the lamp printed circuit board to rotatably align the lamp printed circuit board within the heat sink.

13. The lighting device according to claim 1, wherein, The main body defines a length, a width, and a height, wherein the length is between the front end and the rear end of the main body, the length is greater than the height and the width, and the height is greater than the width; The ratio of the length to the height is between 3.6 and 4.

14. The lighting device according to claim 1, wherein, The main body defines a length, a width, and a height, wherein the length is between the front end and the rear end of the main body, the length is greater than the height and the width, and the height is greater than the width; The ratio of the height to the width is between 1.6 and 2.

15. A lighting device comprising: light source; A power source, which is electrically coupled to the light source; A subframe having an internal volume, end openings, and a sealing surface, wherein the sealing surface surrounds the opening in the subframe, the opening being sized to allow a power source to pass through the opening and be inserted into the internal volume of the subframe, the power source being completely located within the internal volume; A switch assembly that can be engaged by a user from the outside of the lighting device, the switch assembly including a switch button, a sealing sleeve and a wave spring, the switch button having an actuator, the wave spring being compressed between the switch button and the sealing sleeve such that the sealing sleeve covers the end opening of the subframe and makes it liquid-impermeable, the actuator extending through the wave spring; A seal with a periphery attached to the sealing surface, such that the opening in the subframe is liquid-impermeable; as well as A main body having a front end and a rear end, the rear end being opposite to the front end, the main body surrounding the subframe and at least a portion of the light source, the light source extending through the front end of the main body; The subframe and the seal are made of plastic material, and the periphery of the seal is removably attachable and reattachable to the sealing surface of the subframe using an adhesive material.

16. The lighting device of claim 15, wherein the adhesive material is a removable adhesive tape.

17. The lighting device of claim 15, further comprising a switching member located within the internal volume of the sub-frame, wherein, The light source, the power supply, and the switching component are electrically coupled together. The switching component is pressable, such that the actuator engages the sealing sleeve and applies pressure to the switching component. When the switching component is fully pressed, the light source changes between a first operating state and a second operating state.

18. The lighting device according to claim 15, wherein, The wave spring is arranged and compressed between the inner body of the switch button and the flange of the sealing sleeve.

19. The lighting device according to claim 15, wherein, The subframe includes a first retainer and a second retainer adjacent to the rear end of the main body, and The first retainer and the second retainer engage the switch button to secure the switch assembly to the subframe.