Unitary Polymer Torch Body for Waterproofing and Ignition Safety
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Solution Overview
Problem
Conventional torches are prone to physical damage, bulkiness, and complexity, with potential ignition hazards in explosive environments, and lack compactness and simplicity in design.
Innovation Solution
A torch with all components, including a rechargeable battery, LED, energy receiver, and circuitry, embedded in a unitary polymer body, featuring a wireless energy receiver and a user-operable switch, providing robustness, water resistance, and reduced risk of ignition, with a simple and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional multi-component housing is used, then assembly and access to battery compartment is possible, but construction complexity increases and robustness decreases
Solution Approach 1:
The patent merges multiple separate components (housing, battery compartment, lens cover, switch housing) into a single integrated polymer body. The battery, LED, energy receiver device, and switching device are all embedded within one continuous polymer structure, eliminating the need for separate housing components and reducing assembly complexity while improving robustness.
Solution Approach 2:
The polymer body serves multiple functions simultaneously: it provides structural housing, protects internal components, allows light transmission through its transparent portion, provides waterproof sealing, and integrates the battery compartment and switch housing. This multi-functionality reduces the number of separate components needed.
2Device complexity
If LED driver electronics are exposed, then electrical connection is simplified, but risk of damage from rough usage increases
Solution Approach 1:
The LED driver electronics are embedded within the polymer body alongside the LED and battery, integrating them into a protected internal assembly. The polymer material physically surrounds and protects these electronic components from mechanical damage while maintaining their electrical functionality.
Solution Approach 2:
The polymer body provides beforehand protection to the LED driver electronics by embedding them within its structure before use. This protective enclosure prevents rough usage, impacts, and vibration from damaging the electronics, cushioning them against environmental stresses.
3Ease of operation
If switch is externally accessible, then user operation is convenient, but risk of sparking in explosive environments increases
Solution Approach 1:
The switching device is integrated into the polymer body structure, merging the mechanical switch with the protective housing. The switch remains operable from the exterior through the polymer material, but the polymer provides a barrier that prevents sparking from igniting external gases while maintaining user convenience.
Solution Approach 2:
The polymer body acts as an intermediary barrier between the switching device and the external environment. It allows mechanical actuation of the switch from the outside while preventing the harmful effect (sparking) from reaching explosive gases in the external environment.
4Ease of manufacture
If multiple separate components are used, then manufacturing flexibility is maintained, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple components into a single polymer body that can be manufactured in one injection molding process. This eliminates the need for separate manufacturing and assembly operations for housing, battery compartment, lens cover, and switch housing, reducing the number of parts and simplifying production while maintaining manufacturing flexibility through mold design.
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 solution results in a robust, compact, and waterproof torch with reduced ignition risks, simplified construction, and enhanced durability, suitable for various environments, including aquatic and explosive settings.
Implementation Method 1
the energy receiver device comprises a wireless energy receiver which is embedded in and surrounded by the body of polymer material and is adapted to receive energy from an electromagnetic field
Implementation Method 2
at least one LED... the LED being arranged to emit light through the polymer material
Data Source
AI summary
The invention concerns a torch (10) which has a rechargeable electric battery (18), at least one LED (30), an energy receiver device (16) for receiving energy from a charging station (24), circuitry for charging the battery from the energy receiver device, circuitry for supplying electric current from the battery to the LED to drive the LED, and a user-operable switching device (14) for controlling the supply of current from the battery to the LED. In accordance with the invention, the battery, the LED, the circuitry for charging the battery, the circuitry for supplying electric current from the battery to the LED and the switching device are all embedded in a unitary body of polymer material, the LED being arranged to emit light through the polymer material.