Abstract:
An LED flashlight construction is formed from molded plastic housing members joined to provide a tubular section connected to a battery chamber capable of holding one or more disc batteries capable of providing adequate voltage for operating a light emitting diode positioned at the distal end of the tubular section. A conductive metal pocket clip may be elastically deformed for closure of the circuit to provide power to the light emitting diode.

Description:
BACKGROUND OF THE INVENTION 
   In a principal aspect the present invention relates to a flashlight comprised of a light emitting diode (LED) light source mounted in a housing and powered by one or more disc shaped batteries of sufficient voltage. The flashlight includes a pocket clip which may be elastically deformed to complete or close the circuit to activate the light source. 
   The light source may have a selected wave length, for example, an infrared, ultraviolet or white light emitting diode. The choice of the light source enables the user of the flashlight to utilize the light for detecting materials that are reactive to infrared or ultraviolet radiation, for example. 
   There are numerous patents directed to the construction of flashlights wherein the light emitting diode light source is utilized as a means to detect fluid leakage, for example. Among the various patents directed to such light constructions are the following: 
   
     
       
             
             
             
           
         
             
                 
             
             
               U.S. Pat. No. 
               Title 
               Issue Date 
             
             
                 
             
           
           
             
               5,674,000 
               Light Source For Use In Leak Detection 
               Oct. 7, 1997 
             
             
                 
               In Heating, Ventilating and Air 
             
             
                 
               Conditioning Systems That Utilize 
             
             
                 
               Environmentally-Safe Materials 
             
             
               5,742,066 
               Light Source For Use In Leak Detection 
               Apr. 21, 1998 
             
             
                 
               In Heating, Ventilating and Air 
             
             
                 
               Conditioning Systems That Utilize 
             
             
                 
               Environmentally-Safe Materials 
             
             
               5,788,364 
               Compact High-Intensity UVA 
               Aug. 4, 1998 
             
             
                 
               Inspection Lamp 
             
             
               5,959,306 
               Portable Light Source And System For 
               Sep. 28, 1999 
             
             
                 
               Use In Leak Detection 
             
             
               5,975,712 
               Telescopic Illuminating Tool 
               Nov. 2, 1999 
             
             
               6,200,134 B1 
               Apparatus And Method For Curing 
               Mar. 13, 2001 
             
             
                 
               Materials With Radiation 
             
             
               6,355,935 B1 
               Portable Light Source And System For 
               Mar. 12, 2002 
             
             
                 
               Use In Leak Detection 
             
             
               6,491,408 B1 
               Pen-Size LED Inspection Lamp For 
               Dec. 10, 2002 
             
             
                 
               Detection Of Fluorescent Material 
             
             
                 
             
           
        
       
     
   
   One of the challenges facing the design of such light source devices is associated with the necessity to direct the light into a restricted area or space. For example, when a mechanic is attempting to repair a vehicle engine and desires to examine somewhat inaccessible portions of an engine or ancillary equipment attached to the engine in order to locate a fluid leak source, the mechanic will need to carefully direct an ultraviolet or infrared light beam. A typical flashlight construction beam may not be easily directed. Additionally, many prior art light constructions are bulky and not easy to manipulate. 
   Thus, there has developed a need to provide a flashlight construction which utilizes an easily directed light emitting diode light source. Such a construction should preferably rely upon long life, low current batteries of sufficient voltage for a light emitting diode that will produce a highly visible or highly intense beam of light. 
   SUMMARY OF THE INVENTION 
   Briefly, the present invention comprises a light emitting diode (LED) light source flashlight construction incorporated in a pen-sized, unitary, plastic housing. The housing is comprised of an elongate, hollow tubular section connected to a disc shaped battery chamber. Internal wiring connects from the battery chamber through the hollow tubular section to a light emitting diode mounted at the end of the hollow tubular section. The circuit is closed whenever a conductive pocket clip affixed externally to the housing is elastically deformed. The flashlight construction utilizes disk shaped, lithium batteries retained in the battery chamber and which produce an adequate voltage to activate a light emitting diode light source to provide an intense, focused beam of light. 
   Thus, it is an object of the invention to provide an improved light emitting diode (LED) flashlight construction. 
   A further object of the invention is to provide a flashlight construction which may be utilized with a light emitting diode or with other light sources such as an incandescent bulb. 
   Yet another object of the invention is to provide a flashlight construction which is compact, yet rugged and easy to use and store when not in use. 
   Another object of the invention is to provide a flashlight construction which may be utilized in combination with ultraviolet as well as infrared and white light, light emitting diodes. 
   Another object of the invention is to provide an inexpensive, yet highly reliable, long life flashlight construction. 
   These and other objects, advantages and features of the invention will be set forth in the detailed description which follows. 

