(12) United States Patent
`(10) Patent N0.:
`US 7,281,815 B1
`
`Gustafson et a].
`(45) Date of Patent:
`Oct. 16, 2007
`
`U8007281815B1
`
`(54) LIGHTING DEVICE HAVING A
`MULTI-POSITION SWITCH ASSEMBLY
`
`(75)
`
`Inventors: Derek G. Gustafson, Bozeman, MT
`(US); Michael R. Githens, Ramona,
`CA (US); Ken J. Good, La Mesa, CA
`(US); Vaughn D. Baker, Lee’s Summit,
`MO (US); Eric M. Yeates, Virginia
`Beach, VA (US)
`
`ss1gnee:
`(73) A .
`
`roup
`o uc
`ac' aW' n us rles
`[G
`Pr (I
`l\ll
`Bl
`1‘1 d
`t _
`Unlimited LLC, Norfolk, VA (US)
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 64 days.
`
`(21) APP]- N04 ”354,159
`
`(22) Filed'
`’
`
`Oct 19 2005
`'
`’
`Related U.S. Application Data
`(60) Provisional application No. 60/620,020, filed on Oct.
`19, 2004.
`
`(51)
`
`Int Cl
`(2006.01)
`F21L 4/04
`(52) U.S. Cl.
`...................... 362/206; 362209; 36Z276;
`36Z802
`(58) Field of Classification Search ................ 362/158,
`362/205, 206, 208, 276, 294, 802
`See application file for complete search history.
`
`(56)
`
`References Cited
`U S PATENT DOCUMENTS
`i
`'
`1,214,583 A
`4,388,673 A
`4,499,525 A
`Z’géi’ég 2
`4,677,533 A
`4,760,504 A
`4,782,432 A
`4,876,416 A
`
`2/1917 Persons
`6/1983 Maglica
`””85 M31191?
`313::
`ill/[alghca
`6/1987 M:]s)(:im0tt et 31
`7/1988 Schaller et al
`11/1988 Colfman
`10/1989 Frantz et al.
`
`'
`
`4,947,291 A
`5,161,879 A
`5,418,433 A
`5 629 105 A
`’
`’
`5,642,932 A
`5,685,637 A
`5,722,755 A
`5,790,013 A
`
`5,821,697 A
`6’019’482 A
`6,024,471 A
`
`6,046,572 A
`6,079,847 A
`6,095,661 A
`6,183,105 B1
`6,249,089 B1
`
`6,296,367 B1
`6,305,818 B1
`6,385,730 Bl
`
`8/1990 McDennott
`11/1992 McDennott
`5/1995 N'l
`5/1997 gigglws
`
`7/1997 Mme“
`11/1997 Chapman et :11.
`3/1998 Slape
`8/1998 Hauck
`
`10/1998 Weber
`”2000 Everett
`2/2000 McDermott
`
`4/2000 Matthews et al.
`6/2000 Ne130n
`8/2000 Lebens et :11.
`2/2001 Parker
`6/2001 Bruwer
`
`10/2001 Parsons etal.
`10/2001 Lebens et :11.
`5/2002 Matthews
`
`(Continued)
`Primary ExamineriJohn Anthony Ward
`(74) Attorney, Agent, or FirmiBowman Green Hampton &
`Kelly, PLLC
`
`(57)
`
`ABSTRACT
`
`A switch assembly that may be utilized as a tail cap of a
`lighting device. The switch assembly including at least a
`depressible switch with a rotatable portion that allows the
`user to activate distinct filnctional modes of the lighting
`device. In an illustrative, non-limiting embodiment,
`the
`switch assembly has four channels, providing for at least
`three different light filnctions and a locking channel. The
`different channels are defined by the axial position of the
`rotatable portion relative to the lighting device body.
`
`38 Claims, 6 Drawing Sheets
`
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`EXHIBIT
`
`1011
`
`00003 96
`
`

`

`US 7,281,815 B1
` Page 2
`
`U.S. PATENT DOCUMENTS
`
`6,616,296 B1
`6,793,366 B2
`2004/0008510 A1
`
`9/2003 Roux et a1.
`9/2004 Chun
`1/2004 Mah
`
`2005/0122712 A1*
`2005/0122714 A1 *
`
`6/2005 Kim ........................... 362/184
`6/2005 Matthews et a1.
