Abstract:
A manually generatable lighting device utilizes a pull cord, which is mechanically linked to a motor, to charge a power pack for on-demand illumination of at least one light-emitting diode. The lighting device employs circuitry which enables its use as continuous light source, a night light which illuminates automatically in low-light conditions, or an emergency light which illuminates automatically during power failure. The lighting device includes a power plug and may be stored or illuminated portably or as plugged into a power outlet. Built-in charging circuitry allows electrical recharging of the power pack to a maximum of 4 hours of usage, although the pull cord mechanism extends the possible usage time because it allows the power pack to be manually recharged at any time regardless of the level of stored charge available in the power pack. The lighting device requires only minimal effort to achieve maximum brightness, and two complete actuations of the pull cord can achieve maximum charge.

Description:
FIELD OF THE INVENTION  
       [0001]    The present invention relates to improved technology in the field of reliable lighting sources and more particularly to a rechargeable lighting device which may be charged using an AC power outlet or which may be hand-generated, and which is engineered for use as any one of a flashlight, a continuously burning night light, or a self-activating emergency light which illuminates during periods of power failure. 
       BACKGROUND OF THE INVENTION  
       [0002]    Generation of light via a portable lighting product such as a flashlight is a well known expedient in which a tubular body is fitted with a number of series-connected batteries. The main disadvantages of lighting products with this conventional configuration are that (1) non-rechargeable batteries must be replaced regularly, and (2) rechargeable batteries must be recharged regularly, possibly using a separate charging apparatus, and even some rechargeable batteries require replacement over time, and the flashlight does not work when the batteries fail. In either case, replacement and/or recharging of batteries is expensive, time-consuming, and generally requires a considerable degree of forethought, especially where a separate charging apparatus is necessary. 
         [0003]    Absent regular usage of a portable lighting product, an emergency need for lighting is often accompanied by the discovery that the batteries are weak, corroded, or dead. Moreover, the time required to replace or recharge weak or dead batteries may be too protracted to satisfy the immediate need to have a functioning light in hand. 
         [0004]    With respect to efficiency, the majority of portable lighting products fail because they are generally incandescent (heated filament) and are therefore poor at conserving energy usage per unit of illumination. Although a number of generator-type light products are available, most require considerable hand-crank input to effect any significant light output over time. Hand cranks are easily broken because the protrude from the flashlight. As a result, lighting intended for emergency usage can fall short of a need at the most critical moment. 
         [0005]    For example, most lighting products that function as continuously burning night lights will go off in the event of a power failure. During a power failure, flashlights are not always readily available. When greater emergencies accompany power failures, the ability to acquire and use lighting products is diminished. In recent years, some flashlights have the ability to charge and be supported from an outlet. However in an emergency the charging flashlight does not illuminate and does not make itself useful or automatically available in the darkness. In addition, if the batteries are defective from being left in the charging position for a long period of time, the flashlight is useless even if it is located under emergency circumstances. 
         [0006]    Self-activating emergency lights can also be problematic in that they are not portable, require a significant installation cost and trouble, including the extension of an AC mains outlet, a tray for supporting a battery weighing from 40 to 60 pounds, and significant maintenance to insure that the system will always be available. Self-activating emergency lights provide good illumination for a limited period of time, usually a few hours, ideally under the assumption that building occupants will be able to evacuate the premises. However in greater disasters, occupants may be trapped for long periods. Further, occupants may be able to leave the areas which are under emergency illumination only to be forced to move through areas in which there is no emergency illumination or in which the emergency illumination is damaged or depleted. 
         [0007]    What is therefore needed is a rechargeable lighting device which can be stored long term in a position to function either as an area illumination device continuously, or as an energy light to activate upon power failure of the AC mains, and in either event function as an emergency light upon power failure. Further a lighting system is needed in which lights can be portable, and taken with the user through areas without lighting. The lighting should be power replenishable by the user, either in place or as a portable light. The needed light should remain charged automatically, operate without power source maintenance, and continue to operate indefinitely upon power failure. 
