Abstract:
A novel attachment and mounting system for a portable handheld flashlight is provided. A universal mounting bracket including a central raised channel portion and mounting tabs connected thereto is configured to slideably receive a flashlight. The bracket includes several configurations that are tailored to the mounting conditions required. For example, the bracket includes fastener, magnetic and strap mounting configurations. Further, the channel section may be mounted in a pivotable fashion to the mounting tab to allow rotation of the flashlight mounted thereto. The flashlight includes a clip on the back thereof that is slideably received in the channel section to facilitate easy mounting and dismounting of the flashlight in the bracket.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application is related to and claims priority from earlier filed U.S. Provisional Patent Application No. 60/338,894, filed Dec. 10, 2001, earlier filed U.S. Provisional Application No. 60/402,172, filed Aug. 9, 2002, and is a continuation-in part of U.S. patent application Ser. No. 10/308,440, filed Dec. 3, 2002. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    The present invention relates to a new mounting system for a portable flashlight. More specifically, this invention relates to a mounting system that allows a flashlight device to be mounted to a universal mounting receiver, which can be incorporated into a variety of assemblies there improving the overall utility of the light.  
           [0003]    Lights have long been attached centrally to a front portion of mining helmets and other types of hard hats used for construction, maintenance, and other working conditions. Firefighter helmets and most other hats and caps, however, require discretionary attachment of lightweight and more adjustable lights. Additionally, many active sports such as cave exploration and off shore sailing require the use of lighted headgear that is light and durable. As a result, lightweight multi-function lights that are heat and water-resistant are particularly significant to people involved in these activities. It is particularly important that these flashlights be adapted to provide usable light in the required direction wile allowing both of the user&#39;s hands to remain free for the required task. In this manner, the light must be light weight and portable while being adaptable for placement in the user&#39;s head gear or for various other mounting configurations as may be required. It is further desirable that the lighting device not be so specialized that it cannot be effectively used for any function other than as a headlamp.  
           [0004]    Numerous innovations for headgear light holders have been provided in the prior art. While these innovations may be suitable for the specific individual purposes that they address, they differ from the present invention in that they do not teach a universal flashlight receptor system that facilitates the interchangeable wear by a user and universal mounting on a surface adjacent to a work area.  
           [0005]    For example, U.S. Pat. No. Des. 353,221 to Scott et al. teaches an ornamental design for a flashlight that is pivotally mounted to the side of the crown of a helmet using existing face shield holes and/or a rubber strap. U.S. Pat. No. 4,998,187 to Herrick teaches a headlight holder that includes an outer generally convex shape that has a base member with an upper surface and a lower surface. The lower surface has a generally concave curvature allowing it to conform to at least a portion of the convex outer surface of the users helmet. U.S. Pat. No. 4,002,895 to Ketler discloses a mounting bracket that is fixed onto a helmet and receives a mating clip on the light body thereby allowing the light to be removably affixed to the helmet. Finally, U.S. Pat. No. 5,853,242 to Bouffay provides a flashlight with a curved handle that is designed to be selectively mounted in a receiver on a helmet. While this flashlight is well suited for use in headgear, it is not well suited for separate use.  
           [0006]    It is apparent that numerous innovations for headgear light holders have been provided in the prior art. While these innovations may be suitable for the specific individual purposes to which they address, they would not be suitable for the purposes of the present invention as heretofore described.  
           [0007]    There is therefore a need for a simple and universal mounting system for selectively and securely receiving a compact flashlight that is rugged and suited for a variety of mounting conditions and configurations. In addition, there is a need for a mounting system that allows a universal flashlight to be incorporated into cost effective alternative to reed switches that provide a compact multifunctional switching solution.  
         BRIEF SUMMARY OF THE INVENTION  
         [0008]    In this regard, in accordance with the present invention, a novel attachment and mounting system for a portable handheld flashlight is provided. The present invention provides for an attachment clip to be fashioned in on the flashlight that allows it to be detachably mounted to a variety of surfaces. The attachment clip is preferably a spring clip provided on the rear of the flashlight as is typically well known in the art. The spring clip is spring biased against the rear of the flashlight and includes a small detent at its free end.  
