Abstract:
The present invention provides a collapsed flashlight preform having a generally planar foldable portion to form a flashlight body, said foldable portion having a main portion to form the sides of a flashlight body and two end portions adapted to serve as end pieces of a flashlight when assembled; a lamp means attached to one of said two end portions; at least one battery secured to said preform by a holder; said holder having external formations thereon to support said main portion between said end pieces when said flashlight is assembled.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to flashlights particularly those which are assembled by the user from an disassembled or collapsed state.  
         BACKGROUND OF THE INVENTION  
         [0002]    Pre-assembled flashlights can be relatively costly items and are not readily adapted to be able to be used as promotional give aways or in “disposable” situations where a one time use is required.  
         SUMMARY OF THE INVENTION  
         [0003]    The present invention provides a collapsed flashlight preform having a generally planar foldable portion to form a flashlight body, said foldable portion having a main portion to form the sides of a flashlight body and two end portions adapted to serve as end pieces of a flashlight when assembled;  
           [0004]    a lamp means mounted on said preform;  
           [0005]    at least one battery secured to said preform by a holder;  
           [0006]    said holder having external formations thereon to support said main portion between said end pieces when said flashlight is assembled.  
           [0007]    Preferably said lamp means is held by a reflector mounted to one of said two end portions.  
           [0008]    The two end portions can include formations to engage parts of said main portion. The formations can be used to interlock said two end portions and said main portion. Preferably the formations are apertures in the main portions which receive tab formations on said two end portions.  
           [0009]    The end portions can each be of similar shape but of different size. Preferably the flashlight formed therefrom has a tapered construction.  
           [0010]    The preform can be adapted to receive printed matter.  
           [0011]    Preferably a switch means is provided in said preform to switch on or off said flashlight once said flashlight is formed, with the switch being biased to the off position.  
           [0012]    The holder can hold one or more batteries against said main portion. Preferably said holder is made from an injection moulding  
           [0013]    Preferably a contact extends away from said battery to engage a terminal on said lamp means.  
           [0014]    Preferably said switch is activated by a button formed on or being the end of a tongue, said tongue being secured to said preform by an annular formation integrally formed therewith, said annular formation being secured to a front end portion around an aperture from which light is to be emitted. The button can be biased to an off position when said tongue is bent relative to said annular formation when said front end portion is rotated relative to said main portion.  
           [0015]    The bulb is preferably not connected to said battery, until said end portion having said lamp means is rotated to approximately 90° to said main position.  
           [0016]    A switch can be formed by a biased contact which is moved by a tongue member hinged to said main portion. The tongue member can be held within said main body until said flashlight is assembled. It is preferably held by a partial perforation or separation of said tongue member from said main body. The tongue member can be released from said main body by the action of rotating said end portion having said lamp means is rotated to approximately 90° to said main portion. The lamp means can engage a switch contact to push said tongue member away from said main body. The tongue member can be formed from a portion of said main body and a portion of said holder. The portions on said main body and said holder are laminated or adhered together.  
           [0017]    The battery holder can include one or more formations to receive said at least one battery. The battery holder can include a reflector cover or lens. The reflective cover or lens is preferably offset or depressed from a base of said battery holder. The reflector cover or lens can be used to locate said battery holder on said main portion. The reflector cover or lens includes location means to locate said lamp means or reflector having said lamp means. The location means are preferably cut outs which are engaged by projections on said lamp means or reflector having said lamp means.  
           [0018]    The generally planar foldable portion can be made from any one of the following: cardboard; thin cardboard, polymeric material, sheet metal, polystyrene.  
