US20100238654A1 - Work Light - Google Patents
Work Light Download PDFInfo
- Publication number
- US20100238654A1 US20100238654A1 US12/766,514 US76651410A US2010238654A1 US 20100238654 A1 US20100238654 A1 US 20100238654A1 US 76651410 A US76651410 A US 76651410A US 2010238654 A1 US2010238654 A1 US 2010238654A1
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- United States
- Prior art keywords
- light
- handle
- casing
- circuit board
- light device
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21L—LIGHTING DEVICES OR SYSTEMS THEREOF, BEING PORTABLE OR SPECIALLY ADAPTED FOR TRANSPORTATION
- F21L4/00—Electric lighting devices with self-contained electric batteries or cells
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21L—LIGHTING DEVICES OR SYSTEMS THEREOF, BEING PORTABLE OR SPECIALLY ADAPTED FOR TRANSPORTATION
- F21L14/00—Electric lighting devices without a self-contained power source, e.g. for mains connection
- F21L14/02—Electric lighting devices without a self-contained power source, e.g. for mains connection capable of hand-held use, e.g. inspection lamps
- F21L14/023—Electric lighting devices without a self-contained power source, e.g. for mains connection capable of hand-held use, e.g. inspection lamps having two or more, or different light sources
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21V21/00—Supporting, suspending, or attaching arrangements for lighting devices; Hand grips
- F21V21/08—Devices for easy attachment to any desired place, e.g. clip, clamp, magnet
- F21V21/0832—Hook and loop-type fasteners
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21V21/00—Supporting, suspending, or attaching arrangements for lighting devices; Hand grips
- F21V21/08—Devices for easy attachment to any desired place, e.g. clip, clamp, magnet
- F21V21/088—Clips; Clamps
- F21V21/0885—Clips; Clamps for portable lighting devices
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21V23/00—Arrangement of electric circuit elements in or on lighting devices
- F21V23/003—Arrangement of electric circuit elements in or on lighting devices the elements being electronics drivers or controllers for operating the light source, e.g. for a LED array
- F21V23/004—Arrangement of electric circuit elements in or on lighting devices the elements being electronics drivers or controllers for operating the light source, e.g. for a LED array arranged on a substrate, e.g. a printed circuit board
- F21V23/005—Arrangement of electric circuit elements in or on lighting devices the elements being electronics drivers or controllers for operating the light source, e.g. for a LED array arranged on a substrate, e.g. a printed circuit board the substrate is supporting also the light source
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21V31/00—Gas-tight or water-tight arrangements
- F21V31/005—Sealing arrangements therefor
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
- F21Y2103/00—Elongate light sources, e.g. fluorescent tubes
- F21Y2103/10—Elongate light sources, e.g. fluorescent tubes comprising a linear array of point-like light-generating elements
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
- F21Y2115/00—Light-generating elements of semiconductor light sources
- F21Y2115/10—Light-emitting diodes [LED]
Abstract
In one aspect, a light device is provided having an elongate body that has a high strength construction. The high-strength light device is especially well-suited for use as a work light. The work light includes a high-strength body that has a handle and an elongate light-transmissive portion extending from the handle. Preferably, the light-transmissive portion includes a one-piece tubular wall that is tapered and which is molded from a high-strength material. In another aspect, the light device includes anti-rolling surfaces axially between the handle and light transmission portion along the elongate body. The anti-rolling surfaces preferably have a flat configuration so that the flat surfaces keep the elongate body from rolling when placed on a support surface.
Description
- This application is a continuation of prior application Ser. No. 12/001,468, filed Dec. 11, 2007, which is a continuation-in-part of prior application Ser. No. 11/077,682, filed Mar. 11, 2005, now U.S. Pat. No. 7,306,349, which are hereby incorporated herein by reference in their entirety.
- The invention is directed to a lighting device and, more particularly, to an LED work light.
- Work lights or shop lights are useful lighting devices having wide applications for providing illumination in rugged environments such as workshops, garages, campsites, and many other places. Given the rugged environment in which the lights are used in, it is generally required that the work light have a robust construction such that the light source is not damaged or broken during use.
- Common work lights use a variety of different lighting sources to provide illumination. For instance, incandescent or fluorescent light bulbs are common lighting sources used in the work light. While such bulbs are capable of providing sufficient illumination, they have the shortcoming of being fragile and, therefore, requiring relatively large or bulky housings to protect the bulbs from breakage. For instance, incandescent light bulbs, such as a 60-watt light bulb, are often used in work lights, but require bulky, cage structures surrounding the bulb for protection. While the cage may provide limited protection to the bulb, it still does not prevent the bulb from breaking if the work light is dropped. Moreover, the bulky cage structure limits the areas the work light can be used in because its large size prevents the incandescent work light from being used in tight or other confined spaces. Similarly, the fluorescent light bulb, such as the gas-filled, tube light, may be more compact in size than the incandescent bulb, but such bulbs are still very fragile and, therefore, also require extensive protection. In many cases, the protection surrounding the fluorescent light bulb is much larger in terms of its diameter as compared to the diameter of the fluorescent tube itself. As a result, the fluorescent work light also has a limited use in confined spaces. Therefore, while the fluorescent bulb may be narrow, the combination of the bulb or bulbs and required particular housing is quite large, particularly, in the radial direction transverse to the axis of the fluorescent tube.
- Other attempts at work lights use LEDs as the light source. The LED or light emitting diode is a very compact and an efficient, solid state light source that is less fragile than incandescent or fluorescent glass lights, but still provides sufficient illumination, especially when several LEDs are grouped together. As a result, work lights using LEDs may be smaller than incandescent or fluorescent work lights, and also generally require smaller housings encasing the LEDs therein. Current work lights that use LEDs as the light source generally seek to take advantage of the sturdier construction of the LED itself and incorporate less robust housings or casings for the lighting device. In that regard, many housings for LED work lights are fabricated from multiple components, which may compromise the integrity and strength of the housing. For instance, in practice it is believed a typical LED work light housing will include a cylindrical casing assembly that surrounds the LEDs via two elongate semi-cylindrical casing parts that are attached at two part lines 180° spaced from each other about the cylindrical casing assembly. Further, a separate end cap is utilized to enclose the free end of the cylindrical casing assembly. By having a three-piece casing assembly, the semi-cylindrical and end cap housing parts can be more readily formed of high strength material; nevertheless, such a configuration can create areas of weakness at the joints or interfaces between the semi-cylindrical casing parts and the end cap attached thereto that compromises the overall strength of the work light. Moreover, such multiple casing components also require more complicated supply chains, the fabrication of more parts, and the additional assembly step of combining all the parts.
- When not being held, it is common for the work light to be set down on the floor or a flat, work or support surface like on a table. Prior cylindrically configured work lights can roll when placed down on a flat support surface. Often, in addition to the curved light casing, the work lights also have curved handle surfaces, which may provide a comfortable grip, but also permit the light to easily roll upon a support surface. It can be aggravating to have the work light roll beyond one's reach and potentially damaging to the work light should it be placed on a raised table work surface and then roll thereon to where the work light falls off the table.
- Therefore, it is desired to obtain a simplified LED work light having a compact and robust construction. In addition, a work light having a generally cylindrical configuration that does not roll along work surfaces would be desirable.
- In accordance with one aspect of the present invention, a light device is provided having an elongate body that has a high-strength construction. The high-strength light device is especially well-suited for use as a work light as its construction allows it to easily withstand impacts from hitting other hard objects, being dropped, or even run over by an automobile such as can occur when used around workshops, camp sites, and in auto repair facilities. The high strength body includes a handle at one end and a thin elongate light-transmissive portion including a tubular wall that extends from a larger diameter thereof at the handle to a smaller diameter at the other end of the body with a light source contained within an interior space defined by the tubular wall. It has been found that providing the tubular wall of the light transmissive portion with a taper along its length, and particularly along the inner surface thereof, allows the strength of the tubular wall to be optimized by molding the wall from a high strength material and so that it has an integral, one-piece construction.
