Patent Publication Number: US-10775002-B2

Title: Method and apparatus for controlling lighting modules of a multi-element portable light

Description:
PRIORITY CLAIM 
     This application claims priority as a continuation to application Ser. No. 16/384,159 filed on Apr. 15, 2019 and to application Ser. No. 15/916,433 filed on Mar. 9, 2018, and claims benefit of provisional application No. 62/469,788 filed on Mar. 10, 2017; all of which are also entitled “Method and Apparatus for Controlling Lighting Modules of Multi-Element Portable Light” and all of which are incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE TECHNOLOGY 
     This application relates to methods and apparatus for controlling the different light modes of portable lights. Specifically, it relates to switching operations when portable lighting devices are in different physical configurations and a fixed packaging. 
     BACKGROUND 
     The present invention relates generally to Light Emitting Diode (LED) lighting components, lamps, and luminaries or other light sources in various lighting applications, including lights with a forward directing light source and lights with a lateral directing light source. Flashlights having multiple lighting display settings or modes have been previously produced. A limitation with prior art flashlights is that in order to select a desired mode, a user must use two hands to manipulate the flashlight with one supporting the flashlight while the other adjusts an appropriate mode-activation switch, because the switch requires twisting or other manipulation or because multiple switches are utilized that require the user to move between such switches or the switch must be slid along a track to a plurality of different positions. This is particularly bothersome when a lighting device has multiple physical configurations and the user wishes to simplify operations of the device and/or test the device while inside its packaging. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an extendable flashlight in a “closed” configuration in accordance with one aspect of the technology; 
         FIG. 2  is a side view of an extendable flashlight in an “open” configuration in accordance with one aspect of the technology; 
         FIG. 3  as an exploded view of an extendable flashlight in accordance with one aspect of the technology; 
         FIG. 4  is an electrical schematic of a system used in connection with a lighting device in accordance with one aspect of the technology; 
         FIG. 5  is an electrical schematic of a system used in connection with a lighting device in accordance with one aspect of the technology; and 
         FIG. 6  is a view of an extendable flashlight in fixed packaging in accordance with one aspect of the technology. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     Although the following detailed description contains many specifics for the purpose of illustration, a person of ordinary skill in the art will appreciate that many variations and alterations to the following details can be made and are considered to be included herein. Accordingly, the following embodiments are set forth without any loss of generality to, and without imposing limitations upon, any claims set forth. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. 
     As used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a layer” includes a plurality of such layers. 
     In this disclosure, “comprises,” “comprising,” “containing” and “having” and the like can have the meaning ascribed to them in U.S. Patent law and can mean “includes,” “including,” and the like, and are generally interpreted to be open ended terms. The terms “consisting of” or “consists of” are closed terms, and include only the components, structures, steps, or the like specifically listed in conjunction with such terms, as well as that which is in accordance with U.S. Patent law. “Consisting essentially of” or “consists essentially of” have the meaning generally ascribed to them by U.S. Patent law. In particular, such terms are generally closed terms, with the exception of allowing inclusion of additional items, materials, components, steps, or elements, that do not materially affect the basic and novel characteristics or function of the item(s) used in connection therewith. For example, trace elements present in a composition, but not affecting the compositions nature or characteristics would be permissible if present under the “consisting essentially of” language, even though not expressly recited in a list of items following such terminology. When using an open ended term, like “comprising” or “including,” it is understood that direct support should be afforded also to “consisting essentially of” language as well as “consisting of” language as if stated explicitly and vice versa. 
     The terms “first,” “second,” “third,” “fourth,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that any terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Similarly, if a method is described herein as comprising a series of steps, the order of such steps as presented herein is not necessarily the only order in which such steps may be performed, and certain of the stated steps may possibly be omitted and/or certain other steps not described herein may possibly be added to the method. 
     The terms “left,” “right,” “front,” “back,” “top,” “bottom,” “over,” “under,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein. The term “coupled,” as used herein, is defined as directly or indirectly connected in an electrical or nonelectrical manner. Objects described herein as being “adjacent to” each other may be in physical contact with each other, in close proximity to each other, or in the same general region or area as each other, as appropriate for the context in which the phrase is used. Occurrences of the phrase “in one embodiment,” or “in one aspect,” herein do not necessarily all refer to the same embodiment or aspect. 
     As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is “substantially” enclosed would mean that the object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained. The use of “substantially” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. For example, a composition that is “substantially free of” particles would either completely lack particles, or so nearly completely lack particles that the effect would be the same as if it completely lacked particles. In other words, a composition that is “substantially free of” an ingredient or element may still actually contain such item as long as there is no measurable effect thereof. 
