Combination flashlight reflector and LED conversion module

A combination reflector and LED conversion module for a non-LED flashlight includes a cup-shaped reflector including an interior with a reflective surface, an exterior, an open end, and an end opposite the open end; and one or more LEDs carried by the cup-shaped reflector adjacent the end opposite the open end. The combination reflector and LED conversion module replaces an existing non-LED bulb and reflector of a non-LED flashlight to convert the non-LED flashlight to a LED flashlight.

FIELD OF THE INVENTION

The present invention relates to, in general, to replacement reflectors for flashlights, and, in particular, to replacement combination reflectors and LED conversion modules for flashlights.

BACKGROUND OF THE INVENTION

Over the years many consumers have bought flashlights that do not use LED chips for various reasons (e.g., flashlights purchased before LED's were released, lower price, etc.).

However, LED flashlights offer a brighter light, lower energy consumption, and greater durability. LED flashlights can be quite expensive and consumers that already own a non-LED flashlights might not see the reason for investing money into a new more expensive LED light, even if they would like to have the advantages that the LED flashlights offer.

LED conversion kits have been proposed in the past, but one of the problems with these LED conversion kits is that they do not replace the reflector in the LED flashlight. As a result, the beam emitted from the flashlight is not optimized. Additional problems with LED conversion kits proposed in the past is that they are often very highly priced, are very low powered, sometimes offers less light than the bulbs they replace, do not fit seamlessly into the existing flashlight, and/or require the user to modify existing parts inside the flashlight to be able to fit the new LED module.

Therefore, a need exists for a combination reflector and LED conversion module for a flashlight that will fit seamlessly into non-LED flashlights and replace the existing non-LED bulb. In doing so, a conventional non-LED flashlight is converted into a LED flashlight offering all the advantages of a LED, but at a lower cost and without the need to fully replace an existing flashlight.

SUMMARY OF THE INVENTION

Accordingly, an aspect of the invention involves a combination reflector and LED conversion module that replaces the existing non-LED bulb of a non-LED flashlight to convert the non-LED flashlight to a LED flashlight. The reflector configuration is customized for each flashlight model to both optimize light emission beam from the LED(s) and heat transfer away from the LED(s). The reflector includes an exterior cooling mechanism for transferring heat away from the LED(s). Cooling fins and grooves of the exterior cooling mechanism create an efficient heat sink that transfers heat from the reflector to a flashlight outer shell, allowing heat to escape to the outside and preventing the LED(s) from overheating and failing.

Another aspect of the invention involves a combination reflector and LED conversion module for a non-LED flashlight. The combination reflector and LED conversion module includes a cup-shaped reflector including an interior with a reflective surface, an exterior, an open end, and an end opposite the open end; one or more LEDs carried by the cup-shaped reflector adjacent the end opposite the open end; and a contact electrically coupled to the one or more LEDs. The combination reflector and LED conversion module replaces an existing non-LED bulb and reflector of a non-LED flashlight to convert the non-LED flashlight to a LED flashlight.

One or more implementations of the combination reflector and LED conversion module described immediately above includes one or more of the following: the exterior of the reflector includes an exterior cooling mechanism for transferring heat away from the one or more LEDs; the exterior cooling mechanism includes cooling fins that transfer heat away from the reflector; the exterior cooling fins circumferentially radiate outwardly from the exterior of the reflector; the combination reflector and LED conversion module of claim3further includes grooves disposed between the exterior cooling fins; the combination reflector and LED conversion module includes a LED base adjacent the end opposite the open end and the one or more LEDs carried by the LED base; the combination reflector and LED conversion module includes a foot that the contact is disposed at least partially within; a method of converting a non-LED flashlight to a LED flashlight includes providing a non-LED flashlight including a non-LED bulb and reflector; removing the non-LED bulb and reflector from the non-LED flashlight; replacing the non-LED bulb and reflector with the combination reflector and LED conversion module so as to convert the non-LED flashlight to a LED flashlight; the exterior of the reflector includes an exterior cooling mechanism and the method further includes transferring heat away from the one or more LEDs with the exterior cooling mechanism; and/or the exterior cooling mechanism includes cooling fins that transfer heat away from the reflector and the method further includes transferring heat away from the one or more LEDs with the cooling fins.