- Generally, prior work lights suggest use of high strength plastic material, but only with constant diameter, cylindrical light heads, which, in practice, require the light heads to have a two-piece construction that can compromise the strength, and particularly the pressure or compressive force resistance of such two-piece light heads. In contrast, the present light device takes advantage of the provision of a taper to the tubular, light-transmissive wall thereof which generally increases the strength of the wall as it progresses down to smaller and smaller diameters since there is more plastic material per unit area of space that the tubular wall encompasses. Moreover, the taper of the tubular wall permits it to be molded with a high-strength material and to have a one-piece, unitary, or integral construction.
- It is believed that in practice the high-strength plastic or polymer material, for example, polycarbonate or acrylic plastic, typically has not been molded to form unitary cylindrical walls of the prior light heads because of material shrinkage during molding that makes it very difficult and unduly expensive to remove such a unitary cylindrical part from the mold. By contrast, the tapered, tubular wall of the light device herein allows for it to be molded as a single, unitary component even with high-strength plastic material that experiences significant dimensional shrinkage during molding so that it grips tightly onto part forming mold members. In this regard and as mentioned, it is the inner surface of the tubular wall that is tapered, whereas the outer wall surface may or may not include a taper, since it is the inner surface that is formed by a tapered core pin of the mold with the high-strength plastic material shrinking down and tightly gripping the pin. Nevertheless, by tapering the pin, it can more easily be pulled without having to utilize more complex and expensive molding equipment such as a collapsible core as may be necessitated where a constant diameter cylindrical wall is formed as with prior work light devices. Accordingly, as previously discussed, prior commercial work lights provided with a cylindrical, light-transmissive wall formed from two molded halves that are secured together along two-part lines generally will weaken the light head thereat absent additional fastening hardware that can unduly increase the size and expense thereof. In the present elongate, tapered light head, the light-transmissive tubular wall avoids these problems and provides the wall with its high-strength construction both because of its tapered configuration and by way of its one-piece, unitary construction utilizing high-strength plastic material therefor.
- In one form, the light source includes a plurality of aligned LEDs. The use of small LEDs and their alignment is advantageous in keeping the diameters of the tapered, tubular wall to a minimum. In another form, the light source includes a printed circuit board that is inserted into an internal space defined by the tubular wall of the light-transmissive portion. Preferably, the printed circuit board has opposite sides that taper inward toward each other. In this configuration, the printed circuit board generally can have a wedge-type fit in the tapered, tubular wall of the light-transmissive body portion. Preferably, the printed circuit board is elongated and includes the plurality of LEDs aligned along one side of the printed circuit board.
- In another form, the tubular wall has a central axis extending therethrough. Preferably, the printed circuit board has a proximate end in the casing aligned with the central axis at the larger diameter of the tubular wall and a distal end that is offset from the central axis at the smaller diameter of the tubular wall. Such configuration of the printed circuit board is advantageous in conjunction with a tapered inner surface of the tubular wall as it permits the aligned LEDs to be of the same size substantially irrespective of their position along the length on one side or surface of the elongate circuit board. In other words, the space between the LED mounting side of the circuit board and the facing portion of the tubular wall at the proximate end can be approximately the same as the corresponding space at the distal end despite the smaller diameter of the casing at the free end of thereof. Also, if the degree of deviation of the circuit board from the casing axis is greater than the taper of the casing wall, then even larger size LEDs can be used toward the distal end of the circuit board.
- As mentioned above, the tubular wall has an inner surface and the predetermined taper may be on the tubular wall inner surface. Additionally, the plurality of LEDs may include proximate and distal LEDs with a spacing between a top surface of printed circuit board and the inside surface of the tubular wall. In one aspect of a preferred configuration, even with the tapered tubular wall, the distal LED has a spacing that is about the same as a spacing between the proximate LED and the inside wall surface.
- In another form, the tubular wall diameters are optimized for both size and strength advantages. For instance, it is preferred to keep the size of the light-transmissive portion to a minimum for lighting of confined spaces. As a result, in a preferred embodiment, the tubular wall diameters do not exceed approximately 1 inch with an axial length of approximately 14.4 inches; however, longer or shorter light-transmissive portions may utilize larger or smaller diameters. At the same time, while the size is minimized, it is also preferred that the tubular wall have a configuration that is optimized for strength. To this end, the tubular wall may have a ratio of wall thickness to the cross-sectional area that it circumscribes including the internal space about which the wall extends that increases axially along the wall axis from the connection to the handle to the distal end portion. Therefore, such ratio allows the light-transmissive portion to be formed from the high-strength material as described above and, as a result, also have the desired high level of resistance to compressive pressure forces. In one form of the optimized construction, the wall thickness may be constant and the tubular wall may have side portions that taper inward toward each from the connection to the handle to the end portion.
- In another form, the handle has a housing that includes openings and fasteners that extend through the openings for connecting the housing together. The printed circuit board generally has a portion that extends into the handle housing and a portion that extends into the light-transmissive portion. Preferably, the printed circuit board also includes openings, which are aligned with the openings of the housing, so that the fasteners may extend therethrough to secure the printed circuit board to the handle. The light transmissive portion may also include a stop between the printed circuit board and the light-transmissive portion that defines a predetermined position of the printed circuit board in the handle housing and the light-transmissive portion such that the respective fastener openings thereof are aligned.
- Optionally, the light device may further include a mounting assembly connected to the elongate body. The mounting assembly may be configured for optimized flexibility in mounting the elongate body of the light device to differently configured and constructed mounting surfaces. In this regard, the mounting assembly may include a connector portion of the elongate body, a plurality of different mounting devices for mounting the elongate body to differently configured and constructed mounting surfaces, and a releasable connection between the connector portion and each of the different mounting devices.
- In another aspect, the light device may include intermediate anti-rolling surfaces axially between curved surfaces of a forward elongate light head, and a rearward elongate handle of the device with the intermediate anti-rolling surfaces having a generally flat configuration. The flat anti-rolling surfaces keep the light device from rolling when the light device is placed on a flat support surface.
- In one form, the casing includes a rearward, radially extending flange having a periphery extending thereabout on which the anti-rolling surfaces are formed. The flange is sized relative to the light head and handle curved surfaces so that one of the flat surfaces thereof will engage the support surface when the body is placed thereon. In another form, corner projections are formed between adjacent flat surfaces with the corner projections extending radially beyond the curved surfaces of the casing and the handle.
- In a preferred form, the handle curved surface has a varying radius of curvature and includes corner surface portions and support surface portions. The corner surface portions are between adjacent support surface portions and have a radius of curvature larger than the curved corner surface portions. Each of the curved support surface portions of the handle are circumferentially aligned with one of the flat anti-rolling surfaces. In this manner, the light device includes two distinct areas of contact that are axially spaced from each other along the device so that when placed on a support surface, the device will not roll thereon, with one of the areas being at one of the flats and the other area being at the corresponding aligned curved support surface portion of the handle. The handle support surface portions cooperate with the flat anti-rolling surfaces to provide the work light body with additional stability against rolling when it is placed on the support surface.
- In another form, the light device includes an elongate body having a tubular light transmission casing, an elongate handle, and an intermediate nut having flats with the nut disposed between the casing and the handle. The nut is sized so that when the elongate body is placed on a flat support surface, one of the nut flats will engage flush on the support surface to keep the body curved surfaces from rolling on the support surface.
- In one form, the curved surface of the casing has a substantially constant radius of curvature, and the nut is radially enlarged relative to the casing so that the flats thereof project beyond the casing curved surface.