     As used herein, the term “about” is used to provide flexibility to a numerical range endpoint by providing that a given value may be “a little above” or “a little below” the endpoint. Unless otherwise stated, use of the term “about” in accordance with a specific number or numerical range should also be understood to provide support for such numerical terms or range without the term “about”. For example, for the sake of convenience and brevity, a numerical range of “about 50 angstroms to about 80 angstroms” should also be understood to provide support for the range of “50 angstroms to 80 angstroms.” 
     As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary. 
     Concentrations, amounts, and other numerical data may be expressed or presented herein in a range format. It is to be understood that such a range format is used merely for convenience and brevity and thus should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. As an illustration, a numerical range of “about 1 to about 5” should be interpreted to include not only the explicitly recited values of about 1 to about 5, but also include individual values and sub-ranges within the indicated range. Thus, included in this numerical range are individual values such as 2, 3, and 4 and sub-ranges such as from 1-3, from 2-4, and from 3-5, etc., as well as 1, 2, 3, 4, and 5, individually. 
     This same principle applies to ranges reciting only one numerical value as a minimum or a maximum. Furthermore, such an interpretation should apply regardless of the breadth of the range or the characteristics being described. 
     Reference throughout this specification to “an example” means that a particular feature, structure, or characteristic described in connection with the example is included in at least one embodiment. Thus, appearances of the phrases “in an example” in various places throughout this specification are not necessarily all referring to the same embodiment. 
     Reference in this specification may be made to devices, structures, systems, or methods that provide “improved” performance. It is to be understood that unless otherwise stated, such “improvement” is a measure of a benefit obtained based on a comparison to devices, structures, systems or methods in the prior art. Furthermore, it is to be understood that the degree of improved performance may vary between disclosed embodiments and that no equality or consistency in the amount, degree, or realization of improved performance is to be assumed as universally applicable. 
     The term “flashlight” as used herein is used as an example of a lighting device that may employ the technology herein but should not be construed as limiting what kinds of lighting devices may employ the current technology. As such, the term flashlight should be broadly construed to include any hand-held lighting device, lanterns, headlamps, and other various devices that function, at least partially, to provide light for the user. 
     An initial overview of the technology is provided below and specific technology embodiments are then described in further detail. This initial summary is intended to aid readers in understanding the technology more quickly, but is not intended to identify key or essential features of the technology, nor is it intended to limit the scope of the claimed subject matter. 
     Broadly speaking, aspects of the current technology improve and make possible the packaging of products with a “TRY ME” feature that permits stepping through different lighting features available on a light product while the light product is in an “open” or “revealed” configuration. That is, certain work lights comprise a multi-position configuration wherein when the light is in a “closed” configuration, the flashlight appears to be a conventional flashlight (or other lighting device). However, the flashlight may be extended about a body of the light (for example) exposing an additional area or lateral light source. When the flashlight is in the closed configuration, the flashlight is configured such that the area light or lateral light cannot be activated thereby unnecessarily draining the flashlight&#39;s batteries. Certain products may use an auto-on feature when the area light or work light is revealed (i.e., the flashlight is in an extended or open configuration), therefore it cannot be packaged and displayed in the revealed orientation or it will consume the installed batteries. This is a limitation that can be overcome by removing the batteries during the packaging process, thus making the flashlight non-functional in the retail environment. In one aspect of the technology, a flashlight product is marketed in a package with a “TRY ME” feature. This means that the product must have the power source installed and active in order for the consumer to activate the light. Aspects of the present invention seek to overcome this problem through the use of electrical switches and a programmable logic control system permitting activation of aspects of the lighting device while in a fixed position inside product packaging. 
     With reference generally to  FIGS. 1-3 , one example of a lighting device that may employ the current technology is disclosed. The flashlight is generally shown at  10 . In  FIG. 1 , the flashlight  10  is shown in a closed position wherein a first housing or shroud  5  comprises a cavity that encloses a first light source  31  therein. The shroud or housing  5  is coupled to a second housing  3  which comprises, for example, a second (forward-directed) light source  30 , a power source, and a plurality of switches controlling the operation of the lights sources  31  and  30  (or other light sources) disposed in flashlight  10 . In the closed configuration, one of the plurality of light sources (in this case the forward-directed light source  30 ) is not covered while the light source  31  is covered. Meaning, the light source  30  is not blocked by an opaque covering while the light source  31  is. In this aspect, the light source that is covered when the flashlight  10  is in a closed configuration is positioned such that when the light source  31  is uncovered it is capable of emitting light in a direction that is lateral or normal to a longitudinal axis of the flashlight. In other aspects of the technology, however, the forward light source  30  may be covered with the flashlight is in a “closed” configuration and the light source  31  may be uncovered when in that same “closed” configuration. 
