Flashlight assembly

Abstract

To provide an improved portable lighting device that overcomes drawbacks of prior art devices.SOLUTION: 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 the front end of the body, and the switch assembly is secured to the electronics subassembly at the rear end of the body. The electronics subassembly houses a battery and a circuit board in a sealed interior volume. The switch assembly includes a switch button, a sealing boot, and a wave spring.SELECTED DRAWING: Figure 7

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to the field of portable lighting devices, and more particularly to a portable flashlight assembly with a sealed electronics compartment and an improved tail cap switch. [Background technology]

[0002] Flashlight assemblies having sealed electronics compartments are known in the art. Such flashlight assemblies often have large profile sealed electronics compartments that include adhesive or compression seals that span gaps between housing members and / or fasteners. These seals can be bulky, expensive to manufacture, and / or unreliable.

[0003] Existing flashlight assemblies also include a switch located on its rear side, i.e., opposite the lens. Some existing rear switch designs do not provide adequate operational feedback to the user when the switch is depressed. Summary of the Invention [Problem to be solved by the invention]

[0004] Therefore, there is a need for improved portable lighting devices that overcome these and other drawbacks of prior art devices. [Means for solving the problem]

[0005] In one aspect, the present concept provides an electronics subassembly including a body having a front end and a rear end opposite 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, a power source and a switch member, a subframe having an interior volume, an end opening, and a sealing surface surrounding the opening in the subframe, the power source and switch member being positioned within the interior volume, the light source, the power source, and the switch member being electrically coupled together, and a seal having a perimeter attached to the sealing surface such that the opening in the subframe is liquid impermeable. and a switch assembly extending through a rear end of the body, the switch assembly including a switch button, a sealing boot, and a wave spring, the switch button having an actuator, the wave spring being compressed between the switch button and the sealing boot such that the sealing boot covers the end opening and makes it liquid impervious, the actuator extending through the wave spring, the switch assembly being depressible such that the actuator engages the sealing boot and applies pressure to the switch member, and when the switch member is sufficiently depressed, the light source is changed between its first operating state and its second operating state.

[0006] In another aspect, the present concept provides a lighting device comprising a light source, a power source electrically coupled to the light source, a subframe having an interior volume, an end opening, and a sealing surface surrounding the opening in the subframe, the opening sized to permit insertion of the power source into the interior volume of the subframe through the opening, the power source being positioned entirely within the interior volume, and a switch assembly engageable by a user from outside the lighting device, the switch assembly including a switch button, a sealing boot, and a wave spring, the switch button having an actuator, the wave spring configured to seal the end opening of the subframe such that the sealing boot covers the end opening to seal the end opening in a liquid-tight manner. a switch assembly compressed between the switch button and the sealing boot to make the opening in the subframe fluid impermeable, the actuator extending through a wave spring; a seal having a periphery, the periphery attached to the sealing surface so that the opening in the subframe is fluid impermeable; and a body having a front end and a rear end opposite the front end, the body enclosing at least a portion of the subframe and a light source, the light source extending through the front end of the body, wherein the subframe and the seal are made of a plastic material, and the periphery of the seal is removably attachable and reattachable to the sealing surface of the subframe using an adhesive material.

[0007] Lighting devices according to the present disclosure will be further described with reference to the accompanying drawings. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a right-front isometric view of a flashlight assembly according to an embodiment of the present disclosure. [Figure 2] FIG. 2 is a bottom left isometric view of the flashlight assembly of FIG. 1. [Figure 3] FIG. 2 is an exploded isometric view from the rear right side of the body of the flashlight assembly of FIG. 1. [Figure 4] FIG. 2 is an exploded isometric view from the rear right side of the flashlight assembly of FIG. 1. [Figure 5] FIG. 2 is an exploded isometric view from the left side of the flashlight assembly of FIG. 1. [Figure 6] FIG. 2 is an exploded isometric view from the right side of the light assembly of the flashlight assembly of FIG. 1. [Figure 7] 7 is a cross-sectional right side view of the light assembly taken along line 7-7 of FIG. 1. [Figure 8] 8 is a cross-sectional rear side view of the light assembly taken along line 8-8 of FIG. 1. [Figure 9] FIG. 2 is an isometric view of a switch button of the flashlight assembly of FIG. 1; DETAILED DESCRIPTION OF THE INVENTION

[0009] 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 those skilled in the art with an enabling description for practicing exemplary embodiments according to the present disclosure. It should be understood that various changes can be made in the function and arrangement of elements without departing from the spirit and scope of the invention as set forth in the appended claims.

