Note: Descriptions are shown in the official language in which they were submitted.
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Field of the Invention
This invention relates to a flashlight switch
assembly and more particularly concerns a magnet-push-
button-switch combination for a flashlight.
Background of the Invention
Flashlights presently available are generally
fabricated with various sliding switches which are
activated from the outside of the flashlight casing.
These types of flashlights generally require a switch
arrangement whereby sliding means disposed on the outside
of the casing have to be moved parallel to the axis of
the casing to complete the electrical circuit within
the flashlight which~ ln the presence of conventional
cell~, causes the bulb to light. Ihis type switch
arrangement usually can be unlntentionally actuated
while being stored in a rather confined compartment or
when the switch member of the flashlight is accidentally
bumped against an ob~ect.
j Another type of flashlight, as disclosed in
~i 20 U. S. Patent 3,539,800 to Doring et al, emphasizes a
magnet assembly mounted within the battery casing of
the flashlight having spring means for retalning two
elongated magnet members of the assembly within the wall
,.
of the battery casing. The magnet assembly is substan-
tially hidden within the battery casing when not in use
but the ma8net members partially protrude from the battery
casing when the flashlight is positioned near a magnet
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106~4~0 9725
attracting surface so that it magnetically attaches the
flashlight to the surface. This type flashlight employs
a separate sliding switch assembly for activating the
flashlight to the "on" or "off" position.
U.S. Patent 2,886,664 to Graubner discloses a
magnet-switch combination for flashlights wherein magnet
means and switch means are mounted in an assembly that
slides on the battery casing of the flashlight. Again
this type of magnet-switch arrangement can result in
the flashlight being unintentionally actuated if that
assembly housing said switch and magnet means accidently
bumps against an ob;ect~
It is an object of this invention to provide a
magnet-switch combination suitable for use in a flash-
~, light.
It is another object of this invention to provide
a novel magnet-switch combination for a flashlight wherein
` the magnet and switch actuating meàns are compactly
arranged in a non-slideable housing secured to the battery
casing of the flashlight.
Another object of this invention is to provide a
~, novel push button switch fixedly secured within the batterycasing and having its actuation means disposed in a housing
secured to the battery casing and which contains magnet
means for attaching the flashlight to a magnet attractive
sur~ace.
These and other objects are accomplished by
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having a push button switch adapted for mounting within
a battery casing while the actuation means for the switch
along with magnet means are disposed in a housing fixedly
secured to the outside of the battery casing.
Summary of the Invention
The invention relates to a flashlight c~mprising
a lens and reflector unit having a front open end adapt~ed
to be detachably mounted to a battery casing and having
a lens, a lens ring, a lamp holder adapted to accommodate
a lamp and containing a first contact means therein; a ::
battery casing provided with a first open end adapted to
receive a battery means and adapted to be detachably
mounted t~ an end cap for securing battery means therein,
a second open end at the opposite end thereof adapted
~o be detachably mounted to the front end of the lens and ::
re1ector unit, and wherein second contact means are
provided fox electrically connecting the interior vicinity
of the end cap to said first contact means; a push button
switch fixedly secured on a mounting bracket disposed within
the second open end of the battery casing with the button mem-
ber of the switch disposed within an opening in the wall of th~
battery casing adjacent the second open end thereof; a
housing member substant~ally disposed on the outer surface
of the battery casing and having an opening disposed therein
with magnetic means disposed in the surface of said housing
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member adjacent said opening, said housing member aligned
and secured to the battery casing such that the opening
in said housing member is aligned with the opening in
the wall of the casing so as to accommodate the button
member of the switch disposed in the opening in the wall
of the casing; a flexible boot member disposed and secured
over the opening in the housing member so that upon being
depressed, the boot will in turn depress-the button member
of the switch; and third contact means adapted through
actuation of the push button switch in the presence of a
lamp and battery means assembled in the flashlight to
complete or interrupt the continuity of an electrical cir-
cuit between the lamp and the battery means.
