Abstract:
The invention provides a manually-powered electrical assembly. In one aspect, the manually-powered electrical assembly can be a light assembly that comprises a light source, an electrical generator, and a manual actuator assembly. The electrical generator is electrically connected to the light source and is operable to provide an electric current to the light source to operate the light source for providing light. The manual actuator assembly is arranged with the electrical generator for selectively manually operating the electrical generator. The manual actuator assembly includes an operator handle movable over a range of travel between a normal position and an operated position, a biasing mechanism for biasing the operator handle to the normal position, and a drive train connected to the operator handle and the electrical generator for rotating the rotor of the electrical generator. The invention is operable to power other electrical devices such as a mobile phone or a fan.

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATION  
       [0001]     This patent application claims the benefit of priority to U.S. Provisional Application No. 60/651,365, filed Feb. 9, 2005, and entitled “Manual-Powered Generator And Assemblies Therewith,” which is incorporated in its entirety herein by this reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]     This invention pertains to manual-powered generators, and more particularly to manual-powered generators for powering relatively small electronic devices.  
       BACKGROUND OF THE INVENTION  
       [0003]     In the event of an electrical power outage, for example, an alternative source for electricity is often desirable, particularly for providing illumination. Often in such a situation, batteries for flashlights are not on hand or no longer provide a charge. Generators can be relatively large and inconvenient for use with small devices.  
       BRIEF SUMMARY OF THE INVENTION  
       [0004]     The invention provides a manual-powered generator for powering relatively small electronic devices. In one embodiment, the invention is in the form of a light assembly. The light assembly comprises a light source, an electrical generator, and a manual actuator assembly. The electrical generator is electrically connected to the light source and is operable to provide an electric current to the light source to operate the light source for providing light. The electrical generator has a rotor. The manual actuator assembly is arranged with the electrical generator for selectively manually operating the electrical generator. The manual actuator assembly includes an operator handle movable over a range of travel between a normal position and an operated position, and a drive train connected to the operator handle and the electrical generator for rotating the rotor of the electrical generator. The operator handle has a rotatably movable shaft. The biasing mechanism has a reel mounted to the shaft of the operator handle and a tape spring for rotationally biasing the reel to rotate in a return direction. The tape spring is wound on the reel and connected such that when the operator handle is moved in an operating direction toward the operated position, the reel rotates in a forward direction and the tape spring develops a return force. The return force urges the reel and the shaft of the operating handle to move in a return direction. The return direction opposes the forward direction. The drive train includes a plurality of gears, one gear of the drive train being mounted to the shaft of the operating handle and another gear being mounted to the rotor of the electrical generator. In other embodiments, the invention is useful for powering other electrical devices, such as a mobile phone or a fan, for example.  
         [0005]     The features of the present invention will become apparent to one of ordinary skill in the art upon reading the detailed description, in conjunction with the accompanying drawings, provided herein. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0006]      FIG. 1  is a perspective side view of a light assembly in accordance with the teachings of the present invention, the light assembly comprising a manual-powered generator and a light source.  
         [0007]      FIG. 2  is another perspective view of the light assembly of  FIG. 1  with a housing thereof removed for illustrative purposes.  
         [0008]      FIG. 3  is a fragmentary top perspective view of a handle unit of the manual-powered generator of  FIG. 1 .  
         [0009]      FIG. 4  is a perspective view of a first side of a frame plate of the manual-powered generator of  FIG. 1 .  
         [0010]      FIG. 5  is a perspective view of a second side of the frame plate of  FIG. 4 .  
         [0011]      FIG. 6  is a perspective view of a spring housing of the manual-powered generator of  FIG. 1 .  
         [0012]      FIG. 7  is another perspective view of the spring housing of  FIG. 6  and a fragmentary perspective view of the frame plate of  FIG. 4 , showing the spring housing rotatably mounted to the frame plate.  
         [0013]      FIG. 8  is a perspective view similar to  FIG. 2 , but from the second side of the frame plate.  
         [0014]      FIG. 9  is a top view of the manual-powered generator of  FIG. 1 .  
         [0015]      FIG. 10  is a perspective view of a first transfer gear of the manual-powered generator of  FIG. 1 .  