Another aspect of the invention involves a combination reflector and LED conversion module for a non-LED flashlight includes a cup-shaped reflector including an interior with a reflective surface, an exterior, an open end, and an end opposite the open end; and one or more LEDs carried by the cup-shaped reflector adjacent the end opposite the open end. The combination reflector and LED conversion module replaces an existing non-LED bulb and reflector of a non-LED flashlight to convert the non-LED flashlight to a LED flashlight.

One or more implementations of the combination reflector and LED conversion module described immediately above includes one or more of the following: a separate connector to couple the one or more LEDs of the combination reflector and LED conversion module to an energy source of the flashlight; the separate connector includes a circular disc shape; the separate connector includes an upper circular surface with a ring-shaped contact; the separate connector includes a lower circular surface with a pair of terminals; the combination reflector and LED conversion module includes a receiving section that fits over the separate connector; the exterior of the reflector includes an exterior cooling mechanism for transferring heat away from the one or more LEDs; the exterior cooling mechanism includes cooling fins that transfer heat away from the reflector; the exterior cooling fins circumferentially radiate outwardly from the exterior of the reflector; and/or the combination reflector and LED conversion module includes grooves disposed between the exterior cooling fins.

A further aspect of the invention involves a method of converting a non-LED flashlight to a LED flashlight, comprising providing a non-LED flashlight including a non-LED bulb and reflector; removing the non-LED bulb and reflector from the non-LED flashlight; replacing the non-LED bulb and reflector with the combination reflector and LED conversion module of the aspect of the invention described immediately above so as to convert the non-LED flashlight to a LED flashlight.

One or more implementations of the method of converting a non-LED flashlight to a LED flashlight described immediately above includes one or more of the following: the exterior of the reflector includes an exterior cooling mechanism, and the method further includes transferring heat away from the one or more LEDs with the exterior cooling mechanism; the exterior cooling mechanism includes cooling fins that transfer heat away from the reflector, and the method further includes transferring heat away from the one or more LEDs with the cooling fins; a separate connector to couple the one or more LEDs of the combination reflector and LED conversion module to an energy source of the flashlight and the combination reflector and LED conversion module including a receiving section that fits over the separate connector, and the method further includes coupling the separate connector to the energy source of the flashlight, fitting the receiving section over the separate connector, and coupling the one or more LEDs to the separate connector; and/or the non-LED flashlight includes an end cap that screws onto and off of a head of the non-LED flashlight, and the method further includes unscrewing the end cap off of the head of the non-LED flashlight prior to removing the non-LED bulb and reflector from the non-LED flashlight and screwing the end cap onto the head of the LED flashlight after replacing the non-LED bulb and reflector with the combination reflector and LED conversion module.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference toFIGS. 1 and 2, an embodiment of a combination reflector and LED conversion module10that replaces the existing non-LED bulb of a non-LED flashlight to convert the non-LED flashlight to a LED flashlight will be described.

The combination reflector and LED conversion module10includes a cup-shaped reflector20with an interior reflective surface30and an exterior cooling mechanism40. The interior reflective surface30includes a highly efficient reflective coating designed specifically for the LED built into the module10to offer most optimal light beam. The exterior cooling mechanism includes outwardly circumferentially radiating cooling fins50and grooves60disposed between the cooling fins50.

One or more light emitting diode (LED(s)) and printed circuit board (PCB(s))70are fixed in a LED base/housing80of the module10. The LED base/housing80holds the LED and PCB in place, assists with heat dispensation/transfer, and acts as a negative terminal. The LED(s) and PCB(s) are created and programmed to make use of the flashlight's existing circuitry and functions. The PCB(s) may be configured to deliver the maximum rated current to the LED(s) for emitting the brightest light. The shape of the LED base80varies with the shape and size of the cavity inside the flashlight the module10is designed to fit. The reflector20extends upwardly from the base80. The cooling fins50also radiate outwardly circumferentially from the LED base80so as to contact the inner surface of the flashlight head to maximize heat dispensation/transfer. The grooves60increase the surface area of the cooling fins50to maximize heat dispensation/transfer. Providing the exterior cooling mechanism40on the exterior of both the reflector20and the base80enlarges the area through which heat can be conducted more efficiently.