           [0019]    The present invention also provides a flashlight made from a preform as described above. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]    Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which:  
         [0021]    [0021]FIG. 1 is in a perspective view of a flashlight according to the invention;  
         [0022]    [0022]FIG. 2 is a perspective view of a preform from which the apparatus FIG. 1 is formed;  
         [0023]    [0023]FIG. 3 is a preform of FIG. 2 with a first stage in the assembly process applied to it;  
         [0024]    [0024]FIG. 4 is the next step in the assembly process of a flashlight;  
         [0025]    [0025]FIG. 5 is the perspective view of the finished product similar to that of FIG. 1;  
         [0026]    [0026]FIG. 6 is an exploded view of the assembly process of a flashlight similar to that of FIG. 1;  
         [0027]    [0027]FIG. 7 illustrates a cross section through an assembled flashlight of FIG. 6;  
         [0028]    [0028]FIG. 8 illustrates a plan view of a blank from which the preform for the flashlight of FIGS. 6 and 7 is be made;  
         [0029]    [0029]FIG. 9 illustrates a plan view of the battery holder for use in the flashlight of FIG. 6 and  7 ;  
         [0030]    [0030]FIG. 10 illustrates a left side view of the battery holder of FIG. 9:  
         [0031]    [0031]FIG. 11 illustrates a side elevation of the battery holder of FIG. 9;  
         [0032]    [0032]FIG. 12 illustrates a half rear view of the battery holder of FIG. 9;  
         [0033]    [0033]FIG. 13 illustrates a flashlight and assembly method utilising an LED;  
         [0034]    [0034]FIG. 14 illustrates a front view of a reflector for use with the flashlight FIG. 6; and  
         [0035]    [0035]FIG. 15 illustrates a side view of the reflector of FIG. 14 with a lamp in place. 
     
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS  
       [0036]    Illustrated in FIG. 1 is a flashlight  10  having a cardboard or thin plastic body  12  made up of 5 similarly shaped side panels  14 , a front end panel  16 , a rear end panel (not visible), a reflector  20  and a moveable button  22  (which acts as a switch) on an external side thereof. The flashlight  10  is constructed from a cardboard or plastic preform of a generally planar nature as will now be described in detail.  
         [0037]    Illustrated in FIG. 2 is a preform  24  from which the flashlight  10  is formed. The Preform  24  has panels  140 ,  142 ,  144 ,  146  and  148 . Each of the panels  140 ,  142 , 144 ,  146  and  148  are of a similar shape. As can be seen in FIG. 2 each panel  140 ,  142 , 144 ,  146  and  148  has a tapered shape wherein the forward end (that end near to the reflector  20 ) is of a larger dimension than the rear end.  
         [0038]    The panels  140 ,  142 , 144 ,  146  and  148  forms a main portion of the preform  24 . This main portion has integrally formed with it a front end panel  16  and a rear end panel  28 . The panels  16  and  28  are of a generally pentagonal shape with one side of the pentagon joining with the panel  144 . Each panel  16  and  28  has four free sides and each free side has a tab  30  whose purpose will be discussed in more detail later.  
         [0039]    The reflector  20  includes a lamp  32  which is preferably of a non-replaceable type and is preferably irretrievably secured to the reflector  20  so that the lamp  32  and reflector  20  cannot be separated.  
         [0040]    A base electrical contact  34  passes along a length of the panel  144  under a battery  36  to contact the negative end  38  of the battery  36 . The contact  34  is glued to the panel  144  and the battery  36  held in place by a holder  40  which is secured by side flanges  44  and  42  to the panel  144 .  
         [0041]    The holder  40  has two raised formations  46  and  48 . The formations  46  and  48  have four sides  402 ,  400 ,  408  and  406 . When the flashlight is assembled the sides  400  and  408  will support the panels  142 , and  148  which will lie adjacent thereto, when the panels  142 ,  140 ,  148  and  146  are folded around the formations  46  and  48 . The formations  46  and  48  by preventing the joined edges of panels  142  and  148  from moving towards the panel  144  will provide a sufficient degree of rigidity or sturdiness for the cardboard flashlight  10  to function as a flashlight.  
         [0042]    A positive contact  50  is provided which is held by the formation  46  and extends away form it, to make contact with the positive terminal  52  of the battery  36  and with the positive terminal  54  on the lamp  32 . In use the button  22  which is formed on a tongue  56  can be pushed into the body  12  so as to force the terminal  34  into contact with a metallised exterior of reflector  20  thereby forming a circuit with the lamp  32  and the battery  36  to enable the lamp  32  to be illuminated.  