           [0009]    The clip on the rear of the light works in conjunction with several other components of the system to provide a flashlight mounting system that allows the flashlight to be securely selectibly mounted to a variety of surfaces and utilized in a variety of applications. The mounting components include a wall plate that is rigidly attached to a surface, a magnetic plate for attachment to metallic surfaces and a head gear to allow the light to be worn on the users head. All of the mounting components are configured to receive the clip on the rear of the light and selectibly retain the light in the desired mounting position.  
           [0010]    Accordingly, an object of the present invention is to provide a flashlight mounting bracket system that avoids the disadvantages of the prior art. Another object of the present invention is to provide a flashlight mounting bracket system that is simple and inexpensive to manufacture. Still another object of the present invention is to provide a flashlight mounting bracket system that is interchangeable and is simple to use. Yet another object of the present invention is to provide a flashlight bracket mounting that is specifically designed to receive a flashlight that includes a mounting clip on the rear thereof. Still yet another object of the present invention is to provide a flashlight mounting system that can be attached to a variety of surfaces or to a user&#39;s body for a variety of conditions of flashlight use. Still yet another object of the present invention is to provide a flashlight mounting system that receives and selectibly retains a flashlight with a mounting clip on the rear thereof in an articulateable fashion.  
           [0011]    Other objects, features and advantages of the invention shall become apparent as the description thereof proceeds when considered in connection with the accompanying illustrative drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    In the drawings which illustrate the best mode presently contemplated for carrying out the present invention:  
         [0013]    [0013]FIG. 1 is a perspective view of a flashlight incorporating the rotary switch of the present invention;  
         [0014]    [0014]FIG. 2 is an exploded perspective view thereof;  
         [0015]    [0015]FIG. 3 is a cross-sectional view along line  3 - 3  of FIG. 2 with the contact element in the normally closed position;  
         [0016]    [0016]FIG. 3 a  is an exploded view of the contact element of FIG. 3;  
         [0017]    [0017]FIG. 4 is a cross-sectional view along line  3 - 3  of FIG. 2 with the contact element in the open position;  
         [0018]    [0018]FIG. 4 a  is an exploded view of the contact element of FIG. 4;  
         [0019]    [0019]FIG. 5 is a cross sectional view of an alternative embodiment of the rotary switch of the present invention;  
         [0020]    [0020]FIG. 6 is a schematic block diagram of the electronic components of the invention;  
         [0021]    [0021]FIG. 7 is a perspective view of a wall-mounting bracket for use with the flashlight of the present invention;  
         [0022]    [0022]FIG. 8 is a perspective view of a magnetic mounting bracket therefor;  
         [0023]    [0023]FIG. 9 is a perspective view of headgear mounting bracket therefor;  
         [0024]    [0024]FIG. 10 is a cross-sectional view of the headgear bracket in FIG. 9 in a closed position, taken along the Line  10 - 10 ; and  
         [0025]    [0025]FIG. 10 a  is a cross-sectional view of the headgear bracket in FIG. 9 in a tilted open position, taken along the Line  10 - 10 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0026]    Referring now to the drawings, the preferred embodiment of the rotary switch assembly of the present invention is illustrated and generally indicated in connection with a flashlight  10  in FIGS.  1 - 4   a.  Further, a second embodiment of the rotary switch is also shown in connection with a traditionally shaped linear flashlight  100  in FIG. 5. While specific structure is shown utilizing the switch of the present invention within a flashlight, it should be understood by one skilled in the art that the rotary switch of the present invention has broad application that is not limited to use within flashlights. Specifically, the present invention is directed toward a rotary switch for use in any application where multi-functional switching is required.  