[0010] To aid in describing the present disclosure and / or invention as claimed, directional terms may be used in the specification and claims to describe portions of the present disclosure and / or invention (e.g., up, down, left, right, etc.). These directional definitions are intended only to aid in describing embodiments and claiming the invention and are not intended to limit the present disclosure or claimed invention in any way. Also, numerals introduced herein in connection with the drawing figures may be repeated in one or more subsequent figures without further description herein to provide context for other features.

[0011] When an element is referred to as being "connected" or "coupled" to another element, it should be understood that the element may be integral with the other element, that the element may be directly connected or coupled to the other element, or that intervening elements may be present. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, it should be understood that there are no intervening elements present. Other language used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" and "directly between," "adjacent to" and "directly adjacent to," etc.).

[0012] In the embodiments described herein or shown in the drawings, any direct electrical connection or coupling, i.e., any connection or coupling without additional intervening elements, may be implemented by an indirect connection or coupling, i.e., a connection or coupling with one or more additional intervening elements, or vice versa, so long as the general purpose of the connection or coupling is essentially maintained, e.g., to transmit a particular type of signal or to transmit a particular type of information. Features from different embodiments may be combined to form further embodiments. For example, variations or improvements described with respect to one of the embodiments may be applicable to other embodiments unless otherwise noted.

[0013] 1-8 illustrate a flashlight assembly 100 according to an embodiment of the present disclosure. Generally, the flashlight assembly 100 may be configured as a portable lighting device. With reference to FIG. 1 , the flashlight assembly 100 includes a body assembly 102 and a light assembly 104. The body assembly 102 includes a first body member 108 and a second body member 110. As shown, the first body member 108 and the second body member 110 may be secured together via fasteners 112, although other configurations are possible. For example, in some embodiments, the members of the body assembly 102 may be secured together via one or more of a variety of fastening mechanisms, including mechanical fasteners (such as pins, screws, bolts, plugs, rivets, etc.), adhesives, or welding.

[0014] Still referring to FIG. 1 , flashlight assembly 100 includes a charging port 116. Charging port 116 is accessible through an opening 118 formed in first body member 108 of body assembly 102. Opening 118 is generally configured as a side port. Charging port 116 is in electrical communication with battery 120 (see, e.g., FIGS. 4 and 5 ) and is configured to accept an external power source (e.g., a USB power source). Battery 120 may be configured as a rechargeable battery and serves as a power source for illuminating light assembly 104. Thus, the external power source can charge battery 120 of flashlight assembly 100. In some embodiments, charging port 116 may also enable data transmission (e.g., firmware updates) to flashlight assembly 100 and / or provide the ability to charge other external devices that use energy stored in battery 120.

[0015] FIG. 2 shows a rear view of flashlight assembly 100. As shown in FIG. 2, flashlight assembly 100 may further include a clip body 122 secured to second body member 110 and a switch assembly 126 disposed at a rear end 128 of body assembly 102, in what is technically commonly referred to as a tail switch configuration. In this embodiment, switch assembly 126 includes a switch button 130 that extends partially outside of body assembly 102. In use, a user can press (or otherwise engage) switch button 130 in direction D shown in FIG. 2 to activate switch assembly 126 and turn on, off, or otherwise adjust light source 134 (see FIG. 6) of light assembly 104. X The switch button 130 can be pressed (or otherwise actuated) by a spring 192 (in this embodiment, the light source 134 is an LED). The switch button 130 translates a pre-specified distance before reaching its designed travel limit and stopping against the subframe 146. At its fully extended length, the inner center post of the switch button 130 (i.e., the actuator 230) does not fully depress the switch member 198 (which in this embodiment is an electronic tactile switch). In fact, in this embodiment, even at its fully extended length, 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 light is dropped on its tail (i.e., onto the switch button 130). This arrangement also prevents over-compression and breaking of the spring 190. In some embodiments, the measurement of the gap between the end of the actuator 230 and the switch member 198 when the switch button 130 is at its fully extended length is a fraction of the measurement of the thickness of the seal 192, for example, between 1 / 8 and 3 / 8 of a fraction, more preferably between 3 / 16 and 5 / 16 of a fraction, and most preferably 1 / 4 of a fraction (e.g., a gap of 0.010 inches and a thickness of 0.040 inches).

