Abstract:
A novel construction and method for manufacturing a flashlight housing is provided. The housing includes two interior compartments wherein a lighting assembly is installed into a first compartment and a power supply is installed into a second compartment. The lighting assembly includes two contacts that extend from the first compartment into the second compartment and are in electrical communication with the power source thereby providing power for the lighting assembly. The housing is configured to include a faceplate that is permanently sealed to the housing to create a positively sealed assembly that prevents infiltration of water or other contaminants into the housing.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     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 divisional of U.S. patent application Ser. No. 10/601,924, filed Jun. 23, 2003 which is a continuation of U.S. patent application Ser. No. 10/308,440, filed Dec. 3, 2002 now U.S. Pat. No. 6,614,336. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to a new method of manufacturing a sealed flashlight assembly. More specifically, this invention relates to an improved method of assembling a flashlight having a rotary switch that includes a battery compartment tangentially mounted to the flashlight head, wherein a circuit board is placed into the head in contact with the battery compartment facilitating the waterproofing of the entire assembly. 
     The prior art provides various types of multiple position rotary switches for use in connection with electrical devices. One example of a prior art multiple position rotary switch may be found in Erickson, et al., U.S. Pat. No. 4,131,771. The Erickson, et al. switch includes a switch body shaped like a wheel attached to the end of a shaft. The wheel is mounted within a housing between a pair of circuit boards. A spring loaded detent in the wall of the housing engages serrations provided along the outer diameter of the wheel in order to provide tactile feed back and retain the wheel in the desired preset positions that operate the switch functions. The top and bottom of the wheel each include a plurality of brushes that contact pads that correspond to circuit traces formed on the circuit boards as the shaft rotates the wheel. During assembly of the switch, after the circuit boards are properly aligned with the wheel sandwiched therebetween, pins in the housing are melted in order to permanently secure the boards in position relative to one another and the wheel orientation. As the wheel is rotated, the brushes align with contact pads on the circuit boards thereby energizing the corresponding circuits. This type of configuration however is comparatively bulky and requires a great deal of space within a compact electronic device. Further, because of the brush style contacts, the potential for failure of the contacts is high. This further results in the need for a housing that can be readily disassembled to service the switch components, providing a number of case joints that require gasketing. 
     Another example of a prior art switch may be found in the Model 77 Multimeter produced by John Fluke Mfg., Co., Inc. of Everett, Wash. The switch utilized in this device comprises a circular non-conductive stationary disk having a plurality of posts mounted on each of its major surfaces. A smaller rotatable disk is provided in the center of the stationary disk. Each side of the rotatable disk includes a pair of contacts that serve to complete connections between the posts located on each side of the stationary disk as the rotational disk is rotated. The posts are electrically connected to the main circuit board of the device and are permanently held in position upon the stationary disk by rivets. Again, the manner is which the device is assembled requires a rotary post to extend through the housing thereby requiring a seal at this dynamic joint. 
     The prior art further provides an electrical device distributed by the Actron Manufacturing Company. The electrical device includes a switch mechanism having a race that is integrally formed into the top cover of the electrical device. The top cover includes an opening through which a portion of the knob of the switch mechanism extends. The race extends around the entire diameter of the opening along the inside surface of the top cover. The knob is retained within the opening by a circuit board that is mounted to the top cover such that a portion of the knob is sandwiched between the circuit board and the race. The circuit board includes both the circuit traces, which serve to electrically interconnect the electrical components mounted upon the board and the switching circuit, which provides the electronic switching functions for the device. The race includes a plurality of spaced arcuate protrusions that form multiple peaks and valleys along the race. The knob comprises a cylindrical disk having on one surface a handle and at the opposite surface a protruding rim. The rim includes a first and second pair of diametrically opposed upstanding platforms. The first platforms are of sufficient size that rotation of the knob, the first pair of platforms glide along the peaks of the protrusions. The second platforms each include a socket for receiving a spring and a ball bearing. The bearing is located on top of the spring such that the ball bearing is sandwiched between the spring and the race. The spring provides a biasing force that retains the bearing against the race such that as the knob is rotated, the bearing aligns itself in the valleys of the race thereby mechanically stabilizing the knob in preselected positions. Between the preselected positions, the bearing is received within the socket so as to allow the bearing to slide over the top or peaks of the protrusions. The knob includes along its opposite end a plurality of wiping members that rotate with the knob and contact the switching circuit thereby selectively closing the switching circuit as the knob is rotated to preselected positions. In this electrical device, again brushes or wipers are included causing constant rubbing of the switching elements during operation of the switch or the changing of the switch orientation. Further, a number of seals are required in the switch housing to allow the switch to be functional while also remaining serviceable. 
     As an attempt to eliminate the need for brushes and to reduce the constant movement of the contact elements within the switch, multifunctional switching in compact spaces is often accomplished using reed switches. To actuate the switch a magnetic force is applied near the switch moving an actuator arm into contact with a secondary contact arm thereby greatly reducing the operational range of movement of the device. These devices however have a significant dimensional component in all three dimensions. In addition, as a function of the way in which they are constructed, a magnetic force applied proximate to the switch from any direction could potentially operate the switch. This is an undesirable feature in flashlight construction where an external magnet in the proximity of the flashlight may cause it to operate or even malfunction. Reed switches are also quite fragile and care must be taken in handling the component when assembling it into the overall flashlight assembly so as not to damage the operation of the device resulting in a defective end product, causing particular difficulties in devices that are permanently sealed during the manufacture process. This problem is amplified where the desired end product requires a multi-function capability, thus requiring several individual reed switches to be installed to create the multifunctional relationship. Finally, because reed switches are complex they are costly to manufacture thus increasing the cost of the end product. 