As used herein, the button member of the switch
can comprise one long extended member secured to a smaller
button member as shown in Figure 8 or it can comprise only
a relatively small button member as shown in Figure 9. In
the latter embodiment, the flexible boot would extend into
the opening in the wall of the battery casing and be disposed
therein so as to contact the button member of the switch
when said boot is depressed.
As used herein, the second contact means used
to connect the interior vicinity of the end cap, i.e.,
the vicinity within the end cap occupied by a conductive
member, such as a coil spring, that contacts one pole of
the battery disposed at the lower end of the battery casing,
can comprise one or more conductive strips and/or
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the battery casing, when the latter is made of a con-
ductive material. The primary function of the second
contact means is to provide a conductive path from one
pole of a battery to the first contact means contained
in the lens and reflector unit. It is also within the --
scope of this invention to have the switch function as
one of the contact elements in connecting the pole of
the battery disposed at the lower end of the battery casin~
to the first contact means in the lens and reflector unit.
This arrangement is disclosed in my U.S. Patent 3,798,440.
As used herein, battery means shall mean one
or more cells with the specific number and size being ~ ~-
governed by the size and shape o the battery casing. The
m~re conventional size battery casing usually accommodates
, two D-size or C-size cells.
i In one specific embodiment of this invention,
7 the battery casing can be of the usual metallic tubular
type in which the casing itself provides the electrical
path from the vicinity of the end cap to the vicinity of
; 20 the open end adapted to be detachably mounted to the
lens and reflector unit. In another embodiment where
1 .
the battery casing is made of a nonconductive material,
then a conductive strip would have to be employed to
electrically connect the interior of the end cap
to the vicinity of the open end of the battery casing
adapted to be detachably ~ounted to the lens and reflector
6.
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unit. In bcth e~bodiments, it is preferable to have a
coil spring secured to the interior of the end cap so
as to provide sufficient pressure on the battery means
within the casing to insure good electrical contact
between the battery means and the contact means therein.
The coil spring also functions to electrically connect
one pole of the battery to either a conductive battery
casing or to a conductive strip depending upon the
material used for the battery casing.
When the battery casing is made of conductive
material, then the flashlight could comprise a metallic
tubular battery casing closed at its lower or first open
end by means of an end cap o similar material which
could be threadably engaged to said first open end while
the upper or second open end at the opposite end thereof
could be threadably mounted to a lens and reflector unit.
The end cap would preferably contain a coil spring to
constantly supply pressure on the battery means within
the casing to maintain or urge said battery means toward
the upper or second open end of the casing where a push
button switch fixedly secured on a mounting bracket
would be disposed. A suitably shaped contact strip
would be employed to connect the battery casing to the
contact shell of the lens and reflector unit which in
turn would be electrically connected to, or adapted
to be connected to, a lamp bulb mounted in said lens
and reflector unit The battery casing of the
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flashlight would in turn be electrically connected to
one pole of the battery adjacent the end cap via the
coil spring. The push button switch, which is secured
on a mounting bracket within the battery casing with its
button member projecting through an opening in the wall
of the battery casing, would provide the contact means ;
adaptable for electrically connecting the opposite pole -
of the battery (center terminal), or the center terminal
of the battery closest the push button switch when more ~-
than one battery is employed, to the center terminal
of the lamp bulb thereby completing the electrical cir-
cuit for the flashlight when the switch is actuated to
the "on" position. Thus by depressing the button member
of the switch, the ~ectrical contact between the center
terminal of the battery and lamp bulb would be completed
or interrupted depending upon the state of the electrical
connection prior to the button being depressed.
In another embodiment of this invention, the
~ battery casing could be made of a nonconductive material
j~ 20 whereupon a conductive strip would have to be employed
to electrically connect the coil spring which is secured
to the end cap to the contact shell member in the lens
and reflector unit.
