Abstract:
Improvements in an emergency switch for an end cap flashlight that allows conducting power to the light source by applying side or rotational force on the end caps of the flashlight. The cap is designed to give faster and more convenient access to light in an emergency, or when needed. The end cap connects to the inner conductor with a castled shape that allows the conductors to be moved in or out alignment to allow or prevent contact. The gasket or washer provides insulation and spacing of the conductors. Side forces on the end cap overcome the spacing of the washer to make electrical contact. The end cap may also support a glass breaking device. The glass breaker is a hardened tip on the end of the cap.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation in part of Utility application Ser. No. 12/395,346 filed on Feb. 27, 2009 which claims the benefit of Provisional 61/141,582 filed Dec. 30, 2008 the entire contents of which is hereby expressly incorporated by reference herein. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
       [0003]    Not Applicable 
       INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
       [0004]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0005]    1. Field of the Invention 
         [0006]    This invention relates to improvements in a flashlight switch. More particularly the switch allows flashlight to turn on with side pressure or rotation of an end cap of the flashlight. 
         [0007]    2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98 
         [0008]    Tail cap switches are limited to very specific grip positions in the hand to gain access to the switch. Also, tail cap switches interfere with placement of a glass breaking device and are not designed to support strike loads Involved in breaking tempered glass. Flashlight switches generally take a number of different types of configurations. In general these three types of configurations are a slide switch, rotational twist and push switches. The push switches can exist on the back or the side of the flashlight. Several products and patents have been. Exemplary examples of patents covering these products are disclosed herein. 
         [0009]    A flashlight with a slide switch include U.S. Pat. No. 7,393,120 issued Jul. 1, 2008 to Kang et al., discloses a flashlight with a combination side mounted slide and push switch. While the patent discloses a flashlight switch mechanism the operator is required to hold the flashlight with a finger over the flashlight to operate the switch. 
         [0010]    Flashlights with rotational twist to turn on the light include U.S. Pat. No. 4,581,686 issued Apr. 8, 1986 to Normal C. Nelson, U.S. Pat. No. 4,905,129 issued Feb. 27, 1990 to Raymond L. Sharrah, U.S. Pat. No. 5,021,934 issued Jun. 4, 1991 to Hsisn-Der Hou and U.S. Pat. No. 5,122,938 issued Jun. 16, 1992 to Michael J. Pastusek disclose flashlights where turning the front or back of the flash light will conduct power from the batteries to the light source. While these provide switching mechanisms for illuminating the light they do not allow for the light to be illuminated with side motion on the ends of the flashlight. 
         [0011]    Flashlights with push switches on the side of the flashlight include U.S. Pat. No. 3,924,166 issued Dec. 2, 1975 to Robert E. Brindley and U.S. Pat. No. 6,814,466 issued Nov. 9, 2004 to Kevin L. Parsons. While these patents disclose switches that operate by pushing on the sides of the body of the flashlight, they do not provide for pushing or tipping horizontally on the end of the flashlight in any direction. 
         [0012]    Flashlights with push switches on the back of the flashlight includes U.S. Pat. No. 5,642,932 issued Jul. 1, 1997 to John Wallace Matthews, U.S. Pat. No. 6,296,371 issued Oct. 2, 2001 to Wen-Chin Shiau, U.S. Pat. No. 6,491,409 issued Dec. 10, 2002 and U.S. Pat. No. 6,886,960 on May 3, 2005 both to Raymond L. Sharrah. Pushing the back of the flashlight requires the operator to press on only the back of the flashlight. While this allows for a method to operate the flashlight it does not allow an operator to turn on the flashlight from a variety of positions. 
         [0013]    What is needed is a flashlight where the flashlight can be temporally activated by side motion or tipping of one end of the flashlight body. Side motion can be easily placed onto the flashlight with a finger or a hand squeeze. 
       BRIEF SUMMARY OF THE INVENTION 
       [0014]    It is an object of the side action flashlight that allows operation of the flashlight by pressing horizontally on the head or tail of the flashlight. The side activation allows an operator to press on any side of the flashlight ends. The pressing creates an angular rotation of the end cap where it makes contact with the body. This function can be incorporated into either the illumination side or the tail side of the flashlight. 
         [0015]    It is an object of the side action flashlight for the bezel of the light output side of the flashlight to have a scalloped or crowned edge. The scalloped edge allows a person to see that the flashlight is on when resting on the top edge of the flashlight. The scalloped top edge also provides a low output of light without requiring an electrical dimming function. 
         [0016]    It is an object of the side action flashlight to have an off, temporal on function and an off function. These functions are selected by positioning the end of the flashlight at various positions. An optional detent can be designed into the components to provide a positive feedback mechanism to the user to determine the position of the end cap. The electrical connection components are configured in wave, scalloped or crowed configuration to provide the functions described. 
