Patent Publication Number: US-2022221115-A1

Title: Portable light, such as a stick light

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application No. 63/136,448 filed on Jan. 12, 2021, the entire contents of which are incorporated herein by reference. 
    
    
     BACKGROUND 
     The present technology relates to portable lights. More specifically, the technology relates to an LED-based stick light or trouble light that is powered by a DC power source. 
     Stick lights or trouble lights are commonly used to illuminate work areas that are otherwise difficult to light. Examples of these areas include engine compartments, ceiling spaces, basement areas, and the like. The lights are typically positioned such that they shine light in the desired area without being held by a user. 
     SUMMARY 
     In another aspect, a portable light is disclosed. The portable light includes an elongated housing having a first end and a second end opposite the first end, and a light-emitting head pivotably coupled to the second end of the elongated housing. The light-emitting head having a housing portion defining a first end and a second end opposite the first end. A first light source is coupled to a first side of the light-emitting head and is positioned between the first end and the second end of the housing portion. A second light source coupled to the second end of the housing portion. A battery cell is removably coupled to the elongated housing to power the first and second light sources. 
     In another aspect, a portable light is disclosed. The portable light includes an elongated housing having a first housing portion defining a grip portion and a second housing portion coupled to the first housing portion, an interface that rotatably couples the first housing portion to the second housing portion, a light source coupled to the second housing portion of the elongated housing, and a battery cell supported within the first housing portion and configured to power the light source. The battery cell is configured to rotate relative to the first housing portion with the second housing portion. 
     In another aspect, a portable light assembly is disclosed. The portable light assembly includes a portable light having an elongated housing having a first end and a second end opposite the first end. The portable light assembly also includes a light-emitting head pivotably coupled to the second end of the elongated housing. The portable light further includes a first battery cell supported within the elongated housing and configured to power the light-emitting head. The portable light also includes a charging interface positioned on a side of the elongated housing between the first end and the second end. The assembly also includes a charger having a housing defining a first cavity sized to receive at least a portion of the portable light and a second cavity positioned adjacent the first cavity and sized to receive at least a portion of a second battery cell. The charger also includes a first charging interface positioned within the first cavity, the first charging interface configured to interact with the portable charging interface when the portable light is received in the first cavity to charge the first battery cell. The charger also includes a second charging interface positioned within the second cavity, the second charging interface configured to interact with a second battery cell when the second battery cell is received in the second cavity to charge the second battery cell. 
     Other aspects will become apparent by consideration of the detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a portable light, according to some embodiments. 
         FIG. 2  is a front view of the portable light of  FIG. 1 . 
         FIG. 3  is a side view of the portable light of  FIG. 1 . 
         FIG. 4  is another perspective view of the portable light of  FIG. 1 . 
         FIG. 5  is a perspective exploded view of the portable light of  FIG. 1 , illustrating a battery cell removed from the portable light. 
         FIG. 6  is a perspective view of the portable light of  FIG. 1 , illustrating a light emitting head in an open position. 
         FIG. 7  is side view of the portable light of  FIG. 1 , illustrating the light emitting head in the open position. 
         FIG. 8  is a perspective view of a portable light with a portion of a housing removed to illustrate a rotational feature of the portable light, according to some embodiments. 
         FIG. 9  is perspective view of a portable light assembly with the portable light of  FIG. 1  coupled to a charger. 
         FIG. 10  is a perspective exploded view of the portable light assembly of  FIG. 9 . 
         FIG. 11  is a perspective view of the charger of  FIG. 9 . 
         FIG. 12  is a block diagram illustrating the control circuitry of the portable light of  FIG. 1 , according to some embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     Before any embodiments of the herein described technology are explained in detail, it is to be understood that the disclosed technology is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The technology is capable of other embodiments and of being practiced or of being carried out in various ways. 