In both these embodiments, a housing member
; having an opening disposed and defined by a wall of said
! housing and containing projected magnetic means secured
in a surface of said housing adjacent said opening would
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be aligned and secured to the battery casing such that
the opening in said housing would be aligned with the
opening in the wall of the battery casing so as to
accommodate the projected button member of the
switch disposed within the opening of the battery
casing. As shown in the drawings,~the housing could
lock or secure the switch mounting bracket in place
within the battery casing. A flexible boot could then
be secured over the opening in the housing where the
button member of the switch is disposéd. In the flash-
light embodiment utilizing the nonconductive battery
casing, the flashlight could be made waterproof by water-
tightly securing the flexible boot to the opening in the
housing, secur~ng the housing water-tightly to the battery
f casing and by employing suitable O-ring seals at each
threaded area, i.e., between the lens and reflector unit
and the upper end of the battery casing and between the
lower end of the battery casing and end cap. By selecting
a suitable floatable material for the casing of the flash-
light, a waterproof, floatable flashlight can be produced
~ .
which will have the capability of being repeatedly
operated without losing its water-tight features. The
novel push button switch and magnetic arrangement of this
invention can be used with various size and shape battery
casings which would be coupled to various size and shape
lens and reflector units ~o produce flashlights for all
purposes.
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As is apparent from this invention, the only
movable part of the housing assembly would be the flexible
boot which is adapted to contact the button member of the
switch. The flexible boot would be disposed below the
plane defined by the top surface of the projec~ed magnetic
means and thereby would not be subject to being depressed
when the flashlight is attached to a magnetically attrac-
tive surface. In addition, this arrangement would eliminate
~ ,...
the accidental putting "on" of the flashlight which is
sometimes encountered when the magnetic means are mounted
in the slideable housing arrangement of the prior art.
In the drawings:
Figure 1 is a side view of a flashlight embodying
this invention;
Figure 2 is a horizontal section of the flash-
light of Figure l;
Figure 3 is a partial top section of the flash-
1, light of Figure l;
t ~ Figure 4 is an enlarged isometric view of a push
button switch fixedly secured on a mounting bracket;
Figure 5 is a top view of a mounting bracket in
1:
', ~ the open position;
-,
Figure 6 is a side sectional view of Figure 5
taken along lines6-6;
Figure 7 is a sectional view of a mounting bracket
, ~ in the closed position taken along the longitudinal axis;
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Figure 8 is an enlarged partial sectional side
view of a portion of the flashlight of Figure 2 showing
the magentic-switch combination;
Figure 9 is a partial sectional view of a switch
i assembly showing a boot member having an inwardly extended
center portion;
Figure 10 is an exploded view of the magnetic-
switch housing shown in Figure 2;
Figure 11 is an enlarged section view taken along
lines 11-11 of Figure l;
Figure 12 is an enlarged sectional view taken
along lines 12-12 of Figure 10.
Referring to Figures 1, 2 and 3, there is shown
a flashlight 1 ha~ing a battery casing 2, an end cap 3,
and a lens and reflector unit 4. The battery casing 2
is of the usual metallic tubular type of thin gage metal , ~.
