Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is related to and claims priority from earlier filed U.S. Provisional Patent Application No. 60/557,234, filed Mar. 29, 2004. 

   BACKGROUND OF THE INVENTION 
   The present invention relates generally to a sealed flashlight assembly. More specifically, the present invention relates to a new portable flashlight assembly and more particularly to compact flashlight assembly that is highly durable and completely sealed against the effects of environmental pressure changes while also being constructed for easy mounting and integration into a variety of applications. 
   Typically, in prior art flashlights manufactured for use underwater, one of the major problems is making the assembly watertight. Waterproofing the operable components of the switch tends to be particularly troublesome. Often rubber diaphragms and covers have been used as outer seals and the switch must be operated through the seal. After prolonged use, these seals wear and are prone to leakage. Other parts, such as removable ends for replacement of battery and bulb, also must be sealed and servicing the unit often results in damage to or destruction of the seals. Further, if these flashlights are configured for use in deep water at depths approaching 350 feet below sea level, they typically require a pressure-equalizing valve to prevent them from imploding from the force of the surrounding environmental pressures. This problem is further complicated when the same light is also required to operate at high altitudes such as at 35,000 feet above sea level. Again, a pressure-equalizing device must be incorporated to prevent the light from exploding from a build up of internal pressures. Generally, the pressure-equalizing device used for underwater applications will fail at high altitudes and the high altitude device will fail in deep water. 
   These pressure equalization issues are exacerbated by the fact that the portable flashlights in the prior art typically include a cylindrical housing that encloses the light source, power source, required circuitry, the operable switch element and a relatively large volume of air. It is this volume of air that has the greatest effect on the ability of the flashlight to transition from high altitude operation to deep-sea operation. Further, the slide type switch or a spring loaded button type switch of these prior art flashlights require that a portion of the operable components reside on the exterior of the light while another portion is positioned on the interior resulting in a weak point at the interface between these operable elements. 
   Accordingly, there is a need for a flashlight that substantially eliminates the operational disadvantages of prior art flashlights. There is also a need for a flashlight that has a hermetically sealed interior that eliminates substantially all of the air from the interior of the flashlight while also preventing the entry of moisture thereinto. There is a further need for a flashlight that can be actuated using interior and exterior components that do not require a physical interface thereby eliminating a weak point in the housing. There is yet a further need for a sealed flashlight that can serve a variety of different functional needs and provide an ability to interface with a broad range of other equipment. 
   BRIEF SUMMARY OF THE INVENTION 
   In this regard, the present invention provides for a novel lighting assembly that incorporates a high brightness LED in a compact assembly that is sealed and sufficiently durable for a continuous operational range of between 350 feet below sea level and 35,000 feet above sea level. The light includes at least one high brightness light emitting diode to provide high intensity light. The output range may be in any visible light color. Preferably, the output will be in the visible white range either by using an Indium Gallium Nitride/Gallium Nitride chip with a phosphor coating such as a Nichea white LED. Similarly, as would be obvious in the art other white LED&#39;s could easily be substituted for the same effect. For example, an Aluminum Indium Gallium Arsenide LED could easily be substituted. Further, any other white light source such as incandescent, halogen or xenon could also be used. 
   The flashlight may also include auxiliary lighting functions in combination with or in place of the white light element. The present invention may also include a red light diode for night vision operations, an infrared diode for use in conjunction with night vision goggles or a laser diode for automated firing or targeting systems. Any of these features may be included either alone or in combination in the flashlight of the present invention. 
   Further, the flashlight of the present invention includes a novel modular interface arrangement that allows the flashlight to be interfaced with a variety of different equipment or reconfigured in order to facilitate use for different functionality such as a marker light, a runway indicator light or a weapon mounted light. 
   It is therefore an object of the present invention to provide a flashlight that has an operational range that exceeds the operational limits encountered with prior art flashlights. It is a further object of the present invention to provide a flashlight that has a hermetically sealed interior and which eliminates substantially all of the air from the interior of the flashlight while also preventing the entry of moisture thereinto. It is yet a further object of the present invention to provide a flashlight that can be actuated using interior and exterior components that do not require a physical interface thereby eliminating a weak point in the housing. It is still a further object of the present invention to provide a sealed flashlight that can serve a variety of different functional needs and provide an ability to interface the flashlight with a broad range of other equipment and accessories. 
   These together with other objects of the invention, along with various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed hereto and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated a preferred embodiment of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the drawings which illustrate the best mode presently contemplated for carrying out the present invention: 
       FIG. 1  is a front perspective view of the flashlight of the present invention; 
       FIG. 2  is a front view of the flashlight of the present invention with the modular accessory mount removed; 
       FIG. 3  is a bottom perspective view of the flashlight of the present invention with a modular clip installed in place of the modular accessory mount; 
       FIG. 4  is a bottom perspective view of the flashlight of the present invention with the modular clip removed; 
       FIG. 5  is a perspective view of the flashlight of the present invention received on a belt using the modular interface; 
       FIG. 6  is a perspective view of the flashlight of the present invention with a lanyard attached to the modular accessory mount; 
       FIG. 7  is a perspective view showing a gimbal installed on the modular accessory mount; 
       FIG. 8  is a perspective view showing a clip received in place of the modular accessory mount; 
       FIG. 9  is a front view showing a stake installed on the modular accessory mount and a diffuser installed over the output end of the flashlight; 
       FIG. 10  is an exploded perspective view showing the flashlight, stake and diffuser; and 
       FIG. 11  is a cross-sectional view taken along line  11 - 11  of  FIG. 1 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Now referring to the drawings, the lighting assembly of the present invention is shown and generally illustrated in the figures as  10 . The lighting assembly  10  is the central component for the modular system described herein. The lighting assembly  10  can be seen to include an outer housing  12 , at least one slide switch  14 , a head assembly  16  and a modular interface  18  for receiving various modular accessories including the modular accessory mount  20  shown. 