       FIGS. 1-8  illustrate a portable light  10 , such as a stick light or trouble light. The illustrated stick light  10  is a hand-held, electrically powered light that includes an elongated housing  14  having a first end  18  and a second end  22  opposite the first end  18 , a battery housing  24  coupled to the first end  18  of the housing  14  and sized to receive a battery cell  25  ( FIG. 5 ), and a light-emitting head  26  pivotably and rotatably coupled to the second end  22  of the housing  14 . A longitudinal axis  28  ( FIGS. 2 and 3 ) extends centrally through the first and second ends  18 ,  22  of housing  14 . The portable light  10  further includes a user interface  30  formed on the housing  14  to selectively activate the light-emitting head  26 , a charging interface  34  formed on a grip portion  38  of the housing  14 , and a universal serial bus (“USB”) port  42  formed on the housing  14  adjacent the user interface  30 . The charging interface  34  is sized to mate with a corresponding charging interface of an external charger (described in more detail below) to charge the battery cell  25 . Alternatively, a USB cord may be coupled to the USB port  42  to charge the battery cell  25 . 
     The grip portion  38  is configured to be grasped by a user to hold and carry the portable light  10 . In some embodiments, such as the illustrated embodiment, a relatively soft material may be positioned or molded over at least a portion of the grip portion  38  to increase the friction between a user&#39;s hand and the grip portion  38 , which improves the user&#39;s grip of the housing  14 . In operation, the battery cell  25  selectively provides power to the light-emitting head  26  to illuminate an area with the light-emitting head  26 . The light-emitting head  26  is pivotably coupled to the housing  14  at a pivot point  46  and is movable between a first position ( FIGS. 1-5 ) and a second position ( FIGS. 6 and 7 ). The first position may be referred to as a closed or collapsed position. The second position may be referred to as an open or extended position. The light-emitting head  26  is rotatably coupled to the housing  14  such that the light-emitting head  26  can rotate about the longitudinal axis  28  ( FIGS. 2 and 3 ) of the portable light  10 . As a result, the user can maneuver the light-emitting head  26  to a desired position during operation. 
     With reference to  FIGS. 2 and 3 , the illustrated housing  14  is elongated in that an overall length L, or height, of the housing  14  is significantly greater than a width W ( FIG. 2 ), or diameter, of the housing  14 , giving the light  10  a stick or tube-shaped appearance. The elongated housing  14  defines a front side  50  ( FIG. 3 ), a rear side  54 , and right and left sides  58 ,  62  that extend between the front and rear sides  50 ,  54 . When the light-emitting head  26  is in the closed position ( FIG. 3 ), the light-emitting head  26  engages the rear side of the housing  14 . In the illustrated embodiment, the user interface  30  is positioned on the front side  50  of the housing  14  and the USB port  42  and the charging interface  34  are positioned on one of the right or left sides  58 ,  62 . For example, the USB port  42  and the charging interface  34  are both positioned on the right side  58  of the housing  14 . In other embodiments, the USB port  42  and the charging interface  34  may be positioned on opposite sides of the housing  14  from each other. 
     The light-emitting head  26  includes a housing portion  66  having a first end  70  coupled to the second end  22  of housing  14 , a second end  74  opposite the first end  70  (e.g., that terminates proximate the first end  18  of the housing  14 ), and a longitudinal axis  76  extending through the first and second ends  70 ,  74 . The housing portion  66  houses a plurality of light sources  78 ,  82 ,  86  ( FIGS. 4 and 7 ). In the illustrated embodiment, a first light source  78  ( FIGS. 4, 5, and 7 ) is housed on a top surface  88  ( FIG. 7 ) of the housing portion  66 , a second light source  82  (e.g., a spotlight) is housed on the second end  74  of the housing portion  66 , and a third light source  86  is housed on a bottom surface  90  of the housing portion  66 . As such, the light sources  78 ,  82 ,  86  are oriented to emit light outward from each side of the housing portion  66 . In the illustrated embodiment, the light sources  78 ,  82 ,  86  are LED light sources. Each light source  78 ,  82 ,  86  may include a single LED light source or a plurality or array of LED light sources. 
