High-intensity, water- and shock-resistant flashlight

[0002] The invention relates to flashlights, particularly of the high-performance, high-intensity variety.

[0003] Particular niches have developed requiring very bright, durable flashlights. One such niche is law enforcement, where a police officer acting on a call at night will require high quality illumination of an investigation site. If the officer must chase a suspect, the flashlight must stay active despite the removal of the officer's finger from the switch and despite any shock the flashlight might experience during the chase including being dropped. If the officer must extinguish the flashlight in a hurry, its switch must operate easily and conveniently enough that the officer can extinguish the light without removing his or her attention from his or her investigation.

[0004] Another niche requiring bright, durable flashlights is search and rescue. Many of the requirements for search and rescue are the same as those for law enforcement. However, search and rescue often requires water resistance and penetration by the light beam through smoke, dust, fog, and other vision impairing atmospheric anomalies.

[0005] A third niche requiring bright, durable flashlights is diving, such as SCUBA diving. While the shock requirements are not as stringent as those for law enforcement and search and rescue, diving requires a high degree of water resistance and the ability of the light beam to penetrate through murky water.

[0006] Several bright, durable flashlights are available to these niches, but all currently available flashlights have drawbacks. One drawback is that none of the currently available flashlights can endure much in the way of shock; a fall from six feet onto concrete will render most useless. Another drawback is inadequate penetration of vision impairing anomalies, such as fog or murky water; the emission spectrum and light output of most currently available flashlights simply can not go very far through such anomalies. A drawback of those that can penetrate these anomalies to at least some acceptable degree is that they require additional, external power packs that are heavy and unwieldy.

[0007] My invention overcomes all of the drawbacks of the prior art by including a superior shock absorbing system, a superior light delivery system, and a superior power system. The shock absorbing system uses coaxial resilient annuli to support the bulb, absorbing impulse energy delivered to the bulb as the result of an impact of the casing against a more massive object (such as a concrete floor). This easily protects the bulb from a drop of six feet onto a concrete floor, and even allows a user to pound a large nail into a 4×4 with the bell of the flashlight without significant damage to the inner workings of the flashlight.

[0008] The light delivery system employs a metal halide bulb that produces light at an order of magnitude greater intensity than conventional halogen bulbs. Using this bulb, my flashlight can illuminate a spot up to ¾ mile away and can cut through fog, precipitation, and murky water.

[0009] I include a magnetic reed type switch that is self cleaning and allows for easy replacement. The switch includes a retractable shoulder strap mount.

[0010] FIG. 1 is an elevational side view of an embodiment of my flashlight.

[0011] FIG. 2 is a cross section of the flashlight show in FIG. 1.

[0012] FIG. 3 is an elevational side view of the shock absorption system, reflector, and bulb of the flashlight shown in FIG. 1.

[0013] FIG. 4 is an elevational side view of the shock absorption system as shown in FIGS. 1-3.

[0014] FIG. 5 is cross section of the shock absorption system, reflector, and bulb shown in FIG. 3.

[0015] FIG. 6 is a cross section of the shock absorption system shown in FIG. 4.

[0016] FIG. 7 is an elevational top view of the shock absorption system of the flashlight shown in FIGS. 1-6.

[0017] FIG. 8 is an elevational bottom view of the shock absorption system shown in FIGS. 1-7.

[0018] FIG. 9 is an elevational top view of the switch assembly of the invention shown in FIG. 1.

[0019] FIG. 10 is a schematic elevational view of a switch plate of the invention.

[0020] FIG. 11 is a schematic elevational view of a recess usable in the switch assembly of the invention.

[0021] FIG. 12 is a schematic elevational top view of a guide usable in the invention.

[0022] FIG. 13 is a schematic side view of the guide shown in FIG. 12.

[0023] FIG. 14 is a schematic front view of the guide shown in FIGS. 12 and 13.

[0024] FIG. 15 is a schematic top view of a switch block usable in the invention.

