III USOO5678921A

United States Patent (19) 11 Patent Number: 5,678,921

Kish et al. 45) Date of Patent: Oct. 21, 1997
54 FLASHLIGHT 3,162,376 12/1964. Furuya ................................. 24OW10.66
3,175,080 3/1965 Moore ... 24.0/10.65
75) Inventors: Paul A. Kish, Wilkes-Barre, Pa.; 3,196,268 7/1965 Mack .......... ... 362,188
Graham E. Leavy, Montville, N.J.; 3: s
: EN et all a ........
25. X
Randy S. Cramer, Lebanon, Pa. 3,662,165 5/1972 Osteen et all 24.0/103 R
wraa 2s. t 3,794,825 2/1974 Krupansky ...... ... 24.0/10.63
73) Assignee: E. St. stries, Inc., 4,021,659 5/1977 Wiley .......... 240/41.36
es-area. 4,025,743 5/1977 Oswald ..................................... 2OOf60
4,156.271 5/1979 Vercelotti 362/2O2
21 Appl. No.: 354,098 4,286.311 8/1981 Maglica ..... 362?2O5
4,325,107 4/1982 MacLeod 362/183
22 Filed: Dec. 6, 1994 4,357,648 11/1982 Nelson ... 362,183.
6 4,527,223 7/1985 Maglica 362,187
5 1. nt. C. 88 dwi di 88 duo or a dw wow was 88s sists asses F2L. 7/00 4,531,178 7/1985 Uke ........ ... 362/58
52 U.S. Cl. ........................... 362/205; 362/188; 362/202 4,545,000 10/1985 Fraley et al ... 362/304
(58) Field of Search .................................... 362/187, 188, 4,816,972 3/1989 Myhres .. ... 362/2O2
362/197, 202, 203, 205, 208, 348 4,875,146 10/1989 Drane ...................................... 362/2O2
56 References Cited (List continued on next page.)
U.S. PATENT DOCUMENTS Primary Examiner Y My Quach
1253,813 1/1918 Gray. Attorney, Agent, or Firin-Nies. Kurz, Bergert & Tamburo
1260,387 3/1918 Johanson . TRA
1296.404 3/1919 Koretzky. 57 ABS CT
163. M. A flashlight having a reinforced tubular plastic casing
1433. c
433,570 10/1922 Stimson. including a battery compartment and a bulb compartment
1,443,089 1/1923 Pepper. separated by a transverse wall integrally molded with the
20922: 10/1937 forkins et al... 240,1066 casing. Abulb is retained in a socket integrally molded with
2,134,856 11/1938 Burgess .............. ... 24.0/10.68 the wall by a bushing which may be quickly connected and
2,229,486 1/1941 Barash et al. .. ... 24Oy10.66 disconnected from the socket, the bulb and the bushing
2.229,495 1/1941. Desimone ...... ... 24.0/10.6 being resiliently axially moveable with respect to the socket
2,235,714 3/1941 Lennan ....... ... 24.0/10.66 and the transverse wall to prevent breakage of the bulb due
2,263,878 1/1942 Kopp .................................... 2009 to shock or impact. A novel reflector is axially moveable
33% A: old A -- a 29: with respect to the bulb to afford adjustable focussing of the
swar
2,312,670
Othold sereas.............. . ...
3/1943 Olds ...........
. . . .24.0/10.6
. 2007 light emitted from
-
the bulb. The reflective
s
surface of the
2,355.247 8/1944 Slocum ... 24.0/10.68 reflector combines a facetted parabolic surface on the outer
2,477,516 7/1949 Haas... ... 200/60 portion of the reflector with a smooth spherical surface at the
2,493.205 1/1950 Muldoor 362f197 base of the reflector to optimize the amount of light collected
2,500,364 3/1950 Kopp. 240/10.66 from the light bulb and focused in the beam. A novel
2,502,600 4/1950 Spender .................................... 200/60 three-position switch assembly includes a one piece plastic
2,530,505 11/1950 Brill ....... ... 2010.66 actuator having an integrally molded pivotable pushbutton
2,690,503 9/1954 Garland - 299 lever which may be actuated to flash the lamp on and off.
3. s: S. A 2.96. The actuator is quickly and easily snapped into place in a
2.855.499 10/1958 Lewis. switch housing to facilitate assembly.