`.......... 362/206
`
`* cited by examiner
`
`00003 97
`
`

`

`US. Patent
`
`Oct. 16,2007
`
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`US 7,281,815 B1
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`U.S. Patent
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`Oct. 16, 2007
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`US 7,281,815 B1
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`US. Patent
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`Oct. 16, 2007
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`Oct. 16,2007
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`Oct. 16,2007
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`US. Patent
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`Oct. 16, 2007
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`US 7,281,815 B1
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`

`US 7,281,815 B1
`
`1
`LIGHTING DEVICE HAVING A
`MULTI-POSITION SWITCH ASSEMBLY
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`
`2
`These and other features and advantages of this invention
`are described in or are apparent from the following detailed
`description of the exemplary embodiments.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`This application claims the benefit of U.S. Provisional
`Patent Application Ser. No. 60/620,020 filed Oct. 19, 2004,
`the entire disclosure of which is incorporated herein by
`reference.
`
`10
`
`BACKGROUND OF THE INVENTION
`
`Field of the Invention
`
`This invention relates generally to multi-position switch
`assemblies. More specifically, the present invention relates
`to a lighting device having a multi-position switch assembly.
`
`SUMIVIARY OF THE INVENTION
`
`20
`
`The present invention relates generally to multi-position
`switch assemblies. More specifically, the present invention
`relates to a lighting device having a multi-position switch
`assembly.
`In an illustrative, non-limiting embodiment of this inven-
`tion, the switch assembly comprises an switch assembly that
`is utilized as a tail cap of a flashlight. In various, non-
`limiting embodiments, a first portion of the switch assembly
`unscrews from the flashlight body so that a user may, for
`example, replace the batteries in the flashlight. A second
`portion of the switch assembly comprises a depressible
`switch with a rotatable portion, or rotator, to allow the user
`to activate distinct functional modes of the flashlight.
`In an illustrative, non-limiting embodiment of this inven-
`tion, the various fimctional modes of the flashlight may be
`implemented as the output of, for example, a high current
`MOSFET acting as a microprocessor controlled switch, or
`controller. The various output patterns and on/ofl functions
`of the flashlight light source are driven by the controller,
`which may be pre-programmed at the chip production level.
`In an illustrative, non-limiting embodiment of this inven-
`tion, the switch assembly has four positions, providing for at
`least three diflerent light functions and a locking channel.
`The diflerent positions are defined by the axial position of
`the rotator relative to the light body. More specifically, each
`light activating position, or channel,
`is defined by the
`position of a magnet, relative to a sensor.
`Accordingly,
`this invention provides a multi-position
`switch assembly, which provides a flashlight having a multi-
`position switching mechanism using wireless technology.
`This invention separately provides a multi-position switch
`assembly, which optionally provides a positive locking
`feature.
`This invention separately provides a multi-position switch
`assembly, which provides a multi-position, waterproof,
`switching mechanism that allows easy battery replacement.
`This invention separately provides a multi-position switch
`assembly, which is not sealed relative to the outside envi-
`ronment, such that the switch assembly cannot be inadvert-
`ently activated in a high-pressure environment such as
`extreme water depth.
`This invention separately provides a multi-position switch
`assembly, wherein the switch assembly is isolated from the
`switched device.
`This invention separately provides a multi-position switch
`assembly, which provides extended parts life.
`
`30
`
`U1U1
`
`60
`
`The exemplary embodiments of this invention will be
`described in detail, with reference to the following figures,
`wherein like reference numerals refer to like parts through-
`out the several views, and wherein:
`FIG. 1 shows a perspective view of a first exemplary
`embodiment of a flashlight having a multi-position switch
`assembly according to this invention;
`FIG. 1A shows a side view of the first exemplary embodi-
`ment of the flashlight, of FIG. 1, having a multi-position
`switch assembly according to this invention;
`FIG. 2 shows a side cross-sectional view of the first
`exemplary embodiment of the flashlight comprising a multi-
`position switch assembly according to this invention;
`FIG. 3 shows a side view of the first exemplary embodi-
`ment of the flashlight body and head assembly according to
`this invention;
`FIG. 4 shows a cross-sectional view of the first exemplary
`embodiment of the flashlight body and head assembly of
`FIG. 3;
`FIG. 5 shows an exploded side view ofthe first exemplary
`embodiment of the flashlight body and head assembly of
`FIGS. 3 and 4;
`FIG. 6 shows a side view of the first exemplary embodi-
`ment of the switch assembly according to this invention;
`FIG. 7 shows a cross-sectional view of the first exemplary
`embodiment of the switch assembly of FIG. 6; and
`FIG. 8 shows an exploded side view ofthe first exemplary
`embodiment of the switch assembly of FIGS. 6 and 7.