   The outer housing  12  of the lighting assembly  10  of the present invention is configured in a novel manner to allow its integration into various systems and configurations. The outer housing  12  is formed to include a modular interface  18  that serves as one end of a detachable clip element. As can best be seen in  FIG. 2 , the modular interface  18  is shown as being formed as a female receptor end of a detachable clip assembly. Similarly, although not shown, the modular interface  18  provided on the housing  12  of the lighting assembly  10  may be formed as a male end. This allows the corresponding male or female portion to be formed on a variety of other devices such as a modular accessory mount  20 . By providing a modular interface  18 , the lighting assembly  10  can easily be mounted and de-mounted allowing modular accessories to be interfaced with the lighting assembly  10  as desired. 
   The modular accessory mount  20  in its simplest form may be a clip with holes  22  provided therein to facilitate attachment of other accessories.  FIGS. 3 and 4  illustrate a clip accessory  24  that is attached to the modular accessory mount  20  by installing fasteners  26  into the holes  22 . Optionally, accessories may be joined with the accessory mount  22  by riveting, heat staking or direct molding. Similarly,  FIG. 5  illustrates the modular accessory mount  20  attached to a belt or strap  28  with the lighting assembly  10  engaged onto the accessory mount  20 . In this manner, the strap  28  can be worn as a belt, an armband or a headband allowing the lighting assembly  10  to be worn on in a convenient location by the user.  FIG. 6  illustrates a lanyard loop  30  that is passed through the holes  22  in the accessory mount  20  allowing the lighting assembly  10  to be worn around the user&#39;s neck or tied in a desired hanging location.  FIG. 7  further illustrates a swivel or gimbal  32  that is mounted into the rear of the accessory mount  20 . The swivel  32  is also capable of receiving a lanyard loop  30  in the hole  34  provided therein if desired.  FIG. 8  alternately shows that the accessory mount  20  may be formed into different configurations such as a key ring extension  21  with a spring type lock  23 . 
   Turning now to  FIGS. 9 and 10 , to further tailor the lighting assembly  10  to the desired military applications, the accessory mount  20  is shown coupled to a stake  36  to allow the lighting assembly  10  to be staked into a desired location on the ground. The stake  36  allows the lighting assembly  10  to be positioned in a manner that allows it to serve as a locator beacon or a runway marker. To enhance the operation as a runway marker, a diffuser element  38  is shown installed over the output end of the lighting assembly  10 . 
   Turning to  FIG. 11 , the internal components and the operation of the lighting assembly  10  is illustrated. The lighting elements  40  are mounted to a circuit board  42  and extend through openings  44  in a head assembly  16 . As was stated above, the preferred lighting element  40  is a high intensity white LED, although any diode element available on the market including an LED in the visible range, an infrared diode, an ultraviolet diode or a laser diode may also be incorporated into the lighting assembly  10  and still fall within the scope of the present invention. The joint around the LED  40  optical portion is sealed using a potting compound  46 , silicon or epoxy material. Also contained on the circuit board  42  are magnetic sensor elements  48  such as Hall effect sensors or mechanical reed switches, operational circuitry and a power source  50  such as a high capacity coin cell battery. The circuit board  42  and head  16  are placed into a housing enclosure  12 . The void  52  within the enclosure  12  is then injected with a potting compound such as an epoxy or a silicone material to seal the entire assembly and evacuate any air within the housing  12 . To further enhance the sealing process and evacuate any air, the lighting assembly  10  may be placed in a vacuum environment before injecting the sealant material. 
   Operation of the lighting device  10  is accomplished using slide switches  14  placed on the exterior of the housing  12 . The slides  14  have magnets  54  therein that are positioned above the magnetic sensors  48 . Depending on the specific position of the magnet  54  relative to a particular sensor  48 , the circuitry on the circuit board  42  will operate the lighting assembly  10  in a particular manner. For example, one switch  14  may determine which lighting function will operate while another slide  14  may regulate intensity and a third slide  14  would control function such as constant on or strobe. 
   Each switch slide  14  may use any number of sensors  48  and/or magnets  54  from at least one to any greater number, depending on the number of functions desired to be controlled by the switch assembly  14 . The sensors  48  are all electrically connected to a computer logic chip  56  via circuit traces on the surface of the circuit board  42 . When a magnet  54  is placed directly above one of the sensor positions  48  the sensor  48  detects a magnetic field generated by the magnet  54  and creates an “ON” condition that is sensed by the computer chip  56 . In the same manner an array of magnets  54  may be provided in the slide actuator  14  that can be selectively positioned over the array of sensors  48  to create numerous combinations of “ON” and “OFF” codes. 
   In this manner it can be seen that the present invention provides a completely sealed lighting assembly  10  is provided with a greater operational range than was previously known in the art, while also providing a modular interface that promotes integration of the lighting assembly  10  into a variety of configurations. For these reasons, the instant invention is believed to represent a significant advancement in the art, which has substantial commercial merit. 
   While there is shown and described herein certain specific structure embodying the invention, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying inventive concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims.

Technology Category: f