such as chrome plated steel, aluminum, brass or copper
coated steel or other similarly conductive material, pre-
ferably a,metal capable of being finished to a high
polished state. Battery casing 2 is closed at its lower
end by means of end sap 3 which is threadably engaged to
the lower end of casing 2. End cap 3 contains a coil
spring S which electrically connects casing 2 with one
pole of cell 6 while simultaneously exerting pressure on
batteries 6 and 7 to maintain good electrical contact to
conductive strip 8 of push button switch 9. The upper
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open end portion of casing 2 terminates with a threaded
segment 10 designed to engage threaded segment 11 of the
lens and reflector unit 4. Disposed in the side wall of
casing 2 at the vicinity of the upper open end is a
circular opening 120
Lens and reflector unit 4 comprises lens 13, lens
ring 14, reflector 15, contact shell 16, bulb holder 17
and lamp 18. Reflector lS is of the conventional type
comprising a molded reflector body composed of a non-
conductive material, such as plastic, for instance, poly-
styrene, and having substantially corresponding concavè-
convex sides, the concave side of which is provided with
a metallic reflectory coating 19 such as aluminum applied
~` by conventional vacuum-metallizing techniques or the like,;' ~ and a central apertured cylindrical neck not shown. The -
'J, : contact shell 16,~ composed of an electrically conductive
material, is preferably of frusto-conical shape with a
tubular socket axially formed therein. The tubular socket,
e.g. as disclosed in U.S. Patent 3,798,440, is generally
secured within the apertured neck of reflector 15 and has a
,~
; flanged end which interlocks with an annular flange which
~ is integrally molded to the opening of the apertured neck
',~ of the reflector. The frusto-conical portion of contact
shell 16 forms an annular shaped skirt 20 which projects
radially outwardly from and out of contact with reflector
i 15. The flanged end of the tubular socket within reflect-
or 16 also provides a seat against which is mounted the
`~ 12.
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flanged neck of lamp bulb 18 which is of the conventional
type having a cylindrical base 21 including a button type
terminal 23.
Lens ring 14 is preferably made of the same
material as casing 2 so as to give an overall streamline
appearance. It is also within the scope of this invention
to have the lens ring 14 made of a different material than
that of casing 2~ End cap 3 is preferably made of the
same material as casing 2 but if a different material is
desired, then said material has to be conductive so as
to provide a complete electrical path for the flashlight.
; Bulb holder 17 is tubular shaped and is composed
of a resilient material, preferably a molded plastic,
such a~ polyethylene. ~ulb holder 17 is securely mounted
within the tubular socket of reflector 15 by conventional
means as also disclosed in U.S. Patent 3,798,440. To
; remove holder 17 to replace lamp 18, the holder 17 is
simply pulled outwardly from the tubular socket to detach
its forward end. Once the lamp is replaced, it is simply
pushed back into the socket. The assembled unit containing
reflector 15, contact shell 16, bulb holder 17 and lamp 18
is held securely within the lens and lens ring assembly
by friction fit between the reflector rib periphery and
a bead within the lens ring 14. After assembly, the forward
opening of the battery casing entraps t~e reflector between
its forward thread and the lensO
As shown in ~igures 4 to 7, a push button switch
` 13.
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bracket 22 comprises an overall flat sided (24,26) sub-
stantially tubular configuration which is pivotable
about the midpoint 28 of one of the side walls 26. In the
open position, as shown in Figures 5 and 6, a flat base 30
is disposed in one half of the tubular bracket with an in-
wardly projecting annular wall 32 disposed in the other
half of the tubular bracket. Inwardly projecting annular
member 32 defines an opening 34 through which the inner
button member 36 of switch 9 is inserted while the base 38 ~:
of switch 9 seats on base 30 of the mounting bracket 22 as
shown in Figure 2. Disposed on opposite sides of opening ~
34 are semi-circular projection members 40 which help main- .
tain the base 38 of switch 9 in proper alignment when
switch 9 is placed in the mounting bracket 22. The flat
surfaces 42 are aligned such that they are parallel with
the longitudinal side wall of base 38 when switch 9 is
positioned on mounting bracket 22. Disposed at each end
of the longitudinal outer extremities of mounting bracket
22 at the upper vicinity of the annular member 32 are
grooves or openings 44 whose function will be described
below. A longitudinal groove 46 is disposed at the center
i
, of the outer lower half of the bracket to accommodate a
: contact strip as will be described below.
: Mounting bracket 22 can be molded in one piece
as shown in Figures 5 to 7 using a suitable plastic material
suc~ as polyolefin, polyethylene, polypropylene, copolymers
of acrylonitrile, butadiene, or styrene or any other
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1060410 9725
suitable material capable of securing switch 9 within
battery casing 2.