`
`DETAILED DESCRIPTION OF EXEMPLARY
`EMBODIMENTS
`
`For simplicity and clarification, the design factors and
`operatingprinciples of the flashlight having a multi-position
`switch assembly according to this invention are explained
`with reference to various exemplary embodiments of a
`flashlight having a multi-position switch assembly accord-
`ing to this invention. The basic explanation of the design
`factors and operating principles of the flashlight having a
`multi-position switch assembly is applicable for the tinder-
`standing, design, implementation, and operation of the flash-
`light having a multi-position switch assembly of this inven-
`tion.
`Furthermore, it should be appreciated that, for simplicity
`and clarification, the embodiments of this invention will be
`described with reference to the switch assembly being
`implemented as a multi-position switching mechanism for a
`flashlight. However, it should be appreciated that the switch
`assembly of this invention may be utilized as a multi-
`position switching mechanism in other applications. Thus, it
`should be appreciated that the systems, methods, and appa-
`ratuses of this invention may be implemented as a multi-
`position switching mechanism for any switching application
`or as part of any other known or later developed switching
`device.
`It should be appreciated that, for simplicity and clarifi-
`cation, the embodiments of this invention will be described
`with reference to a multi-position switch assembly’s use as
`the tail cap of a Light Emitting Diode (LED) flashlight.
`However, it should be appreciated that the systems, meth-
`ods, and apparatuses of this invention may be implemented
`
`0000404
`
`

`

`US 7,281,815 B1
`
`3
`laser, or
`in conjunction with any incandescent, infrared,
`other known or later developed visible or non-visible wave-
`length illumination device.
`It should also be appreciated that the term “switch assem-
`bly” is for a basic explanation and understanding of the
`operation of the systems, methods, and apparatuses of this
`invention. Therefore, the term “switch assembly” is not to be
`construed as limiting the systems, methods, and apparatuses
`of this invention.
`Turning now to FIGS. 1 through 8, FIGS. 1 through 8
`show a variety of views of a first exemplary, non-limiting
`embodiment of an switch assembly 150 being implemented
`as a multi-position switching mechanism of a flashlight 100.
`However, it should be appreciated that the switch assembly
`150 of this invention may be implemented as a multi-
`position switching mechanism for any switching application
`or as part of any other known or later developed switching
`device.
`the flashlight 100
`As shown in FIGS. 1 through 8,
`comprises at least some of a head assembly 110, a light body
`assembly 130, and an switch assembly 150.
`In various
`exemplary embodiments, the head assembly 110 comprises
`at least some of a bezel 112, a reflector 114, a light source
`116, a lens 118, at least one appropriately sized O-ring 120,
`a heat sink 122, a spacer 124, a controller 126, and a positive
`battery contact 128.
`In various exemplary embodiments, the components of
`the head assembly 110 are assembled as illustrated in FIGS.
`2, 4, and 5. In these exemplary embodiments, the lens 118,
`the reflector 114, the light source 116, the heat sink 122, the
`spacer 124, the positive battery contact 128, and the con-
`troller 126 are situated within a cavity formed in the bezel
`112.
`
`One or more optional, appropriately sized O-rings 120 are
`included between certain of the components of the head
`assembly 110. In this manner, a watertight or water resistant
`seal may be created between the head assembly 110 and the
`light body assembly 130, when the head assembly 110 is
`attached or coupled to the light body assembly 130.
`Although not illustrated in FIGS. 2, 4, and 5, the positive
`battery contact 128 is electrically coupled to the light source
`116, via the controller 126. Additionally, the positive battery
`contact 128 is capable of being electrically coupled to a
`positive terminal of a battery or other voltage source.