         [0017]    It is another object of the side action flashlight for the flashlight to be waterproof. The design of various switches that require movement or twisting for activation of the light the configuration of the switch provides an opening for water intrusion into the flashlight. The electrical insulating O-ring within the flashlight provides both an electrical isolation of the contacts and a waterproof seal to the inside of the flashlight. 
         [0018]    It is still another object of the side action flashlight to include a glass breaker on the end of the flashlight. While the glass breaker does not provide functional operation to the flashlight switch it provides additional function to the flashlight. The proposed switch mechanism is structurally secure enough that repeated use of the glass breaker will not deteriorate the electrical functionality of the switch. 
         [0019]    Various objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         [0020]      FIG. 1  shows a first perspective view of the emergency switch for a tail cap flashlight. 
           [0021]      FIG. 2  shows a second perspective view of the emergency switch for a tail cap flashlight. 
           [0022]      FIG. 3  shows a cross sectional view of the emergency switch components according to a first preferred embodiment. 
           [0023]      FIG. 4  shows a top view of the scalloped components in an off position. 
           [0024]      FIG. 5  shows a top view of the scalloped components in a temporally on position. 
           [0025]      FIG. 6  shows a side view of the inner switch body. 
           [0026]      FIG. 7  shows a cross sectional view of the emergency switch components according to a second preferred embodiment. 
           [0027]      FIG. 8  shows a top view of the switch components. 
           [0028]      FIG. 9  shows a side view of the inner switch body. 
           [0029]      FIG. 10  shows a cross sectional view of another preferred embodiment of the switching mechanism. 
           [0030]      FIG. 11  shows a perspective view of the flashlight with the switch shown in  FIG. 10 . 
           [0031]      FIG. 12  shows an exploded perspective view of the switching components. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0032]    The preferred embodiment and additional embodiments are described in detail with reference to the related drawings. Further embodiments, features and advantages will become apparent from the ensuing description or may be learned by practicing the invention. In the figures, which are not drawn to scale, like reference characters refer to like features throughout the description. The following description of embodiments, even if phrased in terms of what “the Invention does,” is not to be taken in a limiting sense, but is made for the purposes of describing the general principle Invention. The coverage of this patent will be described in the claims. 
         [0033]      FIG. 1  shows a first perspective view of the emergency switch for a tail cap flashlight and  FIG. 2  shows a second perspective view of the emergency switch for a tail cap flashlight. In general the overall size and shape of the flashlight is similar to other flashlights. The elongated body  10  houses the batteries and one end has an illuminating light source  27  that is power by the internal batteries. In the preferred embodiment the housing that surrounds the illumination end of the flashlight has a scalloped or crowned edge  26 . The scalloped edge  26  allows a person to see that the flashlight is on when resting on the illumination edge of the flashlight. The scalloped top edge also provides a dispersed low output of light without requiring an electrical dimming function. 
         [0034]    In the preferred embodiment the end cap provides the switch function, but it is also contemplated that the illumination end of the flashlight can have the switch function disclosed and claimed in this application. One embodiment of a tall cap flashlight allows a variety of grip positions and access to a tail cap switch, while also allows incorporation of a glass breaking device  19  that is capable of supporting strike loads sufficient to break tempered glass, should it be required in an emergency. 
         [0035]    In these figures, a portion of the inner switch body  11  is shown secured to the flashlight body  10 . The O-ring  13  is shown exaggerated in these views to provide a better understanding of its location. The outer switch body  22  with a glass breaker  19  is secured to the inner switch body  11 . The accompanying figures provide greater detail on the structure of the switch components. 
         [0036]      FIG. 3  shows a cross sectional view of the emergency switch components according to a first preferred embodiment. The end cap is threaded  28  onto the body of a flashlight. One terminal of a battery (Not shown) will fit into insulating washer  15  where the contact of the batter will touch the fastener  14 . The fastener  14  threads into the outer switch body or housing  12  being a second conduit. The outer switch body  12  is shown in this figure without a glass breaker. An O-ring  13  insulates and spaces the outer switch housing  12  from the inner switch body or housing  11  being a first conduit. A pin  16  limits rotation of the inner switch body  11  and the outer switch body  12 . In the embodiment shown in  FIG. 7  the pin is replaced with a spring loaded ball that provides detents for the switch positions. 
         [0037]      FIG. 4  shows a top view of the scalloped components in an off position. In the off position the raised inner scallops  31  of the inner switch body  11  are placed out of phase with the raised inner scallops  32  of the outer switch body  12 . When side pressure is applied to the outer switch body  12  the pressure is insufficient to overcome the O-ring  13  (See  FIG. 3 ) and the switch can&#39;t be activated. 