A conventional type push button switch 9 can be
positioned in bracket 22 by inserting the button member 36
through opening 34 whereupon the top surface of the base 38
will rest on the flange 48 of annular wall 32 and be
aligned between members 40 as shown in Figure 2. There-
upon both halves of bracket 22 can be pivoted together so
that the bottom surface of base 38 of switch 9 will rest ::
on base 30 of the bracket. The switch and bracket assembly ` ~-.
along with a conductive strip 49 placed in recess 46 can
then be inserted into the upper end of battery casing 2 and
positioned such that the button 36 of switch 9 is centered
wiShin opening 12 of the side wall of casing 2 as shown in
Figures 2, 4 and 8. Thereafter, an extended cylinder 50,
.~ closed and partially filled at the closed end, is secured
to button member 36 so as to effectively project the
actuation means of the push button switch 9 substantially
through opening 12 in battery casing 20
According to the present invention, novel means
~: are afforded for a magnet-switch actuation combination
, which will enable the flashlight to be supported on a
metal surface in any desired position and yet will not
interfere with the functioning of the switch. As shown
in Figures 2, 8 and 10 to 12, a housing 51 comprises a
rectangular, cup-shaped, box-like segment 52 integrally
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extended at one end to a cylindrical segment 53 and at
the other end to an expodential type curved segment
providing a flange 54 thereat. Cylindrical segment 53 had -~
an opening defined by the internal wall 55 of the housing,
said wall 55 extending below the lower surface 56 of
rectangular segment 52 and having outwardly extending
narrow flexible tabs 57 and 58 disposed along the longi-
tudinal axis of housing 51. Disposed on the inside wall
55 is a groove 59, one side of which is defined by a
radially inwardly protruding flange 60. The rectangular : .
.
s segment 52 comprises spaced side walls 61 joined at one end
to spaced end wall 62 and at the other end to spaced end
wall 63, said end wall 63 also forming part of the wall 55
defining opening 64 in cylindrical segment 53. The walls
61, 62 and 63 are integrally united with a top wall 65
¦ disposed in spaced and generally parallel relation to the
wall of casing 20
The housing 51 can preferably be made of a suitable
~ non-magnetic material such as plastic, eOg., nylon, poly-1~
ethylene, polyolefin, polypropylene, copolymers of acrylo-
nitrile, butadiene or styreneO
Mounted in the rectangular section 52 of housing
51 are a pair of opposed elongated collector bars or angles
l -~
66 made of non-magnetic, but magnet conductive material,
for example, steel. Each collector consists of a relatively
short leg 67 which in assembly with the other collector is
disposed in spaced planar relation thereto and forms a
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1060410 9725
short gap therebetween, and a relatively longer leg 68
adapted to fit into a correspondingly enclosed slot 69
in the housing top wall 65 and extend slightly beyond
said wall 65 thereby forming a tongue and slot connection.
Seated within the hollow rectangular segment 52 and in
nesting engagement with the angled collector bars 66 is ~-
a permanent magnet 70, preferably made of Alnico* metal.
The collector bars 66, which are in magnetic contact with
the magnet 70, serve to conduct the magnetism beyond
the housing 51 in order that the magnet strength may be
strongly applied to a metal surface without significant
loss or attenuation of the magnet strength by the housing
51.
If desired to restrict unnecessary movement of the
magnet inside the switch housing, the magnet may be held cap-
tive therein through the combined action of an elongated
spacer or insulating ~iller member 71 and an elongated spring
strip 72 disposed respectively immediately below and above
the magnet 70 when viewed as in Figure 2. The filler 71
is slightly smaller in dimensions than the lower face of
the magnet 70 and lies between said magnet and said collector
legs 67. The spring strip 72 is arcuately bowed with its
medial portion in resilient engagement with topside of the
`~ magnet 70 and its ends in resilient contact with the under-
, side of the housing top wall 65. A pair of open ended
j slots 73 at the remote ends of the spring 72, constructed
to loosely straddle a pair of reinforcing ribs 74 (Figure 12)
* Trade/~ark for a permanent-magnet alloy containing iron,
nickel and aluminum.