`In various exemplary embodiments, the controller 126
`comprises an integrated circuit that functions as a control
`switch for the flashlight 100. In this manner, the various
`output patterns and on/off fiulctions of the light source 116
`may be driven and/or controlled by the controller 126. In
`various exemplary, non-limiting embodiments, the control-
`ler 126 comprises a high cru'rent MOSFET that fimctions as
`a microprocessor-controlled switch. The controller 126 may
`be pre-programmed at the chip production level.
`In various exemplary embodiments, the controller 126
`may be programmed and/or reprogrammed based on the
`specific fiulctions and/or modes desired by the user. Thus,
`the specific fimctions, channels, and/or modes of the flash-
`light 100 may be established and/or altered by the user.
`In various exemplary embodiments, the controller 126
`may be programmed and/or reprogrammed via a direct or
`indirect linked connection to a programming and/or repro-
`gramming device. For example, one or more plugs and/or
`contact points (not shown) may be electrically coupled to the
`controller 126, such that the controller 126 may be coupled,
`via one or more corresponding plugs and/or contact points,
`to a programming and/or reprogramming device.
`
`10
`
`20
`
`30
`
`40
`
`UIUI
`
`60
`
`4
`it should be appreciated that the linked c011-
`However,
`nection can be any known or later developed device or
`system for connecting the controller 126 to a programming
`and/or reprogramming device, including a direct wired con-
`nection, a connection over a cellular telephone network, a
`very high frequency (VHF) connection, an ultra high fre-
`quency (UHF) connection, a radio frequency (RF) connec-
`tion, a satellite connection, or the like. In general, the linked
`connection can be any known or later developed connection
`system or structure usable to connect a programming and/or
`reprogramming device to the controller 126, including both
`wired and wireless connections.
`
`The controller 126 may, for example, be programmed to
`illluninate the light source 116 at a particular light level. The
`controller 126 may also be programmed to illluninate the
`light source 116 in an on/off, or strobe, mode. In various
`exemplary embodiments, the controller 126 may strobe the
`light source 116 at a rate of greater than 0 to 60 Hz. In other
`exemplary embodiments, the controller 126 may strobe the
`light source 116 at a rate of greater than 0 to 30 Hz. In still
`other exemplary embodiments,
`the controller 126 may
`strobe the light source 116 at a rate of about 8 to 20 Hz.
`The particular strobe rate may be predetermined and fixed
`or may be adjustable. In various exemplary embodiments, a
`particular strobe rate may be chosen based on a desired
`effect of the strobed light on an individual. For example, a
`strobing rate may be chosen, which effectively masks tac-
`tical movement but is not in a realm that can trigger adverse
`effects in an individual.
`
`The controller 126 may be programmed to illluninate the
`light source 116 in a signaling mode. In the signaling mode,
`the controller controls the light source 116 to the emit either
`visible or non-visible light in a predetermined on/off pattern.
`In various exemplary embodiments, the signaling pattern
`may be a standard, preprograrnmed pattern, such as, for
`example, a Morse code pattern. Alternatively, the signaling
`pattern may be a specific, user-defined pattern.
`Visible light and/or non-visible light may be used to
`provide a signaling pattern. For example, a visible light
`signaling pattern may be used in a non-covert emergency
`situation to facilitate the location and/or identification of an
`individual. Alternatively, a non-visible light signaling pat-
`tern may be used to facilitate the location and/or identifica-
`tion of an individual in need of rescue in a covert situation.
`
`It should be appreciated that light signaling patterns may
`comprise visible light patterns, non-visible light patterns, or
`a combination of visible and non-visible light patterns.
`In various exemplary embodiments, the light source 116
`comprises a LED. Alternatively, the light source 116 may
`comprise an incandescent, infrared, laser, or other known or
`later developed visible or non-visible wavelength illumina-
`tion device. In various other exemplary embodiments, the
`light source 116 may comprise a combination ofone or more
`LEDs, incandescent, infrared, laser, or other known or later
`developed visible or non-visible wavelength illumination
`devices.
`
`Although not illustrated in FIGS. 2, 4, and 5, additional
`materials, such as,
`for example, gaskets or additional
`O-rings, may be included between various components of
`the head assembly 110 to provide a level of shock isolation
`to the components of the head assembly 110.