         [0038]      FIG. 5  shows a top view of the scalloped components in a temporally on position. In the on position the raised inner scallops  31  of the inner switch body  11  are placed in phase with the raised inner scallops  32  of the outer switch body  12 . When side pressure is applied to the outer switch body  12  the pressure connects the raised scallop lobes of the switch bodies. 
         [0039]      FIG. 6  shows a side view of the inner switch body  11 . From this side view a raised lobe  31  is shown extending from the inner switch body  11 . The O-ring recess  29  is shown under the extended scallop of lobe  31 . 
         [0040]      FIG. 7  shows a cross sectional view of the emergency switch components according to a first preferred embodiment. The end cap is threaded  28  onto the body of a flashlight. One terminal of a battery (Not shown) will fit into insulating washer  15  where the contact of the batter will touch the fastener  14 . The fastener  14  threads into the outer switch body or housing  12  being a second conduit. The outer switch body  12  is shown in this figure without a glass breaker. A non-conductive washer  13  insulates and spaces the outer switch housing  12  from the inner switch body or housing  11  being a first conduit. A pin  16  limits rotation of the inner switch body  11  and the outer switch body  12 . In the embodiment shown in  FIG. 7  the pin is replaced with a spring loaded ball that provides detents for the switch positions. 
         [0041]      FIG. 8  shows a top view of the scalloped components in an on position. In this on position the inner switch body  11  is in contact  33  with the outer switch body  12 . When side pressure is applied to the outer switch body  12  the pressure is insufficient to overcome the non-conductive insulating washer. 
         [0042]      FIG. 9  shows a side view of the inner switch body  11 . The non-conductive insulating washer recess  29  is shown under the extended inner switch body  11 . 
         [0043]      FIG. 10  shows a cross sectional view of another preferred embodiment of the switching mechanism. In this figure the flashlight body  40  is shown where the body  40  exists on one side of the switch mechanism and the upper flashlight body  50  exists on the other end of the switch mechanism. While this configuration shows the switch mechanism located near the illumination end of the flashlight, the switch mechanism could also be located at the other end of the flashlight body. The switch mechanism has a first inner switch body  42  having or forming a first conductor. The switch mechanism further has a second inner switch body  41  having or forming a second conductor. At least a portion of these two switch bodies are surrounded by an outer switch body  43  being a third conduit. In the preferred embodiment the third conductor  43  is shown and described as a cylindrical ring, it is contemplated that the third conductor can be formed is a sector, or have a non cylindrical shape such as octagonal or ergonomic shape. The preferred embodiment is cylindrical to allow operation of the switch from normal force being applied from any direction on the third conductor  43 . 
         [0044]    The first  42  and said second  41  conductors being adapted to be insulated from each other with an insulator/dielectric  48 . While a separate insulator  48  is shown, working units have been made with anodized surface that provide the insulation. In the preferred embodiment the second inner switch body  41  is electrically connected to the outer switch body  43 . The electrical connection is with a spring  47  and a ball, pin or similar contact  46 . In another contemplated embodiment the second inner switch  41  and the outer switch body  43  is a single integrated unit and can also be formed with the lower flashlight body  40 . 
         [0045]    One or more deformable insulator(s)  44  and  45  at least temporally insulates the first inner switch body  42  from said outer switch body  43  such that when sufficient force or pressure  49  is applied to the outer switch body  43  the sufficient force or pressure  49  will deform the deformable insulator(s)  44  and or  45  whereby allowing the outer switch body  43  to make electrical contact with the first inner switch body  42 . 
         [0046]    In this figure one or more batteries  51  can pass through the center of the switch mechanism. The end of the battery  51  is electrically connected to the illumination element  52  either directly or indirectly. In the preferred embodiment a control circuit  60  is connected between the switch conductors. The control circuit  60  allows for various operations of the illumination device including but not limited to constant on, flashing, Morse code signal(s). The control circuit is commanded based upon holding the switch contact closed or multiple closures of the switch contacts to effect the mode of the control circuit  60 . 
         [0047]      FIG. 11  shows a perspective view of the flashlight with the switch shown in  FIG. 10 . The elongated body  40  houses the batteries and one end has an illuminating light source  27  that is power by the internal batteries the other end of the flashlight includes an optional glass breaker end  22 . In the preferred embodiment the housing that surrounds the illumination end of the flashlight has a scalloped or crowned edge  26 . The scalloped edge  26  allows a person to see that the flashlight is on when resting on the illumination edge of the flashlight. The scalloped top edge also provides a dispersed low output of light without requiring an electrical dimming function. The outer switch body  43  is shown placed near the illumination end  50  of the flashlight to allow an operator to press on the outer switch body from any normal direction to active the flashlight. It is contemplated that the first inner switch body can be integrated with the flashlight body to reduce the number of parts and or simplify the design of the flashlight without detracting from the operation of the switch mechanism. 
         [0048]      FIG. 12  shows an exploded perspective view of the switching components. As depicted in this figure, a switch is composed of six pieces. Three of the pieces can be purpose built and three pieces are pre-manufactured. The two main components are Inner  11  and outer  22  switch bodies. Both of these pieces are preferably hard anodized aluminum or may be made of any material cast, machined, or molded, such as aluminum, steel, brass, zinc, or plastic when appropriate conduits are present. Various plating may be added to enhance conductivity and control oxidation such as, but not limited to, nickel or gold. Pertaining to the switch bodies, a portion of the anodizing is cut away from specific points of the internal peripheries to allow contact at those points to complete circuit. Also one silicone O-ring  13  is used to center bodies and maintain an open circuit. A single fastener  14  centrally located carries voltage from battery to outer switch body  22  and affixes inner and outer switch bodies  11  and  12  together. The insulating washer  14  is insulated from the inner body by purpose built insulting washer  15 . Insulation as mentioned, described as anodized surfaces, may be substituted with other nonconductive materials such as Mylar, phenolic, various coatings and any number of nonconductive substrates. 
         [0049]    In one embodiment, though various materials may be used, fashioned by molding, casting or machining on a lathe to create the major components to the switch, machine turning on a lathe from aluminum is the preferred technique. However, molding in plastic with appropriate incorporated conduits may produce mass production solutions. As depicted in the figure after fashioning switch bodies  11  and  22  from chosen material, by chosen method, O-ring  13  would be installed to inner switch body  11  in appropriate groove. Switch bodies  11  and  22  are then fastened to one and other by a single centrally located threaded fastener  14  which acts as conduit from battery source to outer switch body. Power from a battery  23  in the flashlight body  10  is conducted to the fastener  14 . The bottom of the inner switch body  14  threads  24  or is pressed into the flashlight body  10 . 
         [0050]    A ball bearing  17  is pushed by a spring  18  to provide the switch position. The ball bearing travels in a cam shaped recess  20 . In the cam shaped recess  20  a series of detents  21  identify the position of the switch as no contact, temporal contact and continuous contact to complete an electric circuit. When the outer switch body  22  is further turned on the inner switch body  11 , a continuous contact is made between the outer switch body  12  and the inner switch body  22 . The detents  21  gives the user a better sense of switch position when transitioning between modes. 
         [0051]    In the embodiment shown a glass breaker  19  is inserted into the end of the outer switch body  22 . The top of the outer switch body  22  is formed with a dual angle step  25 . 
         [0052]    One embodiment of a switch, as for a flashlight of the tail cap variety, is affixed threaded to the back of various flashlights by internal or external threaded configurations. The threaded portion  24  of inner switch body  11  is shouldered  30  and when fastened to back of flashlight, creates continuity between Inner switch body and flashlight body at shouldered point of contact. Outer switch body  12  is attached threaded by central fastener  14  which also acts as conduit from battery  23  to carry voltage to outer switch body  12 . The switch can be incorporated with or without a glass breaker  19  in either case access to switch and switch function are Identical. The switch can function with various LED or Incandescent hand held flashlights of the tail Cap variety and is designed to remain in off position until external forces are applied perpendicular to outer switch body or by twisting outer switch body in either direction. 
         [0053]    The lobes or scallops  31  and  32  essentially create positive and negative portions of the switch bodies, while in direct contact along a flat plane, are insulted on that plane and, while centered, maintain uncommon polarities. These flat insulated planes are designed to carry high strike loads perpendicular to insulated planes. The switch bodies being cylindrical have an axis, and while centered maintain uncommon polarities (off position). To complete a circuit, forces of as little as 0.6 kg applied perpendicular to axis of cylindrical switch bodies will displace them from common axis, (though in some applications lower forces may be preferable and in other applications greater actuating forces may be more preferable) the movement along the flat Insulated plane will allow contact at un-insulted Internal peripheries (on position). When displacing force is removed from switch body, the switch bodies will return to common axis and disconnect circuit. To complete the circuit, force may be applied at any point radial perpendicular to outer switch body. 
         [0054]    In one embodiment, when Installed to the back of a flashlight, pressure to the outer switch body by the thumb or while griped In one hand and forcing the side of the outer switch body In the palm of the hand with the fingers of the same hand will close circuit creating (on) position until side pressure is released, at which point switch will return to off position automatically. 
         [0055]    Thus, specific embodiments of an emergency switch for a tail cap flashlight have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.