A foot or bulb housing fitting90extends downwardly from the LED base80and includes a contact or positive terminal100that extends downwardly from the foot90for electrically coupling the module10with one or more batteries. The foot90is the same size as the base of the bulb it replaces (i.e., fits the existing incandescent bulb housing), allowing the module10to make use of the existing energy source, without any modifications to the flashlight, and keeps the module10in place.

Both the reflector20and the base80are preferably produced from solid conductive materials, preferably aluminum, but, in alternative embodiments, other materials are used. The reflector20and the base80are preferably either machined to or casted into the required shape. The overall shape of the module10varies, depending on the flashlight model that the module10is made to fit in, so that the module fits tightly inside the flashlight. A tight fit inside the flashlight is important for increasing the heat conductivity of the module, optimizing the light beam emission, and reducing the chances of flashlight malfunction or other problems during normal operation of the flashlight.

Customizing the shape of the reflector20for each flashlight model optimizes the light emission beam from the LED70. In current existing LED conversion kits, the existing reflector of the flashlight is used to create the beam. These reflectors are not as efficient as the reflector20because these reflectors are not made to reflect light from the LED(s). Light beam profiles from LED chips and incandescent or halogen lamps are different and require reflectors that are specifically made to focus these beams. As a result, there is no need to alter the existing reflector or purchase a new reflector with the module10.

The reflector20transfers excessive heat away from the LED(s), and the cooling fins50and the grooves60create an efficient heat sink that can move heat away from the LED(s). The shape and size of the cooling fins50and the grooves60vary with the shape and size of the flashlight head the module10fits into. By making sure that the reflector20fits tightly inside the head of the flashlight, the cooling fins50are in constant contact with the flashlight outer shell, allowing heat to escape to the outside. The design of the reflector20and cooling fins50/grooves60optimizes the amount of heat transfer away from the LED(s), preventing the LED(s)70from overheating and failing.

The reflector20and LED base80can be manufactured or molded as one single piece or as separate pieces that are fitted together during the manufacturing process, based on requirements of the particular flashlight the module10will fit into.

With reference toFIG. 3, another embodiment of a combination reflector and LED conversion module105will be described. Like elements to those shown and described with respect to combination reflector and LED conversion module10are identified with like reference numbers and an “a” suffix, and the description of these elements is incorporated herein. The combination reflector and LED conversion module105includes a LED base80aand a foot90amade so that the two pieces80a,90amove independently from each other (e.g., foot90aslidably received in a recess110of base80a). Preferably, the two pieces80a,90awill be spring loaded with spring120there between, allowing the LED base80aand reflector20ato move up and down on top of the foot90a,without losing contact with the battery. This embodiment might be desirable for use with lights that have the ability to vary the light beam output by twisting the flashlight head.

With reference toFIGS. 4 and 5, to convert a non-LED flashlight130(FIG. 4) to a LED flashlight140(FIG. 5), an existing non-LED bulb/reflector/base150of the non-LED flashlight130is removed from a head160of the flashlight130and is replaced with the combination reflector and LED conversion module10in the head160of the flashlight140. Because the foot90is the same size as the base of the bulb it replaces, the module10makes use of the existing energy source (e.g., one or more single-use batteries, one or more rechargeable batteries)170, without any modifications to the flashlight.

