Abstract:
A portable utility light has a hollow housing formed of releasably joined front and rear housing halves with a lens opening. A plurality of LEDs is mounted in the housing adjacent the lens opening and positioned in rows and columns. A reflector member has a plurality of cone-shaped apertures each receiving one of the LEDs with a facing reflective surface. A transparent lens member is mounted in the lens opening to permit light generated from the LEDs to exit the housing.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]     This application is a continuation-in-part of the co-pending U.S. design patent application Ser. No. 29/______ filed ______, 2004. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The present invention relates generally to illumination devices and, in particular, to an LED utility light.  
         [0003]     Portable lights, which can be manually moved and suspended about a work site to aid a user to obtain the best lighting conditions, are well known. It has been the practice to use incandescent light bulbs, suitably encased in light guards, for this purpose. Such lights are often referred to as trouble lamps, extension lights, work lights, inspection lights, utility lights, and the like, and are commonly employed by mechanics and other workers who require a concentration of light while frequently changing locations. Such a trouble light is shown in the U.S. Pat. No. 4,774,647 to Kovacik et al. Fluorescent lights have several advantages in use as compared with the incandescent bulbs. As an example, for the same wattage fluorescent lights usually provide more light with less glare. In the past, attempts have been made to convert portable lights such as extension lights to fluorescent tubes.  
         [0004]     Light emitting diodes (LEDs) are well known for providing illumination to digital displays and the like. It has become more common for a concentration of LEDs to be utilized for providing illumination. LEDs are particularly advantageous because of their low power consumption per candlepower produced when compared to incandescent light bulbs and, to a lesser degree, to fluorescent light bulbs.  
         [0005]     The art continues to seek improvements. It is desirable to provide a portable light having lower power consumption that also provides sufficient illumination for a work site. It is also desirable to be able to place and orient the portable light in as many locations and positions as possible. It is further desirable to provide a utility light that does not always require the use of an external power supply cord. It is always desirable to provide utility lamps that are lightweight and cost-effective to produce.  
       SUMMARY OF THE INVENTION  
       [0006]     The present invention concerns a portable utility light including: a hollow housing having a lens opening formed therein; a plurality of LEDs disposed in the hollow housing adjacent the lens opening; a reflector member disposed in the housing and having a plurality of apertures of cone-shaped profile formed therein, each of the apertures receiving an associated one of the LEDs; and a transparent lens member mounted in the lens opening permitting light generated from the LEDs to exit the housing. The housing is formed by a front housing half releasably attached to a rear housing half and is generally arcuate in a horizontal plane.  
         [0007]     The LEDs are mounted on a circuit board in rows and columns. The reflector member has a reflective surface facing the lens member. The light includes a battery disposed in the housing and connected to the LEDs by a switch. An electrical plug is mounted to the housing and connected to the battery for connection to an external power source to recharge the battery. The battery is a DC battery and a transformer means is connected to the battery for recharging.  
         [0008]     A hook member is disposed in a recess formed in an exterior surface of the housing and is rotatable between a stored position in the recess and an extended position. The hook member is attached to the housing by a ball and socket connection permitting the hook member to rotate about a longitudinal axis of the hook member.  
         [0009]     A lanyard can be attached to the housing. A pair of handle cushions is attached to opposite sides of the housing. A carrying case is provided for receiving and retaining the light.  
         [0010]     The lens member has a plurality of focusing portions formed thereon facing the LEDs for focusing light generated by said LEDs. In the alternative, the lens member can be flat or have concave portions for generating a flood light effect.  
         [0011]     The LED utility light in accordance with the present invention advantageously provides a portable handheld utility light that does not need to be connected constantly to an external power supply and may be placed and oriented in many locations and positions with the use of the hook member.  