     Now with reference to  FIG. 5 , a battery receptacle  92  is adjacent the first end  18  of the elongated housing  14 . In the illustrated embodiment, the battery receptacle  92  includes a recess formed in the first end  18  of the housing  14 . The recess is adapted to receive the battery cell  25  and a portion of the battery housing  24 . In other embodiments, the battery receptacle  92  may include guide rails to support a slide-on-style battery pack. In one embodiment, the illustrated battery cell  25  is a 3.6 volt battery cell. In one example, the battery cell  25  may be a lithium-ion battery cell, such as an 18650 cell. However, other battery chemistries, such as lithium iron phosphate, Nickle metal hydride, lead acid, alkaline, etc. are also contemplated. Further, other battery cell designs are contemplated other than the  18650 . 
     As shown in  FIGS. 1-7 , an outer surface of the housing  14  and an outer surface of the battery housing  24  are similarly shaped and contoured such that the battery housing  24  forms an extension of the grip portion  38  when connected to the elongated housing  14 . In the illustrated embodiment, the battery housing  24  further includes a base  94  that stabilizes the portable light  10  when the portable light  10  is positioned on a surface. The battery housing  24  also includes an attachment member  96  pivotably coupled to the base  94 . The attachment member  96  may be used to hang or suspend the portable light  10  from various support structures, including cables, pipes, joists, nails, wall hangers, carabiners, belts, belt loops, shirt pockets, and the like. In the illustrated embodiment, the attachment member  96  is hook. The attachment member  96  is movable (e.g., pivotable) relative to the base  94  between a storage position (as shown) and an operation position. When in the storage position, the attachment member  96  is received within a recess of the base  94  such that the attachment member  96  does not extend beyond a periphery or footprint of the base  94 . When in the operation position, the attachment member  96  extends outwardly away from the base  94  such that the attachment member can engage a support structure. 
     Referring back to  FIGS. 1 and 2 , the user interface  30  includes a power button  100 , a mode selector  104 , and an intensity selector  108  positioned on the front side  50  of the elongated housing  14 . The user interface  30  is electrically coupled to the battery cell  25  and the light sources  78 ,  82 ,  86  through a controller and/or circuit within the housing  14  to control operation of the portable light  10 . The illustrated user interface  30  is located generally in the middle of the elongated housing  14  and on an opposite side of the housing  14  from the light-emitting head  26 . In addition, the user interface  30  is positioned adjacent the grip portion  38  such that a user holding the portable light  10  at the grip portion  38  can easily operate the light  10  with a single hand. 
     In the illustrated embodiment, the power button  100  is a button that may be depressed or otherwise actuated by a user to turn the portable light  10  (particularly the light sources  78 ,  82 ,  86 ) on and off. The mode selector  104  is a button that may be depressed or otherwise actuated by the user to switch between different operational modes. For example, the mode selector  104  may switch between modes where only one of the light sources  78 ,  82 ,  86  is on, two of the light sources  78 ,  82 ,  86  are on, or all three light sources  78 ,  82 ,  86  are on. The intensity selector  108  is a user actuatable input that adjusts the intensity of the light being emitted by the light sources  78 ,  82 ,  86  (e.g., brightens or dims the light sources  78 ,  82 ,  86 ). For example, the intensity selector  108  may be depressed or otherwise actuated multiple times to change the intensity of the light being emitted from a low intensity setting to a high intensity setting, or vice versa. Additionally, the mode selector  104  and intensity selector  108  may each include an indicator, such as a meter, positioned on the housing  14  to indicate to the user the current mode of the portable light  10  or the intensity level of the light being emitted. 
     During operation of the portable light  10 , a user may use the portable light  10  with the light-emitting head  26  in the closed position ( FIGS. 1-5 ) or the open position ( FIGS. 6 and 7 ). Where the light-emitting head  26  is in the closed position, the longitudinal axis  76  and the first light source  78  of the light-emitting head  26  are each parallel to the longitudinal axis  28  of housing  14  ( FIG. 3 ). As such, the first light source  78  may emit light outward from the housing  14  and the light-emitting head  26 . For example, the user may place the portable light  10  on a surface so the base  94  supports the portable light  10  and may turn on the first light source  78  using the user interface  30 . This allows the user to illuminate an area surrounding the portable light  10  while having both hands free. 
