General purpose illuminator assembly

An illuminator assembly is disclosed which is formed from a light emitting diode (LED) having two electrode pins extending therefrom which are cut to predetermined lengths. One lead then is formed to provide a circularly shaped spring support base and the other lead is bent to provide an attachment potion extending through the center of the opening formed by the spring support base. A capture spring of conical configuration then is attached to the centrally disposed lead which extends through the spring support base opening. A compressible coil switching spring then is attached to the spring support base. The assemblage thus formed is employed with a battery of a variety having a forward face which engages the free end of the switching spring and which includes a rod shaped electrode extending from the center portion thereof. Upon providing relative mutually approaching movement of a battery and illuminator assembly, the rod-like cathode is engaged by the capture spring and an electrical circuit is completed to illuminate the LED. Conversely, the releasing or reverse movement under the drive imparted by the switching spring switches the assemblage to an open circuit condition.

BACKGROUND OF THE INVENTION 
A broad variety of utilitarian novelty and recreational implements have 
been proposed or introduced over the past which, in one way or another, 
feature some form of battery powered illumination. In general, these 
devices have resorted to overly complex and impractical illumination 
schemes which involve switching structures and associated wiring providing 
for supplying battery power to the light source. For the most part, the 
need to carry out a switching function has both exascerbated product cost 
and has imposed unfortunate limits upon desired miniaturization. 
The light emitting diode (LED) has become a popular light source for 
miniature devices. However, the diodes are fabricated with rather robust 
dual pin electrodes which are designed for insertion and supportive 
mounting within structures such as circuit boards and the like. The 
devices, for example, are not generally available having low cost light 
socket base configurations or the like. Thus, the designer of small 
illuminated implements faces the task of providing a reliable electrical 
connection with the diode electrode pins, as well as implementing a 
practical switching function while achieving a structure which is 
practical to manufacture at high quantity levels and correspondingly at 
lower costs. 
Applications for which a practical illuminator assembly have been sought 
include, for example, recreational darts, novelty pins, fishing bobbers, 
glow sticks, toy applications, and a wide variety of other items. The 
implementation, for example, of an implement illuminator assembly with 
recreational darts poses particular design difficulties. Typically, the 
recreational dart is formed having a body portion of relatively small 
diameter to which a point is attached at the front end and a flight 
containing tail feathers is attached at the rearward end of the body. To 
illuminate the flight with an LED requires, for example, that the body be 
configured having an internal chamber to carry a battery as well as the 
LED and appropriate switching. The LED then may illuminate the flight once 
the switch is turned on. The use of externally disposed switches is highly 
impractical, essentially precluding the introduction of the dart 
structures. Of further note, when the relatively heavier material of the 
dart body, which may be formed, for example of steel tungsten or the like 
is hollowed to receive a light generating assemblage, the dart loses 
weight to the extent that its weight is below that considered appropriate 
by serious dart recreationists, for example below about 26 gm. 
In view of the foregoing, an illuminator assembly which exhibits a 
capability for very large volume fabrication at low cost and which is 
capable of forming a reliable electrical circuit to a light emitting diode 
under wide fabricational tolerances and with a simplicity of switching 
actuation could find a high level of acceptance in a broad variety of 
industries. 
SUMMARY 
The present invention is addressed to an illuminator assembly, implement 
and method of manufacture of the illuminator assembly which provides a 
highly effective and reliable implement illumination feature with facile 
production procedures. The assembly performs in conjunction with a small, 
lithium pin battery which has a cylindrical, electre-defining outer 
surface extending to and somewhat over a forward face. From the forward 
face there extends a rod-shaped electrode. This battery is employed with a 
dual spring based contact and switching configuration formed in 
conjunction with the electrode pins of a light emitting diode (LED). One 
electrode pin of the light emitting diode is formed to define a circular 
spring support base having an opening therein. The second electrode pin of 
the diode is formed so that a mounting portion is developed which extends 
essentially through the opening in the spring support base. A small, 
conically shaped capture spring is attached to the mounting portion of the 
electrode extending through the spring support base, while a larger 
switching spring is attached to the spring support base formed from the 
other electrode pin. The switching spring has a diameter selected to 
provide electrical contact with the forward face of the battery and the 
capture spring is retained within the inner diameter of the switching 
spring. Thus, by simply contacting the switching spring with the battery 
forward face and providing a relative motion between the diode and the 
battery to thus compress the switching spring, the rod-shaped electrode of 
the battery will move toward and be captured in a reliable electrical 
connection with the capture spring to illuminate the diode. No extraneous 
switching schemes are utilized, and the illuminator assembly thus 
developed is amenable to high production techniques and further 
complements efficient production techniques for fabricating the implements 
within which it and a battery are utilized. 