         [0043]    The tongue  56  is not secured to the panel  144 . Instead an annular portion  58  is attached to the panel  16  and surrounds the aperture  60  in the panel  16  so that when panel  16  is folded to a position approximately perpendicular to the panel  144  as illustrated in FIG. 3, the tongue  56  will be bent at approximately right angles to the annular portion  58 . This bending of the tongue  56  relative to annular portion  58  will generate a bias on the tongue  56  to push against the panel  144 . This bias together with the natural bias provided by the terminal  34  will tend to keep the terminal  34  out of contact with the metallised body of the reflector  20 .  
         [0044]    As can be seen in FIG. 3 once the panel  16  is rotated to 90° the positive terminal  54  of the lamp  32  makes contact with the terminal  50  which in turn is contacting the positive terminal  52  of the battery  36 . The other end  28  is also folded so as to be at approximately right angles to the panel  144  and from these positions the preform can proceed to the next stage of assembly as illustrated in FIG. 4.  
         [0045]    As illustrated in FIG. 4 the next stage consists of the panels  140 ,  142 ,  146  and  148  being folded around the panels  16  and  28  and the formation  46  and  48  so that apertures  70  at either end of each of the panels  140 ,  142 ,  146  and  148  will receive the tabs  30  on each of the panels  16  and  28  and pass therethrough. Once all the panels  140 ,  142 ,  146  and  148  have had the tabs  30  pass through them, the longitudinal tab  72 , which has an adhesive band  74  (maybe either double sided tape or an adhesive covered with a peel off cover), is folded. After the tab  72  has its cover  74  peeled off, the tab  72  can be adhered to the external surface of the panel  140  to render the appearance as in FIG. 5.  
         [0046]    Illustrated in FIG. 6 is a flashlight  200  which is similar to the flashlight  10  of previous figures. Many features of the flashlight  200  are similar to those of the flashlight  10 . Some similar features are those in FIG. 6 which are numbered by a  200  series number with the tens and units number corresponding to a tens and units number in FIGS.  1  to  5 .  
         [0047]    The main differences between the flashlight  200  and flashlight  10 , among other things are that the battery holder  240  includes some improvements as does the switching mechanism.  
         [0048]    The flashlight  200  has the components as illustrated in FIG. 6 pre-assembled to the blank  211  with the final assembly steps as described in relation to FIGS.  1  to  4  being performed by the user.  
         [0049]    The preform or partially assembled flashlight  200  will be manufactured so that the bulb  232  is assembled to the reflector  220  by hot melt gluing the two together. The next stage in the assembly procedure requires a double sided tape annulus  22 , to be attached to the rim of the reflector  220 .  
         [0050]    To construct the rest of the preform the battery holder  240  receives the positive battery contact  254  inside the forward most formation  255  of the battery holder  240 . As can be seen from FIG. 7 the positive terminal  254  has its rearward portion  257  lying adjacent the forward wall of the formation  255 . As also can be seen from FIG. 7 the positive terminal  252  of the battery  261  rests against the portion  257 .  
         [0051]    The batteries  261  and  263  are then inserted into the battery holder  240  from underneath the battery holder  240 . The negative terminal and switch contact  234  is also then passed through the aperture  267  at the base of the formation  255  with the rear end of contact  234  engaging the negative terminal of rear battery  263 . Once positioned the portion  229  of contact  234  will be resting against flap or tongue  230 . The portion  229  will force the flap  320  away from the portion of the battery holder  240  in which it is located because the flap  320  is disconnected from the battery holder  240 , except for the connection by hinge  231 .  
         [0052]    The base of the contact  234  has double sided tape attached to it. When the battery holder  240  and its contents (batteries  261 , 263 , contacts  234  and  254 ) are to be attached to body  212 , the second side of the double sided tape is removed and the base of contact  234  adhered to body  212 . During this sub-assembly a protective cover can be placed on the end  227  of the contact  234 .  
