Patent ID: 12247729

Before any embodiments of the invention are explained in detail, it is to be understood that the invention 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 invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

DETAILED DESCRIPTION

FIG.1illustrates a portable light10that is well-suited for use in areas where conventional lighting may not be available or may be inadequate. The illustrated light10includes a housing15that defines two battery ports20arranged to receive battery packs25to power the light10. In preferred constructions, the battery packs25are power tool battery packs25that are operable at 18 volts or higher. In other constructions, other battery packs25may be used and more than two or a single battery pack25may be employed. In preferred constructions, the light10uses open link protocol and controls the battery packs25so that they transmit information sequentially and so that their messages do not overlap.

The housing15contains the electrical components of the area light10. Specifically, the housing15includes power inputs30and power outlets35(shown inFIG.4). The power inlets30connect the area light10to an external AC power source to power the area light10. The power outlet35connects the area light10to another device to power that device. For example, in some embodiments, the power outlets can connect to another light so that a series of area lights10can be daisy-chained together. In other embodiments, the power outlet35can connect to a power tool to power the power tool. The housing15also supports charging circuits40. The charging circuit40electrically couples the power inlet30to the battery pack25to charge the battery pack25. The charging circuits40are accessible from the exterior of the housing15for inserting and removing the battery packs25. In some embodiments, the battery packs25may be internal or permanently fixed to the area light10but are preferably removable power tool battery packs25.

The illustrated housing15further includes a control panel45and a display panel50for controlling the operation of the area light10and displaying information relevant to the operation of the light10including various operating parameters or conditions of the light10. The control panel45includes, among other things, a power button55, a light intensity control60, a light intensity indicator65, and a power source indicator70. The light intensity control60allows a use to increase or decrease the intensity of the light10. There can be three intensity settings when the area light10is using DC power and six intensity settings when the area light10is using AC power. The light intensity indicator65may include a plurality of indicator bars that depict the level of intensity that the light10is supplying. Additionally the indicator bars may appear one color when the area light10is using DC power and a different color when the area light10is using AC power. The power source indicator70may include a second set of indicator bars that depict the amount of power (i.e., the state of charge) remaining in the battery packs25. The panel50may also include an indicator that indicates what operating mode the light is in or other features and parameters of the light10.

In some arrangements, the light10is operable remotely using any suitable communication scheme (e.g., Bluetooth, ONE-KEY etc.). In one construction, ONE-KEY can be used to remotely control the light10. In these constructions, the panel45,50may include an indicator that operates to notify a user when ONE-KEY is being used to control the light10. In addition, there may be a control that locks the light10from being able to be controlled by a ONE-KEY device. The lock-out could be permanent or it could be for a fixed and predetermined period of time.

ONE-KEY includes an application for use on mobile devices such as smartphones and tablets. The ONE-KEY application could include a battery charge indicator and a status indicator (e.g., charging, waiting to charge, fully charged, etc.). In one construction, a desired run time can be selected (either at the control panel45or in the ONE-KEY application), and the light10computes a light intensity to achieve that run time based on the current state of charge of the battery packs25, and the light output is set to that level of intensity.

In addition, the ONE-KEY application may allow the user to control what is done in response to a loss of DC (battery) power. For example, the light10could turn off, flash, run for a limited additional time period, etc. In one embodiment the light10is configured to adjust its brightness lower based on the proximity of the device that is using the ONE-KEY application to control the light10.

In operation, if both the battery pack25and an AC power source are connected to the area light10, the AC power source will charge the battery pack25and power the area light10. If multiple battery packs25are inserted into the battery ports20(thereby connecting to charging circuits) during this time, the AC power will be used to charge one battery pack25at a time until all of the battery packs25are charged. When the AC power source becomes disconnected from the area light10, the battery pack25(if sufficiently charged) will automatically begin powering the area light10.

Although multiple battery packs25can be inserted into the battery ports20at a given time, the illustrated area light10only utilizes one battery pack25at a time. The area light10will utilize one battery pack25until that battery pack25has been fully drained of power. Then, the next battery pack25will begin powering the area light10. In other words, the area light10is configured to utilize the battery packs25sequentially rather than in parallel.