2.913,570 11/1959 Gough et al. ............................... 240/3
3.017,502 l/1962 Dent ..................................... 24.0/10.68 35 Claims, 5 Drawing Sheets

34
30 (34
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-363SN22N
 5,678,921
Page 2

U.S. PATENT DOCUMENTS 5.126,927 6/1992 Reeves et al. .......................... 362/187

5,138,537 8/1992 Wang ........... ... 362/87
4.914,555 4/1990 Gammache ............................. 362/83 5,165,782 11/1992 Maglica et al. 362/208
4,916,588 4/1990 Chu ....................................... 362/2O3 5,167.447 12/1992 Gonzales ...... ... 362/202
4.951,183 8/1990 Wang . ... 362/187 5,207,502 5/1993 Maglica ... ... 362/158
4,994,948 2/1991 Cooch . ... 362/346 5,213,408 5/1993 Shiau ....... ... 362/187
5,021,934 6/1991 Hou ............. ... 362/187 5,272,408 12/1993 Levin et al. . ... 313/113
5,121,308 6/1992 Maglica et al. 36.2f187 5,272,606 12/1993 Blaney ..... 362/157
5,124,894 6/1992 Shiau ..................................... 362/187 5,315,494 5/1994 Magica .................................. 362/2O7
U.S. Patent Oct. 21, 1997 Sheet 1 of 5 5,678,921

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U.S. Patent Oct. 21, 1997 Sheet 2 of 5 5,678,921
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U.S. Patent Oct. 21, 1997 Sheet 5 of 5 5,678,921

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 5,678,921
1. 2
FLASHLIGHT flood beam. The reflector includes a concave reflecting
surface which combines a facetted parabolic surface on its
BACKGROUND OF THE INVENTION outer larger diameter section and a plain, smooth spherical
This invention relates generally to flashlights, and more surface at its base to optimize the collection of light from the
particularly to a novel flashlight having an all plastic exterior 5 lightbulb positioned centrally within the reflecting surface.
construction suitable for heavy-duty use, easy to assemble, Still another object of the invention resides in the provi
and reasonable in cost. sion of the above novel flashlight which includes a novel
Flashlights are often mishandled and subjected to abusive awaterprooflens, and
head assembly in which a flange on the reflector,
an annular sealing gasket are retained in sealing
use by which they may be damaged or destroyed. For engagement with a head cap or lens ring which threadedly
example, it is not unusual for a flashlight to be bumped or engages on the open front end of the flashlight casing and
dropped, subjecting the components to impact and shock
and often breaking the bulb, fracturing the casing, and seals against an O-ring mounted on the casing. The con
damaging the batteries. In addition, flashlights are often used struction of the head assembly facilitates the overall assem
or stored in a moisture laden environment, and moisture 5 bly of the flashlight parts and thus reduces cost The head
which enters the casing may cause degradation and mal assembly ment of
is moveable axially on the casing to permit move
the reflector relative to the bulb to refocus the light
functioning of the electrical components therein. from a spot to a flood beam.
It has been common in recent years to provide flashlights A further object of the invention resides in the provision
with an adjustable focussing feature whereby the light beam of the above described novel flashlight which further
may be adjusted from a flood beam to a spot beam. This 20 includes a unique three-way switch assembly including a
feature requires some relative axial movement between the one-piece molded plastic actuator moveable between off,
lightbulb and a light reflector. While this is a very desirable flashing, and on positions. The actuator
feature, it does impose more stringent requirements on the pushbutton lever formed integrally therewithhas a pivotable
which is manu
overall construction and rigidity of the flashlight to permit ally operated to intermittently open and close a switch
repetitive refocussing of the light as desired, while, at the 25 and thereby cause flashing of the lightbulb. The actuatorarmis
same time, maintaining the integrity and waterproof char quickly and easily snapped into place on a switch housing
acteristic of the flashlight. Furthermore, many adjustable
focussing assemblies used in the past have not properly formed on the exterior of the flashlight casing, this again
facilitating assembly and reducing costs.
collected the light emitted from the bulb and have wasted a Other objects and advantages of the invention will
good deal of that light. 30
become apparent
Thus, a need exists for a rugged, heavy-duty flashlight description of the invention from reading the following detailed
which is versatile in use, resistant to shock and impact, the in which reference is made to
accompanying drawings.
waterproof, and variably focussing. But it is imperative that
a flashlight of this type be constructed in a way so that it is BRIEF DESCRIPTION OF THE DRAWINGS
easily manufactured and assembled to minimize costs. 35
FIG. 1 is a top plan view of the novel flashlight of the
SUMMARY OF THE INVENTION invention, illustrated in approximate actual size.
FIG. 2 is a sectional side elevational view of the flashlight
Accordingly, the primary object of this invention is to taken along line 2-2 of FIG. 1.
provide a novel flashlight having several unique features
which afford the characteristics and advantages noted above. of FIG. 2A is an exploded view of the various components
the flashlight illustrated in FIG. 2.
A further object of this invention resides in the provision FIG. 3 is afront end view of the flashlight taken along line
of a novel flashlight having an all plastic exterior casing and 3-3 of FIG. 2.
a transverse wall or platform integrally molded with the
casing to separate a rearward battery compartment from a 45 4-4 of4FIG. FIG. is a fragmentary sectional view taken along line
forward bulb compartment. The transverse wall protects twice its actual2A, illustrating the head assembly at about
size.
both the bulb and the batteries from damaging impact and
also serves as an internal base or shelf on which various FIG. 5 is a rear axial view of the head cap or lens ring
components may be mounted. taken along line 5-5 of FIG. 2A, the lens ring being
Another object of the invention resides in the provision of illustrated at about twice its actual size.
the above-described flashlight wherein the plastic casing is FIG. 6 is a fragmentary sectional view of the novel
reinforced by internal and external ribs, the internal ribs also facetted reflector incorporated in the flashlight of the
serving to support batteries and prevent engagement of those invention, illustrating the reflector at about twice its actual
batteries with the usual electrical contact strip extending SAC.
substantially along the length of the compartment. 55 FIG. 7 is a front end view of the reflector taken along line
Still another object of the invention resides in the provi 7-7 of FIG. 6.
sion of the above novel flashlight which includes a novel FIG. 8 is a front axial view of the flashlight casing, at
bulb mounting assembly held in place by a retainer bushing about twice its actual size, taken along line 8-8 of FIG. 2A.
which may be quickly connected and disconnected from the FIG. 9 is a fragmentary sectional view of the casing taken
transverse wall, with both the bulb and the bushing being along line 9-9 of FIG. 2A.
resiliently axially moveable with respect to the wall and the FIG. 10 is a fragmentary plan view taken along line
bulb socket so as to minimize the chance of damaging the 10-10 of FIG. 2A, illustrating the switch mounting housing
bulb from impact or shock. on the outer wall of the casing.