     
    
     DESCRIPTION OF THE DRAWINGS  
       [0012]     The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which:  
         [0013]      FIG. 1  is a perspective view of an LED utility light in accordance with the present invention;  
         [0014]      FIG. 2  is an exploded perspective view of the utility light shown in  FIG. 1 ;  
         [0015]      FIG. 3  is a perspective view of the rear housing half shown in  FIG. 2 ;  
         [0016]      FIG. 4  is a perspective view of the battery retainer shown in  FIG. 2 ;  
         [0017]      FIG. 5  is a front elevation view of the utility light shown in  FIG. 1 ;  
         [0018]      FIG. 6  is a cross-sectional view taken along the line  6 - 6  in  FIG. 5 ;  
         [0019]      FIG. 7  is a cross-sectional view taken along the line  7 - 7  in  FIG. 5 ; and  
         [0020]      FIG. 8  is an electrical schematic of the utility light shown in  FIG. 1 . 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0021]     Referring now to  FIGS. 1-4 , a rechargeable LED utility light in accordance with the present invention is indicated generally at  10 . The utility light  10  includes a horizontally split hollow light housing  12  formed with a rear housing half  14  and a front housing half  16 . When attached, the housing halves  14  and  16  define an upper light portion  18  extending from a hollow lower handle portion  20 . The front housing half  16  has a lens opening  19  formed in the upper light portion  18 . The housing halves  14  and  16  are substantially arcuate in cross section to form the housing  12  with a substantially oval cross section (see  FIG. 7 ). The housing  12  is preferably formed of a lightweight material, such as plastic or the like, as the utility light  10  is contemplated to be both handheld and portable. The rear housing half  14  includes a plurality of strengthening ribs  22  extending across interior walls thereof. A plurality of bosses  24  having a larger diameter portion  26  and a smaller diameter portion  28  extend from an inner surface  30  of the rear housing half  14  for receiving respective fasteners (not shown). The fasteners extend through the bosses  24  from corresponding posts  32  formed in and extending inwardly from an interior surface  17  of the front housing half  16  to secure the halves  14  and  16  together to form the housing  12 , discussed in more detail below. During assembly, the smaller diameter portion  28  of each of the bosses  24  is received by a corresponding aperture  34  formed in an associated one of the posts  32  of the front housing half  16 .  
         [0022]     An exterior surface  36  of the light portion  18  of the rear housing half  14  is formed to define a recess  38  for receiving and storing a hook member  40  therein. The hook member  40  includes a ball portion  42  that is connected to a shank portion  44 . The recess  38  has closed bottom wall  46  at the interior surface  30  of the rear housing half  14 , best seen in  FIG. 2 . The wall  46  interrupts at least a portion of two of the strengthening ribs  22 . The shape of the recess  38  corresponds to the shape of the hook member  40  in plan view. When the hook member  40  is disposed in the recess  38 , the hook member  40  does not extend above the exterior surface  36  of the rear housing half  14 . Adjacent a lower portion of the recess  38  is a sloped surface  36   a  of the exterior surface  36  that provides access to the hook member  40  for improved removal and stowage for the hook member  40 . A plurality of elongated vent openings  37  are formed in the wall of the rear housing half  14 , which provide a flow of cooling air for the electric components disposed in the light housing  12 , discussed in more detail below.  
         [0023]     The ball portion  42  of the hook member  40  cooperates with a hook ball retainer  48  disposed between the housing halves  14  and  16  when the housing  12  is assembled. The hook ball retainer  48  includes a pair of fastener receivers  50  extending from opposing sides of a ball receiver  52 . The fastener receivers  50  are placed between an upper pair of mating bosses  24  and posts  32  of the light portion  18 . The ball receiver  52 , in conjunction with a curved surface  54  defining an upper aperture  56  in the rear housing half  14 , receive the ball portion  42  of the hook member  40 . After the ball portion  40  is snap fit into the aperture  56 , the ball portion  40 , the ball receiver  52  and the curved surface  54  function as a ball and socket connection. As shown in  FIG. 6 , this connection allows the hook member  40  to rotate between the stored position to an extended position as indicated by an arrow  45 . Once out of the recess  38 , the hook member  40  is free to rotate about its longitudinal axis. The hook member  40 , therefore, provides a means for placing and orienting the utility light  10  during use.  
         [0024]     Each of a pair of elongated handle cushions  60  includes a plurality of attachment fingers  62  having a stop portion  64  and a shaft portion  66 . The handle cushions  60  are each attached to the handle portion  20  of the housing  12  by placing the shaft portion  66  of the attachment fingers  62  in corresponding grooves  68  formed between the rear half  14  and the upper half  16  of the housing  12 . The stop portions  64  prevent accidental removal of the cushions  60  from the housing  12  after the housing  12  has been assembled. The handle cushions  60  are each preferably constructed of a soft, easily deflectable material.  