     Now with reference to  FIG. 7 , when the light-emitting head  26  is in the open position ( FIG. 7 ), the light-emitting head  26  is pivoted (e.g., about the pivot point  46 ) relative to the housing  14  so each light source  78 ,  82 ,  86  is visible. As such, the longitudinal axis  76  of the light-emitting head  26  is at an angle relative to the longitudinal axis  28  of the housing  14  of the portable light  10 . In the illustrated embodiment, the light-emitting head  26  is able to pivot freely relative to the housing  14  so the angle between the longitudinal axis  76  of the light-emitting head  26  and the longitudinal axis  28  of the housing  14  is within a range of 0 degrees to 270 degrees. Additionally, the light-emitting head  26  may be rotated about the longitudinal axis  28  (e.g., clockwise or counterclockwise).  FIG. 7  illustrates the longitudinal axis  76  of the light-emitting head  26  positioned at a 90-degree angle relative to the longitudinal axis  28  of the housing  14  of the portable light  10 . As such, each light source  78 ,  82 ,  86  may emit light outward from each side of the light-emitting head  26  to illuminate the area surrounding the portable light  10 . For example, when the light-emitting head  26  is in the open position, the user may grasp the grip portion  38  of the portable light  10  to position the portable light  10  in a desired position (e.g., through pivotable and rotational movement of the light-emitting head  26 ) and turn on one or more of the light sources  78 ,  82 ,  86  using the user interface  30 . 
       FIG. 8  illustrates a stick light  210  according to another embodiment. The stick light  210  is like the portable light  10  shown and described in  FIGS. 1-7 . Therefore, like structures will be referred to by like reference numerals plus “200” and only the differences between the two will be discussed herein. The stick light  210  includes an elongated housing  214  having a first end  218  and a second end  222  opposite the first end  218 , a battery housing  224  coupled to the first end  218  of the housing  214  and sized to receive a battery cell (similar to battery cell  25 ,  FIG. 5 ), and a light-emitting head  226  pivotably coupled to the second end  222  of the housing  214 . The stick light  210  further includes light sources (e.g., three light sources similar to the light sources  78 ,  82 ,  86 ) that are coupled to the light-emitting head  226 . A longitudinal axis  228  extends centrally through the first and second ends  218 ,  222  of housing  214 . The stick light  210  further includes a user interface  230  formed on the housing  214  to selectively activate the light-emitting head  226 . 
     The housing  214  includes a first (stationary) housing portion  232  that defines the grip portion  238  of the portable light  10  and a second housing portion  236  rotatably coupled to the first portion  216  via an interface  240 . In the illustrated embodiment, the first housing portion  232  defines a battery receptacle which is formed as a recess in the first end  218  of the housing  214  to support the battery cell. The second housing portion  236  supports the user interface  230  and other electronic components  244  (e.g., control board, etc.) of the stick light  210 . The interface  240  includes a rail  248  formed on the first housing portion  232  that engages with a protrusion  252  formed on the second housing portion  236  to allow the second housing portion  236  to rotate relative to the first housing portion  232 . When the second housing portion  236  is rotated, the battery cell and the other electronic components  244  rotate with the second housing portion  236 . In some embodiments, the battery housing  224  may rotate with the battery cell. As a result, a user can adjust the position of the light-emitting head  226  during use. 
     Now with reference to  FIGS. 9-11 , a portable light assembly  400  includes a charger  404  and the portable light  10  that can be coupled to the charger  404  to charge the battery cell  25  secured within the portable light  10 . The charger  404  includes a housing  408  that defines a first cavity  412  sized to receive the portable light  10  and a second cavity  416  positioned adjacent the first cavity  412  and sized to receive a second battery cell  420 . The second battery cell may be similar to the battery cell  25 , described above ( FIG. 5 ). The charger  404  further includes a plug  424  coupled to the housing  408 , which couples the charger  404  to an external power supply  428 . For example, the plug  424  may be integrally formed with the housing  408  and sized to engage with a standard 120 VAC outlet (e.g., a wall outlet). In other embodiments, the plug  424  may include a cord so the charger  404  can be spaced from the external power supply  428 . In one embodiment, the plug  424  is a USB plug (e.g., USB 2.0, USB-C, etc.). 