         [0027]    Turning now to FIG. 1 a flashlight  10  incorporating the switch of the present invention is shown. The flashlight  10  includes an outer housing  12  that encloses the operable elements of the flashlight  10  and the switch assembly. The face of the housing  12  includes openings through which the lighting elements protrude and a compartment at the bottom for containing a battery. The bezel of the housing is rotatably mounted to the housing to allow it to operate as an actuator as will be further described below. While a circular array of nine lighting elements is shown in a circular pattern, it can be appreciated that any number of arrangement of lighting elements could be used and still fall within the scope of the present disclosure.  
         [0028]    [0028]FIG. 2 illustrates an exploded perspective view of the flashlight  10  and rotary switch mechanism of the present invention. The key elements of the switch are all shown in their relative positions to one another and include the base  14 , the contact element  16  and the actuator  18 . The operable elements are all assembled and installed into the outer housing  12  to form a completed flashlight  10 . The housing  12  can be seen to have two interior compartments. The lower compartment  20  receives two metallic contact sleeves  22 , 24  that are cylindrically shaped, each having one closed end and shaped to hold a battery  26 . One end of the battery  26  is in electrical communication with one of the contact sleeves  22  and the other end of the battery  26  is in electrical communication with the second contact sleeve  24 . More specifically, the positive terminal of the battery  26  is in contact with the end wall of one contact sleeve  22  thereby making the entire sleeve  22  an extension of the positive terminal of the battery  26  and the negative terminal of the battery  26  is in contact with the end wall of the other contact sleeve  24  thereby making the entire sleeve  24  an extension of the negative terminal of the battery  26 . Once the battery  26  is placed within the compartment  20 , O-rings  28  and a threaded cover  30  are received over the end of the compartment  20  to retain the battery  26  and create a watertight seal over the compartment  20 .  
         [0029]    The base  14  is then received within the second compartment  32  of the housing  12 . The base  14  is preferably formed as a printed circuit board and becomes the central operational element around which the rotary switch of the present invention is built. At the bottom edge of the base  14  are two spring biased electrical contacts  34  that extend downwardly within the housing  32 . Once the flashlight  10  is fully assembled, the spring contacts  34  pass through two openings provided between the upper compartment  32  and the lower compartment  20  and in are in electrical communication with the two metallic contact sleeves  22 , 24  within the lower compartment  20  of the housing  12 . In this manner, energy from the battery  26  travels from the battery  26  through each of the contact sleeves  22 , 24  respectively and into the base  14  through the electrical contacts  34  thereby providing positive and negative power from the battery  26  to the components installed on the base  14 .  
         [0030]    The base  14  is preferably formed as a printed circuit board and configured to support the electronics  36 , lighting elements  38  and contact pads  40  required to make the flashlight  10  operable. The key elements of the base  14  include the contact springs  34  that draw power from the battery  26 , the circuit traces  42  that direct power to the various components mounted thereon, the contact element pads  40  and the control circuitry  36  as will be more fully described below. The circuit traces  42  on the base  14  include small contact pads  40  that are distributed in an array over the face of the base  14 . The contact pads  40  are simply exposed areas in the trace  42  where another contact can be selectively brought into or out of electrical communication with the contact pad  40 . The contact pads  40  also may further include a small bead of solder to create a contact pad  40  that is slightly raised from the surface of the face of the base  14 .  
         [0031]    The objects to be controlled by the switch of the present invention are also connected to the base  14 . In the case of the flashlight  10  of the preferred embodiment, an array of lighting elements  38  to be controlled by the switch of the present invention are mounted directly onto the base  14  with their respective leads in electrical communication with the circuit traces  42  also formed thereon. The lighting elements  38  incorporated into the present invention are preferably light emitting diodes (LEDs), however, it should be understood that because of their identical shape, configuration and form factor, conventional filament type miniature lamps could be interchangeably substituted for the LEDs. Further, while a circular array of lighting elements  38  and contact pads  40  is shown, the disclosure of the present invention is also intended to include any array of lighting elements  38  and contact pads  40  including but not limited to square, rectangular, cylindrical and/or linear.  
         [0032]    The contact element  16  is also mounted onto the base  14 . The contact element  16  generally has a common hub portion  44  with a radial array of contact arms  46  extending therefrom. The contact arms  46  are all connected to and in common electrical communication with the hub  44 . Each of the contact arms  46  may include an area  48  at its free end having an increased dimension to create an enlarged contact surface. This enlarged area  48  is shown as a circular pad at the end of each contact arm  46 . While this feature is helpful to overcome manufacturing tolerances, it is not a required element of the present invention. Similarly, the end of each contact arm may include a small punched dimple  50  to further enhance the contact between the contact arm  46  and the contact pads  40  on the base  14 . If provided, the dimple  50  comes into contact with the switching contact pad  40  before the arm  46  reaches a completely relaxed normal state. Due to the dimple  50  holding the arm  46  in a slightly elevated position, the spring bias in the arm  46  increases the contact force between the dimple  50  and the contact pad  40  providing improved electrical contact. The contact element  16  is preferably formed as a single piece being stamped from a thin sheet of metallic, electrically conductive material. Further, it is preferable, that the metallic material has resilient properties to provide each of the contact arms  46  with a natural spring bias. It is also important that the material selected be of a ferro-magnetic type material to allow the contact arms  46  to be deflected by a magnet as will be described below. While not required, after the contact element  16  is stamped from a ferro-magnetic material, it may be further plated with a more highly conductive material to enhance its functioning within the switch of the present invention.  
         [0033]    The contact element  16  is mounted to the base  14  by fastening the hub  44  onto the face of the base  14 . In this manner, the hub  44  is placed into electrical communication with a circuit trace  42  on the base  14  providing a common electrical connection to the hub  44  and each of the fixed ends of the contact arms  46 . When installed in this position, with the hub  48  fastened directly to the face of the base  14 , the contact ends  48  of the contact arms  46  rest on the contact elements  40  and are slightly deflected from their normal relaxed plane, thereby causing the spring bias in the contact arm  46  to maintain a firm, normally closed position at each of the contact arm  46 —contact element  40  interfaces.  
         [0034]    Once the fully assembled base  14  is installed into the second compartment  32  of the housing, a faceplate  52  is installed with openings through which the lighting elements  38  protrude. The faceplate  52  is sealed onto the housing  12  and the openings around each of the lighting elements  38  are sealed creating a waterproof flashlight housing  12 . Finally, a bezel  18  is rotatably installed and retained in place by a central hub  54 . The rotatable bezel  18  includes a spring loaded ball detent  56  and a magnet  58  installed in the back thereof. The ball detent  56  engages grooves  60  provided in the faceplate  52  to provide tactile feedback to the user of the light when rotating the flashlight bezel  18 . The tactile feedback notifies the operator that the bezel  18  is in one of the several operational positions and serves to retain the bezel  18  in the desired position until intentionally moved by the operator.  
         [0035]    Turning now to FIGS.  3 - 4   a.  The flashlight of the present invention is shown in cross-section to illustrate the functioning of the switch. In this view, it can be seen that the bezel  18  serves as an actuator for the flashlight  10 . This actuator function is accomplished by the small magnet  58  mounted therein. As can best be seen in FIGS. 3 and 3 a  the switch is shown in the normally closed position. The contact arm  46  is in the relaxed state where the contact end  48  of the arm  46  is in firm contact with the contact pad  40  on the base  14 . The cross-sectional view of the bezel  18  shows that the magnet  58  is not in a position above the contact arm  46 . FIGS. 4 and 4 a  show the bezel  18  rotated into a position where the magnet  58  is positioned above the contact arm  46  in an operable position. Because the contact arms  46  are formed from a ferro-magnetic material, with the magnet  58  in the position shown, the magnetic force attracts the particular contact arm  46  located directly beneath the magnet  58 , lifting it from the contact pad  40  on the switch body  14  thereby opening that particular circuit. When the bezel  18  is again rotated and the magnet  58  is moved to the next position, the spring bias in the contact arm  46  causes it to return to its relaxed, normally closed position.  