[0025] FIG. 16 is a schematic bottom view of the block shown in FIG. 15.

[0026] FIG. 17 is a schematic side view of the block of FIGS. 15-16.

[0027] FIG. 18 is a schematic front view of the block of FIGS. 15-17.

[0028] FIG. 19 is a schematic rear view of the block of FIGS. 15-18

[0029] FIG. 20 is a schematic side view of a shoulder strap mount usable in the invention.

[0030] FIG. 21 is a schematic bottom view of the shoulder strap mount of FIG. 20.

[0031] The invention is part of a flashlight 1 shown generally in FIGS. 1 and 2 with a bell 2, handle 3, and butt 4, the butt 4 including a cap 5 and the bell 2 including a retainer 6. Outer bell and butt seals 7, 8 engage the retainer 6 and cap 5, respectively, to provide water resistance. An inner butt seal 38 sits in cap 5 and engages a rear edge of butt 4 when cap 5 is on butt 4. A switch assembly 10, including a switch block 11, provides control over power to the bulb 32 of the flashlight 1.

[0032] As seen in FIGS. 2-8, the invention includes a shock-resisting member 40 of resilient material in the bell 2 that supports the reflector 33 and helps to seal against water leakage into the bell 2. The member 40 has an inner portion 41 with a thin annulus of material 42 at the rear and a frustroconical middle section 43 that extends between the rear section and a front annular section 44. The rear thin annulus 42 is thicker radially than longitudinally, its inner periphery engaging the rear of the reflector 33 and its outer periphery joining the rear of the middle section. An outer portion 45 of the member is substantially annular and its outer periphery engages the inner periphery of the mouth of the bell 2 to prevent rotation and backward motion of the member 40. The outer periphery of the outer portion 45 and inner periphery of the bell 2 preferably include a mechanical arrangement, such as teeth, that allows insertion of the member into the bell 2 in only one orientation to ensure proper assembly. The inner periphery of the bell 2 and the outer periphery of the outer portion 45 also preferably include corresponding marks indicating to the user the proper positioning of the member for quick insertion.

[0033] Part of the outer portion 45 overlies the front annular section 44 of the inner portion 41 so that an annular gap extends between the inner and outer portions 41, 45. At the front of the annular gap, and also at the front of the front annular section 44 of the inner portion 41, a thin annulus 46 extends outwardly to the outer portion 45, the thin annulus 46 allowing limited motion of the inner portion 41 of the member 40 forwards, backwards, and sideways so that, in the event of an impact, the reflector 33 can not hit the wall of the bell 2 or any of the components behind the reflector 33, yet still does not experience the full impulse imparted to the flashlight 1 by the impact. A plurality of blocks 47 extend backward from the thin annulus 46 and between the outer and inner portions 45, 41 to further limit motion of the reflector 33 and strengthen the member 40. Preferably, the blocks 40 are substantially hollow. The very front of the member 40 engages a metal ring 35 that rests between the member 40 and a cover gasket 37 that holds the transparent cover or lens 36. A retainer 6 screws down over the mouth of the bell 2 to hold the cover gasket 37, metal ring 35, reflector 33, and member 40 in place and engages an outer gasket 7 mounted on the outer periphery of the bell 2. Together, the cover gasket 37, outer gasket 7, and retainer 6 render the bell 2 water resistant to 100 meters. Preferably, the outer portion 45 includes a metal ring embedded therein to provide extra strength and rigidity. The cover gasket 37 is also arranged to absorb some of the impulse.