     Now with reference to  FIGS. 10 and 11 , the first cavity  412  includes a first charging interface  432  that interacts with the charging interface  34  of the portable light  10  to charge the battery cell  25  within the portable light  10 . In the illustrated embodiment, the first cavity  412  is sized to engage and receive the contour of the right side  58  of the portable light  10 . For example, the first cavity  412  has a cylindrical shape, the charging interface  432  has a recess sized to receive the charging interface  34 , and a recess  436  is sized to receive the USB port  42 . Further, the recess  436  may include a magnet  438  that cooperates with the portable light  10  to secure the portable light within the first cavity  412 . In the illustrated embodiment, the magnet  438  is positioned proximate a first, top end of the cavity  412  and the first charging interface  432  is positioned proximate a second, bottom end of the cavity  412 . In other words, the first charging interface is vertically spaced from the magnet. 
     The second cavity  416  includes a second charging interface  440  that interacts with the second battery cell  420  to charge the second battery cell  420 . In the illustrated embodiment, the second cavity  416  is cylindrical and is sized to receive the second battery cell  420 . In other embodiments, an alternative battery pack, such as a M12 battery pack sold by Milwaukee Tool, may be used with the portable light  10 . In such embodiments, the second cavity  416  may be differently sized to receive the battery cell or pack. 
     Further, the first cavity  412  and the second cavity  416  are parallel to each other such that the battery cell  25  of the portable light  10  and the second battery cell  420  are inserted within the cavities  412 ,  416  in the same orientation. In other words, the first battery cell  25  and the second battery cell  420  are respectively supported within the first and second cavity  412 ,  416  in the same orientation. 
     Turning now to  FIG. 12 , a block diagram of the portable light  10  is shown, according to one embodiment. It should be appreciated that the block diagram applies equally to the portable light  210 . As shown in  FIG. 12 , the portable light  10  includes an electronic processor  500 , a memory  502 , a power source  504  (e.g., the battery cell  25 ), one or more light sources  510  (e.g., light sources  78 ,  82 ,  86 ), one or more inputs  506 , the USB port  42 , and the charging interface  34 . The electronic processor  500  is electrically coupled to a variety of components of the portable light  10  and includes electrical and electronic components that provide power, operational control, and protection to the components of the portable light  10 . In some embodiments, the electronic processor  500  includes, among other things, a processing unit (e.g., a microprocessor, a microcontroller, or another suitable programmable device), a memory, input units, and output units. The processing unit of the electronic processor  500  may include, among other things, a control unit, an arithmetic logic unit (“ALU”), and registers. In some embodiments, the electronic processor  500  may be implemented as a programmable microprocessor, an application specific integrated circuit (“ASIC”), one or more field programmable gate arrays (“FPGA”), a group of processing components, or with other suitable electronic processing components. 
     In some embodiments, the electronic processor  500  may include a memory  502  (for example, a non-transitory, computer-readable medium) that includes one or more devices (for example, RAM, ROM, Flash memory, hard disk storage, etc.) for storing data and/or computer code for completing or facilitating the various processes, layers, and modules described herein. The memory  502  may include database components, object code components, script components, or other types of code and information for supporting the various activities and information structures described in the present application. The electronic processor  500  is configured to retrieve from the memory  502  and execute, among other things, instructions related to the control processes, algorithms, etc. The electronic processor  500  is also configured to store information on the memory  502 . 