         [0053]    The electrical circuit is preferably tested before assembling the battery holder  240  to the body  212  contained within the blank  211 . This testing is done by using a spare reflector and lamp designated by the letter ‘X’ in FIG. 6, to connect to the terminals, 227  and  254  to ensure that the batteries and the contacts with portion  257  and the rear end of contact  234  are satisfactory  
         [0054]    The protective cover is then removed from the end  227  and the battery holder  240  and its assembled contents (batteries  261 ,  263 , contacts  234  and  257 ) are placed on the body  212  and onto panel  244  so that the portion  229  of the contact  234  nests against the switching flap  222 . The switching flap  222  is only partially perforated and frangible from panel  224 . The partial perforation is sufficient to resist the force exerted by portion  229 , however will fully perforate when the user assembles the flashlight as described below.  
         [0055]    The battery holder, preferably manufactured from PET, is then heat stomped or stamped to the body  212 . This process is sometimes called face sealing and is performed by the application of heat and pressure. It is a process which is commonly used in the formation of blister packaging. The battery holder  240  is effectively a blister package and is relatively inexpensive to manufacture.  
         [0056]    The other side of the double sided tape annulus  221  is then removed and the reflector involved attached around the aperture  260 . Another piece of double sided tape  271  is then attached to the edge of the body  212 . The first stage in the user assembly process is to remove the ends  213  and  215  from the blank  211  leaving just the body  212  whereupon the assembly procedure described above in relation to FIGS.  1  to  5  can be effected.  
         [0057]    As can be seen from FIGS. 6 and 7 the battery holder  240  has four raised formations  246 ,  248  and  247  and  249 . As the flashlight  200  of FIG. 6 and  7  utilises two batteries  261  and  263 , the length of the body  212  is longer than that of the first embodiment and thus greater support along the length of the panels,  240 ,  242 ,  244 ,  246  and  248  is required to give a sturdy feel to the final assembled product.  
         [0058]    As can be seen from FIG. 7 once the flashlight  200  is assembled the portion  229  of contact  234  forces the switch flap  222  to protrude downwardly. By the switch flap  222  being pivoted at  231  to the body  212  some mechanical advantage is provided to push the end  227  into contact with the globe body  232 . In use the contact  254  will be engaging the contact  233  on the lamp  232 .  
         [0059]    As illustrated in FIG. 8 is a plan view of the blank  211  of FIG. 6 showing the location of the batteries  261  and  263 . The blank  211  will have on the side illustrated in FIG. 8 instructions on how to assemble the flashlight  200 , while the other side the blank  211  can bear the advertising and logos of an organisation which may give away the flashlight as part of a promotional exercise. Preferably the user assembly instructions are included on the tear off ends  215  or  213  so the instructions can be visible to the user whilst assembling.  
         [0060]    Illustrated in more detail in FIGS.  9  to  12  is the battery holder  240 . The battery holder  240  comprises the forward formation  255  and raised formations  246 ,  247 ,  249  and  248 . Between the formations  246 ,  247 ,  249  and  248  are curved portions  300 ,  302  and  304  respectively. The end of battery holder  240  has a curved portion  306  as well. The curved portions  300 ,  302 ,  304  and  306  each have a top section which is semi-circular in cross section so as to match closely the shape of batteries  261 ,  263  (as illustrated in FIG. 12) so as to sandwich the batteries  261  and  263  between the holder  240  and the length of the contact  234 , thus the body  212 .  
         [0061]    The forward portion  255  includes the forward aperture  267  through which the electrical contact  234  can pass. The battery holder  240  has side panels  310  and  312 , which by virtue of attachment to the panels  242  and  246 , will hold the battery holder  240  onto the body  212 . The battery holder  240  will be folded along the lines  314  and  316  when assembled. To make the folding process easier the lines  314  and  316  are preferably perforated to decrease the amount of material that has to be bent.  