[0016] As shown in FIG. 2, the switch button 130 may include an embossment 138. In the illustrated embodiment, the embossment 138 includes a plurality of lines (e.g., extending in the y direction according to the x-y-z axis framework shown and established in FIG. 1). The embossment 138 may provide a tactile reference for a user locating the switch button 130. The switch button 130 may include one or more materials, including a polymer or other composite material. For example, the switch button 130 may include or be made of polycarbonate.

[0017] 3, an exploded view of body assembly 102 is shown. Body assembly 102 provides a housing for electronics subassembly 144. Electronics subassembly 144 houses the electronics for flashlight assembly 100, including battery 120, as will be described in more detail below. Light assembly 104 and switch assembly 126 are each electrically coupled to electronics subassembly 144. As shown, switch assembly 126 is coupled to a rear end 128 of electronics subassembly 144, and light assembly 104 is located at the opposite end of the electronics subassembly (e.g., the front end of electronics subassembly 144).

[0018] As shown in Figures 4 and 5, electronics subassembly 144 includes subframe 146 and seal 148. Seal 148 includes a mating surface 150 disposed around the outer periphery of seal 148. Mating surface 150 of seal 148 is dimensioned to engage with a sealing surface 152 of subframe 146 (see Figure 5). During the assembly process, mating surface 150 of seal 148 may be heat welded to sealing surface 152 of subframe 146, or alternatively, may be attached to sealing surface 152 via an adhesive. The material seal between the periphery of subframe 146 and seal 148 can provide a fluid-tight (e.g., waterproof) barrier between the exterior and the interior volume of subframe 146 at sealing surface 152.

[0019] In one embodiment, seal 148 is configured as a plastic film that may be made from a PET material. The use of a plastic film as seal 148 that is heat-welded to subframe 146 eliminates the use of adhesives or compression seals in electronics subassembly 144, thereby simplifying construction and reducing costs. Alternatively, the plastic film forming seal 148 can be attached to the periphery of subframe 146 via removable adhesive tape or other adhesive, such as adhesive tape made by Tesa Tape Inc. of Charlotte, North Carolina, USA. The use of removable tape to form a bond between seal 148 and subframe 146 allows for easier repair or replacement of components, such as battery 120, located within subframe 146, for example, by removing seal 148 and then reattaching it to the periphery of subframe 146. Furthermore, the use of a plastic film for seal 148 also allows seal 148 to have a very small profile, thereby conserving space within body assembly 102. Still further, the seal 148 is flexible, which allows the battery 120 to expand and swell during its life without destroying or reducing the effectiveness of the impermeable barrier formed by the seal 148.

[0020] As shown in FIG. 4 , seal 148 includes a mating surface 150 and a recessed (i.e., recessed from the perspective view of FIG. 4 ) body portion 154. Seal 148 also includes a protruding planar member 156 extending from the recessed body portion 154 toward battery 120, as shown in FIG. 4 . Generally, seal 148 includes a varying cross-sectional thickness across mating surface 150, recessed body portion 154, and protruding planar member 156. These features of seal 148 can enable a close and secure fit with battery 120. When flashlight assembly 100, or at least electronics subassembly 144, is assembled, protruding planar member 156 can contact a side surface 158 (see FIG. 5 ) of battery 120 to secure battery 120 to subframe 146 while cushioning battery 120.

[0021] 4 , subframe 146 includes subport 160. Subport 160 includes a sealing plate and an opening that extends from the exterior of subframe 146 into the interior volume of subframe 146. Subport 160 is configured to align with charging port 116 and opening 118 in body assembly 102 such that an external charger can extend through each of opening 118 and subport 160. Charging port 116 and opening 118 in body assembly 102 mate together to create a liquid-proof seal such that liquids or debris cannot enter the interior volume of subframe 146.