- In a preferred form, the casing is tapered to have a large diameter end adjacent the intermediate nut tapering down to a small diameter distal end of the casing, and the nut has an octagonal configuration so that there are eight flats thereof. With the octagonal configuration, the nut can be sized so that each of the flats thereof only project beyond the curved surface of the adjacent, casing large diameter end by a minimal amount.
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FIG. 1 is a perspective view of a light device in accordance with the present invention showing a handle and an elongate light-transmissive portion extending therefrom; -
FIG. 2 is a plan view of the light device ofFIG. 1 showing a taper of the light transmissive portion and LEDs aligned on a circuit board in the tapered light transmissive portion; -
FIG. 3 is an exploded, perspective view of the light device ofFIG. 1 showing the light-transmissive portion formed as a one-piece tubular casing and the handle having a two-piece construction with the circuit board including portions in both the handle and the casing; -
FIG. 4A is a side elevation view partially in section generally taken alongline 4A-4A inFIG. 6 showing the circuit board extending offset to the axis of the tapered casing; -
FIG. 4B is a cross-sectional view generally taken along line 4B-4B inFIG. 6 showing the connection of the handle, the light-transmissive portion, and the circuit board; -
FIG. 4C is a cross-sectional view taken along like 4C-4C ofFIG. 4A showing anti-rotation structure in engagement between the casing and the handle; -
FIG. 5 is an enlarged, cross-sectional view of the tubular casing portions ofFIG. 3 showing the taper and constant thickness of the side wall portion of the casing; -
FIG. 6 is a front, elevational view of the light device ofFIG. 1 showing the taper of the circuit board; -
FIG. 7 is a plan view of the printed circuit board ofFIG. 3 showing tapered side edges thereof; -
FIG. 8 is a rear, elevational view of the tubular casing taken along line 8-8 inFIG. 5 ; -
FIG. 9 is a cross-sectional view taken along line 9-9 inFIG. 5 ; -
FIG. 10 is a plan view of one of the handle members of the two-part handle housing; -
FIG. 11 is a cross-sectional view of the handle member generally taken along line 11-11 inFIG. 10 ; -
FIG. 12 is a plan view of the other handle member of the two-part handle housing ofFIG. 3 ; -
FIG. 13 is a cross-sectional view of the other handle member generally taken along line 13-13 inFIG. 12 ; -
FIGS. 14-16 are enlarged, fragmentary views of the casing distal end portion showing mounting assemblies including a ball and socket releasable connection between the casing portion and different mounting devices; -
FIG. 17 is an enlarged, fragmentary view of the casing distal end portion showing an alternative mounting assembly; -
FIG. 18 is an enlarged, fragmentary view of the casing distal end portion showing an another alternative mounting assembly; -
FIGS. 19-20 are enlarged, fragmentary views of the casing distal end portion showing alternative LED arrangements; -
FIG. 21 is a sectional schematic of an exemplary cavity mold and core pin for molding the one-piece tubular casings portions of the present light devices; -
FIG. 22 is a perspective view of a battery powered light device in accordance with the present invention; -
FIG. 23 is an exploded, perspective view of the light device ofFIG. 22 similar toFIG. 3 showing a battery electrically connected to the printed circuit board; -
FIG. 24 is an exploded, cross-sectional, side view of another alternative light device in accordance with the present invention adapted for underwater lighting or use in hazardous environments showing a sealed threaded connection between the handle and elongate light-transmissive casing portion; -
FIG. 24A is a detailed cross-sectional view of an alternative sealed threaded connection of the light device ofFIG. 24 ; -
FIG. 25 is a perspective view of an alternative light device in accordance with the present invention showing an intermediate nut including anti-rolling flat surfaces thereof positioned axially between curved surfaces of a forward elongate light head and a rearward, elongate handle; and -
FIGS. 26-28 are elevational views of the light device ofFIG. 25 showing the tapered configuration of a casing of the light head; -
FIG. 29 is a front elevational view of the light device ofFIG. 25 showing the octagonal configuration of the intermediate nut with the flat surfaces disposed radially beyond the casing; -
FIG. 30 is a cross sectional view taken along line 30-30 ofFIG. 28 showing the nut flat surfaces disposed radially beyond an annular portion of the handle adjacent thereto; -
FIG. 31 is a rear elevational view of the light device ofFIG. 25 showing a curved surface of the handle portion having a variable radius of curvature; and -
FIG. 32 is an exploded view showing the intermediate nut formed integrally in one-piece with the casing. - In
FIGS. 1 and 2 , anLED work light 10 is shown that is provided with a high-strength construction in accordance with the present invention. The light 10 may be powered from a standard 110 volt wall outlet through acord 12 plugged into the outlet in a known manner. Battery powered and combination units providing options in terms of powering the light device with either power from a wall outlet or a battery are also contemplated. The batteries can be rechargeable. Further, thecord 12 can be provided with a connector that allows it to be plugged into a typical cigarette lighter in a vehicle to be powered by the electrical power source thereof. In this regard, thepower cord 12 can be provided in different lengths ondifferent light units 10 such as with a twenty foot length for automobiles or a forty foot length for trucks. - In general, the light 10 includes a high-strength,
elongate body 14 including an elongate,light head 15 having a substantially light-transmissive portion orcasing 16, and ahandle portion 18 from which thelight head 15 including its light-transmissive portion 16 extends. Alight source 20 of thelight head 15 is generally disposed in the light-transmissive portion or casing 16 in such a manner to emanate light therethrough. - To provide the high-strength construction, the light-
transmissive portion 16 is fabricated from a high-strength material and includes a one-piecetubular wall 22 that has an elongate axis Z extending therethrough and an annularside wall portion 24 extending thereabout that is tapered relative to the axis Z. The taperedsidewall portion 24 allows thetubular wall 22 to be molded from a high strength material in one piece rather than being molded as multiple components as has previously been described. As will be discussed further hereinafter, the taper may be provided only along aninner surface 28 of theside wall portion 24 to achieve the strength advantages described herein, although the illustratedside wall portion 24 also includes a taper on anouter surface 30 thereof as well. - As best seen in
FIGS. 1-5 , the light-transmissive portion 16 is a generally elongate tubular structure that includes the one-piecetubular wall 22 having a transverseend wall portion 22 b integrally formed with theside wall portion 24 at the distal free end thereof. At the other end of theside wall 24, an integral flange orshoulder wall portion 22 c can be formed. Therefore, theside wall portion 24 extends axially from theshoulder wall portion 22 c to theend portion 22 b to form the elongatetubular casing 16, which is closed at the distal end thereof by theend wall portion 22 b. Accordingly,portions interior space 26 that can receive thelight source 20 therein. - Axially opposite the
distal end portion 22 b is the proximateshoulder wall portion 22 c, which extends or flares radially outwardly from theside wall portion 24 to connect with thehandle 18. The outward extendingshoulder portion 22 c provides further strength enhancement to thecasing 16 due to its flanged construction providing thecasing 16 with a greater radial thickness of the high-strength material at the joint interface between thecasing 16 and thehandle 18. As shown, thecasing sidewall 24 preferably tapers down from a large diameterhandle connecting end 29 to thedistal end wall 22 b so that the largest diameter X is at the connecting end and the smallest diameter Y is at the distal end of the casing. Theshoulder portion 22 c also includes a connectingstructure 22 d for connecting the light-transmissive portion 16 to thehandle 18. The connectingstructure 22 d may include an annular tongue orrib 23 and anannular groove 21 between therib 23 and a rearwardly facingsurface 19 of the radially enlargedwall portion 22 c. Therib 23 has anend stop surface 71 used for positioning thelight source 20 within theinterior space 26, as will be described further hereinafter. Thegroove 21 also includes a key tab orprotrusion 73 for mating with anotch 75 in thehandle 18. Theprotrusion 73 fixedly, circumferentially orients theportion 16 relative to thehandle 18, as will be further described below. - In the preferred and illustrated form, the