         [0062]    The battery holder  240  also includes a flap portion  320  which overlies the switch flap  222  before assembly by the user. The flap  320  is disconnected from the battery holder  240 , other than along the hinge  331 . The switch flap  222  is also connected to the body  212  prior to assembly by the user. The switch flap  222  and the flap portion  320  assume the position as illustrated in FIG. 7 by the user rotating the reflector by approximately 90° from the position illustrated in FIG. 2 to the position illustrated in FIG. 3 which causes the body of the lamp  232  to push the end  227  of contact  234  in a downward direction as illustrated in FIG. 7. This causes the flap  222  to break away from the body  212  whilst remaining hingedly connected.  
         [0063]    The battery holder  240  at its forward end includes an extension  330  and terminates at its forward end with a lens  332  to overlay the aperture  260  on the body  212 . The lens  332  is formed as a depression in the battery holder  240 , as is illustrated in FIG. 10. As can be seen from FIG. 9, around the lens  332  are flanges  333 ,  335 ,  337  and  339  which can be adhered to the body  212  adjacent aperture  260 . Between flanges  333 ,  335 ,  337  and  339  are cut-outs  341 ,  343  and  345 . The purpose of these will be discussed below.  
         [0064]    Illustrated in FIGS. 7, 14 and  15  is a sectional view, front elevation and plan view respectively of the reflector  220  for use with the flashlight  200 . The rim  351  includes three tabs  353 ,  355  and  357 . The tabs  353 ,  355  and  357  are able to be inserted into the cut-outs  341 ,  343  and  345  on the battery holder  240  so that the reflector  220  will be easily and correctly centred over aperture  260  and lens  332 .  
         [0065]    In use the panels  242 ,  240 ,  246  and  248  are folded and taped together by double sided tape  271  along overlapping edges of panels  242  and  248 . This places the panels  242  and  248  over the raised formations  246 , 247 , 249  and  248 . The raised formations  246 ,  247 ,  249  and  248  only make contact with the two top angled faces  440  and  448  at the top of each raised formation  246 ,  247 ,  249  and  248 . The support provided by these top two faces  440  and  448  do provide sufficient rigidity or sturdiness for the flashlight  200  to meet its function requirements. Illustrated in FIG. 13 is an embodiment similar to that of FIG. 6 however the lamp  232  and reflector  220  is not utilised and an LED is used instead inside a housing similar to that of the reflector  220 , so that the housing will interact with the end  227  of contact  234  to push the end  229  to break the flap  222  away from the body  212 .  
         [0066]    The tapered formation of the resultant flashlight allows a single flashlight to be held in a single hand by different aged users which can be important when the preform and flashlight are used in a promotional environment so as to give satisfaction to the user.  
         [0067]    While the preferred method of securing the battery holder  240  and body  212  is by the face sealing of the blister package battery holder  240  to the body  212  (face sealing being a process of the application of heat and pressure) any adhering means can be used, such as double sided tape, gluing, contact adhesive, sonic welding etc.  
         [0068]    The description above in relation to FIGS.  6  to  15  describes the flap  320  on battery holder  240  as being wholly disconnected from the battery holder  240  except along the hinge  331 . If necessary, the free end of flap  320  can remain partially and frangibly connected to the battery holder  240  providing the partial frangible connection can be broken by means of the reflector  220  or the housing of FIG. 13 rotating to its use position thereby forcing the end  229  to break the connection.  
         [0069]    The battery or batteries used can be of any suitable size and as compactness is desirable, AA or AAA batteries are most preferable.  
         [0070]    Such flashlights  10  and  200  are thus relatively cheap to manufacture with little assembly required from the factory, and whilst an excellent for promotional purposes also has a use in such areas as tourism eg cave tours where a disposable flashlight would be helpful.  
         [0071]    It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.  
         [0072]    The foregoing describes embodiments of the present invention and modifications, obvious to those skilled in the art can be made thereto, without departing from the scope of the present invention.