.,
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in the housing 51, are provided for avoiding lateral dis-
placement of the spring 72 and simultaneously affording
the necessary clearance of longitudinal expansion thereof.
While a bowed spring is preferred, it is to be understood
that helically coiled springs are susceptible of use in
the present invention.
Smaller or larger magnets may be employed in the
magnet-switch combination of the invention according to
whether a iower or higher magnetic strength is desired,
additional fillers 71 being provided or removed to suitably
accommodate same. A protective gasket 75 may be disposed
between legs 67 of collector bars 66 and the wall of casing
2, Gasket 75 and flange 54 of housing 51 have openings 76
and 77, respectively, to acconmlodate a rivet 78 for securing
flange 54 of housing 51 to the casing 2 which also has an
opening 79.
After the switch and bracket assembly is disposed
into the upper open end of the battery casing 2 and with
the magnet components assembled in the rectangular section
52, the housing 51 is positioned over battery casing 2
and then the cylindrical member 53 is forced into opening
12 of casing 2. Projecting tabs 57 and 58 of housing 51
are first flexed inwardly until they are aligned with
opening 44 in bracket 22 whereupon they will spring out
and înto said openings 44. This will secure bracket 22
within casing 2 and secure one end of the housing to
casing 2. Thereafter, rivet 78 is passed thralgh rivet
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openings 79 in casing 2, 76 in gasket 75 and 77 in housing
51 thereby securing the flange end 54 to casing 2.
Either before or after housing 51 is secured to
casing 2, the extended cylindrical member 50 is suitably
secured in a conventional manner to button 36 thereby
extending the actuation means of switch 9 into housing 51.
A flexible switch boot 80, made of rubber, a low
density polyolefin, or the like, is assembled above switch
9 in opening 12 of module casing 2. A rigid gasket 81 of
ABS copolymers or some other rigid metallic-like material
provides a seal between boot 8p and opening 12 while
simultaneously securing boot 80 in a molded recess or
groove 59 in housing 51. This boot and gasket arrangement
provides a water-tight assembly ~or switch 9 while also
providing the flexibility necessary for actuating said
switch 9. Thus b-y depressing flexible boot 80, button 36
via extension 50 can be lowered thereby effectively operating
switch 9. ~s shown in the drawings, one pole of battery 6
is electrically connected to coil spring 5 which in turn is
electrically connected to shell 16 via conductive casing 2
and conductive strip 49. Push ~utton switch 9 has two con-
tact strips 8 and 82 as shown in Figures 2 and 4. The latter
strip 82 is aligned and in contact with the lamp tenminal 23
while contact strip 8 is aligned and in contact with the center
tenminal of battery 7. Thus the actuation of switch 9 will
internally couple or uncou~le contact strips 8 and 82, thereby
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electrically connecting of disconnecting, respectively,
the battery terminal 83 to the lamp terminal 23 which
will effectively complete or interrupt, respectively,
the electrical circuit o the flashlight.
In certain applications, i~ may not be desirable
to secure an extended cylindrical member, such as member
50, to the button of the switch. In such applications,
the center portion 83 of flexible boot 84 may be extended
so that it could contact button 36 of switch 9 as shown
in Figure 9, said Figure 9 displaying only a partial
view of a switch actuating assembly idéntical to that
shown in Figure 2 except for the new embodiment of boot 84.
A flashlight constructed in the manner described
above would be admirably suited or use in all applications
requiring a sturdy, durable lightweight flashlight.
Although this invention has been described with reference
to many specific details thereof, it is apparent that the
invention is not limited to such details.
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