         [0016]      FIG. 11  is another perspective view of the first transfer gear of  FIG. 10 , but from the opposite side thereof.  
         [0017]      FIG. 12  is a perspective view of a second transfer gear of the manual-powered generator of  FIG. 1 .  
         [0018]      FIG. 13  is another perspective view of the second transfer gear of  FIG. 12 , but from the opposite side thereof.  
         [0019]      FIG. 14  is a perspective view of a third transfer gear of the manual-powered generator of  FIG. 1 .  
         [0020]      FIG. 15  is a perspective view of a generator of the manual-powered generator of  FIG. 1 , the generator having a rod-combination driven gear extending therefrom.  
         [0021]      FIG. 16  is a perspective view of a second embodiment of a generator suitable for use with the manual-powered generator of the present invention, the generator having a spur gear extending therefrom.  
         [0022]      FIG. 17  is a perspective view of a rechargeable battery pack of the light assembly of  FIG. 1 .  
         [0023]      FIG. 18  is another perspective view of the light assembly of  FIG. 1  having a fan electrically connected thereto.  
         [0024]      FIG. 19  is a perspective view of a manual-powered generator according to the present invention with a cellular phone electrically connected thereto.  
         [0025]      FIG. 20  is a front elevational view of another embodiment of a manual-powered generator in accordance with the teachings of the present invention.  
         [0026]      FIG. 21  is a side elevational view of the manual-powered generator of  FIG. 21   
         [0027]      FIG. 22  is a top plan view of the manual-powered generator of  FIG. 21 .  
         [0028]      FIG. 23  is a front elevational view of another embodiment of a manual-powered generator in accordance with the teachings of the present invention.  
         [0029]      FIG. 24  is a side elevational view of the manual-powered generator of  FIG. 24   
         [0030]      FIG. 25  is a top plan view of the manual-powered generator of  FIG. 24 .  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0031]     Turning now to the drawings, there is shown in  FIG. 1 , a light assembly  50  according to the present invention including a manual-powered generator device  52  contained within a housing  53  and a light source  54 . As shown, the manual-powered generator device  52  comprises a generator  62 , a gear train  64 , a spring housing  66 , a handle  68 , a shaft  70 , a frame  74 , a spring pawl mechanism  76 , and a rechargeable battery  78 . The handle  68  is coupled to the shaft  70  for rotation of the shaft in an operating direction. The spring pawl mechanism  76  is operably arranged with the shaft  70  to prevent the shaft from rotating in a direction opposite the operating direction. The spring housing  66  is connected to the shaft  70  such that a tape spring within the spring housing  66  is wound upon rotational movement of the shaft in the operating direction. The spring housing  66  is also operably arranged with the gear train  64  for providing rotational movement of the gear train when the tape spring is unwound. The gear train  64  in turn, is operably arranged with the generator  62  such that the rotational movement of the gear train is converted to electricity by the generator. The generator  62  is electrically connected to the light source  54  for providing electricity thereto. In one embodiment, as shown, the light source  54  is mounted to the housing  53 . The frame  74  is used to mount and support components of the manual-powered generator device  52 . The housing  53  is provided to contain and protect components of the manual-powered generator device  52 .  
         [0032]     The handle  68  is operated by a user to rotate the shaft  70 , which in turn rotates a portion of the spring housing  66 . A main gear  82 , attached to the spring housing  66 , is rotated when the spring housing  66  is rotated. The main gear  82  acts upon the gear train  64 . The gear train  64  applies rotational force to the generator  62  to generate electricity.  
