Abstract:
The present invention provides a flashlight having two switches, an on-off switch and an intermittent switch. The on-off switch allows the flashlight to be placed in either the on position or the off position. The intermittent switch allows the flashlight to be in the on position only when the switch is depressed and manually held down by the user. The presence of both switches provides the user with the flexibility of using the flashlight in either the on/off mode or the intermittent mode.

Description:
FIELD OF THE INVENTION 
     This invention relates to flashlights and, more particularly, to flashlights having switches to control the operation of the flashlight lamp. 
     BACKGROUND OF THE INVENTION 
     Commercially available flashlights utilize a variety of switches to control the operation of the flashlight lamp. One type of switch is the push button on/off or latching switch that can be activated to open and close a circuit. To operate such a switch, the push button is depressed to close the circuit and place the lamp in its “on” position. The push button is then depressed again to open the circuit and place the lamp in its “off” position. The benefit of such a switch is that the lamp remains in the chosen position, either on or off, until the push button is again depressed. Thus, a continuous light beam can be obtained, without having to continually depress the push button. A disadvantage associated with such a switch is that it does not facilitate the intermittent use of the flashlight. 
     Another type of switch is a push button intermittent, or “deadman,” switch, also known as a momentary switch. With such a switch, electrical contact is only maintained when the switch is depressed and manually held down by the user. Upon the release of the button, the electrical circuit is interrupted. Thus, if the flashlight falls from the user&#39;s hand, pressure on the switch is removed, the circuit is broken, and the light beam is extinguished. The use of a flashlight with a “deadman” switch can be extremely important to law enforcement agents in certain tactical situations. For example, if during pursuit of a suspect a police officer becomes injured or incapacitated in such a way as to drop his or her flashlight, the use of a “deadman” switch will cause the light beam of the flashlight to extinguish, preventing the flashlight from illuminating the fallen officer and thus a suspect from ascertaining the officer&#39;s location. 
     Another common use of a “deadman” switch is to permit intermittent use of a flashlight, such as for signalling purposes. One drawback to the “deadman” switch is that a user cannot place the flashlight in the “on” position or the “off” position, when desired. Thus, if an officer wants to investigate an area, he must keep the switch continually depressed to illuminate the area. 
     Flashlights having either an on/off switch or a “deadman” switch provide a user with only one option for controlling the operation of the flashlight lamp. This arrangement is less than ideal in a panic situation during which a user must turn a flashlight either on or off very quickly. During a panic situation, a user oftentimes loses his fine motor skills and thus is incapable of accomplishing tasks that involve much concentration or thought. Left with only gross motor skills, it is difficult for the user to locate and activate that single switch. 
     Further, there is a known flashlight that has a single switch, which is a combination on/off switch and “deadman” switch. When the switch is fully depressed, the switch functions as an on/off switch. However, if the switch is depressed partially, the switch functions as a “deadman” switch. To actuate this flashlight as desired requires the user to employ fine motor skills. As can be readily understood, a user in a panic situation could very easily actuate the flashlight in a manner that was not intended. 
     Thus, there is a need in the art to provide a flashlight having both an on-off switch and an intermittent switch. Such a flashlight has separate and distinct switches having separate and distinct functions at separate and distinct locations. 
     SUMMARY OF THE INVENTION 
     The present invention provides a flashlight having two switches, an on-off switch and an intermittent switch. The on-off switch allows the flashlight to be placed in either the on position or the off position. The intermittent switch allows the flashlight to be in the on position only when the switch is depressed and manually held down by the user. The presence of both switches provides the user with the flexibility of using the flashlight in either the on/off mode or the intermittent mode. 
     The present invention further provides a flashlight having an on-off switch and an intermittent switch in close proximity to one another. In the present invention, the switches are provided on the endcap of the flashlight. Thus, while grabbing the flashlight in the “overhand” position, the user can conveniently activate either switch. 
     In a panic situation, the present invention provides the user with two options for activating the flashlight. Thus, the chances of the user activating the flashlight as desired are doubled as a result of the presence of the two push button switches. 