When only a single battery pack25is inserted into the battery port20and thereby connected to the charging circuit40, the area light10will engage in a power saving mode. During the power saving mode, the area light10will prolong the battery life by automatically decreasing the light intensity when the charge of the battery pack25falls below a certain level. When two or more battery packs25are inserted into the battery port20, the area light10will continue to operate at the specified intensity level until each battery pack25is drained. When only one battery pack25remains un-drained, the area light10will go back into the power saving mode, reducing the intensity of the light in order to extend the battery life of the remaining battery pack25.

Thus, the light10can be powered by DC current provided by the battery packs25or AC power provided by a conventional AC power source. When the light10is powered by DC from the battery packs25, the light10first takes power from the battery pack25that has the lower state of charge to preserve the charge of the more highly charged battery pack25. The battery packs25are then discharged in sequence and not in parallel. Of course, other arrangements or operating modes may vary the discharge arrangement of the battery packs25.

With reference toFIG.5, an upper portion75of the housing15operates to enclose the top portion of the light10and operate as a lens or diffuser to improve the quality of the light emitted by the light10. A bottom cover80, illustrated inFIG.3and a middle cover85, illustrated inFIG.2cooperate with the upper portion75of the housing15to substantially enclose a water-tight space within the light10.

As illustrated inFIG.2, the light10includes a plurality of printed circuit boards90that control the flow of power (including the charging circuit) and control the operation of the light10. The circuit boards90are positioned within the water-tight space to protect the electronics from moisture.

With reference toFIG.5, the light10includes a plurality of LEDs95that are positioned inside of the housing15and are operable to emit light (e.g.,10klumens or more) as desired. In order to dissipate heat, the light10includes a tube or chimney100and light support member or heat sink105as are best illustrated inFIG.6. The chimney100includes a substantially hollow tube that extends from the bottom of the light10to the top of the light10. Seals are formed between the chimney100and the housings15to maintain the substantially water-tight space.

A finned inlet member110, illustrated inFIG.4, is attached to the bottom of the chimney100or housing15and operates to guide cooling air into the chimney100. A seal between the finned member110, the chimney100, and the housing15inhibits access to the chimney100by a user and/or debris entrance into the chimney100. The top portion of the chimney100includes a plurality of apertures115that facilitate the escape of hot air from the chimney100. A triangular cover member120engages the top of the chimney100to force the air out of the apertures115and also to inhibit access to the chimney100by a user or unwanted debris or water.

The light support member105, illustrated inFIGS.6and10, is formed from a heat conducting material and includes a plurality of LED support surfaces125. The LEDs95are attached to these surfaces125and heat generated by the LEDs95is conducted into the light supporting member105. The member105includes a plurality of arms130that extend outward and support a plurality of fins135that increase the surface area and further enhance cooling. In addition, LEDs95may be attached to a top support member140that attaches to the top of the light supporting member105to emit light from the top of the light10.

As illustrated inFIG.8, a central aperture145formed in the light supporting member105receives the chimney100and provides thermal conduction therebetween. In the illustrated construction, the central aperture145is polygonal with other shapes being possible. In preferred constructions, the circuit boards90are also connected, or at least thermally coupled to the chimney100to aid in thermal conduction and cooling of the circuit boards90.

In operation, the LEDs95are powered by either the DC power supply or the AC power supply to generate the desired illumination. The circuit boards90and the LEDs95generate a significant amount of heat during operation. Some of that heat is conducted into the chimney100either directly, or through the light supporting member105. As the chimney100heats, a natural convection pattern is established. The hot air within the chimney100rises and exits the light10, thereby drawing additional cool air into the bottom of the light10. In this manner, the cooling ability of the light10is enhanced.

FIGS.13-22illustrate another version of the light200ofFIGS.1-12. As illustrated inFIG.13, the light200includes a housing205that is similar to that of the light10ofFIG.1. However, the light200does not include an external handle but rather includes a plurality of legs210that provide support for the housing205while providing an air space under the housing205. In addition, a hinged cover215is provided that can open to receive or remove one or both of the power tool battery packs25. In the illustrated construction, the cover215is illustrated as transparent. However, opaque and colored covers could also be employed if desired.

