Flashlight Tail Switch Sealing With Wave Spring Feedback
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Solution Overview
Problem
Existing flashlight assemblies have bulky, expensive, and unreliable seals in their electronics compartments, and tail switches lack adequate operational feedback.
Innovation Solution
A flashlight assembly with a plastic membrane seal and a wave spring switch assembly that provides a waterproof barrier and improved tactile feedback, featuring a switch button with a sealing boot and actuator that changes the light source's operation state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compression-type seals are used to seal the electronics compartment, then sealing reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent uses a thin film seal member that is crimped onto the electronics compartment opening. This flexible thin film approach provides reliable sealing without the bulk and complexity of compression-type seals, directly resolving the contradiction between sealing reliability and device complexity.
2Reliability
If compression-type seals are used to seal the electronics compartment, then sealing reliability is improved, but manufacturing cost increases
Solution Approach 1:
The thin film seal member with crimped edges provides effective sealing at lower manufacturing cost compared to bulky compression-type seals. The simplified structure and assembly process directly address the manufacturing cost issue while maintaining sealing reliability.
3Ease of operation
If a traditional tail switch is used, then device simplicity is maintained, but operational feedback to user is inadequate
Solution Approach 1:
The patent incorporates a spring-loaded switch assembly where depressing the switch compresses a spring, providing tactile feedback to the user. This feedback mechanism confirms switch activation without significantly increasing device complexity, resolving the contradiction between ease of operation and device complexity.
4Ease of operation
If the switch assembly is made accessible from the rear, then ease of operation is improved, but risk of accidental activation increases
Solution Approach 1:
The spring-loaded switch assembly requires deliberate pressure to activate, and the spring provides a cushioning effect that prevents accidental activation from minor impacts. This beforehand cushioning approach maintains rear accessibility while reducing accidental activation risk.
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
The assembly achieves a compact, cost-effective, and reliable waterproof design with enhanced user feedback, reducing the risk of accidental activation and improving durability.
Implementation Method 1
a wave spring, the wave spring being compressed between the switch button and the sealing boot
Implementation Method 2
a seal having a perimeter, the perimeter being attached to the sealing surface such that the opening in the subframe is liquid impermeable
Data Source
AI summary
A lighting device that includes a body having a front end and a rear end opposing the front end, a light source, and a switch assembly that extends through the rear end of the body. The switch assembly includes a switch button, a sealing boot, and a wave spring. The wave spring is compressed between the switch button and the sealing boot such that the sealing boot covers an end opening of a subframe. The switch button has an actuator extending through the wave spring. The switch assembly is depressible such that the actuator engages the sealing boot and applies pressure to a switch member disposed within the subframe. When the switch member is actuated, a signal is sent to the light source.