[0022] 4 and 5 , electronics subassembly 144 further includes a main printed circuit board (PCB) 164, a PCB holder 166, and a USB assembly 168. Each of PCB 164, PCB holder 166, and USB assembly 168 may be housed within subframe 146 and sealed therein by seal 148. USB assembly 168 includes charging port 116 that aligns with subport 160 and is configured to electrically couple an external charger to battery 120 for charging battery 120. Additionally or alternatively, in other embodiments, an external device may be electrically coupled to battery 120 via USB assembly 168 to draw charge from battery 120 and charge the external device.

[0023] The PCB holder 166 is configured to secure the main PCB 164 relative to the battery 120. As shown in FIG. 5 , the PCB holder 166 may be secured to the subframe 146 at the subframe mount 170 via fasteners 172 (e.g., screws). However, other fastening configurations are possible, such as pins, tabs, press-fit connections, adhesives, etc. In the illustrated embodiment, the subframe mount 170 is integrally (i.e., unitarily) formed with the subframe 146. When assembled, the main PCB 164 is configured to extend along a narrow side 174 (e.g., top side) of the battery 120. This orientation of the main PCB 164 may allow for a narrower and more compact PCB compared to conventional assemblies, thereby allowing for a more compact flashlight assembly 100.

[0024] As shown in FIG. 4 , the USB assembly 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 a signal 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 assembly 168 is in electrical communication with the main PCB 164 and the charging port 116. The printed circuit board 176 of the USB assembly 168 is configured to be retained within the subframe 146 and is aligned with an end opening 180. The end opening 180 of the subframe 146 is an opening in the subframe 146 that extends between an outer surface of the subframe 146 and an interior volume of the subframe 146. At the outer surface of the subframe 146, the end opening 180 is at least partially defined by a retaining portion 182.

[0025] Retaining portion 182 includes a pair of tabs extending in the direction of the x-axis from rear end 128 of subframe 146 (i.e., adjacent rear end 128 of body assembly 102). Generally, retaining portion 182 is configured to retain switch assembly 126 relative to electronics subassembly 144. Retaining portion 182 includes angled tabs 184 that are generally point-shaped at the distal end of retaining portion 182. Retaining portion 182 is positioned to engage switch button 130 of switch assembly 126, with angled tabs 184 each positioned to extend at least partially through a corresponding pair of slits 188 formed in the body of switch button 130. During assembly of switch assembly 126 to electronics subassembly 144, switch button 130 can slide into retaining portion 182 until angled tab 184 deforms slightly and engages slit 188 in switch button 130, at which point angled tab 184 springs back and at least partially enters slit 188. The angled shape of angled tab 184 allows switch button 130 to slide into retaining portion 182 during assembly, but once secured, prevents switch button 130 from accidentally disconnecting from electronics subassembly 144.

[0026] 4 and 5 , the switch assembly 126 may further include a wave spring 190 and a sealing boot 192. The sealing boot 192 is positioned to provide a seal at the end opening 180 of the subframe 146 to prevent liquids and debris from entering the interior volume of the subframe 146. The wave spring 190 extends between an inner body 194 of the switch button 130 and a flange 191 of the sealing boot 192. As will be explained further below, the wave spring 190 provides sufficient pressure against the flange 191 of the sealing boot 192 to achieve consistent compression of the sealing boot 192 against the end opening 180 in the subframe 146 in all of its possible compressed states when the switch assembly 126 is assembled, thereby creating a liquid-tight seal. The wave spring 190 also serves to increase the force required to depress the switch button 130 when compared to a standard tail switch, thereby improving the feel for the user, increasing the required actuation travel distance, and minimizing accidental actuation of the light source 134. In this embodiment, the sealing boot 192 is configured as a flexible seal that can translate travel from the switch button 130. Thus, during use, the switch button 130 is properly positioned (i.e., in direction D of FIG. 2 ). X When pressed (pressed), the movement of the switch button 130 is translated into the sealing boot 192. The sealing boot 192 therefore interacts with a switch member 198 (which may be, for example, a snap-on switch) of the USB assembly 168 to control the light source 134 (or battery 120) of the flashlight assembly 100 (see also FIG. 7).