         [0033]     Referring to  FIGS. 1 and 3 , the handle  68  includes an elongate lever  85  with a handle pawl mechanism  86  disposed at a distal end  87  thereof. The lever  85  extends a predetermined distance such that an operator end  88  thereof is located at a convenient point for use by an operator to operate the manual-powered electric generator device  52 . Referring to  FIG. 3 , the lever  85  includes a pair of arms  89 ,  90  which are in spaced relationship to each other at the distal end  87  of the lever  85 . A shaft  91  extends transversely through the distal end  87  of the lever  85  and has a socket  92  secured thereto. The handle pawl mechanism  86  is disposed between the arms  89 ,  90  of the lever  85  at the distal end  87 . A ratchet gear  93  of the pawl mechanism  86  is secured to the shaft  91 . A pawl  94  of the handle pawl mechanism  86  is pivotally mounted to at least one of the arms  89 ,  90  such that the pawl  94  is operably engageable with the ratchet gear  93 . One of the arms  90  includes a biasing member to prevent the pawl  94  from rotating in one direction, but urging the pawl  94  to rotate in the other direction to engage the ratchet gear  93 . The socket  92  is configured so that it can be coupled to the shaft so as to transmit rotational movement of the handle  68  to the shaft  70  (shown in  FIG. 1 ).  
         [0034]     In operation, the handle  68  rotates the socket  92  (and thus the shaft  70 ) via the handle pawl mechanism  86  when the handle  68  is moved in one direction, i.e. the operating direction. When the handle  68  is moved in the operating direction, the pawl  94  engages the ratchet gear  93  to thereby rotate the shaft  91 , along with the socket  92 . When the handle  68  is moved in the opposite direction, i.e., the return direction, the pawl  94  disengages from the ratchet gear  93 , thereby allowing the lever  85  to rotate with respect to the shaft  91  such that the lever  85  can be moved in the return direction without rotation of the socket  92 .  
         [0035]     Referring to  FIG. 2 , the frame  74  comprises a pair of plates  100 ,  101  disposed in spaced relationship to each other with the spring housing  66 , the gear train  64 , and the generator  62  disposed between the plates  100 ,  101 . There is space within the frame  74  to accommodate the rechargeable battery/rechargeable battery pack  78 .  
         [0036]     Referring to  FIG. 4 , the first plate  100  is similar to the second plate. The first plate  100  supports the spring pawl mechanism  86 .  
         [0037]     Referring to  FIG. 5 , a pair of connecting rods  106 ,  108  are secured to the plate  100 . The connecting rods  106 ,  108  can secure the plates  100 ,  101  together and support various components of the light assembly  50 , as shown in  FIG. 2 .  
         [0038]     Referring to  FIG. 6 , the spring housing  66  includes a reel  112 , a tape spring  114  disposed within the reel  112 , the main gear  82  secured to the reel  112 , and an extension member  118  extending from the main gear  82 . The shaft  70  is operably arranged with the spring housing  66 , as shown in  FIG. 7 .  
         [0039]     Referring to  FIG. 7 , the shaft  70  extends from the reel  112  in opposing relationship to the extension member  118 . The distal end of the shaft  70  is configured to be insertable within the socket  92  of the handle  68 . In other embodiments, the handle can be secured to the shaft by other techniques and can constitute a single component.  
         [0040]     Referring to  FIG. 8 , the spring housing  66  is supported by one of the plates  100  via the extension member  118 . The extension member  118  is rotatably supported within a mounting hole  120  of the plate  100  such that the main gear  82  is free to rotate with respect to the plate  100 . An end of the tap spin is connected to the shaft  70 .  
         [0041]     Referring to  FIG. 2 , the spring pawl mechanism  76  includes a spring pawl  124  that is engaged with a spring ratchet gear  126 . The spring ratchet gear  126  is mounted to the shaft  70 . The spring pawl  124  is pivotally mounted to the plate  100 . A biasing member  128  is provided to urge the spring pawl  124  into operative engagement with the spring ratchet gear  126 . The biasing member  128  is mounted to the first plate  100 . A return stop member  130  is mounted to the first plate and is arranged with the spring ratchet gear  126 .  
         [0042]     The rotation of the shaft  70  in the operating direction winds the tape spring  114  around the reel portion of the shaft  70 . The winding of the tape spring  114  creates a spring force, which is exerted against the reel portion of the shaft  70  in the return direction. As mentioned above, the spring pawl mechanism  76  resists this force on the shaft  70 , resulting in the tape spring  114  urging the spring housing  66  and the main gear  82  to rotate in the forward direction as the tape spring  114  unwinds.  