       SUMMARY OF THE INVENTION  
       [0008]    The lighting device of the present invention is a self contained flashlight which can be used as any one of (1) a portable flashlight, (2) a night light, or (3) an emergency light which self-activates during periods of power failure, and (4) a renewable light which can be manually powered indefinitely. The device may preferably include a power pack which may include rechargeable batteries, a capacitor, or both. Where a rechargeable battery is used in conjunction with either an incandescent light or a series of bright light emitting diodes (high power output), the power pack may be charged for up to approximately four hours of use by plugging the device into an AC power outlet using an attached plug. Where the power pack is a capacitor, and where a single light emitting diode is used, the charge on the capacitor will exponentially decay for several hours before being completely depleted. The user may be permitted to switch between the high power output mode and the low power energy conserving mode. An attached plug will optimally be a folding plug which can be stored during portable use, but which will provide support and an awaiting emergency lighting position while connected to the AC mains. The direction of fold can be from either the front or back end of the device. 
         [0009]    In addition to its compatibility with standard AC power outlets, the lighting device may be charged by manual means, yielding a usage time which can vary from between a few minutes up to 4 hours, depending on the input. Manual charging can be achieved by pulling a cord on the device using an attached handle. This can be accomplished either while the device is seated in a power outlet or where it is desirable to use the device portably. With a single light emitting diode output, two pulls on the cord can provide a full charge. Ideally, the folding plug should not be collapsible directly toward the lighted end of the device especially where the lighting device is to be downwardly directed to energize in the power failure condition. In this case the cord can be pulled to charge the batteries while the device is seated in a power outlet without unseating the device from the outlet unintentionally. 
         [0010]    The lighting device of the present invention may have a sliding switch which allows a user to select between four settings: OFF, ON, NIGHT LIGHT MODE, and EMERGENCY MODE. Regardless of what setting a user selects, the device will pull and store charge to maximum charge storage capacity anytime it is plugged into a working AC power outlet. 
         [0011]    In the night light mode, the lighting device may use a photo sensitive device and relay circuitry to ensure that the light will be off while the room is naturally lighted during the day, and that as a room darkens, the light will illuminate. As long as the device remains plugged into an AC outlet, it can function as a night light throughout the nighttime hours. Where the device is not plugged into an outlet, however, its ability to function will be limited by the power stored. Further, and unlike most conventionally available night lights, the device can be disconnected from the wall outlet and can be used as a portable light. As soon as the device is replaced in the outlet, it will begin recharging toward full capacity. Additionally, the device can be recharged by hand, as described above, where it cannot be replaced in an AC outlet or where a longer usage time is needed. 
         [0012]    In the power failure mode, the lighting device may use a current detector and related circuitry to actuate the device. However, the lighting device can be recharged by hand, as described above, and can be repeatedly recharged by hand to provide illumination indefinitely. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    The invention, its configuration, construction, and operation will be best further described in the following detailed description, taken in conjunction with the accompanying drawings in which: 
           [0014]      FIG. 1  is a perspective view from the front end of the lighting device of the present invention; 
           [0015]      FIG. 2  is a view of the lighting device of  FIG. 1  as plugged into a power outlet near a corner where it may advantageously provide low wall and floor illumination; 
           [0016]      FIG. 3  is an exploded view of the lighting device illustrated in  FIGS. 1 and 2 ; front view of the assembled lighting device seen in  FIG. 2 ; and 
           [0017]      FIG. 4  is a schematic block diagram illustrating the components and circuitry of the lighting device. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0018]    The description and operation of the invention will be best initiated with reference to  FIG. 1 , which is a perspective view of a lighting device  11 . Lighting device  11  may have a tubular housing  13  which may include a first half  15  and a second half  17 . Lighting device  11  may have a first end  19  and a second end  21 . An expanded structure  23  may be attached to housing  13  at first end  19 . Lighting device  11  is illustrated as having a slide knob selector switch  25  mounted to housing  13  adjacent first end  19  and a folding plug  27  mounted to housing  13  adjacent first end  19  and oppositely disposed from slide knob selector switch  25 . Folding plug  27  is illustrated as extending away from housing  13  in an open position, although folding plug  27  may preferably be folded toward second end  21  of lighting device  11  into a closed position. An expanded structure  23  secures a lens  29  in place at first end  19  of lighting device  11 .  FIG. 1  further illustrates lighting device  11  as having a pull handle assembly  31  which is illustrated retracted a short distance away from second end  21  of housing  13  to illustrate additional structure. Pull handle assembly  31  remains attached to lighting device  11  by a cord  33 . Pull handle assembly  31  may include a handle member  35  and a base member  37 . Base member  37  may have a central opening  39  through which cord  33  passes. Base member  37  may support a pair of magnets  41 , each of which may flank central opening  39 . The magnets  41  can serve to assist in the secured orientation of the handle member as it is stored in the non-pulled position onto a flush position at the end of the housing  13 . Handle member  35  may have an opening  43  by which handle member  35  can be more readily grasped and to facilitate pulling. The cord  33  is spring loaded to retract and the combination of the spring loading and the magnets  41  help return the pull handle assembly  31  back to a retracted stable position with respect to the housing  13 . Opening  43  may also allow the lighting device  11  to be suspended, as by a hook on a wall or belt, for instance, for convenience when the lighting device  11  is being used portably. Handle member  35  includes a rim  44  around its circumference immediately adjacent base member  37 . 