Still another object of the invention resides in the provi FIG. 11 is a top plan view of the novel, one-piece, plastic
sion of the above novel flashlight wherein a reflector of 65 switch actuator at about twice its actual size.
novel design is moveable axially with respect to the bulb to FIG. 12 is a fragmentary sectional view taken along line
adjustably focus the light from the bulb as a spot beam or a 12-12 of FIG. 11.
 5,678,921
3 4
FIG. 13 is a fragmentary sectional view taken along line rearwardly, opening 74 clears lens 63 of bulb 56 and flange
13-13 of F.G. 12. 72 engages against bulb flange 62 to push plug 60 rear
FIG. 14 is a fragmentary sectional view taken along line wardly within socket 40 against the bias of spring 54.
14-14 of FIG. 12. When lugs 78 are aligned with slots 84, they will enter
FIG. 15 is an end view of the rear end cap taken along line annular space 86 and the bushing may then be turned so that
1S 15 of FG, 2. the lugs 78 align behind tabs 82. When bushing 70 is
released, tabs 82 and lugs 78 cooperate to lock the bushing
FIG. 16 is a fragmentary side elevational section illus 70 and bulb 56 in place against the bias of spring 54 as
trating the bulb retainer at about twice its actual size. shown in FIG. 2. In that locked position, one of the lugs 78
FIG. 17 is an axial end view of the bulb retainer of FIG. 10 will engage against the leg 98 of the contact strip 93 to
16. establish electrical contact from eyelet 46, spring 54, contact
DETALED DESCRIPTION OF THE
58, filament 64, contact 66, wall 60, flange 62, flange 72.
bushing 70, flange 76, and the lug 78 engaging strip 98 to
INVENTION contact 96.
Referring now to the drawings, the novel flashlight 20 of 15 As shown into FIG. 2, because the axial length of space
the invention includes a one-piece, rigid plastic, tubular 86 exceeds the thickness of lugs 78, there is axial clearance
casing 22 formed by a rearward cylindrical section 23 or end play of lugs 78 within space 86. Also, the axial length
defining a compartment 24 containing for example, two or of socket 40 is such that an axial space 105 exists between
more D size batteries B1 and B2, and a forward enlarged the rear face of flange 62 and the end face 106 of socket 40.
tubular section 25 defining a bulb mounting compartment Consequently, bulb 56 is free to move axially and radially
26, the compartments being separated from each other by a with respect to socket 40 and bushing flange 72, and both
transverse wall or platform 28 integrally molded to the bulb 56 and bushing 70 are axially displaceable together
circumferential wall of casing section 23. The forward end against the force of spring 54 with respect to socket 40 and
of section 25 and the rearward end of section 23 are threaded wall 28.
at 30 and 32 respectively, to receive a head cap assembly 34 25 Head assembly 34 (FIGS. 2, 2A and 4) includes a tubular
and a rear end cap 36. plastic head cap or lens ring 110 having a front opening 111
A small tubular socket 40 is integral with and extends defined by internal flange 112 which also forms together
forwardly from wall 28 within compartment 26 along the with the wall of ring 110 an enlarged gasket receiving
central axis of casing 22. Socket 40 has a central bore 422 counterbore 114. A Neoprene sealing gasket 116, a circular
provided with a plurality of resilient longitudinal ribs 44. An 30 polycarbonate lens 118, and the outer peripheral flange 120
electrically conductive metallic eyelet 46 extends through an of a facetted polycarbonate reflector 122 fit within counter
opening 48 in wall 28, and is crimped at opposite ends to bore 114 and are retained therein by a plurality of thin
provide a flange 50 for engagement by the positive terminal flexible resilient tabs 124 which extend radially inwardly
of battery B1 within compartment 24, and also a flange 52 from counterbore 114 and engage behind the back edge of
at the bottom of bore 42 for engagement by an electrically 35 flange 120. Tabs 124 maintain the elements in tight sealing
conductive spring 54. contact within counterbore 114 and prevent any water or
A standard flashlight bulb 56, e.g., a B 3% type lamp, is other fluids from entering the head assembly through open
mounted within bore 42 and includes a rear contact 58, a ing 111. Head cap 110 also includes an intermediate enlarged
plug having an outer metal wall 60 formed with a plug flange threaded bore section 126 and a larger straight end bore
62, a lens 63, a filament 64 connected at one end to contact section 128.
58 and at its other end to a solder contact 66 on the outer wall Head assembly 34 is assembled on casing section 25 by
60. rotating thread section 126 on threads 30 and an annular seal
Bulb 56 is loosely retained within socket 40 by an is provided between section 128 and section 25 by O-ring
electrically conductive metal bushing 70 (FIGS. 2(a), 16 and 130 which fits within annular groove 132. A cosmetic ring
17), having at its front end an inwardly turned peripheral 45 134 is provided between the end face of ring 110 and annular
flange 72 defining a front opening 74 and at its rear end an flange 136 on section 25. The bottom of flange 136 is
outwardly turned flange section 76 provided with three provided with a flat 137 on which the flashlight may rest
equilaterally spaced radially extending lugs 78. without rolling.
A small circular hub 80 (FIGS. 2, 2(a) and 8) is integral Reflector 122 has a reduced diameter central hub section
with and extends forwardly from wall 28 around socket 40 50 140 having a bore 142 which slides over the outside diam
and includes at its front end three equilaterally spaced eter of bushing 170, the inner end of the bore being provided
inwardly extending radial tabs 82 defining radial slots 84 with a shoulder 144 and a central opening 146 through
therebetween. Tabs 82 are axially spaced from wall 28 to which the lens 63 of bulb 56 will extend for location within
define an annular space 86 having an axial length exceeding the concave reflective surface 164 of reflector 122. The
the thickness of lugs 78 on bushing 70. As shown in FIGS. 55 innermost assembled position of head assembly 34 with
20a) and 8, panel 90 extends radially outwardly from a tab respect to bulb 56 and bushing 70 is illustrated in FIG.2 with
82 and defines a slot 92 coextensive with and radially from shoulder 144 adjacent to but not abutting flange 72. Because
space 86. Abent conductive contact strip 93 has an axial leg of the novel way in which bulb 56 and bushing 70 are
94 fixed to casing 22 via contact rivet 96, and a radial leg 98 resiliently mounted relative to socket 40 and wall 28, the
engaging against the inside face of panel 90. bulb is protected against breakage due to shock or impact
As seen in FIGS. 8 and 9, wall 28 includes three angular caused by rough handling of the flashlight or by dropping the
slots 100 positioned axially behind tabs 82 and a radial slot flashlight, for example on head assembly 34 or on tail cap
102 in axial alignment with panel 90 and strip 98. Wall 28 36. Should the flashlight be dropped, wall 28 prevents
also includes a plurality of larger angular slots 104 posi batteries B1 and B2 from slamming directly into bulb 56 or
tioned closely adjacent the wall of tubular section 23. 65 its mounting.
As shown in FIG. 2, bushing 70 slides over the outside This novel bulb mounting arrangement is a significant
diameter of socket 40, and as the bushing is pushed feature of the invention. Not only does it simplify the
 5,678,921
5 6
assembly of bulb 56 in socket 40 through the quick connect respect to bulb 56, which, however, is retained in place by
disconnect action of lugs 78 and tabs 82, but it also affords bushing 70. Thus, the refocussing is accomplished without
impact and shockproof protection for the bulb. moving bulb 56.
Cap 110 is also provided with a plurality of circumfer Also provided in compartment 26 is a spare bulb socket
entially spaced, axially extending ribs 160, which have 180 (FIGS. 2, 2A, and 8), integrally molded together with
nodules 161 that project over and beyond the front face 162 wall 28 and the outer wall of tubular section 25. Socket 180
of cap 110. Thus, if the flashlight is stored in an upright is provided with a pair of axially extending resilient ribs 182
position with nodules 161 resting on a support surface such which frictionally engage against the plug of a spare bulb
as a storage shelf, table, etc. with the bulb 56 inadvertently 184 to hold the bulb in place. Moreover, socket 180 is
left on, the light emitted from the bulb is readily visible at 10 positioned and sized so that when the bulb 184 is mounted
end face 162. A person may then turn the bulb off to prevent therein, the lens of the bulb is closely adjacent reflector 122.
inadvertent premature discharge of the batteries B1 and B2 If the flashlight is dropped, reflector 122 aids in retaining the
within compartment 24. bulb within socket 180.
As mentioned hereinabove, another important feature of 15
Returning now to the battery casing section 23 (FIGS. 1,
the invention is the adjustable focussing of the light from 2, 2A, and 9), a plurality of battery support ribs 184, 186 and
bulb 56 from a spot beam to a flood beam, and the novel 188 extend longitudinally along the casing section to a
design of reflector 122 enhances that focussing capability. location 190, spaced inwardly from the end face 192 of
As shown in FIGS. 2, 2A, 4, 6 and 7, in reflector 122, the section 23. Ribs 186 and 188 form a channel 194 in which
internal concave reflective surface 164 has a facetted para 20
a conductive metal contact strip 196 extends from a contact
bolic surface section 166, which extends from the outer end rivet 198 to the rear of casing section 23 where it engages the
face 168 of flange 120 to a point 170 at approximately outer diameter of a cylindrical conductive metal contact
two-thirds the depth of the reflector where it blends shell 200 having an outer end flange 202. The shell 200 fits
smoothly with a plain, smooth, spherical surface 172 at the snug within a counterbore 204 and abuts at its inner end
inner end or base of the reflector.
25
against shoulder 206, which prevents axial inward move
In the assembly as illustrated in FIG. 2, the focal point F ment of the shell. The inner face of flange 202 engages
of the light from bulb 56, which is in the form of a against end face 192 of section 23.
cylindrical light source, is located within the region of Rear end cap 36 (FIGS. 1, 2, 2A, and 15) includes a
spherical surface 172. counterbore section 208, a threaded section 210 having a
The facetted surface section 166 is formed by a plurality 30
relief bore 212 at its base and an internal smaller diametered
of concentric rows 174 of rectangular facets 176 extending counterbore 214. A tapered conductive contact spring 216
axially inwardly to point 170 of the reflector. Each row has its large diameter end 218 fitting within relief bore 212
includes eighty rectangular facets extending around the and its small diameter end 220 engaging against the negative
circumference of surface section 166, with the longer dimen terminal of battery B2. Large end 218 has a tab. 222 bent
sion of each facet extending in the axial direction. In each 35 inwardly so that good electrical contact is made between
successive innermost row 174, the number of rectangular shell 200, flange 202, end 218 and tab 222 as illustrated in
facets 176 remains the same at eighty, but the size of the FG, 2.
facets 176 gets smaller because the diameter along the Note particularly in FIG. 2 that the outer wall of batteries
parabolic surface section 166 gets smaller. In practice, it is B1 and B2 engage against ribs 184, 186, and 188 to avoid
desirable that the smallest facets in the innermost row be as any contact with strip 196. Note also that the rear end and
small as possible to optimize the collection of light from negative terminal of battery B2 is spaced inwardly from
bulb 56, the size of course being limited by molding shell 200 under the bias of spring 216 and that shell 200 is
capabilities for the reflector. prevented from moving axially inwardly into engagement
We have found that the combination of the parabolic with battery B2 by shoulder 206 and flange 202. This
surface section 166 and the spherical surface 172, in com 45 configuration of parts prevents any short circuiting between
bination with the generally cylindrical light source provided strip 196, shell 204, and batteries B1 or B2.
by bulb 56 concentrated at focal point F. minimize the light As shown in FIGS. 2 and 2(a), when the end cap is in
spillage from the bulb and maximize the amount of light place a cosmetic ring 226 is located between a flange 228 on
collected by the facets 176 and concentrated in the light section 23 and the inner end face of cap 36 and an O-ring
beam emitted from the flashlight. With the light source from 50 230 positioned in groove 232 on section 23, provides a
bulb 56 basically being a cylindrical light source rather than waterproof seal between end cap 36 and the battery casing
the ideal or perfect pinpoint light source which does not exist section 23.
in the real world, at the base of the reflector the light is A ring hanger 234 is pivotally connected to a lug section
distorted and dissipated in many different directions. Rather 236 and the ring fits within a reduced diameter turned
than extend the facetted parabolic surface section 166 all the 55 section 238 adjacent the back end of cap 36. The end face of
way back to the base, it is better to form the base as a smooth the cap is provided with three equilaterally spaced flats 240,
plain spherical surface 172. The spherical surface smooths on which the flashlight may be supported in an upright
out the light which is emitted from all directions at the back position.
end of the bulb 56 and smoothly blends that light with the Electrical contact is made between contactors 96 and 198
concentrated beam produced by the facetted surface 166. by a switch assembly 241, which includes a bent spring
In the innermost position of lens ring 110 illustrated in contact strip 250. The strip has a flat 252 which is fixed to
FIG. 2, the light beam emitted from bulb 56 and reflector contact 198, an upwardly inclined section 254 bending at
122 will be in the form of a wider floodbeam. To refocus the 256 into a downwardly inclined section 258 which termi
light to a more concentrated narrow spotbeam, ring 110 is nates into a flat terminal end 260 which, in the off position,
rotated axially outwardly fromcasing section 25 by a quarter 65 is spaced away from contact 96. Bend 256 acts as a cam
to one half turn. The rotation of ring 110 away from casing surface. A small longitudinal slot 262 is formed in section
section 25 moves reflector 122 axially outwardly with 254 (FIG. 10).
 5,678,921
7 8
As part of switch assembly 241, a switch housing 242 engages within notch 286 in which position the cams 308
(FIGS. 2, 2A, 9 and 10) is formed on the outer wall of casing and 310 will engage against cam surface 256, pressing strip
22 and includes a flatbottom wall 243, upright vertical walls 250 down to cause edge 260 to engage and stay in contact
244 and 245, a front vertical wall 246, and a short rear with contact 96. Again, the lateral space between cams 308
vertical wall 247. Contacts 96 and 198 extend through and and 310 accommodates stop 264 as the switch is placed in
are fixed to bottom wall 243. its forwardmost "on" position.
A one piece, plastic, three-way actuator 270 (FIGS. A plurality of ribs 320 extend longitudinally along the
11-14) is slidably mounted on bottom wall 243, for longi outside surface of casing 22 and a plurality of ribs 322
tudinal back and forth movement between "off", "flashing". extend partly circumferentially around the bottom of casing
and "on" positions. Actuator 270 is a hollow, box type 10 section 23. The ribs 320 and 322 provide a non-slip grip
structure which includes a configured top wall 272 curved while handling the flashlight. In addition, those ribs and the
downwardly at the rear 274 for ease of finger engagement, internal ribs 184, 186, and 188 reinforce casing 122.
a downwardly depending front wall 276 and downwardly The invention may be embodied in other specific forms
depending sidewalls 278 and 280. Formed at the bottom of without departing from the spirit or essential characteristics
walls 278 and 280 are laterally projecting side rails 282 and 15 thereof. The present embodiments are therefore to be con
284, with rail 284 having three notches 286, 288, and 290 sidered in all respects as illustrative and not restrictive, the
formed therein in correspondence with the "on", "flashing". scope of the invention being indicated by the appended
and "off" positions, respectively, of actuator 270. claims rather than by the foregoing description, and all
Side walls 244 and 245 of housing 242 are provided with changes which come within the meaning and range of
opposed longitudinal slots 292 and 294, respectively, adja equivalency of the claims are therefore intended to be
embraced therein.
cent bottom wall 243 to loosely receive rails 282 and 284 We claim:
therein and to permit longitudinal sliding movement of 1. A flashlight comprising a plastic tubular casing having
actuator 270 back and forth. Actuator 270 is resilient enough a rearward battery compartment adapted to receive a battery
so that rails 282 and 284 are easily and quickly snapped in means and a forward bulb compartment, a transverse wall
and out of slots 292 and 294 to facilitate and thereby reduce 25 integrally molded with said casing and separating said
the cost of assembly. A protruding nodule 296 is formed in battery and bulb compartments, a tubular socket integrally
slot 294 and selectively engages in notches or indents 286, molded with said wall and extending forwardly therefrom
288, or 290 to establish the “on”, “flashing", or “off” within said bulb compartment, a light bulb having a plug
position of switch 270. Vertical walls 246 and 247 captivate portion mounted within said socket, contact means extend
actuator 270 longitudinally within housing 242. 30 ing through said wall for electrically connecting said bulb to
Top wall 272 at its forward end is provided with a a battery means in said battery compartment, said contact
U-shaped cut out pushbutton lever 300 pivotally connected means having a first contact located within said socket
to the top wall by a living hinge 302. A pair of small adjacent said wall, a contact spring electrically connecting
downwardly depending laterally spaced lugs 304 and 306 said bulb to said first contact and permitting resilient axial
are formed on the underside of pushbutton 300. To the rear 35 movement of said bulb relative to said socket, switch means
of pushbutton 300 a pair of laterally spaced cams 308 and mounted on said casing for selectively supplying battery
310 project downwardly from top wall 272. Behind the current to said bulb, retainer means for holding said bulb
cams, a transverse wall 312 extends between side walls 278 within said socket against the bias of said contact spring and
and 280 to reinforce the actuator, with wall 312 provided being axially movable with respect to said wall and said
with a central bottom opening cut out 314 having a width socket, whereby said bulb and said retainer means are
exceeding the width of contact strip 250. resiliently mounted with respect to each other and with
A stop or post 264 projects upwardly outwardly from respect to said socket and said wall, cooperating means on
bottom wall 243 and fits within slot 262 without interfering said retainer means and said wall for permitting quick
with the vertical opening and closing action on strip 250. connection and disconnection of said retainer means from
As already mentioned, actuator 270 is quickly and easily 45 said wall, said cooperating means including a plurality of
snapped into place within switch housing 242 by merely angularly spaced lugs on said retainer means and a plurality
pressing side rails 282 and 284 into slots 292 and 294, of angularly spaced tabs connected to and spaced axially
respectively. With the actuator 270 in its rearmost "off" forwardly of said wall and defining an annular space
position with nodule 296 located in indent 290, contact strip therewith, whereby said lugs are aligned with spaces
250 is in its open position with edge 260 out of engagement between said tabs to enter said annular space and said
with contact 96 as illustrated in FIG. 2. In this position, retaining means is turned to align said lugs with said tabs
pushbutton 300 directly overlies stop 264 which prevents the preventing said retaining means from moving axially away
button 300 from being depressed into engagement with the from said socket.
cam surface 256 of strip 250. In this position, the flashlight 2. The flashlight defined in claim 1, comprising a reflector
is off. 55 mounted within said bulb compartment and having a con
To place the flashlight in a flashing condition, actuator cave reflective surface adjacent to and focussing the light
270 is moved forwardly to its intermediate position in which from said light bulb, said reflective surface having a large
the nodule 296 engages within notch 288 so that pushbutton diameter outer end and a small diameter inner end and
300 no longer overlies stop 264. When the pushbutton is including a parabolic facetted section extending axially
now depressed, it engages against cam surface 256 to make inwardly from said outer end to a point intermediate said
contact between edge 260 and contact296. Repeated depres outer and inner ends and a smooth spherical section extend
sion and release of pushbutton 300 will thereby cause a ing from said intermediate point to said inner end.
flashing of bulb 56. The lateral spacing between lugs 304 3. The flashlight defined in claim 2, said facetted section
and 306 permit longitudinal movement of pushbutton 300 including a plurality of concentric rows of rectangular
past stop 264. 65 facets, the number of facets in each row being the same but
When the flashlight is to be placed in a continuous "on" decreasing in size as the diameter of the facetted section
condition, switch 270 is pushed forward until nodule 296 decreases.
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4. The flashlight defined in claim 3, each of said rectan 15. The flashlight defined in claim 14, said actuator
gular facets having its large dimension extending along an including cam means for holding said contact arm in
axis of said surface. engagement with said other terminal when said actuatoris in
5. The flashlight defined in claim 2, said reflector and said the on position.
light bulb being moveable axially relative to each other to 16. The flashlight defined in claim 15, said switch housing
adjustably focus the light from said light bulb. including a bottom wall and a pair of laterally spaced side
6. The flashlight defined in claim 5, said reflector being walls, said side walls and said actuator together having
axially movably mounted from said casing for axial adjust cooperating guide means permitting longitudinal sliding
ment relative to said light bulb. movement of said actuator along said bottom wall.
7. The flashlight defined in claim 2, comprising a head 10 17. The flashlight defined in claim 16, said cooperating
assembly which includes a tubular head cap, an annular guide means including opposed longitudinal slots on said
gasket, a lens, and said reflector which has an annular flange side walls and laterally extending rails on said actuator
at its large outer end, said tubular head cap having a front which snap into said slots.
end opening and an annular groove surrounding said front 18. The flashlight defined in claim 17. comprising second
end opening, said gasket, said lens, and said annular flange 15 cooperating means on said housing and said actuator to
of said reflector fitting within said annular groove, said head establish the off, flashing, and on positions of said actuator,
cap having resilient radially inwardly extending retainer 19. The flashlight defined in claim 18, said second coop
means adjacent an inner end of said groove for permitting erating means including longitudinally spaced indents on
said flange to be snapped into said groove, the inwardly one of said rails and a nodule in a corresponding slot which
extending retainer means engaging behind said flange to 20 selectively engages in an appropriate indent as said actuator
hold said gasket, said lens, and said flange in sealing is moved longitudinally within said housing.
engagement with said head cap. 20. The flashlight defined in claim 18, a stop projecting
8. The flashlight defined in claim 7, said inwardly extend outwardly from said bottom wall which, when said actuator
ing retainer means including a plurality of angularly spaced is in the of position, underlies said pivotal lever to prevent
resilient tabs. 25 said lever from depressing said contact arm.
9. The flashlight defined in claim8, said cap being axially 21. The flashlight defined in claim 16, a stop projecting
adjustably mounted on a front end of said casing and an outwardly from said bottom wall which, when said actuator
O-ring providing a seal between the cap and the casing. is in the off position, underlies said pivotal lever to prevent
10. The flashlight defined in claim 9, said cap having a said lever from depressing said contact arm.
plurality of angularly spaced nodules extending beyond its 30 22. Aflashlight comprising a plastic tubular casing having
front face so that when the flashlight is supported on said a rearward battery compartment adapted to receive battery
nodules, light is visible from the front face if the flashlight means and a forward bulb compartment, a transverse wall
S. O. integrally molded with said casing and separating said
11. The flashlight defined in claim 1. said casing having battery and bulb compartments, a tubular socket integrally
a rearward tubular section defining said battery compartment 35 molded with said wall and extending forwardly therefrom
with an open rearward end and a rear end cap removably within said bulb compartment, a light bulb having a lens, a
connected on said rearward end, a plurality of ribs formed plug mounted within said socket, and a flange on said plug
internally on said rearward section and extending longitu adjacent said lens, contact means extending through said
dinally therealong for supporting batteries in radially spaced wall for electrically connecting said bulb to a battery means
relation from said tubular section. in said battery compartment, switch means mounted on said
12. The flashlight defined in claim 11, wherein two of said casing for selectively supplying battery current to said bulb,
ribs define a longitudinally extending channel, a contact said contact means having a first contact located within said
strip located within said channel and extending from said socket on said wall, a contact spring electrically connecting
switch means to the rearward end of said rearward tubular said plug to said first contact and permitting resilient axial
section, a cylindrical contact shell mounted at the rearward 45 movement of said bulb relative to said socket, a tubular
end of said rearward tubular section in connection with said retainer bushing having an inwardly turned flange on its
contact strip, a contact spring mounted within said rear end outer end and a plurality of angularly spaced outwardly
cap for electrically connecting said contact shell with a directed radial tabs of a given thickness on its inner end, said
terminal of a rearmost battery of said battery means within retainer bushing being axially displaceable around said
the battery compartment. 50 socket toward said wall so that said inwardly turned flange
13. The flashlight defined in claim 12, said casing com abuts against said plug flange to hold said plug within said
prising means for preventing said shell from moving axially socket against the bias of said contact spring, a plurality of
forwardly in said rearward tubular section into engagement angularly spaced inwardly directed tabs connected to and
with a rearmost battery. spaced axially forwardly of said wall and defining therewith
14. The flashlight defined in claim 1, said switch means 55 an annular space having a given axial width, the axial width
comprising a switch housing formed on an exterior of said of said annular space being greater than the thickness of said
tubular casing, a first terminal connected to said bulb and a lugs, whereby said lugs are aligned with spaces between said
second terminal adapted to be connected to the battery tabs to enter said annular space and said bushing is turned to
means, a contact arm fixed to one of said first and second align said lugs with said tabs preventing said bushing from
terminals and moveable into and out of engagement with an moving axially away from said socket, said bulb and said
other of said terminals, a one piece plastic three-way switch bushing being thereby resiliently mounted with respect to
actuator movably mounted in said switch housing between each other and with respect to said socket and said wall.
off, flashing, and on positions, said actuator including an 23. The flashlight defined in claim 22, an electrical contact
integrally formed pivotal lever which, when said actuator is strip positioned adjacent one of said tabs for engaging one
in said flashing position, may be manually moved down and 65 of said lugs, said strip being connected to said switch means.
up to engage and disengage said contact arm from said other 24. A flashlight comprising a tubular casing having a
terminal to cause flashing of said light bulb. rearward battery compartment adapted to receive a battery
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11 12
means and a forward bulb compartment, a tubular socket means adjacent an inner end of said groove for permitting
mounted within said bulb compartment, support means said flange to be snapped into said groove, the inwardly
connecting said socket to said casing, contact means located extending retainer means engaging behind said flange to
within said socket on said supporting means and adapted to hold said gasket, said lens, and said flange in sealing
be electrically connected to battery means mounted in said 5 engagement with said head cap.
battery compartment, a light bulb having a plug portion 31. The flashlight defined in claim 30, said inwardly
mounted within said socket, a contact spring electrically extending retainer means including a plurality of angularly
connecting said bulb to said contact means and permitting spaced resilient tabs.
resilient axial movement of said bulb relative to said socket, 32. The flashlight defined in claim 30, said cap being
retainer means for holding said bulb within said socket axially adjustably mounted on a front end of said casing and
against the bias of said contact spring and being axially an O-ring providing a seal between the cap and the casing.
movable with respect to said supporting means and said 33. The flashlight defined in claim 30, said cap having a
socket, whereby said bulb and said retainer means are plurality of angularly spaced nodules extending beyond its
resiliently mounted with respect to each other and with front face so that when the flashlight is supported on said
respect to said socket, switch means mounted on said casing 15 nodules, light is visible from the front face if the flashlight
for supplying battery current to said bulb, cooperating 1S O.
means on said retainer means and said support means for 34. A flashlight comprising a tubular casing having a
permitting quick connection and disconnection of said rearward battery compartment adapted to receive a battery
retainer means from said support means, said cooperating means and a forward bulb compartment, a tubular socket
means including a plurality of angularly spaced lugs on said 20 mounted within said bulb compartment, support means
retainer means and a plurality of angularly spaced tabs connecting said socket to said casing, a light bulb having a
connected to and spaced axially forwardly of said support lens, a plug mounted within said socket, and a flange on said
means and defining an annular space therewith, whereby plug adjacent said lens, contact means located within said
said lugs are aligned with spaces between said tabs to enter socket on said supporting means and adapted to be electri
said annular space and said retaining means is turned to align 25 cally connected to battery means mounted in said battery
said lugs with said tabs preventing said retaining means compartment, a contact spring electrically connecting said
from moving axially away from said socket. plug to said contact means and permitting resilient axial
25. The flashlight defined in claim 24, comprising a movement of said bulb relative to said socket, retainer
reflector mounted within said bulb compartment and having means for holding said bulb within said socket against the
a concave reflective surface adjacent to and focussing the 30 bias of said contact spring and being axially movable with
light from said light bulb, said reflective surface having a respect to said supporting means and said socket, whereby
large diameter outer end and a small diameter inner end and said bulb and said retainer means are resiliently mounted
including a parabolic facetted section extending axially with respect to each other and with respect to said socket,
inwardly from said outer end to a point intermediate said switch means mounted on said casing for supplying battery
outer and inner ends and a smooth spherical section extend 35 current to said bulb, said retainer means comprising a
ing from said intermediate point to said inner end. tubular retainer bushing having an inwardly turned flange on
26. The flashlight defined in claim 25, said facetted its outer end and a plurality of angularly spaced outwardly
section including a plurality of concentric rows of rectan directed radial tabs of a given thickness on its inner end, said
gular facets, the number of facets in each row being the same retainer bushing being axially inwardly displaceable around
but decreasing in size as the diameter of the facetted section said socket so that said inwardly turned flange abuts against
decreases. said plug flange to hold said plug within said socket against
27. The flashlight defined in claim 26, each of said the bias of said contact spring, a plurality of angularly
rectangular facets having its large dimension extending spaced inwardly directed tabs connected to and spaced
along an axis of said surface. axially forwardly of said support means and defining there
28. The flashlight defined in claim 25, said reflector and 45 with an annular space having a given axial width, the axial
said lightbulb being moveable axially relative to each other width of said annular space being greater than the thickness
to adjustably focus the light from said light bulb. of said lugs, whereby said lugs are aligned with spaces
29. The flashlight defined in claim 28, said reflector being between said tabs to enter said annular space and said
axially movably mounted from said casing for axial adjust bushing is turned to align said lugs with said tabs preventing
ment relative to said light bulb. 50 said bushing from moving axially away from said socket,
30. The flashlight defined in claim 25, comprising a head said bulb and said bushing being thereby resiliently mounted
assembly which includes a tubular head cap, an annular with respect to each other and with respect to said socket and
gasket, a lens, and said reflector which has an annular flange said support means.
at its large outer end, said tubular head cap having a front 35. The flashlight defined in claim34, an electrical contact
end opening and an annular groove surrounding said front 55 strip positioned adjacent one of said tabs for engaging one
end opening, said gasket, said lens, and said annular flange of said lugs, said strip being connected to said switch means.
of said reflector fitting within said annular groove, said head
cap having resilient radially inwardly extending retainer : k at se