Rechargeable Flashlight Rear Electrode and Heat Sink Design
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Solution Overview
Problem
Rechargeable flashlights face challenges with the placement of charging contacts, increased complexity and cost due to multiple electrical contacts, heat dissipation issues with LEDs, user interface difficulties, inadequate charging monitoring, and durability in harsh environments.
Innovation Solution
A rechargeable flashlight design with the positive electrode located at the rear end, reduced electrical contacts, innovative LED mounting for improved heat dissipation, a simplified user interface, software-controlled charging with a microcontroller, and ruggedized components for durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the positive electrode of the battery is located at the forward end, then the electrical path is simplified, but charging contacts cannot be positioned at the rear end
Solution Approach 1:
The patent inverts the conventional battery orientation by positioning the positive electrode at the rear end of the battery pack instead of the forward end. This inversion enables charging contacts to be positioned at the rear end of the flashlight, allowing the charging device to engage with the flashlight in a reversed configuration that simplifies the overall electrical path and component layout.
2Reliability
If multiple spring probes or electrical contacts are used, then movement accommodation is improved, but cost and design complexity increase
Solution Approach 1:
The patent merges multiple electrical contact functions into a single integrated spring probe assembly. The spring probe serves dual purposes: maintaining reliable electrical contact and accommodating battery movement within the housing. This consolidation reduces the number of separate electrical contacts needed, thereby lowering cost and design complexity while maintaining reliability.
3Illumination intensity
If larger and more powerful LEDs are used, then illumination intensity is improved, but heat dissipation becomes more difficult
Solution Approach 1:
The patent introduces a heat sink as an intermediary component between the LED and the flashlight housing. The heat sink acts as a thermal mediator that captures heat generated by high-power LEDs and transfers it to the housing structure, enabling the use of larger, more powerful LEDs while managing heat dissipation effectively.
4Adaptability or versatility
If integrated charging circuits are included, then charging functionality is improved, but cost and packaging issues increase
Solution Approach 1:
The patent designs the electrical contacts and circuitry to serve multiple functions: power transmission during operation, charging during recharging, and status indication. This multi-functionality eliminates the need for separate integrated charging circuits, reducing component count and packaging requirements while maintaining full charging capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design allows for flexible charging, reduces costs and complexity, enhances user experience, ensures efficient charging monitoring, and provides a durable lighting device capable of withstanding harsh conditions.
Implementation Method 1
a source of energy, e.g., one or more batteries arranged in a rechargeable battery pack
Implementation Method 2
LEDs have been used as the light source for flashlights and other lighting devices
Implementation Method 3
the mounting and positioning of an LED light source within the lighting device raise issues related to heat dissipation
Data Source
AI summary
A portable rechargeable lighting device uses software in a microcontroller to turn on a charger protection circuit when a charging circuit is activated, to monitor at least one electrical characteristic relative to a rechargeable battery, to control at least one charging parameter of the charging circuit, and to alert a user of a low battery condition before light emitted from the device terminates.