[0027] 5 also shows a front opening 202 of the subframe 146. The front opening 202 extends from the outer surface of the subframe 146 into the interior volume of the subframe 146. The light assembly 104 may be secured to the electronics subassembly 144 at the front opening 202 of the subframe 146 so as to be in electrical communication with the main PCB 164.

[0028] 6, the light 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 locating devices 218 extending radially therefrom. The locating devices 218 are each positioned to engage corresponding recesses 222 (see FIG. 7) in the body assembly 102 and rotationally align the light assembly 104 with the body assembly 102. Similarly, the locating pin 210 can extend through the LED PCB 212 to rotationally align the LED PCB 212 with the main PCB 164 in the electronics subassembly 144 for ease of assembly. The subframe pin 210 includes a flange and a shank. The flange is positioned to engage the LED PCB 212, and the shank is positioned to extend through the LED PCB 212. The subframe pins 210 function as centering devices and, in this embodiment, are made of plastic. When the reflector 208 is screwed into the heat sink 214, the subframe pins 210 act to press the LED PCB 212 against the heat sink 214 for good thermal conductivity, ensure concentricity of the light source 134 and the reflector 208, restrain the reflector 208 at the correct height for the focal point of the light source 134, and isolate the reflector 208 (which, in this embodiment, is metal) from contacting the LED PCB 212.

[0029] As shown in FIG. 7 , 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 subframe 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 watertight seal with the heat sink 214. As further shown in FIG. 7 and described above, a positioning device 218 may be received within a recess 222, which may help rotationally position the light assembly 114 relative to the main PCB 164 for ease of assembly. The positioning device 218 may also include an axial step. The heat sink 214 abuts against the step to provide an axial stop between the lens 206 and the heat sink 214.

[0030] Generally, electronics subassembly 144 provides a complete seal (e.g., a watertight seal) between the exterior of subframe 146 and the interior volume of subframe 146, which houses battery 120 and main PCB 164, etc. The overall seal is provided by subframe 146 in sealing contact with seal 148 at seal mating surface 150 and subframe sealing surface 152, subframe 146 in sealing contact with first body member 108 near opening 118 via a sealing plate in subport 160, subframe 146 in sealing contact with switch assembly 126 at end opening 180 via sealing boot 192, and subframe 146 in sealing contact with light assembly 104 at front opening 202 with seal 216 and heat sink 214.

[0031] As further shown in FIG. 7 , the switch assembly 126 is aligned with the printed circuit board 176 of the USB assembly 168 in the x-axis direction so that actuation of the switch button 130 in the x-axis direction activates the switch member 198 of the printed circuit board 176 to control the flashlight assembly 100. As further shown in FIG. 7 , the main PCB 164 extends along the narrow upper side 174 of the battery 120. The main PCB 164 also extends generally perpendicular to the seal 148 (not shown in FIG. 8 ). That is, the largest planar surfaces of the main PCB 164 and the seal 148 are orthogonal to each other. Therefore, when assembled, the main PCB 164 does not engage with the seal 148. The PCB 164 is securely attached to the body assembly 102 via the main PCB retainer 166. As such, advantageously, when battery 120 expands or seal 148 bends during use, main PCB 164 remains unaffected, which may improve the durability and longevity of flashlight assembly 100 compared to conventional flashlights. USB assembly 168 (at least in its printed circuit board 176, and optionally, charging port 116 as well) may also be positioned perpendicular to each of main PCB 164 and seal 148.

[0032] 7 , as previously described, wave spring 190 extends between inner body 194 of switch button 130 and sealing boot 192. The use of a wave spring in place of a conventional round wire spring in this embodiment has the benefit of providing a nearly continuous, “shim”-like end (i.e., the last turn of material in wave spring 190 is flat at each end), helping to apply a uniform compression force to flange 191 of sealing boot 192, as well as allowing for a greater force in a shorter compression distance (thus improving user feel, as previously described). When switch button 130 at rear end 128 of flashlight assembly 100 is actuated, the user may experience the same or similar compression of switch button 130 as would be experienced with a conventional compression spring, while switch assembly 126 experiences less axial force than if a conventional compression spring were used.