`The light body assembly 130 comprises at least some of
`a light body 132, a battery housing 134, and a battery
`compartment 136. In various exemplary embodiments, the
`components ofthe light bodyassembly 130 are assembled as
`illustrated in FIGS. 2, 4, and 5.
`
`0000405
`
`

`

`US 7,281,815 B1
`
`5
`In various exemplary embodiments, at least a portion of
`the light body 132 has a 1 inch outer diameter. This allows
`the flashlight 100 to be mounted 011 a variety of devices
`using known ring mounts. At least a portion ofthe light body
`132 may include a groove or flat portion that provides an
`anti-rotation feature to the flashlight 100 when held within
`a ring mount.
`As illustrated in FIGS. 2, 4, and 5, the battery housing 134
`is positioned within a cavity formed by the light body 132.
`A11 interior cavity of the battery housing 134 forms the
`battery compartment 136. The battery housing 134 and a
`battery compartment 136 are formed so as to allow one or
`more batteries to be housed within the battery compartment
`136.
`
`When positioned within a cavity of the light body 132, the
`battery housing 134 provides electrical
`isolation of the
`batteries from the light body 132. In various exemplary
`embodiments, the battery housing 134 provides a measure of
`shock isolation to the batteries.
`
`In various exemplary embodiments, the battery housing
`134 includes one or more recessed channels formed in the
`outer surface of the battery housing 134. Thus, when the
`battery housing 134 is positioned within a cavity of the light
`body 132, a flexible circuit may be disposed between the
`battery housing 134 and the light body 132.
`In various exemplary embodiments, the head assembly
`110 is permanently attached or coupled to the light body
`assembly 130.Alternatively, the head assembly 110 may be
`removably attached or coupled to the light body assembly
`130. One or more optional, appropriately sized O-rings 120
`may be included between the head assembly 110 and the
`light body assembly 130.
`In various exemplary embodiments, at least a portion of
`the bezel 112 has a 1% inch outer diameter. Thus, a wide
`variety of known external light filtering and/or shuttering
`devices may be coupled to the bezel 112. The bezel 112 may
`include a scalloped surface or end portion.
`In various exemplary, non-limiting embodiments, Hall
`effect sensors 184 are positioned about the battery housing
`134. The Hall effect sensors 184 are coupled to the battery
`housing 134 such that the Hall effect sensors 184 are capable
`of detecting a relative position of the magnet 174, which is
`coupled to the actuator 172.
`As described herein, three Hall effect sensors 184 are
`positioned at three discrete locations around the battery
`housing 134. The position of each of the Hall effect sensors
`184 corresponds to one of the three light activating posi-
`tions, or channels, of the rotator 154. Thus, each light
`activating channel is defined by the position of the magnet
`174, which is coupled to the actuator 172, relative to the Hall
`effect sensors 184, which are optionally coupled to the
`battery housing 134.
`It should be understood that while the switch assembly
`150 is described as having four positions, providing for three
`light activating channels and a locking channel, the number
`of light activating channels of the switch assembly 150 is a
`design choice based 011 the desired functionality of the
`flashlight 100. Thus,
`the switch assembly 150 may be
`provided with more or less than three light activating
`channels and may or may not include a locking channel.
`Furthermore, it should be understood that a separate Hall
`effect sensor 184 is included for each light activating chan-
`nel of an switch assembly.
`It should be appreciated that in various alternative exem-
`plary embodiments,
`the Hall effect sensors 184 may be
`coupled to an appropriate portion of the light body 132.
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`Although not shown, it should be appreciated that the Hall
`effect sensors 184 are electrically coupled to the controller
`126, such that signals from the Hall effect sensors 184 may
`be received by the controller 126. In various exemplary
`embodiments, a flexible circuit, which is included between
`the battery housing 134 and the light body 132, is used to
`electrically couple the Hall effect sensors 184 to the c011-
`troller 126.
`the
`In various exemplary, non-limiting embodiments,
`controller 126 is included between the battery housing 134
`and the light body 132.
`The switch assembly 150, or tail cap, comprises at least
`some of a threaded collar 152, a rotator 154, a button 156,
`a button return spring 158, a cross pin 160, a bearing sleeve
`162, bearings 164, spacers 166, rollers 168, an axle pin 170,
`an actuator 172, a magnet 174, a detent ring 176, an
`alignment means 178, an O-ring 180, an O-ring 182, a Hall
`effect sensors 184, a switch cup 186, and a conical negative
`battery contact spring 188.