         [0019]      FIG. 2  is a view of the lighting device  11  of  FIG. 1  and illustrates lighting device  11  shown adjacent a wall  44  and plugged into a power outlet  45  supported by wall  44 .  FIG. 2  illustrates tubular housing  13 , lens expanded structure  23 , slide knob selector switch  25 , and pull handle assembly  31  including handle member  35 . In  FIG. 2 , the lighting device  11  is illustrated as on and is illuminating the wall  44  and adjacent floor. 
         [0020]      FIG. 3  is an exploded view of the lighting device  11  illustrated in  FIGS. 1 and 2 .  FIG. 3  more clearly illustrates first half  15  and a second half  17  of tubular housing  13 . Note that the overall shape of housing  13  is not limited to a tubular shape, but can be any one of a variety of sizes and shapes, such as square, rectangular, or spherical, for example. First half  15  and second half  17  may snap or glue together at prongs  46 . When lighting device  11  is assembled, first end  19  of housing  13  may be joined by locking ring  47  and the edge of second end  21  may have a recessed ledge  49 . 
         [0021]    First half  15  of housing  13  may have a plug-shaped recess  51  near first end  19  into which folding plug  27  can be collapsed for convenience when the lighting device  11  is in use. Although folding plug  27  is illustrated here as having only two prongs, it is conceivable that folding plug  27  may have a third, grounding prong for increased support. Thus, folding plug  27  may be a three-prong plug or may have any other prong configuration which would allow the lighting device  5  to be plugged into a power outlet for charging. 
         [0022]    Lighting device  11  is illustrated in  FIG. 3  as having a lighting assembly  53  adjacent first end  19  of housing  13 . Lighting assembly  53  comprises (in order of assembly from first end  19  toward second end  21 ) lens expanded structure  23  which may be a cap or other retaining structure, lens  29 , plurality of convex lenses  55 , a reflector base  57 , and a plurality of light emitting diodes (LEDs)  59 . 
         [0023]    Lens expanded structure  23  may have a locking edge  61  which may be compatible with locking ring  47  at first end  19  of housing  13  to enclose lens  29 , convex lenses  55 , reflector base  57  and LEDs  59 . Reflector base  57  may include a plurality of tubes  63 , each of which may have by a first opening  65  and a second opening  67 . When lighting assembly  53  is fully assembled, convex lenses  55  are seated in first openings  65  of each of tubes  63  of reflector base  57  and LEDs  59  which are preferably mounted on an LED printed circuit board (PCB)  69 , may extend into second openings  67  of tubes  63  of reflector base  57  so that light will project from the LEDs  59  through convex lenses  55  and subsequently through lens expanded structure  23  when the lighting device  11  is illuminated. LED PCB  69  may include a plurality of screw holes  70  by which it may be attached to reflector base  57  for stability. 