     Further, the present invention allows the customer to determine the location of the on-off switch and the intermittent switch. Thus, the flashlight can be customized according to the customer&#39;s needs. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a flashlight made in accordance with the present invention. 
     FIG. 2 is cross-sectional view of the endcap of the flashlight shown in FIG. 1, depicting the switch assembly contained therein. 
     FIG. 3 is a top view of the endcap of the flashlight shown in FIG.  1 . 
     FIG. 4 is a cross-sectional view of the endcap taken along line  4 — 4  of FIG.  3 . 
     FIG. 5 is a side view of the endcap of FIG.  3 . 
     FIG. 6 is a cross-sectional view of the endcap taken along line  6 — 6  of FIG.  5 . 
     FIG. 7 is a perspective view of the endcap closure of the flashlight shown in FIG.  1 . 
     FIG. 8 is a cross-sectional view of the endcap closure of FIG.  7 . 
     FIG. 9 is a front axial view of the first circuit board of the present invention. 
     FIG. 10 is a rear axial view of the first circuit board of the present invention. 
     FIG. 11 is a plan view of the second circuit board of the present invention. 
     FIG. 12 is a front axial view of the third circuit board of the present invention. 
     FIG. 13 is a rear axial view of the third circuit board. 
     FIG. 14 depicts part of the electrical circuit of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As used herein, “electrically connected” means connected via an electrically conductive pathway comprising one or more passive components. Thus, when two components are electrically connected, current may be able to flow between them, provided that a voltage having the correct polarity is applied between them. 
     A flashlight made in accordance with the present invention is depicted in FIGS. 1-14. As can be seen in FIG. 1, the flashlight  10  is generally comprised of a flashlight body  20 , a head assembly  30  and a switch assembly  40 . With respect to the details of the flashlight body  20  and the head assembly  30 , U.S. patent application Ser. No. 08/738,858, filed on Oct. 28, 1996 for a “Tactical Flashlight,” is hereby incorporated by reference. U.S. patent application Ser. No. 08/738,858 provides a detailed description of the flashlight body  20  and the head assembly  30  shown in the flashlight of the present invention. Of course, the present invention is in no way limited to the flashlight body and head assembly shown therein and may be adapted for use with any flashlight and head assembly. 
     The switch assembly  40  is depicted in further detail in FIGS. 2-14. As can be seen in FIGS. 2 and 4, the switch assembly  40  includes an endcap  45  having a first end  452 , a second end  454 , a sidewall  455 , and an axial bore  457  extending therethrough, between the first and the second end. The axial bore  457  is provided with internal threading  459  adjacent the first end  452  and internal threading  462  adjacent the second end  454 . The internal threading  459  is intended to mate with threading provided on the flashlight body  20  while the internal threading  462  is to mate with threading provided on an endcap closure  47  (shown in FIG.  7 ). The endcap  45  further includes a countersunk radial bore  465  that accommodates a switch cover, as will be described later in detail. As can be seen in FIG. 4, endcap  45  is provided with a number of internal shoulders, including shoulders  467  and  469  against which circuit board  50  and circuit board  60  respectively abut. Both the endcap  45  and the closure  47  are preferably made of aluminum. 
     Disposed within endcap  45  is a switch circuit assembly  400  which comprises a first circuit board  50 , a second circuit board  55  and a third circuit board  60 . The second circuit board  55  is provided with push button switch  65 , the circuit board  55  and the switch  65  both being electrically connected with the first circuit board  50 . The third circuit board  60  is provided with push button switch  70 , the third circuit board  60  and the switch  70  both being electrically connected with the first circuit board  50 . 
     First circuit board  50  has a first side  501  and a second side  502 . As can be seen from FIGS. 9 and 10, the first circuit board  50  is provided with a plurality of through holes that extend between first side  501  and second side  502 , namely a central hole  504 , two conductive fastener holes  506 ,  508 , two through holes  511 ,  513 , and a slot  516 . Each of the holes  504 - 516  is provided with conductive material along its length, so as to provide an electrically conductive pathway from first side  501  to second side  502 . Threaded inserts (not shown) are provided in holes  506 ,  508 . These inserts, along with the conductive fasteners  85  that will be discussed below, provide the interconnection between circuit board  50  and circuit board  60 . 