`As shown in FIGS. 2, 7, and 8, in an illustrative, 11011-
`limiting embodiment of this invention, the switch assembly
`150 has four positions, providing for three light activating
`channels and a locking channel. It should be appreciated that
`the number of positions and the fiulction of each position of
`the switch assembly 150 is a design choice based 011 the
`desired functionality of the flashlight 100. Thus, the switch
`assembly 150 may be provided with more or less than four
`positions.
`Each position of the switch assembly 150 is defined by the
`position of the rotator 154/actuator 172 pair relative to the
`light body 132. More specifically, each light activating
`channel is defined by the position ofthe magnet 174, relative
`to the Hall effect sensors 184.
`in FIGS. 2, 7, and 8, the
`As shown in greater detail
`actuator 172 is indexed to the bearing sleeve 162 and the
`button 156, via a generally hex shaped outer connector
`portion of the actuator 172 and a corresponding, generally
`hex shaped inner receiving portion of the bearing sleeve 162
`and generally hex shaped outer connector portion of the
`button 156. Invarious exemplary embodiments, the actuator
`172 is free to slide through the bearing sleeve 162 along a
`long axis of assembly.
`The button return spring 158 is positioned within a pocket
`formed in the center of an upper portion of the actuator 172
`so as to provide a measure of retum force to the button 156
`when the button 156 is depressed.
`Axle pin 170 is positioned within a groove formed along
`the long axis the actuator 172. Spacers 166 and rollers 168
`assist in maintaining the axle pin 170 within the switch cup
`186.
`The detent ring 176 is rotatably positioned around the
`outer connector portion of the actuator 172. The rotational
`travel of the detent ring 176 relative to the actuator 172 is
`limited by the cross pin 160.
`A11 outer connecting portion of the bearing sleeve 162 is
`formed so as to be received and maintained within a corre-
`sponding inner receiving portion ofthe rotator 154. Bearings
`164 are secured between the bearing sleeve 162 and the
`rotator 154. In this manner, as the rotator 154 is rotated, the
`bearing sleeve 162 and the actuator 172 are also rotated.
`In various exemplary embodiments,
`the bearings 164
`comprise individual ball or roller bearings secured between
`the bearing sleeve 162, the rotator 154, and the tail cup 186.
`In other exemplary embodiments, the bearings 164 comprise
`individual ball or roller bearings secured as a unit by a cage
`or retainer (not shown). If the bearings 164 are secured by
`a cage or retainer, the balls are separated by an even and
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`US 7,281,815 B1
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`7
`consistent spacing and may be more accurately guided
`between the bearing sleeve 162, the rotator 154, and the tail
`cup 186 during rotation.
`In still other exemplary embodiments, the bearings 164
`are replaced by corresponding opposing protrusions and
`detents in mating surfaces of the bearing sleeve 162 and the
`rotator 154. Thus, when assembled, the mating surfaces of
`the bearing sleeve 162 and the rotator 154 are nested
`together.
`The magnet 174 is coupled to a lower portion of the
`actuator 172 such that the magnet 174 is maintained in a
`fixed position relative to the actuator 172. In various exem-
`plary embodiments, the magnet 174 is a cylindrical magnet.
`The switch cup 186 is attached to the rotator 154 via a
`flexible snap retention detail on the rotator 154. The
`threaded collar 152 is positioned and maintained between
`the switch cup 186 and the rotator 154 such that when the
`switch cup 186 is attached to the rotator 154 the threaded
`collar 152 is free spinning relative to the switch cup 186 and
`the rotator 154.
`In various exemplary embodiments, the threaded collar
`152 includes a plurality of lugs that extend substantially
`radially from the threaded collar 152. The lugs assist in the
`assembly and disassembly of the flashlight 100 and provide
`an anti-roll featured to the flashlight 100. The lugs may be
`contoured so as to assist in certain specialized grip tech-
`niques when employed with a firearm or be used as a
`defensive tool or a tool
`in personal control
`techniques.