         [0025]     A battery  70  is disposed in a recess formed between the rear half  14  and the front half  16  of the handle portion  20 . The battery  70  is preferably a rechargeable battery, such as a nickel metal hydride battery or similar rechargeable-type battery. The battery  70  is maintained in its position in the recess by a battery retainer  72  (see  FIG. 4 ) disposed on an upper surface thereof. The battery retainer  72  includes a pair of legs  74  each extending downwardly from opposing ends thereof and defining an aperture  76  therein, and a pair of wing portions  78  extending upwardly from the opposing ends. The apertures  76  of the legs  74  each receive a free end of a post  80  extending upwardly from the interior surface  17  of the front housing half  16 . The wing portions  78  extend beyond the outer edges of the battery  70  to provide additional support for the battery  70  when the utility light  10  is assembled.  
         [0026]     The hollow housing  12  defines a space between the rear half  14  and the front half  16  thereof for receiving a plurality of electrical lighting components, including an LED circuit board assembly  82 , a reflector member  84 , a lens member  86 , and a switch  88 . The switch  88  is disposed in an aperture  90  formed in the rear half  14  of the housing  12  and electrically connects power from the battery  70  to the LED circuit board assembly  82 . No power converter for the circuit board assembly  82  is necessary since the battery  70  is a DC power source, advantageously reducing the size and weight of the utility light  10 . The LED circuit board assembly  82  includes a plurality of LEDs  92 , best seen in  FIGS. 6 and 7 , extending from an upper surface  94  thereof. The LEDs  92  are operable to emit light in a well-known manner when electrical power is connected from the battery  70  to the circuit board assembly  82  through the switch  88 . A plug circuit board  87  is disposed between the rear half  14  and the front half  16  of the housing  12  and electrically connects a pin-type electrical plug  89  and the battery  70 . The plug circuit board  87  is preferably attached to a pair of posts  81  extending upwardly from the interior surface  17  of the front housing half  16 . The plug  89  is disposed in an aperture  91  formed between the rear half  14  and the front half  16  of the housing  12 .  
         [0027]     The reflector member  84  is fit over the front surface of the LED circuit board assembly  82 . The reflector member  84  includes a plurality of spaced apart through apertures  85 . The front surface of the reflector member  84  is preferably mirror chrome plated or has a similar highly reflective surface. The number of apertures  85  corresponds to the number of LEDs  92  on the circuit board assembly  82 . The walls of the reflector member  84  that define each of the apertures  85  are also mirror chrome plated and taper radially outwardly from the rear surface of the reflector member  84  to the front surface of the reflector member  84  to form a generally cone-shape profile, best seen in  FIG. 6 . A width, indicated by an arrow  96  in  FIG. 2 , of the reflector member  84  is greater than a width, indicated by an arrow  98 , of the circuit board assembly  82 . A plurality of support legs  100  is formed on the periphery of the reflector member  84 . The support legs  100  extend rearwardly from the rear surface of the reflector member  84  and, because the width  96  is greater than the width  98 , when the reflector member  84  is placed over the circuit board assembly  82  the support legs extend beyond the periphery of the circuit board assembly  82  and rearwardly of the rear surface of the circuit board assembly  82 . The support legs  100  engage with corresponding support pins  102  extending inwardly from outer edges of the support ribs  22  of the lower housing half  14 . A flange  120  extends from opposed upper and lower ends of the reflector member  84 . The flange  120  has an upwardly extending portion  120   a  and an outwardly extending portion  120   b , best seen in  FIG. 6 .  
         [0028]     The lens member  86  is received in the lens opening  19  extending through the upper portion of the front housing half  16  during assembly of the utility light  10 . The lens member  86  is preferably constructed of clear plastic material or similar material. The lens member  86  includes a plurality of posts  104  extending rearwardly therefrom that cooperate with apertures  106  formed in the reflector member  84  and with apertures  108  formed in the circuit board assembly  82  during assembly of the utility light  10 . The lens member  86  includes a flange  122  extending from opposed upper and lower ends thereof. The flange  122  includes a stepped portion  122   a , best seen in  FIG. 6 . A flange  123  extends from opposed ends of the front housing half  16  that define the aperture  102 , best seen in  FIG. 6 , for cooperating with the stepped portions  122   a  during assembly of the utility light  10 .  