Another feature of the invention is to provide an illuminator assembly for 
use with a battery of given outer diameter and having a centrally disposed 
rod-shaped electrode extending outwardly from the forward face thereof a 
predetermined length. The assembly includes a light emitting diode having 
first and second thin metal electrode pins extending from a back surface 
thereof, the first pin extending rearwardly from the back surface to a 
base position and is configured thereat to define a spring support base 
disposed along a plane generally parallel with the back surface and having 
a base opening therein. The second electrode pin is configured to extend 
to and provide a mounting portion located at the center of the base 
opening. A compressible coil switching spring of predetermined inner and 
outer diameter is provided having a base end fixed to the spring support 
base and extending outwardly therefrom to a switching end. A compressible 
coil capture spring of generally conical configuration having a 
constricted connecting end of first predetermined inner diameter is 
connected to and extends from the diode second electrode pin mounting 
portion and further extends within the switching spring to a wider capture 
end of second inner and outer diameter selected for receiving the battery 
rod-shaped electrode. 
Another feature of the invention provides an illuminated implement 
including a body component having an internally disposed chamber extending 
along a given axis between an illuminating first end and an oppositely 
disposed second end. A battery having an electrode defining outer surface 
of given outer diameter and a centrally disposed rod-shaped electrode 
extending outwardly from the forward face thereof is provided. This 
battery is located within the chamber in a manner wherein the electrode 
extends toward the illuminating first end and substantially along the 
given axis. A compressible coil switching spring is located within the 
chamber and has a given inner diameter and an outer diameter selected for 
abuttable electrical engagement with the battery outer surface at the 
forward face and is positioned over and in non-contacting relationship 
with the centrally disposed rod-shaped battery electrode and further has a 
base end facing the chamber first end. A light emitting diode is located 
at the chamber illuminating first end and has first and second electrode 
pins extending from a back surface thereof, the first pin extending 
rearwardly from the back surface to a base position and being configured 
thereat to define a spring support base disposed along a plane generally 
parallel with the back surface and having an opening therein. The base is 
in electrical contact with the switching spring base end. The second pin 
is configured to extend to the base opening and provide a mounting portion 
thereat substantially aligned with the axis. A compressible coil capture 
spring of generally conical configuration is provided having a connecting 
and electrically coupled and mounted to the second pin mounting portion, 
and is extensible in non-contacting relationship within the switching 
spring to a wider capture end of inner diameter selected for receiving the 
battery electrode in electrical contacting association. An actuator 
arrangement is provided which selectively effects the mechanical capture 
and electrical coupling of the end of the battery rod-shaped electrode and 
the capture spring through relative movement between the diode and battery 
effecting the compression of the switching spring. 
Another feature of the invention provides a method for making an 
illuminator assembly for use with a battery having an electrode defining 
outer surface of given outer diameter and a centrally disposed rod-shaped 
electrode extending outwardly from the forward face, comprising the steps 
of: 
providing a light emitting diode having a diode portion with a rearward 
face and first and second electrode pins extending therefrom; 
cutting the first electrode pin to a predetermined length effective to form 
a spring support base at a base location; 
cutting the second electrode pin to a predetermined length effective to 
provide a centrally disposed mounting portion; 
bending the second electrode pin to position the mounting portion centrally 
of the diode portion; 
bending the first electrode pin at the base location to form the spring 
support base within which a base opening is provided through which the 
second electrode pin extends; 
providing a compressible coil capture spring of generally conical 
configuration having a connecting end of predetermined internal diameter 
and an oppositely disposed capture end of predetermined outer diameter and 
dimension to receive the rod-shaped electrode; 
attaching the capture spring connecting end to the second electrode pin 
mounting portion; 
providing a compressible coil switching spring having an inner diameter 
greater than the capture spring capture end outer diameter; 
positioning the switching spring substantially over the capture spring; and 
attaching one end of the switching spring to the spring support base. 