[0033] With continued reference to FIG. 7, flashlight assembly 100 has 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 is X and height H Z The ratio between is approximately 3.82. X :H Z In another embodiment, the ratio of the length L of the flashlight assembly 100 is approximately 3.82:1. X and height H Z In another embodiment, the ratio between the length L of the flashlight assembly 100 and the length L of the flashlight assembly 100 is between 3.5 and 4.1. X and height H Z The ratio between is between 3.6 and 4.

[0034] Referring now to FIG. 8, flashlight assembly 100 has a width W measured in the y-axis direction. Y As shown, the width is defined by the body assembly 102 and does not include the clip body 122 (not shown in FIG. 8). In some embodiments, the height H of the flashlight assembly 100 Z and width W Y The ratio between is 1.8. Z :W Y In another embodiment, the height H of the flashlight assembly 100 is Z and width W Y In another embodiment, the ratio between the height H of the flashlight assembly 100 and the height H of the flashlight assembly 100 is between 1.4 and 2.2. Z and width W Y The ratio between is between 1.6 and 2.

[0035] 9 shows an isometric view of the switch button 130 and its inner body 194. The inner body 194 includes four ribs that meet at a centrally located actuator 230 that protrudes 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 an engagement point for the switch button 130 to engage the sealing boot 192 (which in turn engages the switch member 198 of the USB assembly 168) when the switch button 130 is actuated (i.e., fully depressed). The four angled ribs of the inner body 194 are each interrupted by a seating surface 228 against which an end of the wave spring 190 rests.

[0036] While example implementations of the systems and methods described herein have been described in detail above, those skilled in the art will readily appreciate that many additional modifications are possible in the example embodiments without substantially departing from the novel teachings and advantages of the systems and methods described herein. Accordingly, these and all such variations 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 following example claims. [Explanation of symbols]

[0037] 100 flashlight assembly 102 Main body assembly 104 Light assembly 108 first body member 110 second body member 112 Fasteners 116 Charging port 118 Opening 120 batteries 122 Clip body 126 Switch assembly 128 Rear end 130 Switch Button 134 Light source 138 Emboss 144 Electronic equipment subassembly 146 subframe 148 stickers 150 Mating surface 154 Concave body part 156 Projecting planar members 158 Side 160 subports 164 Main printed circuit board, main PCB 166 PCB holding part 168 USB assembly 170 Subframe mounting section 172 fasteners 174 Thin Side 176 Printed Circuit Board 180 End opening 182 Holding part 184 Diagonal Tab 188 Slit 190 Wave spring 191 flange 192 Seals, sealing boots 194 Inner Body 198 Switch components 202 Front opening 206 Lens 208 Reflector 209, 211 O-rings 210 Locating pin, subframe pin 212 LED PCB 214 Heatsink 216 Stickers 218 Positioning device 222 recess 228 Seating surface 230 Actuator D X Direction to press switch button 130 L X Length of flashlight assembly 100 H Z Height of flashlight assembly 100 W Y Width of flashlight assembly 100

Claims

1. a body having a front end and a rear end opposite the front end; a light source having a first operational state and a second operational state, the light source extending through the front end of the body; an electronics subassembly including a power source and a switch member; a subframe having an interior volume, an end opening, and a sealing surface surrounding the opening in the subframe, the power source and the switch member being positioned within the interior volume, the light source, the power source, and the switch member being electrically coupled together; a seal having a perimeter, the perimeter attached to the sealing surface such that the opening in the subframe is liquid impermeable; and a switch assembly extending through the rear end of the body, the switch assembly including a switch button, a sealing boot, and a wave spring, the switch button having an actuator, the wave spring compressed between the switch button and the sealing boot such that the sealing boot covers the end opening and renders the end opening liquid impervious, the actuator extending through the wave spring, the switch assembly being depressible such that the actuator engages the sealing boot and applies pressure to the switch member, and when the switch member is sufficiently depressed, the light source is changed between its first operating state and its second operating state; A lighting device comprising:

2. The lighting device of claim 1 , wherein the wave spring is disposed and compressed between an inner body of the switch button and a flange of the sealing boot.

