Flashlight assembly

Abstract

A flashlight assembly with an electromechanical switch assembly and internal sealed subframe, and methods of assembling and operating same, are disclosed.

What is claimed is: 
     
         1 . A lighting device comprising:
 a light source having a first state of operation and a second state of operation,   a power source,   at least one button, the at least one button being depressible, wherein the light source, the power source, and the at least one button are electrically coupled together, and   a switch assembly, the switch assembly comprising
 a wheel that is engageable by a user from an exterior of the lighting device; 
 a spring having at least one spring arm, and 
 a cam that is rotatably fixed to the wheel, the cam having a plurality of detents circumferentially arranged therein, each of the detents of the plurality of detents being capable of receiving at least a portion of the spring therein,
 wherein the switch assembly is rotatable between a first position in which the at least one spring arm is located within a first detent of the plurality of detents and a second position in which the at least one spring arm is located within a second detent of the plurality of detents, wherein in the first position the cam does not depress the at least one button, resulting in the light source being placed in its first state of operation, and wherein in the second position the cam at least partially depresses the at least one button, resulting in the light source being placed in its second state of operation. 
 
   
     
     
         2 . The lighting device of  claim 1 , wherein the first state of operation of the light source is a constant-off state and the second state of operation of the light source is a constant-on state, wherein in the second state of operation the light source and power source interact such that light of a first intensity is emitted from the light source. 
     
     
         3 . The lighting device of  claim 2 , the light source further having a third state of operation in which the light source and power source interact such that light of a second intensity is emitted from the light source, the second intensity having a greater value than the first intensity, wherein an additional pressing force must be actively maintained on the switch assembly to maintain the light source in its third state of operation, the third state of operation corresponding with a third position of the switch assembly in which the at least one spring arm is located within a third detent of the plurality of detents. 
     
     
         4 . The lighting device of  claim 3 , wherein the at least one button comprises a first button and a second button, wherein in the third position the cam at least partially depresses both the first button and the second button, resulting in the light source being placed in its third state of operation. 
     
     
         5 . The lighting device of  claim 4 , wherein if the additional pressing force is removed from the switch assembly while the switch assembly is in its third position, the at least one spring arm of the spring automatically biases the switch assembly into its second position. 
     
     
         6 . The lighting device of  claim 1 , the at least one spring arm of the spring comprising a first spring arm and a second spring arm located opposing each other, wherein the plurality of detents comprises a first detent that is located diametrically opposite a second detent and a third detent that is located diametrically opposite a fourth detent, wherein in the first position of the switch assembly the first spring arm is located in the first detent and the second spring arm is located in the second detent and wherein in the second position of the switch assembly the first spring arm is located in the third detent and the second spring arm is located in the fourth detent. 
     
     
         7 . The lighting device of  claim 6 , wherein the plurality of detents further comprises a fifth detent that is located diametrically opposite a sixth detent, the light source further having a third state of operation corresponding with a third position of the switch assembly in which the first spring arm is located in the fifth detent and the second spring arm is located in the sixth detent. 
     
     
         8 . The lighting device of  claim 7 , wherein the first state of operation of the light source is a constant-off state and the second state of operation of the light source is a constant-on state, wherein in the second state of operation the light source and power source interact such that light of a first intensity is emitted from the light source. 
     
     
         9 . The lighting device of  claim 8 , wherein in the third state of operation the light source and power source interact such that light of a second intensity is emitted from the light source, the second intensity having a greater value than the first intensity, wherein an additional pressing force must be actively maintained on the switch assembly to maintain the light source in its third state of operation. 
     
     
         10 . The lighting device of  claim 9 , wherein if the additional pressing force is removed from the switch assembly while the switch assembly is in its third position, the first spring arm and second spring arm automatically bias the switch assembly into its second position. 
     
     
         11 . The lighting device of  claim 6 , wherein the cam further comprises at least one ramped surface located thereon, the light source further having a third state of operation corresponding with a third position of the switch assembly in which the first spring arm is located on the at least one ramped surface. 
     
     
         12 . The lighting device of  claim 11 , wherein the first state of operation of the light source is a constant-off state and the second state of operation of the light source is a constant-on state, wherein in the second state of operation the light source and power source interact such that light of a first intensity is emitted from the light source. 
     
     
         13 . The lighting device of  claim 12 , wherein in the third state of operation the light source and power source interact such that light of a second intensity is emitted from the light source, the second intensity having a greater value than the first intensity, wherein an additional pressing force must be actively maintained on the switch assembly to maintain the light source in its third state of operation. 
     
     
         14 . The lighting device of  claim 13 , wherein if the additional pressing force is removed from the switch assembly while the switch assembly is in its third position, the first spring arm and second spring arm automatically bias the switch assembly into its second position. 
     
     
         15 . The lighting device of  claim 1 , further comprising a printed circuit board on which the at least one button is located. 
     
     
         16 . The lighting device of  claim 1 , the lighting device further comprising:
 a subframe having an interior volume and a sealing surface that surrounds an opening in the subframe, the power source being located within the internal volume;   
       a seal having a perimeter, the perimeter being attached to the sealing surface such that the opening in the subframe is liquid and gas impermeable; and a vent that acts to prevent liquids from entering the interior volume, while permitting for gases to be released from the interior volume through the vent. 
     
     
         17 . A lighting device comprising:
 a light source;   a power source, the power source being electrically coupled to the light source;   a switch assembly that is engageable by a user from an exterior of the lighting device;   a subframe having an interior volume and a sealing surface that surrounds an opening in the subframe, the opening being sized to allow for insertion of the power source into the interior volume of the subframe through the opening, the power source being located entirely within the interior volume;   a seal having a perimeter, the perimeter being attached to the sealing surface such that the opening in the subframe is fluid-impermeable; and   a body, the body enclosing the subframe and at least a portion of the light source.   
     
     
         18 . The lighting device of  claim 17 , wherein the opening has a non-circular cross-sectional shape. 
     
     
         19 . The lighting device of  claim 18 , wherein the opening has a rectangular cross-sectional shape. 
     
     
         20 . The lighting device of  claim 17 , wherein the subframe and the seal are comprised of a plastic material. 
     
     
         21 . The lighting device of  claim 20 , wherein the perimeter of the seal is heat-welded to the sealing surface of the subframe. 
     
     
         22 . The lighting device of  claim 17 , further comprising a switch opening through which the switch assembly extends between the interior volume of the subframe and an exterior of the subframe, the switch opening further comprising a seal that is liquid-impermeable. 
     
     
         23 . The lighting device of  claim 17 , further comprising a light opening through which the light source extends between the interior volume of the subframe and an exterior of the subframe, the light opening further comprising a seal that is liquid-impermeable. 
     
     
         24 . A method of assembling a lighting device, the method comprising:
 placing a power source entirely interior to an interior volume of a subframe through an opening located in the subframe, the subframe further comprising a sealing surface that surrounds the opening;   heat-welding a perimeter of a seal to the sealing surface of the subframe to create a fluid-impermeable seal about the opening;   placing a light source and the subframe and the seal into a body, the light source being electrically coupled to the power source; and   closing the body.   
     
     
         25 . The method of  claim 24 , wherein the step of placing the power source entirely interior to the interior volume of the subframe through the opening in the subframe further comprises inserting the power source through the opening, the opening having a non-circular cross-sectional area, wherein the heat-welding step further comprises heat-welding the seal to the subframe, wherein both the seal and the subframe are comprised of a plastic material.