# Patent

## Title
Weapon mounted light and operation thereof

## Abstract

A novel flashlight assembly that includes an interface integrated into the housing thereof to facilitate mounting of the flashlight to the dovetail rail on a modern combat weapon. The outer body of the flashlight includes a head mounted to a flashlight body at one end and a tapered tail extending outwardly at the other end of the body. Further, the flashlight includes a clamping interface that is a seamless and integrated feature of the outer housing of the flashlight itself for interfacing the flashlight with a firearm. The operational modes of the flashlight are controlled by a single push button and a selector switch. To facilitate a highly compact design the flashlight employs two circuitry arrangements positioned remote from one another and in communication with one another via a single conductive trace to operate at a first signal frequency or a second signal frequency.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 13/309,702, filed Dec. 2, 2011, which is a non-provisional of and claims priority to earlier filed U.S. Provisional Patent Application No. 61/418,944, filed Dec. 2, 2010, the entire contents of which is incorporated herein by reference.


BACKGROUND OF THE INVENTION
The present invention relates generally to a multi-function flashlight assembly that is configured in a manner that includes an integrated weapon mounting interface. More specifically, the present invention relates to a compact, high intensity, multi-purpose flashlight assembly that includes a high level of functionality in connection with an integrated weapon mounting interface, thereby making the flashlight capable of being utilized as an accessory for a variety of devices such as standard military style rail type mount, for example.
In the prior art, flashlights for use in military applications have typically been constructed in a standard fashion utilizing a tubular outer housing. As a consequence, in order to facilitate mounting of the flashlight onto other devices, such as military weapons, a relatively large mounting assembly was required. Usually, the prior art mounting assembly that is used in connection with a flashlight having conventional construction includes a heavy gauge band that is wrapped around the entire outer housing of the flashlight. In addition, these bands include projections from at least one side where a large thumbscrew is positioned to allow a user to tighten the band around the flashlight. The difficulty encountered with this construction is that in some cases it creates a greater opportunity for the flashlight and mounting assembly to be caught on clothing or brush while the firearm is being carried, thereby knocking the flashlight out of alignment, dislodging the flashlight from the firearm or damaging the flashlight. Further, the interface between the outer tubular housing and the mounting band leaves the potential that the flashlight may slide or rotate within the band requiring frequent repositioning. While this may be acceptable for a sport type firearm, it is not acceptable for a firearm employed for field use, such as hunting or combat environments where immediate, fully aligned use of the flashlight assembly is required.
Actuation of a flashlight retained in such a manner on the fire arm required a user to press a button at the rear of the flashlight in an axial manner. Such pressure not only contributes to the displacement of the flashlight within the mounting band but also requires a user to move their thumb in an awkward manner to operate the flashlight.
Other difficulties with such flashlights include the fact that they were typically single function devices that had to be exchanged for a different flashlight should the need for an additional function arise, such as for example, in infra-red applications. In these situations, the user must carry several different lighting devices with them so that, as the need arises, the user can exchange lighting devices. In addition, should a flashlight include multi-functional features, often the controls are small and fussy making them difficult to operate in the typical military environment where the user is often wearing gloves. In these applications small buttons, sliders and knobs are nearly impossible to operate in a reliable fashion.
In view of the foregoing disadvantages inherent in the prior art devices, there is a need for an assembly that provides an improved method of compactly and reliably mounting a flashlight onto a firearm. There is a further need for an interfaceable flashlight assembly that is multi-functional, easy to operate and provides an improved engagement method for firearms that has the ability to consistently and quickly engage, and provide accurate alignment, while providing a reduced profile, thereby reducing potential interference with other devices and attachments. There is a further need for a device that provides multi-functionality in an improved flashlight construction that is easier to operate and exhibits a high degree of reliability even in the most rugged environment.
BRIEF SUMMARY OF THE INVENTION
In this regard, the present invention provides for a novel flashlight assembly that includes an interface integrated into the housing thereof to facilitate mounting of the flashlight to the dovetail rail on a modern combat weapon. Generally, the outer body of the flashlight includes a head mounted to a flashlight body at one end and a tapered tail extending outwardly at the other end of the body. Further, the flashlight includes protrusions extending from the side of the body for interfacing the flashlight with a firearm. It is preferable that the outer housing of the flashlight includes such a clamping interface that is a seamless and integrated feature of the outer housing of the flashlight itself.
The operational modes of the flashlight are controlled by a single push button and a selector switch. To facilitate a highly compact design the flashlight employs two circuitry arrangements positioned remote from one another and in communication with one another via a single conductive trace. The push button consists of a single momentary switch while the selector includes a magnet and a Hall Effect sensor that operate together to toggle between an open and closed position. In this manner the selector switch, when moved between an open and closed position, provides a signal to the circuitry at the rear of the flashlight to operate at a first signal frequency or a second signal frequency.
In addition to using a change in frequency to toggle the selection of light sources, the present invention also provides additional operational modes such as high illumination, low illumination and strobe by way of example.
Accordingly, it is an object of the present invention to provide a flashlight having a housing that includes a mounting interface that is integrated into the construction of its housing that provides an improved method of compactly and reliably mounting a flashlight onto a firearm. It is a further object of the present invention to provide an interfaceable flashlight assembly that is multi-functional, easy to operate and provides an improved engagement method for firearms that has the ability to consistently and quickly engage, and provide accurate alignment, while providing a reduced profile, thereby reducing potential interference with other devices and attachments. It is still a further object of the present invention to provide a device that provides multi-functionality in an improved flashlight construction that is easier to operate and exhibits a high degree of reliability even in the most rugged environment.



BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings which illustrate the best mode presently contemplated for carrying out the present invention:
FIG. 1 is a side view of the flashlight assembly of the present invention;
FIG. 2 is a top view of the flashlight assembly of the present invention;
FIG. 3 is a prior art combat firearm;
FIG. 4 is a front view of the flashlight assembly of the present invention;
FIG. 5 is a cross-sectional view taken along the line 5-5 of FIG. 2;
FIGS. 6 and 6a are cross-sectional views of the flashlight head portion;
FIG. 7 is a perspective view of the internal cartridge of the flashlight;
FIG. 8 is an exploded perspective view of the internal cartridge of the flashlight;
FIG. 9 is a cross-sectional view taken along the line 9-9 of FIG. 2;
FIG. 10 is a side view of the flashlight assembly of the present invention with a safety feature disengaged;
FIG. 11 is a side view of the flashlight assembly of the present invention with a safety feature engaged;
FIG. 12 is a side view of an alternate embodiment of the flashlight assembly of the present invention with a selector in the white mode;
FIG. 13 is a side view of an alternate embodiment of the flashlight assembly of the present invention with a selector in the IR mode; and
FIG. 14 is an alternate embodiment of the present invention wherein an operational switch is shown as a retrofit for an existing weapon mounted flashlight.



DETAILED DESCRIPTION OF THE INVENTION
Now referring to the drawings, a flashlight assembly is shown and generally illustrated in the figures. As can be seen in FIGS. 1 and 2, the flashlight assembly 10 includes an interface 12 integrated into the housing 14 thereof to facilitate mounting of the flashlight 10 to the dovetail rail on a modern combat weapon. Generally, the outer body of the flashlight includes a head 16 mounted to a flashlight housing body at one end and a tapered tail 18 extending outwardly at the other end of the body. Further, the flashlight 10 includes protrusions extending from the side of the body that serve as an integrated interface 12 for interfacing the flashlight 10 with a firearm.
As depicted at FIG. 3, modern type firearms 20 generally include an interface rail integrated 22 thereon for the mounting of auxiliary devices. Additionally, there are several supplemental rail systems that mount onto such firearms 20 and extending along and around the barrel 24 to provide additional interface rails 22 both along the top of the firearm 20 as well as at the 3, 6 and 9 o'clock positions around the barrel 24. All of the interface rails 22 are provided having a standardized profile and are configured specifically for the mounting of various accessories depending on the type environment in which the firearm will be used. The outer housing of the flashlight 10 includes such a clamping interface 12 that is a seamless and integrated feature of the outer housing of the flashlight itself.
As can be seen at FIG. 4, when the flashlight assembly 10 is mounted onto a firearm the lower portion of the clamping interface 12 is a dovetail that may be formed as a rigid profile that is simply slid onto the firearm accessory rail and retained in place using setscrews. In the alternative, the dovetail interface 12 may be formed as a clamping assembly to engage the accessory rail on the firearm. In this configuration, the mounting interface 12 may include a single tightening mechanism that engages both the second clamping arm that engages the flashlight and the rail interface clamp at the same time. Similarly, the mounting interface may have a separate dedicated clamping member for the dovetail interface. The tightening mechanism for both the clamping arm and the dovetail interface may be set screws, thumb screws, quick release type mechanisms, spring loaded clamps or combinations thereof to allow easy mounting and demounting of the flashlight relative to the firearm. Further, a locking mechanism may be provided that serves to prevent accidental disengagement of the flashlight from the rail. In this embodiment such a lock is shown as a screw 26 that extends when rotated to prevent movement of the clamp.