With reference toFIGS. 6-11, another embodiment of a combination reflector and LED conversion module200is shown. Like elements to those shown and described with respect to combination reflector and LED conversion module10are identified with like reference numbers and a “b” suffix, and the description of these elements is incorporated herein. The combination reflector and LED conversion module200includes a LED mounting seat210, holes220(for screws holding mounting seat200in place), an upper part230(of LED base80b), a lower part240(of LED base80b,screws onto upper part230), a cavity250(inside LED base80b), a bulb fitting guide260(made to be same size of existing incandescent bulb, holding the module200in place, works in cooperation with foot90b,configuration/size depends on overall flashlight design and might not be required in some models), a cavity270(where incandescent socket of flashlight fits into, some flashlights may require cavity270, some flashlights may not require cavity270, depends on overall flashlight design), floor280(of LED base80b), a cavity290(inside of LED base80b), a cavity300, and a lip310(inside reflector20b,holds the reflector20bin place around the LED70b,lip310may or may not be included in alternative embodiments of module200).

With reference toFIGS. 12-30, another embodiment of a combination reflector and LED conversion module400is shown. Like elements to those shown and described with respect to combination reflector and LED conversion modules10,105,200are identified with like reference numbers and a “c” suffix, and the description of these elements is incorporated herein. As shown inFIG. 20, the combination reflector and LED conversion module400receives a circular disc-shaped connector or connection disc410for coupling the combination reflector and LED conversion module400to the energy source (e.g., one or more disposable batteries or rechargeable batteries) of flashlight130c.The combination reflector and LED conversion module400includes a pair of terminals420in base80c.A receiving section430extends from the base80c.

The circular disc-shaped connector410includes a ring-shaped contact440on an upper circular surface450of disc member460. The disc member460includes a peripheral circular lip470. A pair of terminals480connected to the ring-shaped contact440extend downward from a lower circular surface490through holes in the disc member460.

With reference back toFIG. 20, to convert a non-LED flashlight130cto a LED flashlight130c,an end cap500of the non-LED flashlight130cis unscrewed and removed from head housing495and the existing non-LED bulb/reflector/base of the non-LED flashlight130cis removed from the head160cof the flashlight130c.The circular disc-shaped connector410is inserted in the direction shown into the head160cof the flashlight so that the terminals480extend through holes in the head160cand are coupled to the energy source (e.g., one or more disposable batteries or rechargeable batteries) of the flashlight130c.The combination reflector and LED conversion module400replaces the existing non-LED bulb/reflector/base. The combination reflector and LED conversion module400slides onto the head160cof the flashlight130cso that the receiving section430fits over the circular disc-shaped connector410. When fully inserted, the ring-shaped contact440of the circular disc-shaped connector410contacts the terminals420of the combination reflector and LED conversion module400. The end cap500is then screwed onto the head housing495of the head160cto secure the combination reflector and LED conversion module400in the head160cof the flashlight.

The addition of the separate circular disc-shaped connector410with the combination reflector and LED conversion module400makes the installation procedure for the end user as simple and easy as possible. Compared to a combination reflector and LED conversion module400where the pin terminals480are integrated into and permanently connected to the combination reflector and LED conversion module400, such a module400would make it very difficult to align the pin terminals480with the holes in the flashlight head160c.This is because the cooling fins50chide the pin terminals480, making it difficult for the end user to try blindly insert these pin terminals480into the holes of the flashlight head160c.Another advantage of the circular disc-shaped connector410being separate from the module400is that it makes it much easier to replace the pin terminals480that insert into the holes of the flashlight head socket160cin the event of the end user breaking the pin terminals480when trying to force the pin terminals480into the holes of the flashlight head160cor in the event of wear and tear on the pin terminals480caused by extended use. If the pin terminals480were permanently connected to the module400, the whole module400would need replacing whereas with the separate circular disc-shaped connector410, the lowest cost part of the module400is the only piece that will need replacing.

The above figures may depict exemplary configurations for the invention, which is done to aid in understanding the features and functionality that can be included in the invention. The invention is not restricted to the illustrated architectures or configurations, but can be implemented using a variety of alternative architectures and configurations. Additionally, although the invention is described above in terms of various exemplary embodiments and implementations, it should be understood that the various features and functionality described in one or more of the individual embodiments with which they are described, but instead can be applied, alone or in some combination, to one or more of the other embodiments of the invention, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus the breadth and scope of the present invention, especially in any claims that follow, should not be limited by any of the above-described exemplary embodiments.