As illustrated inFIG.14, circuit boards220including the light controls as well as a power control and charging circuits are disposed within the housing205. In addition, a tube or chimney225that at least partially defines a cooling air path230extends through the light200from the bottom of the housing205. As shown inFIG.15, the chimney225opens at the bottom of the housing205to receive a flow of cooling air. In this arrangement, the legs210maintain the position of the opening above the ground to assure that air is free to flow between the legs210and into the opening as may be required.

FIGS.18-22best illustrate the chimney225and a light support member or heat sink235of the construction ofFIGS.13-22. As can be seen, the shape and arrangement of these features is different than those of the construction ofFIGS.1-12.

The light support member or heat sink235includes a plurality of light support surfaces240that are arranged around the perimeter of the light support member235and that each support a plurality of LEDs245much like the construction ofFIGS.1-12. Specifically, a plurality of circuit boards are attached or bonded to the light support surfaces240and are thermally connected to allow the LEDs245to emit light outward from the light support member235and to allow heat produced by the LEDs245to conduct into the light support member235. The arrangement of the light200ofFIGS.13-22is such that light is emitted in a 360 degree pattern around the light200. In addition, a flat light support250is positioned on top of the light support member235and includes a plurality of LEDs245arranged to project light upward in a direction substantially parallel to a central axis255of the light200(i.e., the chimney axis).

With reference toFIG.21, the light support member or heat sink235includes a central body260that defines a central aperture265and a plurality of external apertures270. The central aperture265and the external apertures270extend along parallel offset axes such that they do not intersect and they extend the full length of the heat sink235. The central body260is substantially triangular in cross-section. Each of a plurality of arms275extends from the central body260and includes one of the light support surfaces240. In addition, a plurality of fins280extends from each of the light support surfaces240toward the central body260to provide additional surface area for cooling. The triangular shape of the central body260provides space for nine arms275with two arms275extending from each side of the triangular cross section and one arm275extending from each vertex. Of course other arrangements of the heat sink235are possible.

The central aperture265includes a plurality of interior fins285that further increase the surface area in the central aperture265. Additionally, the external apertures270provide more surface area that can be utilized to enhance the cooling effect as air passes through the external apertures270and the central aperture265.

While the chimney100of the construction ofFIGS.1-12includes a single tube100that extends the full length of the light10, the construction ofFIGS.13-22includes a shorter tube225that cooperates with the central aperture145to complete the cooling flow path230. The chimney225, best illustrated inFIG.19, extends from the bottom of the light200to the bottom of the heat sink235where it connects to the heat sink235. In the illustrated construction, the chimney225threadably engages the heat sink235with other attachment methods also being possible.

A shorter tube290, shown inFIG.18, is connected to the top of the heat sink235to complete the cooling flow path through the light200. A cap295is placed on top of the opened short tube290to cover the opening to reduce the likelihood of water entering the cooling flow path230. As with the larger tube or chimney225, the short tube290threadably engages the heat sink235. The cap295can attach using a simple frictional engagement or can threadably attach to the shorter tube290as desired.

In operation, the user uses a power button55to actuate the light200and select an operating mode. The power control circuit or charging circuit40determines where power for the LEDs245should come from. First the power control circuit40determines if AC power is available from an external source. If AC power is not available, the power control circuit40will use the battery packs25if they are positioned in the battery pack ports20. If only one battery pack25is present, power will be drawn from that battery pack25. If two battery packs25are present, the power control circuit40first determines the state of charge for each of the battery packs25and then selects the battery pack25with the lowest state of charge to deliver power to the LEDs245much like the embodiment ofFIGS.1-12.

As the LEDs245operate, they emit light and produce heat. The heat conducts into the heat sink235and increases the temperature of the heat sink235. The higher temperature of the heat sink235heats the air within the central aperture265, the external apertures270, and the air around the various fins280. As the air is heated it rises, thereby producing a natural convection current through the heat sink235. In the natural convection current, cool air enters the cooling flow path through the bottom opening in the tube or chimney225. The air rises through the tube225, through the central aperture265, into the short tube290and out the top of the light200to complete the cooling flow path. Similarly, air flows through the external apertures270and the various fins280from the bottom of the heat sink235to the top of the heat sink235to enhance the cooling ability of the heat sink235.