         [0024]      FIG. 3  more clearly illustrates pull handle assembly  31 .  FIG. 3  illustrates, in order of assembly from first end  19  of housing  13  toward second end  21  of housing  13 , handle member  35 , base member  37 , and a reinforcing member  71  therebetween. Handle member  35  may include a recess  73  into which reinforcing member  71  is fittable. Handle member  35  may further includes a pair of screw receptacles  75 , each of which may flank recess  73  and both of which may allow base member  37  to be securely fastened to handle member  35  to enclose reinforcing member  71 . 
         [0025]    Reinforcing member  71  may include a pair of ridges  77  and a hitch  79  to which cord  33  is secured. Base member  37  may include a pair of wedge-shaped stops (not illustrated) which extend just inside the space between ridges  77  in reinforcing member  71  to maintain ample space between reinforcing member  71  and base member  37  such that cord  33  is not impinged by hitch  79 . 
         [0026]    Base member  37  includes a pair of openings  83  into which a pair of screws  85  may be inserted to secure base member  37  to handle member  35  at screw receptacles  75 . Eyelet  87  may fit inside central opening  39  of base member  37  to ensure that the integrity of cord  33  is minimally impacted when pull handle assembly  31  is actuated. Eyelet  87  may be made from any material which is compatible with the cord  33  to give minimum friction and wear. 
         [0027]    Following the path of cord  33  in  FIG. 3 , cord  33  is shown as passing through a plate  89  through a central opening  91 . Plate  89  may further include a pair of metal plugs  93  on either side of central opening  91  and which are constructed of a metal to which magnets  41  will be attracted for the purpose of keeping pull handle assembly  31  firmly seated on recessed ledge  49  at the edge of second end  21  of housing  13  when the pull cord  33  not in use. Eyelet  95  fits through the central opening  91  in plate  89  to protect the integrity of cord  33  as it passes back and forth through central opening  91 . Linking pins  99  and  101  may be secured by a keeper  97  and operate with other structures to enable the pulling motion of the cord  33  to be translated into circular mechanical action. 
         [0028]    Once the cord  33  passes through the central opening  91  of plate  89 , it winds partially around a around a cord carriage  103 , which comprises a first bracket  105  and a second bracket  107 . A first set of projections  109  at the center of first bracket  105  extend perpendicularly away from the plane of first bracket  105  toward second bracket  107 , and a second set of projections  111  at the center of second bracket  107  extend perpendicularly away from the plane of second bracket  107  toward first bracket  105 . When the lighting device  11  is assembled, projections  109  and  111  fit together to form the center of cord carriage  103  around which cord  33  coils. When not being charged, cord  33  is coiled around cord carriage  103  and pull handle assembly  31  is seated adjacent second end  21  of lighting device  11 . As the pull handle assembly  31  is actuated, cord  33  unwinds from cord carriage  103  such that cord carriage  103  is rotated. 
         [0029]    Immediately adjacent and axially aligned with first bracket  105  of cord carriage  103  is a spiral torsion spring  113 . Spring  113  has a central hub  115  and a peripheral eye-loop  117 . A securing member  119  is axially aligned and adjacent to spring  113  and includes a slot  121  to allow securing member  119  to fit over eye-loop  117  of the spring  113  to hold the spring  113  in a fixed position relative to the second half  17  of housing  13 . Securing member  119  may further include a central opening  123 . As assembled, screw  125  passes through central opening  123  and subsequently through eye-loop  117  of spring  113  and into corresponding screw receptacles  127  in second half  17  of housing  13 . 
         [0030]    Shown immediately adjacent and axially aligned with spring  113  is an engaging member  129 . Engaging member includes a slot  131  which allows the engaging member  129  to fit over the hub  115  of spring  113 . A second set of projections (NOT ILLUSTRATED) at the center of first bracket  105  are axially aligned with first set of projections  109  on first bracket  105  and extend perpendicularly away from the plane of first bracket  105  in a direction opposite that of first set of projections  109 . As engaging member  129  is fitted over spring  113 , slot  131  catches hub  113  of spring  113 . Engaging member  129  then engages with projections second set of projections  133  to link the cord carriage  103  with the spring  113 . The underside of engaging member  129  includes a series of stops  135  to help prevent slippage and to facilitate translation of rotation from the cord carriage  103  to the spring  113 . 