Other objects of the invention will, in part, be obvious and will, in part, 
appear hereinafter. 
The invention, accordingly, comprises the apparatus and method possessing 
the construction, combination of elements, arrangement of parts, and steps 
which are exemplified in the following detailed disclosure. For a fuller 
understanding of the nature and objects of the invention, reference should 
be had to the following detailed description taken in connection with the 
accompanying drawings.

DETAILED DESCRIPTION 
To facilitate the description to follow, the illuminator assembly of the 
invention initially is described in conjunction with its application to 
recreational darts. The discourse then turns to a detailed description of 
the illuminator assembly itself and a technique for carrying out its 
fabrication at high volume production levels. The description then looks 
to a variety of exemplary applications or illuminated implements with 
which the illuminator assembly may be employed. 
Referring to FIG. 1, a recreational dart is revealed generally at 10, the 
embodiment shown being referred to in the industry as a "soft tip" dart. 
Such soft tip darts as at 10 generally will have a lesser overall weight 
than conventional "hard tipped" darts inasmuch as they are employed with 
automatic scoring dart board which would be injured if used in conjunction 
with heavier hard tip darts. The application herein, however, is one 
wherein the dart which incorporates the illuminator features of the 
invention may be either hard tipped or soft tipped. Dart 10 is seen to 
have a cylindrical thin elongate body component 12 which typically will be 
formed of a metal carrying some form of external ornamentation. The point 
of the dart at 14 is replaceable and conventionally is threadably engaged 
with the end 16 of dart 10. The rearward or illuminating end of the dart 
10 at 18 is shown threadably receiving a flight represented generally at 
20 and including a light transmitting clear plastic stem 22 which supports 
feathers 24. An LED positioned at the end 18 of the device 10, when 
illuminated, will, in turn, transmit light along the stem 22 which may be 
reflected or otherwise disposed of to give the dart a "tracer like" 
appearance as it progresses toward a target dart board. 
Looking to FIG. 2, a sectional review of the body component 12 reveals an 
internally bored chamber 28 which is positioned coaxially with the central 
axis of body component 12. It may be observed that the point 14 is 
threadably engaged with the end portion 16 of component 12, while the stem 
22 of flight 20 is shown fully threadably engaged with illuminating end 18 
of the component 12. Stem 22 may be seen to be formed having an opening 30 
therein which receives a light emitting diode (LED) 32. Alternatively, no 
such opening as at 30 is required. LED 32 preferably is provided as formed 
utilizing a double heterojunction (DH) AlGaAs/GaAs material technology. 
For example, the LEDs exhibit a high output efficiency over a wide range 
of drive currents. One such LED is a type HLMP K105 having a minimum axial 
luminous intensity at 25.degree. C. of 35 MCD at 20 mA and a typical 
output of 65 MCD at 20 mA. The device also exhibits a viewing angle of 
about 45.degree.. LEDs as at 32 are marketed, for example, by Hewlett 
Packard Corporation. Extending from the back surface 34 of LED 32 are two 
thin metal electrode pins 36 and 38. Pins 36 and 38 may have a square 
cross section having a principal dimension or diametric dimension, for 
example of about 0.025 inch. Electrode pin 36 is shown extending 
rearwardly from the back surface 34 to a base position 40 and is 
configured thereat to define a generally circular spring support base 42. 
The base 42 is disposed along a plane generally parallel with the back 
surface 34 of LED 32 or perpendicular to the central axis of the body 
component 12. Electrode pin 38 is configured such that it extends to 
provide a mounting portion 44 which is coaxial with the axis of body 
component 12 and which extends to the center of a base opening within 
support base 42. To the outwardly facing circular surface of spring 
support base 42 there is connected the base end 46 of a compressible coil 
switching spring 48. Preferably, the base end 46 of spring 48 may be 
connected to spring support base 42 by soldering or spot welding o provide 
both an assemblage rigid connection and an assured electrical coupling. To 
facilitate this connection, practitioners may find it desirable to form 
the spring 48 such that the base end 46 thereof includes one or more 
closed coils. Spring 48 may be provided as a carbon steel wire having a 
spring rate ranging from about 0.24 lbs/inch to 0.96 lbs/inch. For most 
applications, spring rate of about 0.48 lbs/inch will be found desirable. 