FIG.23illustrates an area light1000that is operable under either AC power or DC power. The illustrated area light1000includes a foot1014, a base1018, a body1022, and a head1026. The foot1014forms a platform that supports the base1018and the remainder of the area light1010. The body1022is positioned above the base1018and is supported by the base1018. The head1026extends from the body1022and forms the topmost portion of the area light1010.

FIGS.24-25better illustrate the head1026, which is hexagonally shaped and includes six tubes1030connected by six arms1034. The arms1034extend radially inward to couple the head1026to the body1022. As shown inFIG.24, the foot1014similarly defines a hexagonal shape that includes six tubes1038connected by six legs1042. The legs1042couple the foot1014to the base1018. The tubes1038of the foot1014and the tubes1030of the head1026can be used as carrying handles when transporting the area light1010. The foot1014and the head1026can take on other shapes, for example, a circle, square, or octagon as may be desired.

With reference toFIGS.27-30, the body1022includes a main housing1050, a plurality of lights1054, a plurality of heat sinks1058, a plurality of spacers1064, and a central tube1062. The main housing1050extends vertically from the base1018to the head1026and includes a cylindrical upper portion1066and a sloping or frustoconical lower portion1060. The main body1022is hollow and partially houses the central tube1062. The central tube1062extends vertically from the body1022into the base1018and provides structural support for the area light1010as well as some heat dissipating capacity. The lower portion1060is wider than the upper portion1066near the base1018and narrows into the upper portion1066. The lower portion1060includes six ribs1070spaced around the circumference of the area light1010to define six slots1068with each slot1068being wide at its lower portion1060and narrowing as it approaches the upper portion1066. Each of the spacers1064sits on one of the ribs1070and extends vertically upward to separate the slots1068in the upper portion1066.

With reference toFIG.30, the heat sinks1058are positioned around the upper portion1066of the main housing1050of the body1022. The heat sinks1058connect to the main housing1050and extend parallel to one another in a vertical direction with each heat sink1058disposed within one of the slots1068adjacent the upper portion1066of the main housing1050. Each heat sink1058includes an arcuate plate1076that supports two radially extending legs1072. At the end of each leg1072a light receiving structure is formed. In the illustrated construction, the light receiving structure includes a slot sized to receive the individual lights. A plurality of fins1080extend from each of the legs1072to provide increased surface area for the heat sinks1058. An annular disk1074, best illustrated inFIGS.24-25covers the top of the heat sinks1058and includes slotted vents1078arranged above each of the heat sinks1058. The heat sinks1058absorb some of the heat produced by the lights1054to help keep the lights and the internal components of the area light1010cool.

As illustrated inFIG.32, the plurality of lights1054include a plurality of individual LEDs arranged on an elongated strip that is sized to be supported by one of the heat sinks1058in one of the slots1072. In preferred constructions, the strip includes a circuit board that provides the necessary electrical connections to each of the individual LEDs and also thermally couples the LEDs and/or the circuit board to the heat sinks1058. As shown inFIG.32, the strips supporting the LEDs extend parallel to one another and parallel to the heat sinks1058in a vertical direction. While LEDs are used in the illustrated construction, other types of lights could be used in place of or in conjunction with LEDs if desired.

As illustrated inFIG.25, the illustrated area light1010also includes a series of lights1086(preferably LEDs) disposed above the heat sinks1058and arranged to emit light upward. The LEDs1086are coupled to a metallic plate that is thermally coupled to the heat sink to provide cooling.

With reference toFIGS.25-26, the base1018extends from the body1022to the foot1014. The base1018includes panels1090that form a generally hexagonal frame1094. In some embodiments, the base1018includes an elongated handle1098disposed on the frame1094and extending along one of the panels1090of the frame1094. In some embodiments, the base1018includes two projections1102coupled to the exterior of the frame1094. The illustrated projections1102are cord wraps that allow an electrical cord to be wrapped around the two projections1102when the area light1010or the cord are not in use.

The base1018houses electrical components of the area light1010. As shown inFIGS.25-26, the base1018includes an AC power input1106, AC power outlets1110, and rechargeable battery slots1116. The power input1106connects the area light1010to an AC power source to power the area light1010. The power outlets1110connect the area light1010to other devices to power those devices. For example, in some embodiments, the power outlets1110can connect to other area lights so that a series of area lights1010can be daisy-chained together to illuminate a larger area. In other embodiments, the power outlets1110can connect to power tools to power the power tools. The base1018also supports a power distribution circuit1114and any electrical components needed for the power distribution circuit1114(e.g., switches, transformers, heat sinks, a control system (including a processor, memory or other data storage, and an input/output interface), rectifiers, inverters, and the like).