[0034] The invention also includes a magnetic switch 10, shown in FIGS. 1 and 9-21 that operates the flashlight 1 without intruding into the interior of the casing to provide water and dirt resistance. While magnetic switches themselves are not new, the invention includes an arrangement of the switch that is self-cleaning and easy to replace. A block 11 and a guide 12 sit in a recess 13 in the exterior of the handle 3 casing and retained within the recess 13 by a switch plate 14 held on by screws 15. A gasket around the recess 13 engages the switch plate 14 and the casing of the handle 3 to retard entry of dirt and other debris into the recess 13. The recess 13 includes an outer wall 16 and two cross walls 17 with central apertures 18 through which necks 19 of the guide 12 extend, and between which a body 20 of the guide extends. The guide 12 and recess 13 include detents 21 that hold the block 11 of the switch 10 in off, partial on, and full on positions. The block 11 includes fore and aft runners 22, 23, the fore runners 22 engaging the detents 21 in the guide 12 and the aft runners engaging the detents 21 in the recess 13. The fore runner 22 is preferably resilient and is arranged so that depression of the block 11 into the recess 13 compresses the fore runner 22 and pivots the aft runners 23 out of engagement with detents 21 corresponding to the position the block 11 occupies, thus allowing the user to move the block 11 to a different position. The runners 22, 23 are shaped so that any debris entering the switch 10 is removed by operation of the switch 10, and if it can not be purged in this manner, the switch 10 can be easily disassembled for more intensive cleaning. The block 11 preferably holds a permanent magnet 24 that closes a circuit within the casing of the handle 3 when moved to an on position.

[0035] The switch assembly 10 includes a retractable shoulder strap mount 25 in a head of the guide 12 lying between the front cross wall 17 and the front portion of the outer wall 16 of the recess 13. The mount 25 slides in and out of the casing and is held in each position by interaction with mechanical detents 26 that hold in each position until sufficient force is applied to release button 27 to disengage the detents 26. The shoulder strap attaches to a hole 28 in the mount 25 and to a cap attachment point 9 in the cap 5.

[0036] The flashlight 1 includes a metal halide bulb 32 mounted in the rear of the reflector 33 that produces an extraordinary amount of light for its size and power consumption. To drive the bulb 32, driving circuitry 30 is mounted in the casing of the handle 3. Driving circuitry for such bulbs is known in the art and so disclosure of the details of its fabrication are unnecessary to enable one to make and use the instant invention. Though the interior of the casing is water-resistant to 100 meters, I encase the circuitry in resinous material to further protect against contamination by water. An additional advantage of encasing the driving circuitry in such a fashion is that the resinous material acts as a heat sink and draws heat away from the driving circuitry.

[0037] 1 Flashlight

[0038] 2 Bell

[0039] 3 Handle

[0040] 4 Butt

[0041] 5 Cap

[0042] 6 Retainer

[0043] 7 Outer bell seal

[0044] 8 Outer butt seal

[0045] 9 Cap shoulder strap attachment point

[0046] 10 Switch assembly

[0047] 11 Block

[0048] 12 Guide

[0049] 13 Recess

[0050] 14 Plate

[0051] 15 Screws

[0052] 16 Outer wall

[0053] 17 Cross walls

[0054] 18 Apertures

[0055] 19 Necks of guide

[0056] 20 Body of guide

[0057] 21 Detents

[0058] 22 Fore runner of block

[0059] 23 Aft runner of block

[0060] 24 Magnet

[0061] 25 Retractable strap mount

[0062] 26 Strap mount engaging detent

[0063] 27 Release button

[0064] 28 Hole

[0065] 29 Power source/battery

[0066] 30 Driving circuitry

[0067] 31 Bulb holder

[0068] 32 Bulb

[0069] 33 Reflector

[0070] 34 Front lip of reflector

[0071] 35 Washer/metal ring

[0072] 36 Lens

[0073] 37 Inner bell seal/Lens holder/cover gasket

[0074] 38 Inner butt seal

[0075] 40 Shock resisting member/absorption system

[0076] 41 Inner portion of resisting member/rear portion

[0077] 42 Rear annulus

[0078] 43 Frustroconical middle section

[0079] 44 Front section

[0080] 45 Outer portion

[0081] 46 Thin annulus between inner and outer portions

[0082] 47 Blocks