       FIG. 2  shows the flashlight of  FIG. 1  in an extended or open position wherein the shroud  5  has been extended away from the second housing  3  thereby exposing the light source  31 . The light source  31  is slidably mounted within the cavity of the shroud or housing  5  and is fixedly attached to a second housing  3 . The light source  31  is incorporated into a housing that includes a power source (e.g., batteries) disposed within its interior. The power source is used to provide power to the plurality of light sources, including, in one aspect, the light source  31  as well as the forward-directed light source  30  emanating from the distal end  12  of the flashlight  10 . Each of the plurality of light sources can be activated either together or independently by depressing the button  28 . While a button  28  is specifically referenced, it is understood that any control mechanism may be used to activate the light sources through various switches (discussed further herein) disposed about the lighting device  10 . A second housing  3  contains the forward-directed light source  30  and its attendant components (i.e., lens  16 , LED  30 , etc.). However, in one aspect of the technology the first light source  31  and the second light source may be located in the same housing. In one aspect of the technology, the flashlight  10  is converted from a closed configuration to an open configuration by moving the shroud  5  away from the second housing  3 . However, the flashlight  10  may be converted into an open configuration from a closed configuration by any means whereby a light source that was covered in a first configuration is uncovered in a second configuration. 
     In accordance with one aspect of the technology, the operation of one or more light sources disposed about the flashlight  10  are controlled by switches. For example, in one aspect of the technology, one of the switches is a mechanical reveal switch. In a first position, the switch indicates to the programmable logic control system that the flashlight  10  (or other lighting device) is in a closed position, thus indicating that the non-revealed (or covered) lighting element should not be activated. In a second position, the switch will indicate to the control system that the flashlight  10  is in open (or extended) position, thus indicating that the lighting element ( 30 ,  31 , etc.) is now revealed and may or may not be activated—depending on the activation of either software or logic controlled switches (S 3 ) or the mechanical switch (e.g., S 1 , S 2 ). 
     In one aspect of the technology, the flashlight  10  is packaged in a rigid or semi-rigid plastic package often referred to as a “clam-shell” or “blister” package. The term “rigid” means the package may not be moved without suffering plastic deformation. The term “semi-rigid” means that the package is firm and solid but not inflexible. The rigid or semi-rigid plastic package minimizes in-store theft of lighting products in that it is difficult to remove the lighting products from the packaging in order to hide the light in a pocket or bag. The packaging itself is cumbersome so that it likewise creates a disincentive to would-be thieves. In one aspect of the technology, the flashlight  10  is disposed within the clam-shell or blister package in an at least partially open configuration so that the potential purchaser can see at least a portion of the features of the flashlight  10  when it is in the open configuration. The flashlight  10  is packaged within the clam-shell  40  (or other packaging) in such a manner that the flashlight  10  cannot be placed in the closed configuration without first removing the flashlight  10  from the packaging or breaking the packaging. That is, in one aspect, the packaging  50  in connection with enclosure  40  encases the first housing  5  and second housing  3  in such a manner that two housings ( 3  and  5 ) cannot be substantially moved with respect to the other without first removing the flashlight  10  from the enclosure  40  or breaking the enclosure  40 . While reference is made herein to plastic packaging and clam-shell or blister packaging, it is understood that other packaging may be used to accomplish the object of the current technology. For example, the package may comprise cardboard, paper, plastic, or any other rigid or semi-rigid material that creates a bigger volume around the flashlight dissuading shoplifting and also presenting the flashlight  10  (or other product) in a “TRY ME” configuration that allows the user to observe operation of the flashlight  10  when it is in its open configuration. 