     As shown in FIG. 9, first side  501  is provided with a first conductive trace  518  and a second conductive trace  520 . First conductive trace  518  electrically interconnects the through holes  511 ,  513  with the slot  516 . Second conductive trace  520  electrically interconnects the central hole  504  and the conductive fastener holes  506 ,  508 . 
     The second side  502  is provided with the same trace pattern as the first side  501 . As can be seen in FIG. 10, the second side  502  includes a third conductive trace  524  and a fourth conductive trace  526 . Third conductive trace  524  electrically interconnects the through holes  511 ,  513  with the slot  516 . Fourth conductive trace  526  electrically interconnects the central hole  504  and the conductive fastener holes  506 ,  508 . Through holes  511 ,  513  are electrically conductive such that the first conductive trace  518  and the third conductive trace  524  are in electrical contact. 
     Referring back to FIG. 2, an electrically conductive eyelet  52  is fitted into central hole  504  of the first circuit board  50 , and preferably soldered into place, so that eyelet  52  is in good electrical contact with conductive traces  520  and  526 . Eyelet  52  is connected to spring  54 , so that spring  54  is also electrically connected to conductive traces  520  and  526 . Spring  54  is adapted for contact with the negative terminal of a battery (not shown). 
     The second circuit board  55 , which has a first side  551  and a second side  552 , is similarly provided with a number of conductive traces. As can be seen in FIG. 11, the first side  551  of board  55  has a first conductive trace  554 , a second conductive trace  556 , and a third conductive trace  558 . Board  55  also has electrically conductive pin holes  560 - 570  that are aligned about the major axis of board  55 . Pin hole  560  is in electrical contact with first trace  554 , pin hole  562  is in electrical contact with second trace  556 , and pin holes  564 ,  566  are in electrical contact with third trace  558 . 
     Those skilled in the art will understand that the second side  552  (not shown in FIG. 11) of board  55  may be similarly configured as first side  551  to aid in the assembly of the switch circuit assembly  400 . Board  55  further defines a tab  573 , which is disposed to seat in slot  516  of first board  50  to permit the first board  50  to be joined to the second board  55 . When first board  50  is joined with second board  55 , the third conductive trace  524  of the first board  50  is in electrical contact with the first and the second traces  554 ,  556  of the second board  55 , and the fourth trace  526  of the first board  50  is in electrical contact with the third trace  558  of the second board  55 . 
     Referring back to FIG. 2, switch  65  is carried by second board  55 . Switch  65  is of the push-button type that is commercially available from E-Switch, Brooklyn Park, Minn. A suitable type is Model TL-2201 OA, which is a DPDT momentary contact switch. It is typically characterized by very quiet operation due to its size and construction. Switch  65  is provided with an actuator  651 , preferably in the form of a plunger, and six electrical attachment pins  652 - 662  (only pins  652 ,  656 , and  660  are depicted). The pins are disposed for receipt, preferably by soldering, into holes  560 - 570  of second board  55 . In the preferred embodiment, switch  65  is a deadman switch or an intermittent switch. With an intermittent switch, electrical contact is maintained only when the actuator  651  is depressed and manually held down by the user. 
     When switch  65  is attached to board  55 , plunger  651  can be manipulated to establish electrical contact between the first, second, and third conductive traces of the second board  55 . Specifically, when plunger  651  is depressed, an electrical circuit is established between the first, second, and third conductive traces of the second board  55 . As a result, an electrical current applied to spring  54  from the negative terminal of the battery passes through eyelet  52 , to second trace  520  of the first board  50 , to fourth trace  526  of the first board  50 , to the third trace  558  of the second board  55 , to switch  65  via switch attachment pins, out of switch  65  via switch attachment pins, to first and second traces  554 ,  556  of the second board  55 , and to the third trace  524  of the first board  50 . Furthermore, since through holes  511 ,  513  establish electrical contact between the third trace  524  and the first trace  518  of the first board  50 , first trace  518  is also included in the circuit. Because the outer periphery of traces  518  and  524  abut against endcap  45 , the electric circuit is established through the metal sidewall  455  of the endcap  45 , along the flashlight body  20 , and ultimately to one of the light bulb connections in the head assembly  30 . 
     Switch assembly  40  is further provided with switch cover  73 , which protects the switch  65  from moisture and debris. Switch cover  73  is integrally formed of a bowl shaped section  75 , an o-ring  77  disposed about the open end of bowl shaped section  75  and axially aligned therewith. Switch cover  73  may be formed of any flexible electrically insulating material, such as, for example, rubber. The switch cover  73  is disposed within bore  465  and above plunger  651  of switch  65 , such that stem  79  is axially aligned above plunger  651 . Stem  79  functions both to provide support to bowl section  75  and to engage plunger  651  when switch cover  73  is depressed. Thus, switch  65  may be operated by applying pressure through switch cover  73 . 
     The switch circuit assembly  400  further includes a third switch circuit board  60 . The third switch circuit board  60  has a first side  601  and a second side  602 . As can be seen from FIGS. 12 and 13, the third board  60  is provided with a plurality of through holes that extend between first side  601  and second side  602 , namely a central hole  604 , six switch mounting holes  606 - 611 , two conductive fastener holes  613 ,  615 , and four additional holes  618 - 624  whose function will be described below. Each of the holes  604 - 624  is provided with conductive material along its length, so as to provide an electrically conductive pathway from first side  601  to second side  602 . 
     As shown in FIG. 12, first side  601  is provided with a first conductive trace  626 , a second conductive trace  628 , a third conductive trace  630 , a fourth conductive trace  632 , a fifth conductive trace  634 , and a sixth conductive trace  635 . First and sixth conductive traces  626  and  635  are provided along the periphery of the board  60 . Second conductive trace  628  electrically interconnects the conductive fastener holes  613 ,  615  and additional holes  618  and  622 . Third conductive trace  630  electrically interconnects switch mounting holes  606  and  609 , and additional holes  620  and  624 . Fourth conductive trace  632  electrically interconnects switch mounting holes  607  and  610 , and the central hole  604 . Fifth conductive trace  634  electrically interconnects switch mounting holes  608  and  611 . 
     As shown in FIG. 13, second side  602  is provided with a seventh conductive trace  636 , an eighth conductive trace  638 , and a ninth conductive trace  640 . Seventh conductive trace  636  is provided along the periphery of the board  60  and electrically interconnects switch mounting holes  608  and  611 . Eighth conductive trace  638  electrically interconnects switch mounting holes  607  and  610 , and the central hole  604 . Ninth conductive trace  640  electrically interconnects switch mounting holes  606  and  609 , and additional holes  620  and  624 . 
     Wire jumpers  642 ,  644  are provided between additional holes  618  and  620 , and between additional holes  622  and  624 . The function of these jumpers is to electrically interconnect second trace  628  with third trace  630 , and then interconnect the third trace  630  with the ninth trace  640 . 
     As seen in FIGS. 12 and 13, a number of holes (not labelled) are provided along the periphery of both sides  601  and  602 , on traces  626  and  636 . These holes are plated through and function to electrically interconnect traces  626  and  636 . 
     To structurally and electrically interconnect the third board  60  to the first board  50 , the assembly is provided with a set of conductive fasteners  85 . Referring back to FIG. 2, the fasteners  85  extend from the first board  50  to the third board  60 . The threaded fasteners  85  extend through the inserts of holes  506  and  508  of first board  50  and holes  613  and  615  of third board  60 . These fasteners  85  along with the inserts of holes  506  and  508  provide the connection between first board  50  and third board  60 . 
     As can be seen in FIG. 2, switch  70  is mounted on second side  602  of third board  60 . Switch  70  is of the push-button type that is commercially available from E-Switch, Brooklyn Park, Minn. A suitable type is Model TL-2203, which is a DPDT latching contact switch. It is typically characterized by very quiet operation due to its size and construction. Switch  70  is provided with an actuator  701 , preferably in the form of a plunger, six electrical attachment pins  703 - 713  (only pins  703  and  705  are depicted), and a normally open pair of contacts. Pins are disposed for receipt, preferably by soldering, into holes  606 - 611  of third board  60 . In the preferred embodiment, switch  70  is an on/off switch. To operate such a switch, the actuator is depressed to close the circuit and place the lamp in its “on” position. The actuator is then depressed again to open the circuit and place the lamp in its “off” position. 
