Flashlight Sealed-Subframe Assembly With Multi-Mode Rotary Switch

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Solution Overview

Problem

Existing flashlight assemblies with sealed electronics compartments have bulky and expensive seals, and are limited to bimodal operating states.

Innovation Solution

A flashlight assembly with a subframe enclosing electronic components, using a V-ring and plastic membrane seal for a low-profile, fluid-impermeable design, and a rotary switch with detents for multiple operating modes including a temporary surge mode.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high-profile sealed electronics compartments with adhesives or compression-type seals are used, then waterproof integrity is achieved, but the device becomes bulky and expensive to produce

Engineering Contradiction:

Improvewaterproof integrityVSAvoidbulkiness and production complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs a V-ring seal and plastic membrane seal that are thin and flexible, replacing the bulky adhesives and compression-type seals. These flexible sealing elements conform to the mating surfaces while maintaining a low profile, thus achieving waterproof integrity without increasing device bulk or production complexity

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent uses cost-effective sealing materials such as V-rings and plastic membranes that are simpler and cheaper to manufacture than adhesive-based or compression-type seals. These seals can be easily replaced if needed, reducing production costs while maintaining reliable waterproofing

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Device complexity

If pushbutton actuation with limited mode selection is used, then device simplicity is maintained, but operational versatility is limited to bimodal states

Engineering Contradiction:

Improveoperational simplicityVSAvoidoperating mode selection

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent introduces a rotary switch with multiple detent positions that allows dynamic selection between multiple operating modes (e.g., low, medium, high, and strobe modes). This dynamic control mechanism replaces the static pushbutton actuation, providing operational versatility while maintaining user-friendly control through tactile detents

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The rotary switch assembly serves multiple functions: mode selection, on/off control, and potential emergency strobe activation. This single component provides universal control for all operating states, enhancing versatility without significantly increasing device complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12435867B2Flashlight assembly with rotary switch and body enclosing sealed subframe

Publication Date: 2025.10.07 STREAMLIGHT INC

AI summary

A lighting device comprising a light source, a power source, a switch assembly, a subframe having an interior volume and a sealing surface that surrounds a first opening in the subframe, the interior volume of the subframe being sized to receive the power source, a membrane that seals to the sealing surface of the subframe, and a vent that acts to prevent liquids from entering the interior volume of the subframe via a second opening, while permitting for gases to be released from the interior volume through the vent.