tubular wall 22 has a generallyconstant thickness 25 with the tapers of the wall surfaces 28 and 30 being the same, e.g., 0.10 inch. The taperedside wall portion 24 has a diameter of about 1 inch at the wallouter surface 30 atconnection end 29 tapering down to a diameter of about 0.7 inch at the wallouter surface 30 atend portion 22 b. As shown, the distalend wall portion 22 b can also be of the same thickness as theside wall portion 24 so that thetubular casing 16 is of substantially constant thickness except at the connectingend structure 22 c thereof. - The tapered casing configuration is advantageous in terms of the strength enhancement it provides the
present work light 10. As previously mentioned, molding the light-transmissive portion 16 of high strength material while keeping it as a unitary component is extremely difficult. However, herein such molding is readily accomplished by providing thesidewall portion 24 with the aforedescribed tapered configuration in contrast to the cylindrical shapes of prior work light casings. Accordingly, thepresent casing 16 is formed of high-strength polymer material and does not include part lines extending therealong which can create areas of weakness in a work light. - A further strength advantage obtained by the tapered
sidewall portion 24 for the light-transmissive portion 16 herein is achieved by the greater concentration of the rigid wall material in a progressively smaller space as thewall 24 tapers down towards itssmaller diameter end 31. As previously described, thewall 24 tapers from the largerproximate end 29 down to the smaller diameterdistal end 31 so that thewall 24 provides increasing strength down toward its distal end. In other words, because there is progressively more plastic material in a smaller and smaller cross-sectional area of thelight head 15, there is more resistance to breakage due to impacts and compressive forces as the ratio of the wall thickness of thecasing 16 to the cross-sectional area circumscribed by thecasing wall 24 increases. For instance, with a constantthickness casing wall 24, this ratio will be greatest at thedistal end 31 of thecasing 16 because of the taper of the side wall to its smallest diameter Y thereat so that the light head cross-sectional areas defined by the formula Πr2 is also the smallest, whereas at thehandle connecting end 29, the diameter X and thus the light head cross-section area is largest decreasing the ratio to its smallest extent. - As discussed above, the taper of the
side wall portion 24 is preferred because it allows both high strength material to be utilized for thecasing 16 and to form it with a one-piece construction, which also provides high strength to the light 10 herein, and particularly thecasing portion 16 thereof. To this end, molding thecasing 16 in one piece from a high-strength material can be done in a relatively straight forward and inexpensive molding process employing atapered cavity mold 1000 and a tapered core pin 1200 (FIG. 21 ). The use of complicated mold components such as collapsible cores and the like is avoided even though molding with high strength material. The high-strength material may be any moldable, high-strength material that allows light transmission therethrough such as polycarbonate or acrylic polymer materials. For example, it is believed that with the present taperedcasing 16 formed of polycarbonate material, thecasing 16 will be capable of withstanding a compression force at least about 500 pounds per square inch with strengths of greater than 2000 pounds per square inch also being achievable. - Referring to
FIGS. 3 , 4A, and 7, the preferredlight source 20 will next be described. Thelight source 20 generally includes an elongate printedcircuit board 34 having an electronics receivingbase portion 36 and an elongate,illumination portion 38 extending therefrom. The electronics receivingbase portion 36 has thepower cord 12 connected thereto, an on/offswitch 40, and otherelectrical components 41 for providing electrical power to the light source carried thereon. As shown, switch 40 is a rocker-type switch; however, other switching devices may also be used. Thecomponents 41 can include various diodes, capacitors, and resistors that convert the 110 volt AC obtained from the wall outlet via thepower cord 12 to about 30 volt DC for energizing theLEDs 42. Manifestly, these electrical components and/or circuitry can be varied to accommodatelight units 10 adapted to be plugged into cigarette lighters or for those that utilize battery power. - The electronics receiving
base portion 36 of thecircuit board 34 is disposed within thehollow handle 18 of the light 10. As best illustrated inFIGS. 3 and 7 , the circuitboard base portion 36 may include one ormore fastening structures 46 that mate with one or morecorresponding fastening structures handle 18. Preferably, circuitboard fastening structures 46 are recess openings and/or apertures in the electronics receivingbase portion 36 that can be aligned with thefastening structures handle 18. Protrusions orabutments 76 of thecircuit board 34 are provided at a predetermined position along the length of thecircuit board 34 so that when brought into engagement with thecasing stop surface 71, the circuitboard fastening structures 46 are aligned with thehandle fastening structures fastening structures fastener 67, such as a screw, rivet, or the like, to extend therethrough to secure thecircuit board 34 in thehandle 18 andcasing 16, and the electronics receivingbase portion 36 to thehandle 18 and, more specifically, to keep the circuitboard base portion 36 from shifting axially relative to thehandle 18. In this manner, thecircuit board 34 is axially fixed in thehollow body 14 of thelight device 10 when thehandle members bosses handle members members circuit board 34, and specifically thebase portion 36 thereof, fits in this small gap so that thebase portion 36 generally extends centrally in the handle cavity along the central axis Z aligned with the part lines 61 a, 61 b on either side thereof formed between theconnected handle members - The elongate
circuit board portion 38 includes anillumination source 42, which is preferably a plurality of LEDs. Conductive traces formed on the printedcircuit board 34 electrically interconnect the LEDs with the power source via on/offswitch 40, theelectrical components 41, and thepower cord 12. It is preferred that LEDs be aligned along the circuit board as shown inFIG. 7 to keep the diameters of the light-transmissive portion 16 to a minimum. In particular, the aligned LEDs allow the smallest diameter Y of thecasing 16 to be minimized in size. As illustrated inFIG. 7 , theLEDs 42 are also preferably disposed on asingle surface 50 of theillumination portion 38 which also assists in keeping the light-transmissive portion 16 size to a minimum. In addition, the single side arrangement of theLEDs 42 on the printedcircuit board 34 maximizes the light emanated from thelight transmissive portion 16 from one side thereof. - As illustrated in
FIGS. 3 , 4B, and 7, theillumination portion 38 of thecircuit board 34, like thecasing 16, also has an elongate configuration and, preferably, has side edges 44 a and 44 b that taper inward toward each other from the electronics receivingbase portion 36 to adistal end 38 b of theillumination portion 38. In this configuration, theillumination portion 38 is received in theinterior space 26 of the light-transmissive portion 16 and may have a generally wedge fit in such space. The side edges 44 a and 44 b may be frictionally received in theinterior space 26 such that theedges 44 a and 44 b contact theinside surface 28 of thetubular wall 22 when thecircuit board portion 38 is fully received in thecasing 16. For this purpose, the taper of the side edges 44 a and 44 b generally corresponds to the taper of thesidewall portion 24 of thetubular wall 22. Therefore, in addition to providing high strength, the taper of theside wall portion 24 may also aid in the positioning and/or securing of thelight source 20 in theinterior space 26. Alternatively, there may be a slight clearance between the circuit board edges 44 a and 44 b and thecasing wall 24, but the cooperating tapered configuration of each assists in positioning theillumination portion 38 in theinterior space 26 generally laterally centered relative to the central, longitudinal axis Z, but preferably offset therefrom as will be described hereinbelow. In either case, the wedge-fit makes insertion of thecircuit board portion 38 in thecasing 16 easier since the smallest widthdistal end 38 b thereof is the leading end that is initially inserted in the largest diameter end of the casing taperedinterior space 26. - The printed