       FIG. 3  discloses another example of a lighting device with similar (but not necessarily identical) structural features. Like numerals are used throughout the figures for like features. The lighting device is shown with its component parts exploded and comprises a first housing or shroud  5  that covers a light source/control assembly. Generally speaking, the light source/control assembly comprises a light source  31  coupled to a secondary switch (S 2 )  33  and main switch (S 1 )  32  and a microprocessor controlled switch (S 3 )  13 . The main switch  32  is operatively coupled to the main switch activator pin  19  that is covered by a silicone switch cover  28 . The secondary switch  32  is housed within a support structure  20 . The light source/control assembly is also operatively coupled to the forward-directed LED  30  by power leads  35 . A heat sink  11  is coupled to LED  30 . Forward-directed LED  30  passes light through the flashlight by way of LED reflector  17  and lens  16 . A portion of the light source/control assembly is housed within support cylinder  6  which also comprises a cavity for the placement of batteries therein. A reflector  14  is placed on top of support cylinder  6  and about the periphery of light source  31 . A lens  22  is placed on top of the reflector  14  and light source  31  to complete the cylindrical shape of the support  6 . A proximal end of support  6  comprises a tail cap  7  which includes a battery circuit therein. The tail cap  7  and proximal end of support  6  are enclosed by an additional tail cap  8  having a magnetic base. While reference is made herein to batteries, it is understood that the flashlight may also be powered by a tethered cable. 
     A cylindrical slidable housing (or reveal shroud)  5  encloses the cylindrical support  6  and is configured such that the support  6  can be slid from the interior of the housing  5 . A compressible friction washer  27  is disposed between the housing  5  and a threaded tension ring  4 . A distal end of the flashlight comprises a cylindrical body  3  that supports the forward-directed LED  30  and its attendant components. A tactical bezel  1  is disposed about the distal end of a manual focus ring  2  which is also operatively coupled to cylindrical body  3 . 
     As noted above, in marketing certain products, it is useful to build the intelligence or configuration of dependent switches into the portable lighting to be able to display or package the product in the configuration where the normally non-revealed element (when in a closed configuration) is revealed (i.e., when in an open configuration)—but not active. Certain products may use an auto-on feature when the element is revealed, therefore it cannot be packaged and displayed in the revealed (or open) orientation or it will consume the installed batteries. In one aspect of the technology, a flashlight  10  product is marketed with a “TRY ME” feature. This means that the flashlight  10  must have the power source installed and active. In one aspect, the flashlight  10  is equipped with a programmable processor. The software in the processor is configured such that the “TRY ME” feature will only allow any one of the plurality of lighting sources that are activated to remain in operation for only a short predetermined period (i.e. 6, 8, or 10 seconds, for example) if the user presses any of the mechanical operation buttons (S 1 ), or if they extend the reveal shroud and activate the mechanical shroud switch (S 2 ) to examine the elements that were normally not revealed. In this manner, the flashlight cannot be left on thereby draining the batteries. 
     In another aspect of the technology, the product is sealed within a package so the mechanical shroud is opened to the full reveal position when the product is packaged in order to successfully show the product&#39;s normally hidden lighting feature. In this case the “TRY ME” feature will not allow the automatic operation of revealed element, but would allow the user to momentarily activate the lighting modes by utilizing switch  32  (i.e. S 1 ) to control the sequencing of S 3  switches which would allow the activation of the now revealed element since S 2  (via  33 ) is active. 
       FIG. 4  represents the cascade design in one aspect of the technology. Two mechanical switches  32  (S 1 ) and  33  (S 2 ), where S 2  is dependent on S 1  for power. S 2  is the reveal mechanical switch but even if the shroud is opened to activate the reveal light, it will not activate unless S 1  is active. Meaning, S 2  is activated when the covered light is uncovered via a mechanical movement. For example, when the distal portion  12  of light  10  is extended and light  31  is exposed, switch S 2  is activated. However, the light source  31  would not turn on until S 1  is also activated. In this arrangement, when the flashlight  10  is in a closed configuration, light  31  cannot ever be activated because switch S 2  is open. In one aspect, S 1  is a variable voltage switch (e.g., an internal potentiometer) which could allow for dimming of any of the plurality of light sources. 
       FIG. 5  discloses an additional aspect of the technology using a microprocessor to support the mechanical switches  32  and  33 , but with an additional control via software controlled (S 3 ) switches that are part of the output control ports in the microprocessor. The software allows the manufacturer of the flashlight  10  to make any of the switches subject to the other, and by activating the “TRY ME” feature upon application of power during product assembly (for example), the flashlight  10  functionality can be configured to support an open reveal assembly without activating the light(s), and giving the potential purchaser of the product an opportunity to activate all of the different lights of the flashlight  10  when it is in an open configuration without the risk of completely depleting the batteries within the flashlight  10 . In one aspect of the technology, a flashlight  10  uses an auto-on feature for the lighting element that is concealed by the reveal shroud  5 . In that case, when the shroud  5  is extended and the flashlight  10  is in an open configuration (e.g., as shown in  FIG. 2 ), switches S 2  and S 3  are needed to activate the lighting source  31 , and S 1  is used to cycle between a plurality of lighting options that may be part of the revealed lighting source (white work light, red map light, etc.). 