         [0036]    Referring to FIG. 6, the present invention further provides electronic control circuitry  36  on the base  14  that is in electrical communication with the battery  26 , the lighting elements  38  divided into three color groups of red  38   a,  yellow  38   b  and white  38   c,  the contact elements  40   a - 40   h  and the switching element  16 . The control circuitry  36  monitors the status of each of the switching positions  40   a - 40   h  on the base  14  to determine which switch positions  40   a - 40   h  are closed and which single switch position  40   a - 40   h  is open. The control circuit  36  has programming that includes a discrete set of instructions that corresponds to each of the possible switching configurations and uses the instruction set corresponding to each particular switch position to illuminate the lighting elements  38  in a particular manner or pattern. For example, the first position  40   a  has an instruction set that provides an off position where all non-control functions of the light  10  are de-energized. Other positions include illumination of a discrete number of the lighting elements  38  to provide a high  40   b  and low  40   b  illumination of the white lighting elements  38   c.  Further, the instructions included with other positions of the switch include programming that provides a blinking SOS pattern  40   d  of the white lights  38   c,  red light only  38   a,  red/yellow flash  40   f  where the control circuit  36  cycles an alternating red light  38   a,  yellow light  38   b  flashing pattern, a red/yellow/white flash  40   g  and a white light  38   c  strobe pattern  40   h.    
         [0037]    Now turning to FIG. 5, a second embodiment of the rotary switch of the present invention is shown. In this embodiment, the switch is again shown in connection with a flashlight  100 , however the flashlight  100  is of a more traditional tubular configuration. As described above, the present invention includes an outer housing  102 , a base  104 , a contact element  106 , contact pads  108 , lighting elements  110 , control circuitry  112 , a rotatable actuator  114  that includes a magnet  116  and batteries  118 . While all of the functional elements remain the same, the relationship between the functional elements is slightly varied. In this case, the base  14  is formed in a cylinder having a cylindrical outer surface. The contact pads  108  are arranged in a circular pattern or array around the circumference of the cylindrical outer surface. The hub  122  of the contact element  116  is mounted to the top end of the base  104  and the contact arms  120  of the contact element  116  are bent to a position that is substantially perpendicular to the hub  122 . The contact arms  120  are spring biased inwardly where a cylindrical contact element  124  is placed having the contact element pads  108  thereon in locations that correspond to the contact arms  120 . As can be seen in FIG. 5 the actuator  114  is provided as a ring that is rotatable around the outer housing  102  of the flashlight  100  and includes a magnet  116  mounted therein for opening the contact arm  120  located directly thereunder. In this manner, the switch operates exactly as described above. The magnet  116  lifts one contact arm  120  creating an open circuit. When the circuit opens, the control circuitry  112  performs the instructions that correspond to that discrete circuit location. When the magnet  116  is again rotated, that particular contact arm  120  is released closing the circuit at that location.  
         [0038]    Alternately, the hub of the switch element may be rigidly connected to the base and the contact element pads may be provided on a flexible circuit tape structure that is placed on the interior of the flashlight barrel. In this configuration, each of the discrete switches would be spring biased to a normally open position. The magnet is installed in the rotatable sleeve on the exterior of the flashlight, allowing the user to selectably rotate the sleeve thus changing the contact configuration of the contact arms to a closed position. It should be understood that while a circular and cylindrical array is shown and illustrated herein, any desired switching configuration could be achieved. For example, a linear switch could also be provided where the hub is linear and the contact arms extend outwardly along one side. The actuator would then be slideably mounted above the switch element. Once assembled in this manner, it can be seen that the switch would then operate as described above.  