   
     BRIEF DESCRITION OF THE DRAWING 
     In the detailed description which follows, reference will be made to the drawing comprised of the following figures: 
       FIG. 1  is an isometric view of the flashlight construction of the invention; 
       FIG. 2  is a top plan view of the construction of  FIG. 1 ; 
       FIG. 2A  is a cross sectional view taken along the line  2 A— 2 A in  FIG. 2 ; 
       FIG. 2B  is an inside plan view of the battery cover for the housing of the battery in the chamber section of the light construction; 
       FIG. 2C  is a side view of  FIG. 2B ; 
       FIG. 2D  is an outside plan view of the cover of  FIG. 2B ; 
       FIG. 3  is a side elevation of the construction of  FIG. 2 ; 
       FIG. 4  is an end view of the construction of  FIG. 3 ; 
       FIG. 5  is a top plan view of the half of the housing utilized in the flashlight construction of the invention; 
       FIG. 6  is a side elevation of  FIG. 5 ; 
       FIG. 6A  is an end view of the housing section of  FIG. 6 ; 
       FIG. 7  is a bottom elevation of the construction of  FIG. 5 ; 
       FIG. 8  is a plan view of the bottom portion of the housing of the flashlight construction; 
       FIG. 9  is a side elevation of  FIG. 8 ; 
       FIG. 9A  is an end view of the housing section of  FIG. 9 ; 
       FIG. 10  is a plan view of the inside of the housing of  FIG. 8 ; 
       FIG. 11  is the circuit subassembly incorporated in the flashlight construction of the invention; and 
       FIG. 12  is a an exploded isometric view of the flashlight construction of the invention. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENT 
   General Overview: 
   Referring to the figures, the flashlight construction of the invention is comprised of three molded plastic component parts; namely, an upper or outside or top housing or housing section  10  depicted in  FIGS. 5 ,  6 ,  6 A and  7 ; a generally mirror image bottom or inside or lower housing or housing section  12  depicted in  FIGS. 8 ,  9 ,  9 A and  10  and a molded battery cover  14  for the battery chamber section of the joined housings  10 ,  12  depicted in greater detail in  FIGS. 2B ,  2 C and  2 D. The flashlight construction further includes a flexible, elastic, conductive metal clip  16  attached to the outside surface of housing section  10  and projecting through the outer housing section  10  to provide for controlled closure of an electric, direct current series circuit. Contained within the joined housings  10 ,  12  is a direct current circuit assembly depicted in  FIG. 11  including a light emitting diode  20  connected with an insulated cathode wire  22 . The cathode wire  22 , in turn, is connected with a conductive metal biasing member  24  in contact with series arranged, disc shaped batteries  32 ,  34 . The light emitting diode  20  is further connected with a lead wire anode  26  that is insulated but electrically connected from LED  20  to a cylindrical, conductive metal contact  28 . Contact  28  is positioned within the housings  10 ,  12  for engagement by flexed clip  16  through a passage  17  in housing  10 . The circuit assembly of  FIG. 11  is retained within the housings  10  and  12  for cooperative action with first and second lithium disc shaped batteries  32  and  34  as well as the metal clip  16 . 
   Thus, the overall construction of the flashlight comprises joinder of the upper or outside housing  10  with the lower or bottom housing  12  to encapsulate the batteries  32 ,  34  as well as the circuit assembly of FIG.  11 . The battery cover  14  retains batteries  32  and  34  within a cylindrical battery chamber section  13  defined by the coupled housings  10  and  12 . The metal clip  16  includes prongs  16 A which serve the dual function of attachment of the clip  16  to the housing  10  and to provide an electrical conductive path to one of the poles of the disc shaped batteries  32 ,  34  which are arranged in stacked, series in the chamber section  13  of the coupled housings  10 ,  12 . The metal clip  16  is normally biased so that it does not engage with the cylindrical metal conductor member  28 . However, manual engagement of the metal clip  16  will flex and close the circuit through the cylindrical metal section  28  thereby closing the circuit through the batteries  32 ,  34  and providing electrical current of adequate voltage to the light emitting diode  20  positioned within the coupled housings  10 ,  12 . 
   Housing Construction: 
   The coupled housings  10 ,  12  include a longitudinal, centerline axis  15  which is an axis of symmetry. The longitudinal length of the housings  10 ,  12  in the direction of the axis  15  is in the range of 4-6 inches in the preferred embodiment. The lateral side-to-side dimension of the housings  10 ,  12  is in the range of ¾ to 1½ inches. The thickness or transverse dimension of the assembled light construction is in the range of ¼ to ½ inches. As a consequence, the entire assembly may be easily retained within the pocket of a user for ease of access and ease of storage. The conductive metal clip  16  retains the item in a pocket. As a result, the flashlight construction is extremely easy to access. 