Turning to FIGS. 4-6, within the head portion 16 there is a composite heat sink/reflector assembly 28 to collect and dissipate the waste heat generated during operation of the flashlight. Adjacent a rear surface of the heat sink is positioned a circuit board 30 that includes an array of at least two LEDs positioned thereon. In the preferred embodiment the LEDs include a visible white LED 32 positioned centrally within the reflector and one or more infra-red LEDs 34 positioned adjacent the white LED 32 and at the periphery of the opening in the reflector 28. This arrangement facilitates the use of a dual operational mode such that the output of the LEDs is maximized regardless of the mode in which the flashlight is being operated. In the prior art, vias were created within the surface of the reflector to allow light from ancillary LEDs to emit through the same lens as the light from the primary LED. However, in such an arrangement, the vias created an interruption in the surface of the reflector, causing dark spots in the light output of the primary LED. In the arrangement of the present invention the white LED 32 is positioned such that all of the light emitted therefrom passes above the level of the front of the ancillary LEDs 34 and is captured and projected forward by the reflector (see FIG. 6a). The output from the ancillary infra-red LEDs is captured by the optic on each of the infra-red LEDs 34 themselves and is directed forward in a relatively narrow beam such that the output does not impinge on either the white LED 32 or the reflector 28 surface. It should be appreciated that while in this description the ancillary LEDs 34 are referred to as being infra-red and the primary LED 32 is described as being white, such a description is for illustration purposes and description of a preferred embodiment. It should be understood by one skilled in the art that any arrangement and variation of LEDs and colors could be substituted for the white and infra-red color scheme and still fall within the scope of the present disclosure.
As can best be seen in FIGS. 5-8, a cross section of the flashlight of the present invention is shown. Within the rear portion of the flashlight there can be seen to be a switching mechanism 36 positioned and supported at a tapered angle relative to the central longitudinal axis of the flashlight for selective operation of the flashlight. Generally, the internal operational components of the flashlight are contained and supported on a cartridge insert 38 (shown at FIG. 7) that holds and supports the switching mechanism 36 on an angled die cast platform 40, a sensor circuit 42 to switch operational modes of the flashlight as will be described in detail below, a power source 44 contained within the rear portion of the light and an electrically conductive strap 46 to carry modulated power and an operational signal to the flashlight head for operation thereof.
The operational modes of the flashlight are controlled by a single push button 48 and a selector switch 50. To facilitate a highly compact design the flashlight employs two circuitry arrangements positioned remote from one another and in communication with one another via a single conductive strap 46. The push button 48 consists of a single momentary switch while the selector 50 includes a magnet and a Hall Effect sensor 54 that operate together to toggle between an open and closed position. In this manner the selector switch 50, when moved between an open and closed position, provides a signal to the circuitry at the rear of the flashlight to instruct the flashlight to operate at a first signal frequency or a second signal frequency. That frequency is transmitted from the first circuit board 56, along the single conductive strap 46, along with modulated power to the second circuit board 30 at the head of the flashlight. When the circuit board 30 at the head of the flashlight receives the first frequency signal it operates by illuminating the white LED in accordance with the operational instructions. Similarly, when the circuit board 30 at the head of the flashlight receives the second frequency signal it operates by illuminating the infra-red LEDs in accordance with the operating instructions. It is of note that when moving the selector switch 50 the flashlight includes an instruction to power off the LEDs until a new operating instruction is received from the push button. This prevents the accidental switching from infra-red to visible white light simply by bumping the selector switch while the flashlight is in an on mode.
In addition to using a change in frequency to toggle the selection of light sources, the present invention also provides additional operational modes such as high illumination, low illumination and strobe by way of example. These modes are known in the art and do not require further illustration herein. However, many users have a preference as to the manner in which the various operational modes are presented or arranged. For example, some users do not want a strobe function. The present invention allows the toggling on or off of various modes to allow customization of the flashlight operational modes. For example, if the user places the flashlight into strobe mode and then fully de-powers the light (by partially removing the flashlight head), holding the rear push button as the light is powered up will cause the strobe mode to be dropped from the operational modes menu. If the flashlight is again fully de-powered and the push button is held while the light is powered up, strobe functionality will again be toggled on. Similarly, other functions may be toggled on or off or their operation reversed such as making high or low illumination the first menu selection.
As illustrated at FIG. 9, there is a novel manner for the attachment for a selector switch 50 illustrated here as a slide switch used for toggling of the illumination mode of the flashlight. A pin 58 is provided that is mounted into the flashlight perpendicular to the direction of the slide switch motion. The pin 58 has an opening positioned axially therein to receive a spring 60 and ball detent 62. Further the pin 58 includes an opening into which a slide pin 64 is received. The slide pin 64 has detents formed in the outer surface thereof to interact with the ball detent 62 such that at least two positions of the slide pin 58 provide tactile location feedback when the ball 62 engages the detents in the outer surface thereof. A cover is then installed over the slide pin to create an actuator surface for the slide switch 50. In this arrangement all of the wearing surfaces can be formed of metal yet all of the operational forces of the ball detent arrangement are contained so that they only transfer to the slide pin preventing wear of the switch.
Turning now to FIGS. 10 and 11, a safety feature is provided in the form of a bail 66 that is movable between a clear position, illustrated at FIG. 10 and a blocking position, illustrated at FIG. 11. When rotated up into the blocking position, the bail 66 prevents the momentary switch 48 from being accidentally depressed thereby preventing the flashlight from accidentally being energized. When the user wishes to operate the flashlight, the bail 66 can easily be rotated to the clear position to allow normal operation of the flashlight.
As can be seen in FIGS. 12 and 13 an alternate arrangement for a selector switch 150 is shown. In this embodiment, a rotating lever is used instead of a slide switch and also includes a magnet and a Hall Effect sensor that operate together to toggle between an open (depicted at FIG. 12) and closed position (depicted at FIG. 13). In this manner the lever switch 150, when moved between an open and closed position, provides a signal to the circuitry 56 at the rear of the flashlight to operate at a first signal frequency or a second signal frequency. That frequency is transmitted from the first circuit board 56, along the single circuit trace 46, along with modulated power to the second circuit board 30 at the head of the flashlight. When the circuit board 30 at the head of the flashlight receives the first frequency signal it operates by illuminating the white LED in accordance with the operational instructions. Similarly, when the circuit board 30 at the head of the flashlight receives the second frequency signal it operates by illuminating the infra-red LEDs in accordance with the operating instructions.
In another alternate arrangement of the present invention, the push button 48 in the ergonomic arrangement of the present invention is provided at FIG. 14 as a retrofit attachment 118 for an existing weapon mounted flashlight. The details and manner in which the retrofit switch 118 affixes to the existing light will vary from model to model depending on the particular construction of the light being retrofit. However, the present invention provides for a push button operator on an existing light to be removed and exchanged for an operator that is ergonomically shaped as has been discussed herein.
Accordingly, it can be seen that the present invention provides a flashlight having a housing that includes a mounting interface that is integrated into the construction of its housing that provides an improved method of compactly and reliably mounting a flashlight onto a firearm that is multi-functional, easy to operate and provides an improved engagement method for firearms that has the ability to consistently and quickly engage, and provide accurate alignment, while providing a reduced profile, thereby reducing potential interference with other devices and attachments. It can be further seem that the present invention provides a device that includes multi-functionality in an improved flashlight construction that is easier to operate and exhibits a high degree of reliability even in the most rugged environment. For these reasons, the instant invention is believed to represent a significant advancement in the art, which has substantial commercial merit.
While there is shown and described herein certain specific structure embodying the invention, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying inventive concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims.