Similarly, for a large variety of implementations, a retractability or 
compliance in compression of 0.30 inch is desirable. The switching end 50 
of spring 48 is seen to be abuttably engaging the forward face 52 of a 
lithium pin battery 54. Battery 54 is configured having an external 
surface electrode which extends partially over the forward face 52 thereof 
so as to provide an electrical contact with the switching end 50 of spring 
48. Extending from the center of battery 54 is a rod shaped electrode 56 
which, for the type battery illustrated is the cathode of the device. For 
the application shown, the battery 54 may be provided, for example, as a 
type BR435 marketed by the Battery Sales Division of Panasonic Industrial 
Company, Division of Matsushita Electric Corporation of America. The 
battery has a nominal voltage of 3 volts and a nominal capacity of 50 mAh, 
a diameter of 4.2 mm, a height of 35.8 mm, and a weight of 0.92 g. Note 
that the battery 54 slideably nests within the chamber 28 and that its 
outside diameter is essentially the same as the corresponding outside 
diameter of switching spring 48. No permanent connection is made between 
the forward face 52 of battery 54 and the switching end of spring 48, thus 
permitting battery replacement for the device 10. However, a desirable 
compression based electrical contact is provided between end 50 and face 
52. 
Rod shaped electrode 56 is seen extending to and in engagement with the 
wider open end of a compressible coil capture spring 58. Spring 58 may be 
formed, for example, of phosphor-bronze wire and has a generally conical 
configuration with a constricted connecting end 60 and a wider diameter 
capture end 62. Practitioners may find it desirable to provide the capture 
end 62 of spring 58 having closed coils as shown. The connecting end 60 of 
spring 58 is fixed to mounting portion 44 of electrode pin 38. Preferably, 
this connection is assured by soldering. In general, the inner diameter of 
connecting end 60 will correspond with the principal dimension of 
electrode pin 38, for example about 0.025 inch. Spring 58 is seen to 
extend through the opening of base 42 formed from lead 36 to present the 
capture end 62 thereof at a location within spring 48 selected to permit 
reception of the end of rod shaped electrode 56 of battery 54. In the 
configuration thus shown, the electrical circuit of the assemblage is 
closed and LED 32 will be illuminated. The switching for this embodiment 
is carried out, for example, by the act of screwing flight stem 22 into 
the end 18 of body component 12 to thus move LED and its associated 
configuration toward battery 54 and cause the capture and engagement of 
rod-like electrode 56 with the capture spring 58. Note that as the stem 22 
is engaged within the end portion 18, the assemblage compresses spring 48 
against the face 52 of battery 54. Battery 54, in turn, is restrained from 
movement by virtue of its abutting contact with internally disposed 
surface of tip 14. Of course, switching can be carried out by the 
tightening of tip 14 as the stem 22 is fully inserted, a relative motion 
being all that is required. Thus, a very simple switch actuation is 
accomplished with no external switches required and with a high level of 
reliability particularly suited for the rigorous dynamic environment of a 
recreational dart. 
Now looking to FIG. 3, the cross section represented in FIG. 2 is 
reproduced but in an open switch or open circuit configuration. Note that 
the stem 22 of flight 20 has been partially threadably unscrewed from 
illuminating end 18 of body component 12. This action permits the 
switching spring 48 to expand or recover to urge the LED 32 and capture 
spring 58 to move axially rearwardly and effect the disengagement of 
rod-like electrode 56 of battery 54 from capture spring 58. The circuit is 
open and off mode switching thus is accomplished with highly desirable 
simplicity. The utilization of the spring circuit-switching assembly 
disclosed is highly electrically efficient and quite inexpensive. 
Additionally, the illuminator assemblage provided is amenable to desired 
high volume production procedures. Where the dart 10 is of a hard point 
variety, then, the formation of chamber 28 therein, for conventional 
materials would render the dart somewhat light for competitive dart 
throwing. However, the desired weight of dart 10 with the hard point may 
be regained by forming the body component 12 of depleted uranium. This 
material heretofore has found little use in the industry, being used 
principally, for example, as armour piercing material for implements of 
war. However, depleted uranium has a density which will achieve a desired 
dart 10 weight, for example of above about 26 g. The density of this 
material is in excess of about 18 grams per cubic centimeter. 