circuit board 34 may also have atransition section 52 at which theillumination portion 38 is angled away from the electronics receivingbase portion 36. Generally, the transition orbent section 52 can take the form of atransverse bend line 52 between the base andillumination portions circuit board 34. As previously mentioned, thebase portion 36 is captured by the internal projections orbosses handle 18 to extend centrally therein. Accordingly, when assembled in thecasing 16, theillumination portion 38 will generally extend transversely at an oblique angle to the longitudinal axis Z. Thus, when received in theinterior space 26, theillumination portion 38 has a proximal end 38 a adjacent theportion 36 that is generally aligned with the central longitudinal axis Z as is the electronics receivingbase portion 36 itself, and adistal end 38 b that is offset from the longitudinal axis Z. In other words, when received in theinterior space 26 of the light-transmissive portion 16, the proximal end 38 a is aligned with the longitudinal axis Z near theshoulder wall portion 22 c and thedistal end 38 b is above or below the axis Z near theend portion 22 b. Such angled configuration of theillumination portion 38 relative to the electronics receivingbase portion 36 generally permits theLEDs 42 to be of the same size substantially irrespective of the position of theLEDs 42 along the length of the printedcircuit board 34. - As shown, the
illumination portion 38 extends substantially linearly in the casinginterior space 26 but at a greater angle of deviation from the axis Z than thesidewall 24. In this manner, aspace 54 between theLED mounting surface 50 of theillumination portion 38 and the facing side of theinside casing wall 28 will become progressively larger as theillumination portion 38 extends distally in theinterior space 26. This allows the size of thedistal LED 42 b to be just as large as the proximate LED 42 a, or even larger if desired. On the other hand, aspace 56 between the opposite side of theillumination portion 38, which does not includeLEDs 42, and theinner wall surface 28 will become progressively smaller as theillumination portion 38 extends distally in theinterior space 26. As is apparent, the angle of theillumination portion 38 can be the same as the taper of thecasing wall 24 so that theLEDs 42 can be of the same size since thespace 54 between theboard surface 50 and thecasing wall 24 also stays the same along the length thereof. - A
stop 69 between thecircuit board 34 andcasing 16 is preferably provided which defines how far the printedcircuit board 34 extends into theinterior space 26 of thecasing 16. As shown inFIGS. 3 and 4 , thestop 69 includes thestop surface 71 of thecasing 16 and theabutment tabs 76 of thecircuit board 34 to define a predetermined position of the circuitboard illumination portion 38 within theinterior space 26 of the light-transmissive portion 16. Thecasing stop surface 71 has an annular configuration with an inner diameter that is smaller than the distance across the laterally extendingtabs 76. Accordingly, when the circuitboard illumination portion 38 is inserted into theinterior space 26, thecasing stop surface 71 and theprotrusion tabs 76 on the electronics receiving base portion 36 (FIGS. 3 and 4B ) interfere with each other to abuttingly engage and define the predetermined longitudinal or axial position of thecircuit board portion 38 in thecasing 16. Preferably, theprotrusion tabs 76 are disposed on the electronics receivingbase portion 36 adjacent thetransition section 52 such that when inserted in the light 10, the predetermined longitudinal position of the circuitboard base portion 36 is entirely within thehandle 18 and theillumination portion 38 is disposed entirely in thecasing 16 with a predeterminedsmall gap 75 between thedistal end 38 b of theboard 34 and theend wall portion 22 b of the casing 16 (FIGS. 2 and 4B ). Preferably, thegap 75 is ¼ inch or less. - Referring to FIGS. 3 and 10-13, the
handle 18 will now be described in more detail. In the preferred and illustrated form, thehandle 18 includes twoshell members hollow handle 18 having acavity 60 for receiving the electronics receivingbase portion 36 of thelight source 20 as previously described. Theshell members portion 62 and a mountingportion 64 of thehandle 18. Preferably, the grippingportion 62 is contoured to have a slight curve or bulge as it extends axially and sized to comfortably fit in a user's hand. The mountingportion 64 is slightly radially enlarged relative the grippingportion 62 and configured to be connected with the connectingportion 22 d of thecasing 16. As illustrated, the mountingportion 64 includes anannular rib 72 that projects radially inwardly, and anannular groove 74 adjacent therib 72 to interfit with theannular groove 21 andrib 23 of thecasing connecting portion 22 d. More particularly, when thehandle members rib 23 of thecasing portion 22 d fits in thehandle groove 74, and the handleannular rib 72 fits in the casingannular groove 21. - To keep the
casing 16 from rotating relative to thehandle 18,anti-rotation structure 77 is provided therebetween. More particularly, so that theribs annular grooves tab 73 of thecasing connector 22 d is configured to seat in anotch 75 of thehandle connector 64. Manifestly, thetab 73 could instead be on thehandle connector 64 and thenotch 75 formed on thecasing connector 22 d. Referring toFIGS. 3 , 5, and 12, it can be seen that as illustrated that thetab 73 is in the casingannular groove 21 and thenotch 75 is formed in the handleannular rib 72. It should be also noted that until thecasing 16 is properly circumferentially aligned relative to thehandle 18 to position thetab 73 in alignment with thenotch 75, thehandle member 58 and 58 b will not be able to be properly secured together so as to be clamped along theirpart lines 61 a and 61 b. - As previously mentioned, the shell members also include fastening structures in the form of integral annular bosses formed in the
respective shell members bosses 48 define through holes through which thescrew fasteners 67 extend, thebosses 66 are internally threaded blind bosses that do not open to the exterior surface of thehandle member 58 b. - The assembly of the preferred
light device 10 will next be described. To secure theshell members base portion 36 therebetween, thecorresponding fastening structures stop 69. More particularly, the circuitboard illumination portion 38 is first advanced into theinterior space 26 of thecasing 16 until thecircuit board protrusions 76 engage thecasing stop surface 71. The taper of thecircuit board 34 assists in fitting theboard 34 in thecasing 16 as previously discussed and theedges 44 a, 44 b thereof can engage the casinginner surface 28 or be closely adjacent thereto with theboard 34 fully inserted to provide a wedge fit of theboard 34 in the casing. Then thehandle members base portion 36 of thecircuit board 34. First, thehandle member 58 a is circumferentially oriented so that thenotch 75 is aligned with thecasing tab 23. Then, thecasing rib 23 is seated in the half of thegroove 74 in thehandle member 58 a with the half of therib 72 in thehandle member 58 a being fully seated in thecasing groove 21. In this manner, the apertures andrecess 46 of the circuitboard base portion 36 are aligned with the correspondingbosses 48 of thehandle member 58 a. Next, theshell 58 b is clamped on theshell 58 a in a similar manner with thecasing rib 23 seated in the other half of thegroove 74 in thehandle member 58 b and the other half of therib 72 in thehandle member 58 b seated in thecasing groove 21. In this arrangement, thebosses 66 of thehandle member 58 b will also be aligned with the circuit board recesses andapertures 46 and handlebosses 48. Finally, thefasteners 67 are inserted through the alignedfastening structures handle shells handle cavity 60 that is closed at one end and has anopening 61 at the other end. The printedcircuit board 34 extends through theopening 61 after being secured within the handle. - The
shell members shell member 58 b preferably includes anopening 68 sized to receive the on/offswitch 40 mounted on the printedcircuit board 34. As best shown inFIG. 1 , the on/offswitch 40 protrudes through theopening 68 when theshells circuit board 34 are assembled as previously described. To limit the instances of inadvertent switching, theopening 68 has aflange 70 extending thereabout so that theswitch 40 is surrounded thereby. - Referring to
FIGS. 14-18 , a mountingassembly 100 for mounting thelight device 10 to a variety of different configurations and constructions of mounting surfaces or members is depicted. In general, the mountingassembly 100 includes aconnector portion 110, a plurality ofdifferent mounting devices 112, and areleasable connection 114, which allows the mountingdevices 112 to be readily interchanged for use with thelight device 10 depending on what it is to be mounted to. In this manner, thelight device 10 is provided with flexibility in being able to be mounted in different locations and environments of use to provide hands-free illumination of a wide variety of work areas. - More specifically, the
releasable connection 114 can be in the form of a ball-and-socket joint 115 with theconnector portion 110 extending outwardly from theend wall portion 22 b of thecasing 16 and having aball member 110 a formed at the free end thereof. The mountingdevices 112 can each include a resilientarcuate clip 117 that is configured to tightly grip onto theball member 110 a. As shown,resilient clip 117 can have a C-shaped configuration so that it can snap on and off theball member 110 a. In this manner, the mountingassembly 100 preferably provides a universal or other “quick” connect feature so that a variety ofdifferent mounting devices 112 can be mounted to the samelight connector portion 110. - Instead of the ball-and-socket type quick connect 115, alternatively, the