         [0031]    On actuation of the pull handle assembly  31 , cord  33  unwinds from and rotates cord carriage  103 . Translation of the rotation of cord carriage  103  to spring  113  activates the spring  113 . When the pull handle assembly  31  and cord  33  are released, the tension on the spring  113  is released, causing the cord  33  to automatically recoil around the cord carriage  103  to its neutral coiled position. Second half  17  of housing  13  includes a support structure  137  which lends lateral stability to the above described rotating parts. It should be noted here that, ideally, folding plug  27  should collapse only unidirectionally, for example toward pull handle assembly  31  or perpendicular to pull handle assembly  31  in either sideways direction to prevent unseating the lighting device  11  from a power outlet unintentionally when the pull handle assembly  31  and cord  33  are actuated. 
         [0032]    A second set of projections  139  at the center of second bracket  107  extend perpendicularly away from the plane of second bracket  107  in a direction opposite that of first set of projections  111 . Second set of projections  139  on second bracket  107  support a pair of clutch pawls  141  which engage with and turn a drive gear  143  as the cord carriage  103  rotates with each pull of the pull handle assembly  31  and cord  33 . Drive gear  143  includes a cylindrical space  145 , only the outside of which is seen in  FIG. 3 , into which clutch pawls  141  extend and selectively engage. Cylindrical space  145  may have a series of teeth, projections, stops or other structures around its inner circumference (not visible in this illustration) which enable the clutch pawls  141  to positively engage, without slippage, during rotation of cord carriage  103  in one direction to result in a ratchet-type rotation of drive gear  143 . 
         [0033]    Drive gear  143  intermeshes with an intermediate gear  147 , which, in turn, intermeshes with a pinion  149 . When pinion  149  is driven by drive gear  143  and intermediate gear  147 , pinion  149  rotates a motor axle  151  which activates a generator, hereinafter referred to as a motor (the internal details of which are omitted for clarity) located in motor housing  153 , which is mounted to support flange  155 . Support flange  155  may include a plurality of openings  157  by which support flange  155  can be secured to housing  13  using screws  159 . Support flange  155  supports a shaft  161  on which intermediate gear  147  rides. A main axle  163  supports drive gear  143 , cord carriage  103 , spring  113  and engaging member  129  when the lighting device  11  is assembled. Activation of the motor by actuation of the pull handle assembly  31  and cord  33  results in generating the power necessary to incrementally charge a built-in power pack  165  which may be a capacitor, or rechargeable battery or some other device or a hybrid power pack. Power pack  165  and plug  27  are mounted on a support  167 . Contacts  169  are mounted to support  167  and are illustrated as being fitted with members  171 . Support  167  includes a plurality of small openings  173  by which a plug cradle  175  and power pack bracket  177  may be mounted to support  167  using screws  179 . Plug-shaped recess  51  includes an opening  181  through which plug cradle  175  extends to support folding plug  27  when the lighting device  11  is assembled. 
         [0034]      FIG. 3  illustrates a switch PCB  183  adjacent and slightly offset from support  167 . Adjacent switch PCB  183  is a sliding switch  185  which is mountable to switch PCB  183 . Sliding switch  185  has a projection  187  which extends through a cover plate  189  via a first opening  191  in cover plate  189  when the lighting device  11  is assembled. Cover plate  189  includes a second opening  193  which allows it to be attached to the underside of slide knob selector switch  25  by passing a screw  195  through a slot  197  in second half  17  of housing  13 . Switch PCB  183  includes a plurality of openings  199  by which it may be attached to second half  17  of housing  13  using screws  201  and corresponding screw receptacles  203 . 
         [0035]    Also illustrated adjacent switch PCB  183  is a bracket  205  which can support an adjacent photo sensitive device  207 . Second half  17  of housing  13  further includes an opening  209  over which a light-permeable cap  211  is positioned. Light-permeable cap  211  seals opening  209 , yet still allows light to be transmitted through opening  209  to photo sensitive device  207 . 