3. 3. The lighting device of claim 2, wherein the inner body of the switch button comprises a plurality of ribs, the ribs intersecting to form the actuator.

4. 10. The lighting device of claim 1, wherein the electronics subassembly further comprises a main printed circuit board and a USB assembly, the main printed circuit board and the USB assembly being electrically coupled to each other and to each of the light source and the power source.

5. The lighting device of claim 4 , wherein the switch member is located on the USB assembly.

6. The lighting device of claim 4 , wherein the main printed circuit board, the USB assembly, and the seal are each in a perpendicular relationship to one another.

7. 5. The lighting device of claim 4, wherein the USB assembly includes a charging port, the main body includes an opening, and the subframe includes a sub-port that allows access to its internal volume, and wherein the charging port, the opening, and the sub-port are aligned when the lighting device is assembled.

8. 8. The lighting device of claim 7, wherein the charging port is accessible from the outside of the body, and the charging port is liquid-impermeable such that liquid is prevented from entering through the opening in the body and into the interior volume of the subframe.

9. the subframe includes first and second retention portions adjacent the rear end of the body; the first and second retaining portions engage the switch button to secure the switch assembly to the subframe; 10. The lighting device of claim 1.

10. 2. The lighting device of claim 1, wherein the light source is part of a light assembly, the light assembly further comprising a lens, the lens comprising at least one positioning device extending radially from the lens and dimensioned to engage with at least one recess in the front end of the body to rotationally align the light assembly with the body.

11. 11. The lighting device of claim 10, wherein the light assembly further comprises a heat sink, and the one or more positioning devices define a step in the axial direction that is dimensioned to engage with the heat sink to axially align the lens with the heat sink.

12. 12. The lighting device of claim 11, wherein the light assembly further comprises an optical printed circuit board and one or more alignment pins extending axially through the optical printed circuit board for rotationally aligning the optical circuit board within the heat sink.

13. the body defines a length between the front end and the rear end thereof, a width, and a height, the length being greater than the height and the width, and the height being greater than the width; the ratio of said length to said height is between 3.6 and 4; 10. The lighting device of claim 1.

14. the body defines a length between the front end and the rear end thereof, a width, and a height, the length being greater than the height and the width, and the height being greater than the width; the ratio of said height to said width is between 1.6 and 2; 10. The lighting device of claim 1.

15. A light source and a power source electrically coupled to the light source; a subframe having an interior volume, an end opening, and a sealing surface surrounding the opening in the subframe, the opening being sized to allow insertion of the power supply into the interior volume of the subframe through the opening, the power supply being positioned entirely within the interior volume; a switch assembly engageable by a user from outside the lighting device, the switch assembly comprising a switch button, a sealing boot, and a wave spring, the switch button having an actuator, the wave spring being compressed between the switch button and the sealing boot such that the sealing boot covers the end opening of the subframe to render the end opening liquid impervious, and the actuator extending through the wave spring; a seal having a perimeter, the perimeter attached to the sealing surface such that the opening in the subframe is fluid impermeable; and a body having a front end and a rear end opposite the front end, the body enclosing the subframe and at least a portion of the light source, the light source extending through the front end of the body; Equipped with the subframe and the seal are comprised of a plastic material, and the periphery of the seal is removably attachable and reattachable to the sealing surface of the subframe using an adhesive material; Lighting device.

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

17. 16. The lighting device of claim 15, further comprising a switch member positioned inside the internal volume of the subframe, wherein the light source, the power source, and the switch member are electrically connected together, and the switch assembly is depressible so that the actuator engages the sealing boot and applies pressure to the switch member, and when the switch member is sufficiently depressed, the light source is changed between a first operating state and a second operating state.

18. 16. The lighting device of claim 15, wherein the wave spring is disposed and compressed between an inner body of the switch button and a flange of the sealing boot.

19. the subframe includes first and second retention portions adjacent the rear end of the body; the first and second retaining portions engage the switch button to secure the switch assembly to the subframe; 16. A lighting device according to claim 15.

Images