         [0039]    Turning to FIG. 7, one embodiment of a wall-mounting bracket  200  of the present invention is shown. A plate  202  is provided, that is preferably formed from a molded plastic material although is could also be formed of any suitable material such as a stamped or cast metal. The plate  202  has a central portion  204 , which projects forward relative to the plane of the plate  202 . The central portion  204  is configured to receive the flashlight  10  in a mated fashion. The plate  202  is mounted to a surface where the flashlight  10  is desired to be placed by installing fasteners  205  such as screws or by using an adhesive material. In this manner, the plate  202  is rigidly connected to the desired mounting surface. Once, the plate  202  is in stalled in the desired location, the flashlight  10  can be installed onto the plate  202 .  
         [0040]    To facilitate mounting onto the plate  202 , the flashlight  10  includes a clip  206  mounted to the rear of the flashlight  10  housing  12 . The clip  206  is preferably a metallic material that is rigidly attached to the housing  12  as one end. The clip  206  could also be formed from a plastic material and could be formed integrally as a component of the housing  12  and still fall within the scope of this disclosure. The opposite end of the clip  206  is spring biased against the housing  12  to assist in holding the flashlight  10  in the position where it is placed. Specifically, the flashlight  10  is installed onto to the plate  202  by sliding the clip  206  on the back of the flashlight  10  housing  12  behind the central portion  204  of the plate  202 . When fully installed onto the mounting bracket  200 , the detent  208  on the free end of the clip  206  is extended below a bottom edge of the plate  202  thereby holding the flashlight  10  firmly in place on the mounting bracket  200 .  
         [0041]    Turning now to FIG. 8, the mounting bracket  200  is shown installed in conjunction with a magnet  210 . The plate  202  of the mounting bracket  200  is adhered to the magnet  210  as described above. The use of the magnet  210  in conjunction with the mounting bracket  200  allows the mounting bracket  200  to be temporarily installed onto any ferro-magnetic surface to assist in placement and direction of the light output from the flashlight  10 . For example, should the light output from the flashlight  10  be needed when the user is working on repairing an automobile, the magnet  210  allows the mounting bracket  200  to be placed on the interior of the vehicle&#39;s engine compartment thereby directing illumination onto the area requiring repair will allowing the user two free hands with which to effect the repair.  
         [0042]    Turning now to FIG. 9, another embodiment of the mounting bracket  300  is shown. Again, a plate  302  is provided. However, in this embodiment the plate  302  is configured to receive a mounting strap  304 . The mounting strap  304  is attached to the plate  302 , allowing the plate  302  to be attached to a variety of objects. In particular, the mounting strap  304  can serve as a headband allowing the mounting bracket  300  to be worn on the head of a user. Alternatively, the strap  304  could also be worn around other body parts such as on the user&#39;s arm thereby placing the mounting bracket  300  in the most desirable location for the user. The mounting bracket  300  of this embodiment also includes a raised central portion  306  that is a separate component, which is attached to the mounting bracket  300  in a pivotable fashion. A fastener  308  is provided to attach the central portion  306  to the plate  302 , while allowing the central portion  306  to be articulated relative to the plate  302  around the axis of the fastener  308 . As can be best seen in FIGS. 10 and 10 a,  the clip  206  on the flashlight  10  is received behind the central portion  306  of the bracket  300 . When the flashlight  10  is mounted in this manner, articulation of the central portion  306  relative to the mounting plate  302  allows the flashlight  10  to be tilted relative to the surface to which the bracket  300  is mounted. A further feature is that when the central portion  306  is rotated, the detent  208  on the bottom of the clip  206  is captured beneath the plate  302  preventing the light from being accidentally dislodged from the mounting bracket  300 . It should also be evident that the mounting plate  200  shown in FIGS. 7 and 8 above could also be fabricated using the articulating assembly shown in FIG. 9 and still fall within the scope of this disclosure.  
         [0043]    It can therefore be seen that the present invention provides a universal flashlight mounting assembly for use with a flashlight device. Further, the present invention can be modified to accommodate a number of different configurations to facilitate its incorporation with a broad variety mounting conditions where illumination by a portable flashlight may be required. For these reasons, the instant invention is believed to represent a significant advancement in the art, which has substantial commercial merit.  
         [0044]    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.