connector portion 110 may be either apin 110 b having a locking groove 111 (FIG. 17 ) or apin 110 c having a through aperture 113 (FIG. 18 ). Referring toFIG. 17 , the mountingdevice 112 can include aresilient sleeve member 119 in which a ball-bearingassembly 120 is held. Therace 122 of the ball-bearingassembly 120 is press-fit into thesleeve 119. The balls 124 generally are in interference with the outer diameter of thepin 110 b so that inserting thepin 110 b into the open-endedsleeve 119 will cause thesleeve wall 126 to deflect outwardly until thegroove 111 is aligned with the balls 124 which then snap into thegroove 111 to releasably connect the mountingdevice 112 b ofFIG. 17 to thelight device 10. The other mountingdevices 112 a and 112 c can also be provided with thesleeve member 119. - In
FIG. 18 , the mountingdevice 112 also includes aconnector sleeve member 130; however, it can be of more rigid construction than theresilient sleeve member 119 ofFIG. 17 . Thearms 132 a and 132 b of thesleeve member 130 have alignedapertures 134 for being brought into alignment with the pin throughaperture 113 as shown. Afastener 136 is then inserted through the aligned apertures and is held at its projecting end by acotter pin 138 so that the mountingdevice 112 b ofFIG. 18 is releasably connected to thelight device 10. The other mountingdevices 112 a and 112 c can also be provided with thesleeve member 130. - The mounting
device 112 may be a variety of different structures designed to mount to a variety of differently constructed or configured mounting surfaces or members. For instance, mountingdevice 112 may include a magnet 112 a (FIG. 14 ), anopen hook 112 b (FIGS. 15 , 17-18), or a pinching-type hook 112 c (FIG. 16 ). The magnet mounting device 112 a is useful for hanging thelight device 10 from a metallic surface such as from under an automobile hood, to its undercarriage, or to the underside of a shelf. Thehook mounting device 112 b can mount thelight device 10 to rest along power cords or in apertures or over edges of other structures. Thehook 112 c has spring loadedarm members 140 a and 140 b that are biased to a closed position to provide more secure mounting of the light device to an object extending through theclosed hook device 112 c. While the figures illustrate exemplary mountingdevices 112, such devices can be any other known devices that will mount an object to a mounting surface or mounting member. - Each mounting device also includes a portion that connects with the
connector portion 110 such that the mountingdevice 112 and theconnector portion 110 also form thereleasable connection 114 as previously described. Thereleasable connection 114 is designed to allow the variety ofdifferent mounting devices 112 to be quickly connected to and disconnected from theconnector portion 110. Therefore, only oneconnector portion 110 is necessary to accommodate the variety of mountingmembers 112. - Referring to
FIGS. 19-20 , alternate configurations of theLEDs 42 on thedistal end 38 b of thecircuit board 34 are illustrated. For instance,FIG. 19 shows an arrangement having two closely spacedLEDs light device 10. Alternatively, as shown inFIG. 20 , thedistal end 38 b of thecircuit board 34 may include theadditional LED 42 c oriented at a right angle or orthogonal to the other LEDs to extend along the axis Z directed toward thecasing end wall 22 b. This allows thelight device 10 to be used as a more traditional flashlight as light also emanates from the elongatelight device 10 in the direction it is pointed. - Referring to
FIGS. 22-23 , analternative work light 210 is illustrated. Work light 210 is similar to light 10 except that light 210 is battery powered. Thework light 210 generally includes anelongate body 214 and alight source 220 therein. As with the other embodiment, theelongate body 214 includes a light-transmissive portion 216 and ahandle portion 218. The light-transmissive portion 216 is formed from the same high-strength material and includes a preferred tapered configuration of aside wall portion 224 as previously described with the light 10. The discussion below highlights the differences with the battery poweredlight 210. - The light 210 includes a modified printed
circuit board 234 having an electronics receivingbase portion 236 for use with a battery and anillumination portion 238. The electronics receivingbase portion 236 is truncated as compared to the electronics receivingbase portion 36 because the light 210 does not need to convert 110 volt AC power to 12 volt DC power that is necessary to illuminate the preferred LEDs as theillumination source 42. In that regard, the electronics receiving portion includes arechargeable battery 237, a rechargingport 239, and a modified on/offswitch 240. As illustrated,switch 240 is a push button switch having a flexible cover 240 a; however, other types of switches may also be used. Rechargingport 239 is a known type of connection to recharge thebattery 237 that connects to a recharging plug (not shown) in a known manner to a wall outlet. - The light 210 also has the
handle portion 218, which is similar to thehandle portion 18, but is modified to accommodate both theswitch 240 and the rechargingport 239, which generally extend through corresponding openings of thehandle 218. For example, thehandle 218 is also formed from twoshell members 258 a and 258 b. In one form, theshell member 258 b includes two apertures 268 a and 268 b to receive the rechargingport 239 and the on/offswitch 240, respectively. In a preferred configuration, each half of theshell members 258 a and 258 b may also include a portion of the aperture 268 a; therefore, when combined, the portions of opening 268 a in eachshell 258 a and 258 b combine to form a complete opening to receive the rechargingportion 239. - Referring to
FIG. 24 , another embodiment of the work light is illustrated. This embodiment is to a light 310 that includes anelongate body 314 having both a one-piece light-transmissive portion 316 and a one-piece handle portion 318. The light 310 is suitable for underwater use, in explosive environments, or other hazardous environments that may require air, vapor, or water-tight housings. -
Light 310 is similar to previous described light 10 andlight 210, but includes appropriate modifications so that the light is suitable in the water or explosive environments. The differences will be highlighted below. To begin with, light 310 is also battery powered, but light 310 uses standard single-use or separatelyrechargeable batteries 337 that are incorporated in thehandle 318. Thebatteries 337 are in electrical communication with an electronics receivingbase portion 336 of a printedcircuit board 334 which is housed within handle portion. Next, thehandle 218 has a one-piece construction rather than the two half shells of the previous embodiments. The one-piece construction is preferred for use in the above described wet or hazardous environments. - Additionally, to render the light 310 suitable for underwater or explosive environments, a sealed
connection 315 between thehandle 318 and light-transmissive portion 316 is provided. For instance, theconnection 315 must substantially avoid water or gases from entering thehandle 318, which could disrupt the electrical operation of the light 310. Preferably, theconnection 315 usesinterengaging threads 317 a and 317 b such that the light-transmissive portion 316 can be screwed or threaded onto thehandle 318. As illustrated, the grooves 317 a are external threads on the projectingend portion 340 of thelight transmissive portion 316 and thegrooves 317 b are internal threads on an inside surface of an enlarged mountingportion 342 of thehandle 318. Thethreads 317 a and 317 b mate so that the light portions can be screw threaded together. In addition, to provide a water-tight or vapor-tight seal, theconnection 315 also uses a sealingmember 319, such as an o-ring, gasket, or other suitable sealing member, to seal thehandle 318 to thelight transmissive portion 316 when threaded together. In that regard, the sealingmember 319 inserted over the threaded portion 317 a and then the light-transmissive portion 316 is screw threaded into thehandle 318. Theseal member 319 is then compressed between ashoulder surface 321 extending radially outward from the threadedportion 340 of thecasing 316 and theend surface 344 of thehandle mounting portion 342 to form the tight seal. - Alternatively, as illustrated in