         [0029]     As seen in  FIGS. 6 and 7 , the lens member  86  has a plurality of focusing portions  125  that correspond in number and position to the LEDs  92 . Each of the focusing portions  125  is formed as a convex protrusion on the rear surface of the lens member  86  facing the reflector member  84 . The focusing portions  125  collect and focus light from the corresponding LEDs  92  to generate a collective focused beam of light exiting the lens member  86 . However, the rear surface of the lens member  86  could be flat, so that no focusing is provided, or the areas adjacent the LEDs  92  could be formed with concave shapes, so that the light exiting the lens member  86  is dispersed for a flood light effect.  
         [0030]     A lanyard  110  is preferably provided for routing through a hole  114  formed in a flange  112  on a lower portion of the rear housing half  14 . An A/C transformer means  116  is preferably provided for attachment to the electrical plug  89  for recharging the battery  70 . The transformer means  116  connects to a source of standard AC power “120 V”, reduces it to a lower voltage and converts to DC power to operate the LEDs  92 . A carrying case  118  is preferably provided for attachment to a belt loop or the like (not shown) for ease of portability of the utility light  10 .  
         [0031]     During assembly of the utility light  10 , the hook member  40  and the handle cushions  60  are placed in their respective mounting locations. The switch  88  is placed in the aperture  90 , the reflector member  84  is fit over the upper surface  94  of the LED circuit board assembly  82  (placing the LEDs  92  in the respective apertures  85  of the reflector member  84 ), and the support legs  100  are placed on the support pins  102 . The battery retainer  72  is placed on the posts  80  and the battery  70  is placed on the battery retainer  72 . The lens member  86  is placed in the aperture  102 , and the stepped portion  122   a  engages with the flange  123  of the upper housing half  16  to retain the lens member  86  in the aperture  102 . Alternatively, the lens member  86  is placed on the reflector  84  with the stepped portion  122   a  resting on the outwardly extending portion  120   b . The upper housing half  16  is placed on the lower housing half  14 , and a flange  124  on the outer edge of the upper housing half  16  overlaps a corresponding flange  126  on the outer edge of the lower housing half  14 , best seen in  FIG. 5 , and the respective bosses  24  are received and engaged in corresponding posts  32 , best seen in  FIG. 5 . When the halves  14  and  16  are joined, a tongue  128  extending from a rear edge of the housing half  14  cooperates with a groove  130  formed between a pair of flanges  132  extending from a rear edge of the housing half  16 , best seen in  FIG. 7 , to provide ease of alignment of the split halves  14  and  16  during assembly of the light housing  12 . A flange  134  on the outer edge of the upper housing half  16  overlaps a corresponding flange  136  on the outer edge of the lens member  86 , best seen in  FIG. 7 . Fasteners such as screws (not shown) or the like are then placed in each of the engaging bosses  24  and posts  32  and the housing halves  14  and  16  are secured together to form the housing  12 .  
         [0032]     The switch  88  includes a switch housing  88   a  with a pair of electrical terminals (not shown) extending from a lower surface thereof and a switch rocker  88   b  on an upper surface. One of the terminals is connected to the battery  70  through the circuit board  87  and the other of the terminals is connected to the LED circuit board assembly  82 . The switch rocker in the on and off positions alternately provides power from the battery  70  to the LED circuit board assembly  82 . The switch  76  is easily actuated by a thumb or finger of a person (not shown) holding the handle portion  20  to light the LEDs  92  of the circuit board assembly  82  with one hand while also orienting and hanging the light  10  with the same hand.  
         [0033]     An electrical schematic of the utility light  10  is shown in  FIG. 8 . The A/C transformer  116  is provided for a charging connection from an external power source  117  through the transformer  116  to the battery  70 . The electrical power from the battery  70  is directed through the switch  88  to the LED circuit board assembly  82 .  
         [0034]     In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.