`Additionally, the lugs may include one or more holes or
`other attachment means such that a lanyard or other device
`may be attached to the threaded collar 152, via one or more
`lugs. It should be understood that while the threaded collar
`152 is shown as having four lugs, the number and shape of
`the lugs is a design choice based on the desired fimctionality
`of the lugs.
`The switch cup 186 and the light body 132 include
`cooperating alignment means 178. The alignment means
`178 operate such that, when the switch assembly 150 is
`coupled to the lightbody132, the switch cup 186 is properly
`indexed to the light body 132. In various exemplary embodi-
`ments, the alignment means 178 comprise an anti-rotation
`pin extending from either the interior of the light body 132
`or the exterior of the switch cup 186 and positioned so as to
`engage a corresponding alignment groove formed in either
`the exterior of the switch cup 186 or the interior of the light
`body 132, respectively.
`In various exemplary embodiments, the alignment means
`178 comprise an notch formed in either the light body 132
`or the switch assembly 150 and positioned so as to engage
`a corresponding mating block formed in either the switch
`assembly 150 or the light body 132, respectively.
`An inner threaded portion of the threaded collar 152
`corresponds to an outer threaded portion of the light body
`132. Thus,
`the switch assembly 150 may be removably
`attached to the light body 130.
`In various exemplary
`embodiments, an O-ring 180 is included in an appropriately
`sized groove in the outer surface of the light body 132 to
`provide a watertight or water resistant seal between the outer
`surface of the light body 132 and an inner surface of the
`threaded collar 152. In various exemplary embodiments, an
`O-ring 182 is included in an appropriately sized groove in
`the inner surface of the light body 132 to provide a water-
`tight or water resistant seal between the inner surface of the
`light body 132 and an outer surface of the switch cup 186.
`The conical negative battery contact spring 188 is elec-
`trically coupled to the switch cup 186 such that a negative
`terminal of a battery or other voltage source may be elec-
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`trically coupled to the switch cup 186. When the switch
`assembly 150 is attached to the light body 130, the switch
`cup 186 is electrically coupled to the light body 132 and, the
`controller 126.
`In various exemplary, non-limiting embodiments, at least
`some of the head 110, the body 132, and the threaded collar
`152 may be formed of aluminum; the button 156, the rotator
`154, the switch actuator 172, and the battery housing 134
`may be formed of a plastic, such as, for example, a ther-
`moplastic or a polypropylene plastic; and the bearings 164,
`the button return spring 158, and the negative battery contact
`spring 188 may be formed of stainless steel.
`this listing of
`However,
`it should be understood that
`exemplary materials is not to be construed as limiting the
`materialsthat are used to form thevarious components ofthe
`flashlight 100. Alternate materials of construction may
`include one or more of the following: steel, aluminum,
`titanium, and/or other ferros or non-ferros metals, as well as
`various alloys and composites thereof, glass-hardened poly-
`mers, polymer or fiber reinforced metals, carbon fiber or
`glass fiber composites, therrnoset or thermoplastic resins,
`chopped glass or carbon fibers used for injection molding
`compounds, laminate glass or carbon fiber, epoxy laminates,
`woven glass fiber laminates, impregnate fibers, polyester
`resins, epoxy resins, phenolic resins, polyimide resins, cyan-
`ate resins, high-strength plastics, polymers, polymeric com-
`posites,
`thermoplastics, polypropylene, nylon, glass, or
`polymer fiber reinforced plastics, thermoforrn and/or ther-
`moset sheet materials, and/or various combinations of the
`foregoing. Thus, it should be understood that the material or
`materials used to form the various components of the
`flashlight 100 is a design choice based on the desired
`appearance and functionality of the various components of
`the flashlight 100.
`During use of the flashlight 100, when the button 156 is
`depressed, the actuator 172 is moved from a spring biased,
`or first position within the switch cup 186 (as shown in FIG.
`2) to a depressed, or second position within the switch cup
`186. When the actuator 172 is moved from the first position
`to the second position, the magnet 174 is moved to a position
`that is proximate one of the Hall effect sensors 184.
`When the magnet 174 is moved to a position that is
`proximate one of the Hall effect sensors 184, the magnetic
`field from the magnet 174 activates the proximate Hall effect
`sensor 184. When the Hall effect sensor 184 is activated, a
`signal is sent to the controller 126.
`When the controller 126 receives a signal that a Hall effect
`sensor 184 has been activated, the cont