       FIG. 6  shows a rigid or semi-rigid enclosure  40  about an exterior of the flashlight  10  securing the flashlight  10  in a second configuration where both the forward directed, and always open or revealed light  30 , and the light  31 , which is covered in a first configuration, are each uncovered or open. In one aspect of the technology, packaging  50  includes multiple components that operate with enclosure  40 . For example, packaging  50  may include a cardboard component that couples to a plastic clam shell enclosure. In another aspect, however, the entire package  50  may be plastic and may be integrally formed with the enclosure  40  that secures the flashlight  10  in its second configuration. The flashlight  10  is secured within the rigid or semi-rigid enclosure  40  in such a manner that a potential customer may not move the flashlight  10  into the first configuration (i.e., where the light  31  is covered) without first removing the flashlight  10  from the enclosure  40  or breaking the enclosure  40  in some manner. In one aspect of the technology, a least a portion of the enclosure  40  is translucent so that a potential purchaser may view the product and test the product within packaging  50 . More specifically, in one aspect, the enclosure  40  about the first light source  30  and/or second light source  31  is translucent. An opening is present about the power switch  28 . In another aspect, the enclosure  40  comprises an opening about the first light source  30  and/or the second light source  31 . 
     While specific reference is made herein to light source  30  and  31 , it is understood than more than two light sources may be used in connection with the light device. For example, a plurality of light sources may be disposed about the distal end  12  of the flashlight. A first “forward facing” light (i.e., the LED or other source propagating light in parallel with the longitudinal axis of the lighting device) may comprise a spot light configuration and a second forward facing light may comprise an annular LED or other light configured as an area light. The lighting device may further comprise more than one light source that are covered when the lighting device is in the first configuration. More specifically, reference is made herein to a second configuration where the covered light is exposed. However, the lighting device can comprise a second configuration where a second light covered in the first configuration is uncovered and further comprises a third light that remains covered in the second configuration. The lighting device may also comprise a third configuration where the second and third lights are both exposed or the second light remains covered and the third light is exposed or uncovered. In that aspect, one or more additional switches would be incorporated into the physical structure of the lighting device about the shroud to activate the different lights when the lighting device is in the second or third configuration. 
     Aspects of the technology also include a method of packaging a flashlight  10  that is equipped with one or more switches to operate the light in an open configuration. The method comprises obtaining a lighting device  10 , said lighting device being enclosed in a removable rigid or semi-rigid enclosure. The lighting device  10  comprises a first configuration wherein a first light source  30  is exposed and a second light source  31  is covered and a second configuration wherein the first light source  30  is exposed and the second light source is also exposed  31 . The removable rigid or semi-rigid enclosure secures the lighting device in the second configuration so that the second light source  31  is exposed. The lighting device  10  further comprises a power source coupled to the first and second light source and a switch (S 1 , S 2 , or S 3 ) coupled to the first and second light sources and the power source. The switch is configured to permit propagation of power from the power source to the first and second light source. The method comprises activating the switch to provide power to the second light source while the lighting device is within the removable rigid or semi-rigid enclosure and activating the switch to provide power to the first light source while the lighting device is within the removable rigid or semi-rigid enclosure. In one aspect, the method further comprises removing the lighting device from the enclosure and moving the lighting device into the first configuration. In this aspect, the switch is configured to permit power to propagate from the power source to the second light source only when the lighting device is in the second configuration. 
     The foregoing detailed description describes the technology with reference to specific exemplary aspects. However, it will be appreciated that various modifications and changes can be made without departing from the scope of the present technology as set forth in the appended claims. The detailed description and accompanying drawings are to be regarded as merely illustrative, rather than as restrictive, and all such modifications or changes, if any, are intended to fall within the scope of the present technology as described and set forth herein. 
     More specifically, while illustrative exemplary aspects of the technology have been described herein, the present technology is not limited to these aspects, but includes any and all aspects having modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the foregoing detailed description. The limitations in the claims are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the foregoing detailed description or during the prosecution of the application, which examples are to be construed as non-exclusive. For example, in the present disclosure, the term “preferably” is non-exclusive where it is intended to mean “preferably, but not limited to.” Any steps recited in any method or process claims may be executed in any order and are not limited to the order presented in the claims. Means-plus-function or step-plus-function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation: a) “means for” or “step for” is expressly recited; and b) a corresponding function is expressly recited. The structure, material or acts that support the means-plus-function are expressly recited in the description herein. Accordingly, the scope of the technology should be determined solely by the appended claims and their legal equivalents, rather than by the descriptions and examples given above.