## Claims

1. A flashlight comprising:
an elongate body having a head portion at one end and an opposing tapered tail portion;
a clamping assembly on a bottom side of said body, said clamping assembly being configured and arranged to releasably clamp said body to a dovetail rail,
said tail portion of said body tapering rearwardly towards a tail end thereof and downwardly from an upper side of said body towards said bottom side of said body, such that said tail end of said tail portion merges with the bottom side of said body and forms an inclined angled surface extending from said bottom side to said top side;
a push-button switch mounted within said inclined angled surface of said tapered tail portion; and
a U-shaped safety bail pivotably mounted to said tapered tail portion of said body,
said safety bail spanning a width of said body and being pivotably movable between a clear position wherein said safety bail is pivoted downwardly toward said bottom side of said body and operation of said push-button switch is unimpeded, and a blocking position wherein said safety bail is rotated upwardly away from said bottom side and a transverse portion thereof spans across said tapered tail portion and over said push-button switch such that operation of said push-button switch is mechanically impeded.

2. The flashlight of claim 1 further comprising a selector switch configured and arranged to control separate operational modes of said flashlight.

3. The flashlight of claim 2 wherein said selector switch is a slide switch.

4. The flashlight of claim 2 wherein said selector switch is a lever.

5. The flashlight of claim 1 wherein said clamping assembly comprises a first dovetail protrusion formed with said body and extending longitudinally along said bottom side of said body, and a second dovetail member mounted to said body in spaced opposing relation to said first dovetail protrusion,
said first dovetail protrusion and said second dovetail member cooperating to engage said dovetail rail,
said clamping assembly further comprising a threaded locking screw extending through said second dovetail member for selective locking engagement with said body.

6. A flashlight comprising:
an elongate body having a head portion at one end and an opposing tapered tail portion;
a clamping assembly on a bottom side of said body,
said tail portion of said body tapering rearwardly towards a tail end thereof and downwardly from an upper side of said body towards said bottom side of said body, such that said tail end of said tail portion merges with the bottom side of said body and forms and inclined angled surface extending from said bottom side to said top side;
a switch mounted within said includes angled surface of said tapered tail portion; and
a U-shaped safety bail pivotably mounted to said tapered tail portion of said body,
said safety bail spanning a width of said body and being pivotably movable between a clear position wherein said safety bail is pivoted downwardly toward said bottom side of said body and operation of said switch is unimpeded, and a blocking position wherein said safety bail is rotated upwardly away from said bottom side and a transverse portion thereof spans across said tapered tail portion and over said switch such that operation of said switch is mechanically impeded.

7. The flashlight of claim 6 further comprising a selector switch configured and arranged to control separate operational modes of said flashlight.

8. The flashlight of claim 7 wherein said selector switch is a slide switch.

9. The flashlight of claim 7 wherein said selector switch is a lever.

10. The flashlight of claim 6 wherein said clamping assembly comprises a first dovetail protrusion formed with said body and extending longitudinally along said bottom side of said body, and a second dovetail member mounted to said body in spaced opposing relation to said first dovetail protrusion,
said first dovetail protrusion and said second dovetail member cooperating to engage said dovetail rail,
said clamping assembly further comprising a threaded locking screw extending through said second dovetail member for selective locking engagement with said body.

11. A flashlight comprising:
an elongate body having a head portion at one end and an opposing tapered tail portion;
a clamping assembly on a bottom side of said body,
said tail portion of said body tapering rearwardly towards a tail end thereof and downwardly from an upper side of said body towards said bottom side of said body, such that said tail end of said tail portion merges with the bottom side of said body and forms an inclined angled surface extending from said bottom side to said top side;
a switch mounted within said inclined angled surface of said tapered tail portion, said switch being mounted on an angled platform of an insert body received within said tail portion.

12. The flashlight of claim 11 further comprising:
a U-shaped safety bail pivotably mounted to said tapered tail portion of said body,
said safety bail spanning a width of said body and being pivotably movable between a clear position wherein said safety bail is pivoted downwardly toward said bottom side of said body and operation of said switch is unimpeded, and a blocking position wherein said safety bail is rotated upwardly away from said bottom side and a transverse portion thereof spans across said tapered tail portion and over said switch such that operation of said switch is mechanically impeded.

13. The flashlight of claim 12 wherein said clamping assembly comprises a first dovetail protrusion formed with said body and extending longitudinally along said bottom side of said body, and a second dovetail member mounted to said body in spaced opposing relation to said first dovetail protrusion,
said first dovetail protrusion and said second dovetail member cooperating to engage said dovetail rail,
said clamping assembly further comprising a threaded locking screw extending through said second dovetail member for selective locking engagement with said body.

14. The flashlight of claim 11 wherein said clamping assembly comprises a first dovetail protrusion formed with said body and extending longitudinally along said bottom side of said body, and a second dovetail member mounted to said body in spaced opposing relation to said first dovetail protrusion,
said first dovetail protrusion and said second dovetail member cooperating to engage said dovetail rail,
said clamping assembly further comprising a threaded locking screw extending through said second dovetail member for selective locking engagement with said body.