Turning to FIG. 4, the illuminators assembly, per se, of the invention is 
revealed generally at 70. In the figure, the LED is shown at 72 having 
electrode pins 74 and 76 extending from the back surface 78 thereof. 
Electrode pin 74 is configured to provide a circular spring support base 
82 which, as revealed in FIG. 5, is of circular configuration to provide a 
base opening 82. Returning to FIG. 4, secured to the spring support base 
80 is the base end 84 of a compressible coil switching spring 86 which 
extends along the central axis of the assembly 70 to a switching end 88. 
FIGS. 4, 5, and 6 reveal the mounting portion 90 of electrode pin 76 to 
which the connecting end 92 of a conically shaped compressible coil 
capture spring 94 is attached (see FIG. 7). Spring 94 extends in conical 
fashion to capture end 96 which may be provided, for example, with a 
closed coil configuration to facilitate the capture of the rod electrode 
of a battery as earlier described at 54. 
The general procedure for fabricating the assembly 70 is shown commencing 
with FIG. 8 wherein LED 72 is revealed having electrode pins 74 and 76 
extending therein to their normal extent as received from the supplier. 
FIG. 9 reveals a next fabrication procedure wherein these electrode pins 
74 and 76 are cut to lengths appropriate for their subsequent 
manipulation. Then, as represented in FIG. 6, the spring support base 80 
is configured at base position 98 and the electrode lead 76 is bent or 
configured to provide a mounting portion 90 extending through the opening 
82 formed by spring support base 80 (see FIG. 5). The connecting end 92 of 
capture spring 94 then is attached to mounting portion 90 of electrode pin 
76 and is soldered in place, for example, using a conventional lower 
temperature solder such as tin-lead. Next, as represented in FIG. 4, the 
base end 84 of switching spring 86 is attached to spring support base 80, 
preferably by soldering using the noted lower temperature solder. 
Referring to FIGS. 10 and 11, a manufacturing jig which may be employed in 
configuring the pin leads 74 and 76 of LED 72 to the length represented in 
FIG. 9 is represented generally at 110. The device 110 is shown having a 
base 112 to which are attached two parallel guideway components 114 and 
116. These components are retained upon base 112, for example, by machine 
screws as represented at 118 and 120. Attached, in turn, to the top of 
components 114 and 116 is a top guide block 122 which is configured having 
an off center guide slot 124 formed therein. The block 122 is affixed to 
components 114 and 116, for example, by machine screws 126-129. Slideably 
movable within the assemblage thus formed is a pusher block 132 which is 
reciprocably driven by a cylinder, the rod for which is represented at 
134. Block 132 is configured having a lower rectangular portion 136 and an 
integrally formed upstanding portion 138 which rides within guide slot 
124. Positioned at the front face of top guide block 122 is a knife block 
140 which is retained in position by machine screws as at 142-145. The 
upper inwardly disposed edge of block 140 at a slot 148 shown therein is 
provided as a sharp blade edge, while, correspondingly, an inwardly 
disposed lower edge at surface 150 thereof forms a next cutting edge. LEDs 
as at 72 are positioned upon the assembly 110 such that lead pins 74 and 
76 extend through appropriately positioned slots 152 and 154 formed within 
knife block 140. As revealed in FIG. 11, as the pusher block 132 is driven 
forwardly, the electrode pins 74 and 76 are pushed against the appropriate 
knife edges at slot 148 and surface 150 to form the LED 72 structure 
represented in FIG. 9. Following cutting, rod 134 withdraws the pusher 
block 132 to commence a next cutting operation. 
Referring to FIG. 12, a pin forming assembly for deriving the LED 72 
configuration shown in FIG. 6 is revealed generally at 160. Assembly 160 
includes a ram block 162 which is slideably connected to a base 164 by 
rods 166 and 168. These rods ride, for example, in bores, one of which is 
represented at 170. Block 162 further supports a clamping mechanism 
represented generally at 172 which includes a hinged clamping bar 174 
which is pivotally mounted to block 162 at a pin 176 and which functions 
to retain LED 72 in position as shown when pivoted downwardly to be 
engaged by clamp retainer 178. Leads 74 and 76 of the LED 72 are retained 
in position by slots (not shown) within block 162 and the LED itself is 
positioned and secured by virtue of its abutment with a retainer 180. A 
cylinder driven rod to which the retainer 180 is affixed, moves the block 
162 assemblage toward base 164 upon mounting the LED 72 therein as shown. 