         [0036]    Slide knob selector switch  25  allows a user to control the operational mode of lighting device  11 . Slide knob selector switch  25  has at least four possible positions: a first OFF position, a second ON position, a third NIGHT LIGHT MODE position, and a fourth EMERGENCY LIGHT MODE position. The third and fourth positions can be optional depending upon whether one or both or none of the special features are desired. In the OFF position, the lighting device  11  is not illuminated and will revert into and out of a self-charge mode as needed. In the ON position, the lighting device  11  will be switched on all the time and which can be used as a 24 hour per day always on wall mounted light as well. 
         [0037]    When slide knob selector switch  25  is in the NIGHT LIGHT MODE position, photo sensitive device  207  is activated and receives light input through photo sensitive device cap  211 . Relay circuitry is then activated such that, when photo sensitive device  207  detects daylight, the lighting device  11  turns off automatically. Likewise, when photo sensitive device  207  detects darkness, the lighting device  11  turns on automatically. If lighting device  11  is being used in NIGHT LIGHT MODE and is being stored plugged into a power outlet, it can provide uninterrupted light throughout the nighttime hours without any effort on the part of the user. 
         [0038]    When slide knob selector switch  25  is in the EMERGENCY LIGHT MODE position, current detecting circuitry receives input such that interruption of current (as occurs with loss of power) activates illumination of the lighting device  11 . In the absence of power from the AC mains, the lighting device  11  will continue to illuminate the dark areas as the stored power is depleted. However, the lighting device  11 , without even having removing it from its wall support from a power outlet  45  charge the lighting device  11  by hand using the pull handle assembly  31  and cord  33  as described above. In this configuration, a number of the lighting devices  11  can be used to illuminate hallways and exit paths, with intermittent re-charging by a responder. 
         [0039]    Assuming that the lighting device  11  is stored as plugged into a working power outlet, lighting device  11  will self-charge regardless of the position of slide knob selector switch  25  and will cease charging once the power pack  165  is fully charged. This self-charge feature relieves the user from continually having to think ahead to change or charge the batteries. 
         [0040]    Referring to  FIG. 4 , a block diagram illustrates one possible configuration of the components within the lighting device  11 . The slide knob selector switch  25  is represented in block diagram form as a series of switch position blocks S 1 , S 2 , S 3  and S 4 , which correspond with the positions “off”, “on”, “emergency illumination light”, and “night light” which have been previously described. The switch position blocks S 1 , S 2 , S 3  and S 4 , connectot a CONTROL CIRCUITRY PROCESSOR block  251  in which switch selection and a variety of other monitoring and computational tasks may occur. The CONTROL CIRCUITRY PROCESSOR block  251  is connected to the power pack  165 , and the power pack  165  is shown as being connected to a CHARGING CIRCUIT block  253 . It is clear that the CONTROL CIRCUITRY PROCESSOR block  251  and CHARGING CIRCUIT block  253  could be formed as one common circuit or even use a common microprocessor or controller chip. In the configuration shown, the emphasis is operational, namely that anytime that the wall plug  27  receives power into the CHARGING CIRCUIT block  253 , the power pack  165  will automatically be under charge. In addition to the connection between the CHARGING CIRCUIT block  253  and the power pack  165 , an optional connection is shown between the CHARGING CIRCUIT block  253  and the CONTROL CIRCUITRY PROCESSOR block  251  so that the CONTROL CIRCUITRY PROCESSOR block  251  will have instant access to a state of failure of the energization of the wall plug  27 . 
         [0041]    Also shown connected to the CONTROL CIRCUITRY PROCESSOR block  251  is the photo sensitive device  207 . All of the aforementioned inputs to the CONTROL CIRCUITRY PROCESSOR block  251  enable it to control the light emitting diode  59  throughout all of the “off”, “on”, “emergency illumination light”, and “night light” modes of control described. 
         [0042]    Although the invention has been derived with reference to particular illustrative embodiments thereof, many changes and modifications of the invention may become apparent to those skilled in the art without departing from the spirit and scope of the invention. Therefore, included within the patent warranted hereon are all such changes and modifications as may reasonably and properly be included within the scope of this contribution to the art.