FIG. 24A , the sealingmember 319 can be disposed tightly between facing surfaces of thecasing 316 and handle 318 that can shift relative to each other as the casing and handle are threaded together, such as on an inner,annular surface portion 350 of thehandle mounting portion 342, and a corresponding outer,annular surface portion 352 of the light-transmissivecasing end portion 340. The sealingmember 319 may be seated in anannular recess 354 that extends about the casingannular surface 352. Therefore, as thecasing 316 and thehandle 318 are threaded to each other, as described above, the sealingmember 319 is rotatively and axially translated relative to thesurface portion 350 to form the sealedconnection 315 between thehandle 318 andlight casing 316. The sealingring member 319 is thus tightly compressed between thesurfaces member 319 could be carried on thehandle 318 rather than thecasing 316, as shown. - Optionally, the
casing end portion 340 may operate aswitch 358 in thehandle 318 while maintaining the sealedconnection 315 between thecasing 316 and handle 318. For example, with the sealedconnection 315 established, thesurfaces member 319 therebetween are such that additional rotation in the tightening direction, as by a predetermined number of corresponding turns or fractions of a turn of the handle relative to the casing causes thecasing end portion 356 to move further axially into thehandle 318 to operate theswitch 358. In this regard, thecasing end portion 356 can include a projection that engages a switch actuator to power the light source when the requisite relative rotation of the sealed handle and casing occurs. In this configuration, thelight device 310 does not require any openings or other holes in thehandle 318 as with other embodiments for on/off switches or recharging ports. Once thecasing 316 is threadably received by thehandle 318 to form theconnection 315, a substantially air-tight and/or water-tightelongate body 314 is formed having a sealed inner cavity therein. Thelight device 310 may be energized and de-energized by rotating the casing in a clockwise and counterclockwise direction, respectively, without breaking the air-tight and/or water-tight connection 315. - Turning to
FIGS. 25-32 , an alternativelight device 410 is illustrated that includes one or moreanti-rolling surfaces 411 to keep thelight device 410 stably supported on a flat support surface such as a work surface for keeping the light device from rolling along the surface when placed thereon. Thelight device 410 is similar to thework light 210 as illustrated inFIGS. 22 and 23 and described in the accompanying description therewith; therefore, only the differences therefrom will be described in detail herein. - Referring initially to
FIG. 25 , thelight device 410 includes anelongate body 414 and alight source 420. In thelight device 410, thelight source 420 includes an increased number of closely spacedLEDs 442 to provide an increased level of illumination. For example, thelight device 410 can include between 20 and 30 or even more longitudinally alignedLEDs 442. As with the previously described light devices, theelongate body 414 of thelight device 410 includes a forward, elongatelight head 415 having a casing or light-transmissive portion 416 in which thelight source 420 is disposed and a rearwardelongate handle portion 418 for enclosing a circuit board and power source. Thecasing 416 preferably has the same tapered configuration forside wall portion 424 thereof as previously described with thework light 210 so as to permit theside wall portion 424 to be formed of a one-piece construction with a high strength material, as has previously been discussed. - The illustrated tapered
side wall portion 424 has an annular configuration in cross-section with outercurved surface 425 of thecasing 416 having a substantially constant radius of curvature. In addition, theelongate handle portion 418 has a curved, outergripping surface 464 about a contoured, rear grippingportion 419 thereof. Accordingly, when placed on a generally flat support surface, such a light device including the described forward and rearward curved surfaces may tend to roll therealong. However, herein theanti-rolling surfaces 411 are disposed axially between thecurved surfaces casing 416 and handleportion 418, respectively. The anti-rolling surfaces 411 preferably have a flat configuration so that one of theflat surfaces 411 can be placed flush onto a flat support surface 480 (FIG. 26 ) keeping thelight device 410 from rolling thereon. - More particularly, the
anti-rolling surfaces 411 are provided about the periphery of aradially extending flange 450 between theforward light head 415 and rearward handle 418. Theflange 450 is sized relative to thecasing side wall 424 so that thesurfaces 411 are disposed radially beyond thecurved surface 425 thereof, as best seen inFIG. 29 . In this manner, thesurfaces 411 can engage a support surface when thedevice 410 is place thereon. Further, it can be seen by reference toFIGS. 28 and 30 , therear handle portion 418 has anannular wall portion 421 immediately behind or rearwardly of theflange 450. Theflange 450 is sized so that thesurfaces 411 are disposed radially beyond the curved,cylindrical surface 423 of the adjacent handleannular portion 421. Accordingly, when thedevice 410 is placed on a support surface, one of theanti-rolling surfaces 411 as well as thecurved surfaces casing side wall 424 and the enlarged rearhandle gripping portion 419 rearward of the reducedportion 421 of thehandle portion 418 engage the support surface with the engagedanti-rolling surface 411 keeping thedevice 410 from rolling on the support surface via thecurved surfaces device 410 engaged therewith. - It should be noted that the handle
annular portion 421 has an on-off switch 401 provided in arecess 402 formed therein, as shown inFIG. 25 . Raisedridges 403 extend longitudinally on either side of therecess 402. Theridges 403 are aligned with one of the flange surfaces 411 and have a height extending from thewall portion 421 sufficient so that theridges 403 also will engage thesupport surface 480 when the alignedflat surface 411 is engaged therewith to provide additional stability for theelongate body 414 against rolling on thesurface 480. - Continuing reference to
FIG. 28 , theflange 450 is axially positioned along longitudinal axis X of theelongate body 414 of thedevice 410 closer to therear end 423 thereof than itsforward end 427. In this regard, theflange 450 can be formed integrally at therear end 423 of thecasing 416 which is axially longer than therear handle 418. - As shown, the
flange 450 has a narrow width in the axial direction so that the periphery thereof on which theanti-rolling surfaces 411 are formed extending about the longitudinal axis X with thesurfaces 411 extending lengthwise in a direction transverse to axis X. More specifically, the flat,anti-rolling surfaces 411 have a length L (FIG. 31 ) in a direction transverse to the longitudinal axis X and a width W (FIG. 27 ) in the axial direction along the longitudinal axis X where the length of each flat,anti-rolling surface 411 is greater than the width thereof. By way of example and not limitation, each flat 411 can have a length L of about 10 to about 20 mm and a width of about 4 to about 6 mm; however, other sizes are suitable depending on the size of the work light. - The illustrated and preferred radially extending
flange 450 is in the form of a nut-like structure 460 wherein theanti-rolling surfaces 411 are in the form offlats 452 of thenut 460 with the length L of each flat,anti-rolling surface 452 being substantially the same, and the width W of each flat,anti-rolling surface 452 being substantially the same. As shown, the lengths are preferably longer than the widths as discussed above; however, other configurations are also suitable depending on the configuration of the light device. - The nut-
like structure 460 preferably has an octagonal configuration so that there are eightflats 452 circumferentially disposed about the periphery of thenut 460. The octagonal structure of theflange 450 is preferred because it is effective to minimize the amount 462 that theflats 452 thereof extend radially beyond theelongate body 414, and specifically thecurved surfaces respective casing 416 and handle 418 thereof. Similarly,corner projections 454 formed at the juncture betweenadjacent flats 452, which are at the maximum distance from thecurved surfaces flange 450 hasflat surfaces 452 thereof that generally do not include large or relatively pointed projections extending radially from the otherwise generallycylindrical body 414 of thelight device 410, which could otherwise interfere with holding of the work light or otherwise provide a hindrance to the use of thelight device 410. By way of example and not limitation, thecorner projections 454 can be disposed at adistance 462 a of about 4 to about 6 mm from the casing curved surface 425 (FIG. 29 ) and adistance 462 b that is even less thandistance 462 a such as about 1 to about 2 mm from the adjacent handle portion 421 (FIG. 31 ); however, these distances may vary as needed for a particular application. - Turning to
FIG. 31 , theouter surface 464 of the rear contoured grippingportion 419 has varying radius of curvature. In particular, the contoured,curved surface 464 of thehandle 418 includes curvedcorner surface portions 466 and curvedsupport surface portions 468 where thecorner surface portions 466 are between adjacentsupport surface portions 468. Preferably, thesupport surface portions 468 have a radius of curvature larger than thecorner surface portions 466. - Each of the