At base 164 there is mounted a rotatable forming die 184, which, in turn, 
is rotationally supported from a shaft 186 extending through and supported 
by a bearing block 188. Cap 186, in turn, is driven by an electric motor 
190 supported from base 164 by plate 192. 
FIG. 13 reveals that the forming die 184 is configured having a centrally 
disposed bore 194 formed therein and extending from a conical forming 
surface 196. Thus, as the LED 72 is moved into the die 184, shorter lead 
76 is maneuvered into bore 194 and is formed or bent so as to be 
positioned centrally of the diode 72 structure. Simultaneously, the 
electrode pin 74 enters a slot 198 as shown in FIGS. 13 and 14. Slot 198 
communicates with a ramp shown in FIG. 13 at 200. When this insertion is 
completed, the die 184 is rotated by motor 190 and the ramp 200-slot 198 
combination serves to form the circular spring support base 80 as shown in 
FIG. 6 in the course of 360.degree. of revolution. 
Referring to FIG. 15, an assembly jig for attaching springs 86 and 94 to 
the LED 72 structure revealed in FIG. 6 is shown. The assembly jig 210 
includes a base 212 having a clamping mechanism represented generally at 
214 fixed thereto. The mechanism 214 includes an LED receiving block 216 
to which a pivotal clamp bar 218 is attached by pivot connection at pivot 
pin 220. The clamp bar 218 is retained in clamping orientation by a clamp 
retainer 222. LEDs as at 72 and 72' are shown retained by this assembly 
214 and, initially, the capture springs 94 are soldered thereto. Following 
this attachment of the clamping springs, the switching springs as shown at 
86 and 86' are positioned and appropriately located by locating block 224 
and then soldered to spring support bases as at 80. The illuminator 
assembly 70 as shown at FIG. 4 is then completed. 
The illuminator assembly 70 has a myriad of uses in developing illuminated 
implements which are limited only by the imagination of those having 
access to it. For example, in FIG. 16, a small flashlight is revealed at 
230 having a body component 232 extending to a transparent illuminating 
end 234 and having a fixed plug retaining opposite end 236 with a small 
piston like plunger 238 extending therefrom which communicates to the 
rearwardly disposed end of the elongate battery used with the assemblage. 
Thus, the LED as at 72 is stationary and the battery is moved to compress 
the switching spring 86 for this embodiment. Plunge 238 is automatically 
returned by that same spring. 
FIG. 17 shows an ornamental bug 240 having a head 242 formed as part of a 
body component 244 and further incorporating such elements as wings 246 
and 248 and a clasp represented generally at 250. The illuminating end of 
body component 244 is provided as a transparent end 252 which is 
threadably engaged with body component 244 and, in the same manner as the 
dart embodiment herein, upon being screwed in, causes the compression of 
switching spring 86 and the movement of components together to provide an 
illumination in firefly fashion at tip 252. 
FIG. 18 shows a bicycle wheel 260 having a hub 262 and spokes, one of which 
is shown at 264. Upon the spoke 264 there is positioned a small body 
component 266 having an illuminating end 268 and, instead of a plunger as 
at 238 in FIG. 16, a weight is incorporated within the opposite end of 
body component 266, to centrifugally move the battery outwardly and effect 
compression of switching spring 86 and movement into an on or circuit 
completing orientation. 
Looking to FIG. 19, a miniature illuminator of generally cylindrical 
configuration is shown coupled to a fish hook 272. Bait feathering as at 
274 is shown schematically to represent the formation of a lure. The body 
component 270 is provided with a transparent illuminating end 276 and a 
threadably engaged opposite end 278. By threadably securing the tip 278 
within the body component 270, the illuminator assemblage is secured 
against water incursion and is turned on. The degree of miniaturization 
available with the illuminator assembly 70 is revealed by the embodiment 
of FIG. 18. Because no external switching is required of the device, the 
illumination feature can be provided in devices which are immersed. 
Since certain changes may be made in the above-described apparatus and 
method without departing from the scope of the invention herein involved, 
it is intended that all matter contained in the description thereof or 
shown in the accompanying drawings shall be interpreted as illustrative 
and not in a limiting sense.