     As can be seen in FIG. 8, the endcap closure  47  is provided with an axial bore  472  and a switch cover  76 , which protects switch  70  from moisture and debris. Switch cover  76  is made of a flexible electrically insulating material, such as rubber. The switch cover  76  is disposed within bore  472  and then the closure is threaded onto the second end  454  of the endcap  45 . The switch cover  76  is thus positioned adjacent to the actuator  701  of switch  70 . When the cover  76  is depressed, it can, in turn, depress the actuator  701  and actuate the switch  70 . 
     When switch  70  is attached to board  60 , plunger  701  can be manipulated to establish electrical contact between the seventh, eighth, and ninth conductive traces of the third board  60 . Specifically, when plunger  701  is depressed, an electrical circuit is established between the seventh, eighth, and ninth conductive traces of the third board  60 . As a result, an electrical current applied to spring  54  from the negative terminal of the battery passes through eyelet  52 , into second trace  520  of the first board  50 , into fourth trace  526  of the first board  50 , through the conductive fasteners  85 , into the second trace  628  of the third board  60 , through holes  618  and  622  and jumpers  642 ,  644 , into ninth trace  640 , into switch  70  via switch attachment pins, out of switch  70  via switch attachment pins, and into seventh and eighth traces  636 ,  638  of the third board  60 . Traces  626  and  636  connect the metal sidewall  455  of the endcap  45  to the normally open pair of contacts of switch  70 . The plunger  701  of switch  70  connects traces  626  and  636  via conductive fasteners  85  and spring  54  to the negative terminal of the battery. Because the outer periphery of traces  626  and  636  abut against endcap  45 , the electric circuit is established through the metal sidewall  455  of the endcap  45 , along the flashlight body  20 , and ultimately to one of the light bulb connections in the head assembly  30 . 
     For the electrical circuit up to the point where the spring  54  abuts against the battery, reference should be made to U.S. patent application Ser. No. 08/738,858, previously incorporated by reference. The remainder of the circuit is depicted in FIG.  14 . When the plunger of switch  65  is depressed, the electric circuit is completed and electric current flows from the spring  54 , through the switch  65  and into the sidewall  45 . Alternately, when the plunger of switch  70  is depressed, the electric circuit is completed and electric current flows from the spring  54 , through the fastener  85  and the switch  70  and into the sidewall  45 . 
     As is apparent, one advantage to the present invention is that the two switches are independent of one another. Thus, when switch  70  is in its off position, intermittent switch  65  can be used. Similarly, when switch  65  is in its normal off position, switch  70  can be used to place the lamp in the on position. The use of switch  65  does not interfere with the use of switch  70  and vice versa. When switch  70  is in its on position, the actuation of switch  65  is redundant and the lamp remains in the on position. When switch  65  is in its on position, actuating switch  70  is redundant and does not operate to place the lamp in its off position. 
     Another advantage to the present invention is the interchangeability of the switches. In the embodiment discussed above, the on/off switch was provided in the rear of the flashlight while the intermittent switch was provided on the side of the flashlight. Due to customer preference, there may be a need to exchange the location of these two switches. Thus, in an alternate embodiment, the on/off switch may be provided on the side of the flashlight while the intermittent switch is provided in the rear of the flashlight. This alternate embodiment would require placing an intermittent switch on board  60  and an on/off switch on board  55 . From a manufacturer&#39;s perspective, such an alternate embodiment is simply a matter of selecting a different switch and requires no design modifications to the circuit boards. Consequently, providing on/off or intermittent switches at the side or end of the flashlight is a matter of switch selection and does not require any modification or redesign of the circuit boards. Thus, the flashlight can be customized according to the customer&#39;s needs. 
     While the invention has been described in connection with certain embodiments, it should be understood that it is not intended to limit the invention to these particular embodiments. To the contrary, it is intended to cover all alternatives, modifications and equivalents falling within the spirit and scope of the invention.