     There is therefore a need for a simple, compact device that has limited moving components, that is rugged and that is easy to assembly. Further, there is a need for a flashlight assembly wherein the battery can be mounted tangentially to the flashlight head while providing a waterproof assembly with a minimum number of components. 
     BRIEF SUMMARY OF THE INVENTION 
     In this regard, in accordance with the present invention, a novel construction for a multifunctional rotary switching device in a waterproof flashlight housing is provided. The body of the switch includes a radial array of switching contact arms, each arm being connected at one end to a central hub. The switch is preferably stamped from a thin sheet of flexible metallic material having magnetic characteristics. The metallic material has a sufficient thickness dimension that causes the material to have an internal spring bias causing the arms of the switch to remain in a normally flat position, i.e. the arms stay normally aligned with the plane of the central hub. Each of the contact arms of the switch, on the end opposite the hub, may have an increased width dimension (bump or shoulder) to provide an enlarged contact area wherein the switch arm contacts the respective switch circuit traces as shown in the drawings. 
     The switch of the present invention is then installed onto a printed circuit board switching substrate in the preferred embodiment. The central hub of the switch is rigidly connected to the switching substrate and an electrical connection is made thereto, providing a common electrical connection to each of the switching arms. On the switching substrate, at locations that correspond to the contact end of each of the switching arms, is a contact pad that the contact end of each arm comes into contact with in the relaxed, normally closed state. Further, a magnet is installed into a rotatable actuator in close proximity to the surface of the switch of the present invention. The magnetic force of the magnet mounted in the actuator lifts the contact arm of the switch over which the magnet is aligned. In this position, the magnet opens the corresponding contact arm of the switch. 
     A microprocessor device is provided on the switching substrate that periodically samples the electrical contact at each of the contact pads of the switch. Upon the opening of one of the normally closed contacts, the microprocessor senses the open circuit and performs an instruction that corresponds to that contact being open. As can be seen all of the active switch components are completely contained within the housing and do not require physical contact with the actuator to operate. 
     The flashlight housing includes two separate compartments that are located adjacent to one another. The switch compartment is configured to receive the switching substrate. The switching substrate includes two lower contacts that extend downwardly into the switch compartment and through two openings in the bottom wall of the switch compartment. The second compartment is connected adjacent to the bottom wall of the switch compartment. The second compartment houses power supply and two contact cups that provide electrical communication between the battery and contact points adjacent the openings between the compartments. The lower contacts of the switching substrate contact the contact points on the contact cups thereby providing power from the power supply to the switching substrate. 
     A second embodiment of the switch of the present invention provides for a switch that has the contact arms bent at a perpendicular angle to the central hub. This embodiment creates a cup shaped switch configuration that can be installed into the barrel of a cylindrical flashlight handle. 
     Accordingly, one of the objects of the present invention is the provision of a rotatable, multi-function switch that includes a waterproof housing assembly. Another object of the present invention is the provision of a compact, lightweight, low cost rotary switch mechanism with a flashlight mounted tangentially to the battery compartment that can be substantially waterproofed without additional seals or gaskets. Yet another object of the present invention is the provision of a compact rotary, multi-function flashlight device that is easily manufactured and waterproofed from low cost components. 
     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 
     In the drawings which illustrate the best mode presently contemplated for carrying out the present invention: 
     FIG. 1 is a perspective view of a flashlight incorporating the rotary switch of the present invention; 
     FIG. 2 is an exploded perspective view thereof; 
     FIG. 3 is a cross-sectional view along line  3 — 3  of FIG. 2 with the contact element in the normally closed position; 
     FIG. 3 a  is an exploded view of the contact element of FIG. 3; 
     FIG. 4 is a cross-sectional view along line  3 — 3  of FIG. 2 with the contact element in the open position; and 
     FIG. 4 a  is an exploded view of the contact element of FIG.  4 . 
     FIG. 5 is a cross sectional view of an alternative embodiment of the rotary switch of the present invention. 
     FIG. 6 is a schematic block diagram of the electronic components of the invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     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. 
     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. 
     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 . 
     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 . It should be clear that while two openings are disclosed between the upper and lower compartments  20 ,  32 , a single larger opening might also be provided. 
     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 . 
     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. 
     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. 
     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. 
     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 . The faceplate  52  may be attached to the housing  12  in any manner known in the art such as by heat welding, ultrasonic welding or through the use of adhesives. Further, the openings around each of the lighting elements  38  are sealed with a sealant material such as an epoxy potting compound, a clear silicone or any other suitable sealant, 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. 
     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. 
     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.    
     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. 
     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. 
     It can therefore be seen that the present invention provides a rotary switch that has a compact profile, is lightweight and has a reduced number of operable components that allows the switch to be incorporated into a variety of devices. Further, the present invention can be modified to accommodate a number of different configurations to facilitate its incorporation into a broad variety of devices that require multi-functional switching. For these reasons, the instant invention is believed to represent a significant advancement in the art, which has substantial commercial merit. 
     While there is shown and described herein certain specific structure embodying the invention, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying inventive concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims.