Reflector

The light reflector assembly disclosed herein is provided to minimize labor by utilizing automatic progressive dies to form all electrical contact and buss work from a coil or sheet of electrically conductive metal with or without corrosive resistant plating.

After formation of the contact and the buss work the last stage of the progressive die automatically inserts (by means of mechanical transfer) these formations onto a plastic reflector. The reflector has posts which accept the contacts and buss work. The contact and buss work are, in turn, secured to the reflector by means of "tinnerman" type locks already formed on the metals by progressive dies. These can also be accomplished by heat staking or heat heading the posts.

The injection molded reflector also contains support to hold a printed circuit card which contains the circuit and switching means. The end result is the elimination of any wiring from the PC Card to the battery and fluorescent tube contacts. These connections are constructed by the method mentioned above, placed so as to make contact with the proper terminal areas. The plastic plate has mounds which have the function of directing any misaligned battery contacts to the proper contact area. Trusses from the reflector are aligned to support the battery pick-up contacts to avoid contact deflection and arrangement of the battery pick-up contacts enable standard (coil type contact) 6 volt lantern batteries to be inserted in any manner of contact orientation while assuring proper battery voltage polarity to the ballast on the PC board.

The switch is aligned on the PC Card in such a manner that it protrudes through a preformed window in the lantern case after assembly. Since the negative contact on the battery is common to one end of the fluorescent tube in the circuit, the connection can be made by means of an extention of the B-contact plate into the appropriate fluorescent tube holder.

It is an object of the invention to provide an improved fluorescent light reflector.

Another object of the invention is to provide an improved assembly of contact and fluorescent lamp reflector with printed circuit card that can be formed by a continuous progressive die.

Another object of the invention is to provide an improved combination battery and terminal connections and printed circuit card and reflector.

Another object of the invention is to provide a reflector and circuit arrangement for a battery operated light, that is simple in construction, economical to manufacture and simple and efficient to use.

With the above and other objects in view, the present invention consists of the combination and arrangement of parts hereinafter more fully described, illustrated in the accompanying drawing and more particularly pointed out in the appended claims, it being understood that changes may be made in the form, size, proportions, and minor details of construction without departing from the spirit or sacrificing any of the advantages of the invention.

FIG. 1 is an isometric view of the light according to the invention.

FIG. 2 is a side view of the light shown in FIG. 1.

FIG. 3 is a rear isometric view of the reflector.

FIG. 4 is an assembly of the terminal support board and first contact plate and second contact plate, and third contact plate.

FIG. 5 is an isometric view of the high voltage contact.

FIG. 6 is an isometric view of the printed circuit card.

FIG. 7 is a view of the terminal support board.

FIG. 8 is a view of the first battery pick-up plate.

FIG. 9 is a view of the second battery pick-up plate.

FIG. 10 is a view of the third battery pick-up plate.

Now, with more particular reference to the drawings, a reflector assembly 10 and contact assembly is shown made up of a reflector 11, the reflector has a concave reflecting first side 12 and second side 13. The lamp 14 is supported on the first side. The reflector has a plurality of the first trusses 15, 16, 17 and 18 and second on a side in the contact plate 19 is supported on the trusses. The trusses 15, 16, 17 and 18 have posts 30 which extend through openings in the support plate 19 and through the Tinnerman fasteners on the first terminal plate 28 and second terminal plate 29 and third terminal plate 44. The second trusses 24 and 26 have posts 36 and 37 that are received in openings in the printed circuit card 23. The printed circuit card 23 has a switch 38 with an actuating member 39 which extends out through a window in the case 40 of the light. The first terminal plate 28, the second terminal plate 29 and the third terminal plate 44 form contacts for the battery. The battery is guided into position by the mounds 35 on the support plate.

The high voltage contact 32 has a contact member 31 that engages the elements on the bottom of the printed circuit card 23. The terminals 43 and 42 on the contact plate 28 and on the contact member 44 engages terminals on the circuit card 23. When the contact plate 19 is supported on the trusses 15, 16, 17 and 18 with the posts 30 extending through the opening therein and up through the Tinnerman fasteners on the first, second and third terminal plates, these elements are held in position. A post 31' holds the high voltage contact 32 on the reflector 11. The battery terminals are guided onto them by mounds 35 on the support plate 19. The printed circuit card has the switch 38 and an electronic element 45, and 46 to supply energy to 47 and 48. The light has two batteries 50 and 51 that are received in the lamp case. Each has a center terminal B+ and a side terminal B-. The center terminal on battery 50 engages contact 44 while the side terminal engages the one of the legs 52, 53 or 54 on contact plate 29. The center terminal on battery 51 engages leg 36 on plate 28, while the side terminal on battery 50 engages one of the legs 55, 56 or 57 on plate 28, thereby connecting the batteries in series with each other. The terminal ends 42 and 43 engage terminals on the PC board, connecting battery positive terminal and battery minus to the printed circuit board 23. Terminal 60 extends through a hole in reflector 10 like hole 53 and engages a terminal on the end of lamp 14 opposite terminal 52.