The power distribution circuit114is arranged to control the distribution of electrical power to the lights and to or from any available battery packs1118. The power distribution circuit1114is electrically connected to each of the battery slots1116, the AC power input, the AC power output, and the LEDs to distribute power as required.

In the illustrated construction, the battery packs1118are power tool battery packs1118that are designed and manufactured for the purpose of powering power tools such as drills, saws, and the like. In preferred constructions, the battery packs1118are arranged to operate at 18 volts or higher. Each of the battery slots1116is arranged to receive one of the battery packs1118for use in supplying power to the area light1010or for recharging of the battery pack1118.

The base1018further includes a control panel1122for controlling the operation of the area light1010, as shown inFIG.13. The control panel1122includes, among other things, a power button1126, a light intensity control1130, a light intensity indicator1134, and a power source indicator1138. The light intensity control1130allows a user to increase or decrease the intensity of the light. In the illustrated construction, there are three intensity settings when the area light1010is using DC power and six intensity settings when the area light1010is using AC power. The light intensity indicator1134includes a plurality of indicator bars1142that depict the level of intensity that the light is supplying. Additionally the indicator bars1142appear one color when the area light1010is using DC power and a different color when the area light1010is using AC power. The power source indicator1138includes a second set of indicator bars1146that depict the amount of power remaining in the DC power source.

In operation, the user first activates the light by depressing the power button1126or otherwise activating the area light1010. If AC power is connected to the area light1010via the power inlet, the lights are activated and illuminated at the selected setting. In a preferred construction, the controller provides for a soft start feature for the lights. During a soft start, the level of illumination is slowly brought up to the selected level rather than immediately transitioning to the full illumination. The user can select any one of the six available illumination levels by depressing the illumination up or down buttons as required. The display includes a visual indication of the selected illumination level. In the illustrated construction, the visual indication includes six bars1142or lights with additional bars1142turning on as the level is increased. Of course, other constructions could employ different visual indicators.

If one or more battery packs1118are installed in the battery slots1116, the controller will determine the level of charge for each of the battery packs1118. In some constructions, a display is provided to illustrate the charge level of each of the battery packs1118. If one or both of the battery packs1118require charging, power is delivered to the battery port to charge the battery packs1118. The controller selects one of the ports to receive power until that battery pack1118is fully charged. Once charged, the controller will direct power to the other battery pack1118to complete the charging. Power is also available at the AC outlets if desired.

When no AC power is provided to the area light1010, the area light1010will provide illumination using any available DC power from any attached battery packs1118. The controller will determine the total power available from the battery pack1118or battery packs1118attached to the area light1010. Based on this available power the controller may override the users selected illumination level to extend the duration that the light1010can operate. For example, if the controller determines that the level of power available will only power the light1010for one hour at the selected level, the controller may select one illumination lower to extend the operating time to something greater than one hour.

Although multiple battery packs1118can be inserted into the power distribution circuit1114at a given time, the illustrated area light1010only utilizes one battery pack1118at a time. The area light1010will utilize one battery pack1118until that battery pack1118has been fully drained of power. Then, the next battery pack1118will begin powering the area light1010. In other words, the area light1010is configured to utilize the battery packs1118sequentially, one at a time.

Additionally, during operation the LEDs generate a large amount of excess heat. The heat is drawn from the LEDs into the heat sinks1058where the heat is dissipated. The arrangement of the main body1050further enhances the dissipation rate. Specifically, the vertical orientation of the heat sinks1058within the slots1068produces a chimney effect. As the air around each heat sink1058is heated, it naturally rises. The rising air draws additional cooler air into the slots1068via the slopping portion1060of the main body1050. Thus, the arrangement produces a natural draft to increase the convention rate between the air and the heat sinks1058.

It should be noted that any feature described with regard to one construction is equally applicable to any of the other constructions described herein.

Various features and advantages of the invention are set forth in the following claims.