         [0043]     Referring to  FIG. 9 , the gear train  64  includes three transfer gears  140 ,  142 ,  144 . The transfer gears  140 ,  142 ,  144  transmit rotational force from the main gear  82  to the generator  62 . Referring to  FIGS. 10-14 , each transfer gear  140 ,  142 ,  144  includes a shaft  148 ,  149 ,  150 , a driven gear  152 ,  153 ,  154 , and a driving gear  156 ,  157 ,  158  for transferring rotational force. The driven gear on any of the transfer gears  140 ,  142 ,  144  can be a rod combination unit.  
         [0044]     Referring to  FIG. 9 , the shafts  148 ,  149 ,  150  of the transfer gears  140 ,  142 ,  144  are rotatably mounted to at least one of the plates  100 ,  101  such that the transfer gears  140 ,  142 ,  144  are free to rotate with respect to the plates  100 ,  101  along an axis defined by each respective shaft. The driven gear  152  of the first transfer gear  140  is operably arranged with the main gear  82  of the spring housing  66  such that rotation of the main gear  82  rotates the first transfer gear  140 . The driving gear  156  of the first transfer gear  140  is operably arranged with the driven gear  153  of the second transfer gear  142  such that rotation of the first transfer gear  140  also rotates the second transfer gear  142 . The driving gear  157  of the second transfer gear  142  is operably arranged with the driven gear  154  of the third transfer gear  144  such that rotation of the second transfer gear  142  also rotates the third transfer gear  144 . The driving gear  158  of the third transfer gear  144  is operably arranged with the generator  62  such that the generator creates electricity when the third transfer gear  144  is rotated.  
         [0045]     As shown in  FIG. 15 , the generator  62  is relatively cylindrical in shape. The generator  62  comprises a body  172 , a shaft  174 , a driven gear  176 , and a bracket  178 . The shaft  174  extends from the body  172  with the driven gear  176  disposed at a distal end thereof. The driving gear  158  of the third transfer gear  144  is in operable position with the driven gear  176  of the generator  62  such that when the third transfer gear  144  rotates, the driven gear  176  will rotate the shaft  174  resulting in the generation of electrical energy by the generator  62 . The mounting bracket  178  can be used to mount the generator  62  to the second plate  101 . As shown in this figure, the driven gear  176  is a rod-combination. In another embodiment of the generator  180 , as shown in  FIG. 16 , the driven gear  182  can be a spur gear.  
         [0046]     Referring to  FIG. 17 , the rechargeable battery or battery pack  78  can be connected to the generator such that the electricity created by the generator can be stored and used at a later point in time rather than immediately during operation of the generator. A cable  192  can be used to connect the battery  78  to the generator.  
         [0047]     Many types of electrical devices can be powered by the invention. For example, the manual-powered generator can be used to power items such as the light source  54  (shown in  FIG. 18 ), a fan  194  (as shown in  FIG. 19 ), or a mobile phone  196  (as shown in  FIG. 20 ). Additionally, as shown in  FIG. 19 , the manual-powered generator device  52  can be connected to more than one device at a time, e.g. the assembly can include a light source  54  mounted to the housing  53  and another device such as the fan  194 . In yet other embodiments, the manual-powered generator can be used to power any suitable electrically-powered device.  
         [0048]      FIGS. 20-22  show another embodiment of a manual-powered generator device  200  with a fourth transfer gear  202 . The manual-powered generator device  200  of  FIG. 20  is similar in other respects to the manual-powered generator device  52  of  FIG. 1 .  FIGS. 23-25  show yet another embodiment of the manual-powered generator device  300  with a fourth transfer gear  302  and wherein the generator  304  is mounted on the exterior of the frame  306 . The manual-powered generator device  300  of  FIG. 23  is similar in other respects to the manual-powered generator device  52  of  FIG. 1 .  
         [0049]     In yet other embodiments of the manual-actuated generator, a biasing mechanism can be provided that urges the operator handle to move in a return direction toward a return position. In use, the operator can move the operator handle in the operating direction to generate electricity. At the end of the stroke, the operator can stop applying force to the handle such that the biasing mechanism urges the operating handle to move in the return direction toward the return position such that the handle is ready to be moved again in the operating direction to continue to generate electricity.  
         [0050]     All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.  
         [0051]     The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.  
         [0052]     Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.