     In some embodiments, the power source  504  (e.g., the battery cell  25 ) is coupled to and transmits power to the electronic processor  500  and to one or more of the light sources  510 . The power source  504  may include one or more batteries, as described above. The batteries may be removable and/or rechargeable. In some examples, the power source  504  includes other power storage devices, such as super-capacitors or ultra-capacitors. In some embodiments, the power source  504  includes combinations of active and passive components (e.g., voltage step-down controllers, voltage converters, rectifiers, filters, etc.) to regulate or control the power provided to the electronic processor  500  and/or the light sources  510 . In some embodiments, the power source  504  is configured to provide a drive current to the light sources  510  based on control signals received from the electronic processor  500  to control an intensity of one or more of the light sources  510 . In other words, an intensity of the light sources  510  is dependent on the drive current (i.e., power) received from the power source  504 . In some embodiments, the electronic processor  500  is configured to control the drive current provided by the power source  504  to one or more of the light sources  510  by controlling a pulse width modulation (“PWM”) duty cycle that controls when the power source  504  provides the drive current to the light sources  510 . 
     In one example, the electronic processor  500  is configured to detect a user actuation of one or more of the inputs  506 , such as the power button  100 , the mode selector  104 , and/or the intensity selector  108  of the user interface  30 , by detecting a change in the state of the inputs  506 . Based on the detected user actuation of the mode selector  104 , the electronic processor  500  determines an operational mode for the light source  510  (for example, a high output operation mode, a low output operation mode, an off mode, single light mode, multiple light mode, or the like). Similarly, in response to detecting a user actuation of the intensity selector  108 , the electronic processor  500  may vary the intensity of one of more of the light sources  510 . In some embodiments, the portable light  10  may only have a power button  100 . The power button  100  may be a temporary push button, a slider switch, a rotating knob, etc. Accordingly, in such embodiments, the power button  100  may provide both ON/OFF inputs, as well as allow a user to select a mode. For example, a user may actuate the power button  100  a certain number of times to switch the mode of the portable light  10 . In one embodiment, the user may quickly actuate and release the power button  100  to change modes (e.g., HIGH mode, MED mode, LOW mode, single light mode, multiple light mode, etc.), and actuate and hold the power button  100  to power the portable light  10  ON or OFF. Similarly, where the portable light  10  includes the mode selector  104  and the intensity selector  108 , actuations of the mode selector can indicate a desired mode and actuations of the intensity selector  108  can indicate a desired light intensity of the light source  510 . For example, the user may actuate the mode selector  104 , which cycles through the available modes of the portable light  10  (e.g., single light source one, two light sources on, three light sources on, etc.). The user may also actuate the intensity selector  108 , which cycles through the available intensity modes of the portable light  10  (e.g., HIGH mode, MED mode, and LOW mode, etc.). Based on the selected mode, the electronic processor  500  then controls the power source  504  to provide a drive current to the one or more light sources  510  that corresponds to the selected operational mode. In some embodiments, the portable light  10  may include a separate actuator to select each mode. 
     The USB port  42  and the charging interface  34  are electronically connected to the power source  504  (e.g., the battery cell  25 ) via the electronic processor  500 . The USB port  42  and/or the charging interface  34  may be electrically connected to an external power supply  428  to charge the power source  504  (e.g., the battery cell  25 ). In one embodiment, the external power source is a 5 VDC power supply, such as a USB connection. In other embodiments, the external power source may be a DC power source provided by a charger, such as charger  404  described above. In some instances, the external power supply may be an AC utility power supply that has been converted to DC for supply to the power source  504 . In the illustrated embodiment, a USB cable may be used to electrically connect the USB port to the external power supply  428 . Alternatively, the charging interface  34  mates with the charging interface  432  of the charger  404 , which is coupled to the external power supply  428 . 
     In some embodiments, one or more of the components shown in  FIG. 12  may be located on a printed circuit board (“PCB”). In some embodiments, one or more of the components shown in  FIG. 12  may be located elsewhere within or on the housing  14  of the portable light  10 . In some embodiments, the portable light  10  includes additional, fewer, or different components than the components shown in  FIG. 12 . For example, the portable light  10  may additionally include a display to indicate an operational mode of the portable light  10 . As another example, the portable light  10  may include current and/or voltage sensors that measure the current being drawn by the light source  510  (i.e., drive current) and/or the voltage of the power source  504 . 
     Although the various embodiments have been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects as described. Various features and advantages are set forth in the following claims.