   In the preferred embodiment, the light construction utilizes two  2016  coin cell lithium 3-volt batteries in series. Any of a number of light emitting diodes having various wavelength characteristics may be utilized. For example, an infrared, ultraviolet or white light, light emitting diode may be utilized in the flashlight construction. An incandescent bulb may be utilized. Further, it is possible to color code the molded plastic housings  10  and  12 , for example to indicate the wavelength of the light emitting diode. For example, for an ultraviolet flashlight construction, the plastic housing may be molded from a blue plastic material, for example, an ABS plastic material. For an infrared flashlight construction, the molded plastic components may be manufactured from a red ABS plastic material. Other colors may be utilized. However, the color coding system facilitates the functionality of the flashlight construction enabling the user to immediately understand the capability of the flashlight in terms of the wavelength associated with the light emitting diode (LED). 
   Referring to  FIGS. 2B ,  2 C,  2 D,  5 ,  6 ,  7 ,  6 A,  8 ,  9 ,  9 A and  10 , there is depicted in greater detail the construction of the component plastic parts which are used to construct the light emitting diode flashlight construction. Referring first to  FIGS. 5 ,  6 ,  6 A and  7 , there is depicted the top or outer housing  10 . The top or outer housing  10  is symmetric about the longitudinal axis  15  and includes a semi-tubular section  11  connected to an upper chamber section  13 . The semi-tubular section  11  comprises a hollow semi-cylindrical section having a longitudinal passage  17  formed therein for cooperation with the cylindrical, conductive member  28  and the LED  20 . The chamber section  13  is formed so as to receive the disc shaped batteries  32 ,  34 . The chamber section  13  further includes parallel slits  19  and  21  for receipt of conductive attachment prongs  16 A of the metal clip  16 . The conductive metal prongs  16 A fit through the slits  19  and  21  for engagement with one of the conductive poles; namely, the anode pole of a disc battery  32  or  34  within the cylindrical chamber  13 . The outer housing  10  semi-tubular section  11  further includes first and second radially projecting prongs or tabs  23  and  25  which are cooperative with and engage with radial receptors or receptacles associated with the bottom housing  12 . In this manner, the housing sections  10  and  12  may be aligned or joined or retained together by ultrasonic welding, for example. 
   Within the tube section  11  are various transverse wall sections. Thus, a first wall section  31  is positioned on one side of the slot  17 . A second wall section  33  is positioned on the other side of slot  17 . The wall sections  31 ,  33  cooperate with the cylindrical conductive member  28  to hold member  28  in position aligned with the tubular passage  17 . Spaced third and fourth transverse wall sections  35  and  37  at the outer end of the tube section  11  cooperate with a peripheral rib  39  in  FIG. 11  of the light emitting diode  20  to retain the light emitting diode in position within the tube  11 . 
     FIGS. 8 ,  9 ,  9 A and  10  depict the bottom or inside housing  12 . The bottom or inside housing  12  is, in general, a mirror image of the outer housing  10 . The bottom housing  12  thus includes a semi-tubular section  11 A and chamber section  13 A. The chamber section  13 A, however, is open and includes a notched periphery  13 B for receipt of battery cover  14  having compatible notches and teeth. The battery cover  14  is depicted in  FIGS. 2B ,  2 C and  2 D and comprises a molded flat plastic member with radially projecting teeth  60  that cooperate with notches  62  in periphery  13 B. The inside face of the battery cover  14  includes a central rib  64  that provides for molding a slot or recess in the outside of cover  14 . The outside of the cover  14  includes slot  66  in  FIG. 2D  which can receive a coin or some other item to effect turning and locking of the cover  14  in position within the notches  62  of the bottom housing  12 . 
   Referring again to  FIGS. 8 ,  9 ,  9 A and  10 , the bottom housing  12  also includes transverse walls or wall sections  70  and  72  cooperative with the external rib  39  on the light emitting diode  20 . The bottom section  12  further includes, on the inside thereof, receptacles  74  and  76  for cooperation respectively with the projecting tabs  23  and  25  of the top housing  10  so that the component housings  10 ,  12  may be aligned for joinder by adhesive, or sonic welding, or other means. Further, the interior of the bottom section  12  includes a longitudinal rib  28 A that serves as a key to engage and retain the conductive member  28  by fitting into a longitudinal slot  28 B in the member  28 . 
   Referring to  FIG. 12 , the battery chamber or battery section  13 A of the housings  10 ,  12  comprises a generally cylindrical chamber having a cylindrical axis  11 B that is transverse to the longitudinal axis  15 . The longitudinal axis  15  thus comprises a cylindrical axis for the tubular section  11  of the housings. Axis  11 B defines a cylindrical axis for the chamber section  13 B. The axes  11 B and  15  are generally normal to each other. 
   The cross sectional configuration of the tubular section is generally cylindrical but may be polygonal or comprise other shapes. Likewise, the battery chamber may have various shapes or configurations other than cylindrical. 
   Thus, it is possible to vary the shape and arrangement of the various component parts comprising the flashlight construction without departing from the spirit and scope of the invention. The invention, therefore, is limited only by the following claims and equivalents thereof.