support surface portions 468 extend axially along thehandle gripping portion 419 and are preferably generally circumferentially aligned with or in-line axially with one of the flat,anti-rolling surfaces 452 of theradially extending flange 450. In this manner, when thelight device 410 is placed on thework surface 480, one of thesupport surface portions 468 and the alignedflange surface 452 can cooperate to provide two areas ofcontact light device 410 and thework surface 480, as illustrated inFIG. 26 . It should be noted that because of the reducedsize handle portion 417 axially between thehandle portions clearance space 475 axially between the engagedsurfaces flats 452 and the aligned handlesupport surface portion 468 having a large radius of curvature, i.e., a very gentle curvature, will also cooperate with the alignedflat surface 452 to support theelongate body 414 onflat support surface 480 against rolling thereon. As shown inFIG. 26 , such cooperative support enables the light device to be stably supported on thesurface 480 and also positions the tapered light casing portion 418 adistance 476, e.g., approximately 6 to 7 mm, spaced above thesupport surface 480 at thedistal end 427 thereof. - As best illustrated in the exploded view of
FIG. 32 , as previously mentioned theradially extending flange 450 may be formed integral with the casingside wall portion 424 as by molding thecasing 416 including therear nut flange 450 thereof to have a unitary, one piece construction. In this manner, theradially extending flange 450 is also formed of the same high-strength, light-transmissive material as thecasing 416. With the flange formed of the light-transmissive material, one or more of theLEDs 442, such asLED 442 a (FIG. 28 ), may be positioned in longitudinal alignment with theflange 450 in theinterior space 417 defined by the casingside wall portion 424 to provide illumination through theflange 450 and, in particular, to provide illumination through one or more of theflat surfaces 452 thereof. Due to the generally radially thicker light-transmissive flange 450, the illumination projected therethrough is generally more diffused relative to the illumination projected through thecasing portion 416. Manifestly, theradially extending flange 450 may also be molded in one piece with thehandle 418 and, in this manner, could be fabricated out of an opaque or non-light transmissive material. Alternatively, theflange 450 may be a separate member secured to thelight device 410, such as between thecasing 416 and handle 418. - The
casing 416 and handle 418 are assembled similar to the previously described light devices to form a self-contained and compact hand held lighting device that provides for stable contact on a work surface when not being held. Optionally, thelight device 410 includes a holdingmember 401, which in one form may be a hook member as illustrated. The holdingmember 401 may be snap-fit in anopening 402 at adistal end 427 of thecasing 416 via abarb 406 or other friction-fit type securing member. As shown, thelight device 410 includes arechargeable battery 437 to energize thelight source 420 similar to thelight device 210 and includes acorresponding recharging port 403 therefor extending through anaperture 404 in thehandle 418; however, thelight device 410 may also include non-rechargeable batteries or a plug suitable for connection to a 110 volt power source similar to the previously described light devices. - The
light source 420 may include areflective coating 422 to aid in the focusing of the illumination. By one approach, thelight device 410 includes an elongate printedcircuit board 434 having aillumination portion 438 extending therefrom in thelight casing 416 similar to the other embodiments. Thereflective coating 422 may be applied to the elongate printedcircuit board 434 and, preferably, to the extendingillumination portion 438 thereof that includes the one ormore LEDs 424 thereon - It will be understood that various changes in the details, materials, and arrangements of the parts and components that have been described and illustrated in order to explain the nature of the invention may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims.
Claims (20)
1. A light device for providing illumination to work areas, the light device comprising:
an elongate body having a high-strength construction;
a handle of the body at one end thereof;
a light source;
an elongate, substantially light-transmissive portion of the body in which the light source is disposed for emanating light therefrom and extending away from the handle;
a predetermined high-strength material of the light-transmissive portion for optimizing pressure resistance thereof; and
a one piece tubular wall of the light-transmissive portion having a predetermined taper so that the wall has a larger diameter adjacent the handle and a smaller diameter distal therefrom with the taper of the tubular wall permitting the tubular wall to be formed both of one piece and with the high strength material to provide the elongate body with the high-strength construction thereof.
2. The light device of claim 1 , wherein the light source comprises a plurality of aligned LEDs to keep the diameters of the tapered tubular wall to a minimum.
3. The light device of claim 1 , wherein the light source includes a printed circuit board having opposite sides that taper inward toward each other so that the printed circuit board generally has a wedge fit in the tapered, tubular wall of the light-transmissive body portion.
4. The light device of claim 1 , wherein the predetermined high strength material is one of a polycarbonate and an acrylic polymer material.
5. The light device of claim 1 , wherein the light source comprises an elongate printed circuit board and a plurality of LEDs that are aligned along one side of the printed circuit board, and the tubular wall has a central axis extending therethrough with the printed circuit board having a proximate end aligned with the central axis at the larger diameter of the tubular wall and a distal end that is offset from the central axis at the smaller diameter of the tubular wall to permit the LEDs to be of the same size substantially irrespective of the position along the length of the elongate circuit board.
6. The light device of claim 5 , wherein the tubular wall has an inner surface and the predetermined taper is on the tubular wall inner surface, and a spacing between the distal end of the printed circuit board and the tubular wall inner surface being about the same as a spacing between the proximate end of the printed circuit board and the tubular wall inner surface.
7. The light device of claim 1 , wherein the tubular wall diameters do not exceed approximately 1 inch to keep a size of the light-transmissive portion to a minimum for lighting of confined spaces therewith.
8. The light device of claim 1 , wherein the handle includes a housing having openings and fasteners extending through the openings for connecting the housing together,
the light source includes an elongate printed circuit board that extends into the handle housing and the light-transmissive portion, the printed circuit board includes openings for the fasteners, and
a stop that defines a predetermined position of the printed circuit board in the handle housing and the light-transmissive portion such that the openings of the printed circuit board and the housing are aligned to allow the fasteners extend therethrough.
9. The light device of claim 1 including a mounting assembly connected to the elongate body that is configured for optimized flexibility in mounting the elongate body to different configurations and constructions of mounting surfaces.
10. The light device of claim 9 , wherein the mounting assembly includes a connector portion of the elongate body, a plurality of different mounting devices for mounting the elongate body to the differently configured and constructed mounting surfaces, and a releaseable connection between the connector portion and each of the different mounting devices to allow a user to select and readily interchange one of the plurality of mounting devices for another for being attached to the same connector portion of the elongate body.
11. The light device of claim 10 , wherein the plurality of mounting devices includes a magnetic mounting device and a hook mounting device.
12. The light device of claim 10 , wherein the releaseable connection comprises a ball and socket connection with the connector portion including one of the ball and the socket and the mounting devices each including the other of the ball and the socket.
13. The light device of claim 1 , wherein the body includes a seal member between the handle and the light-transmissive portion to form a substantially air-tight seal therebetween such that the light device can provide illumination in explosive work areas.
14. A work-light device for providing illumination to work areas, the work-light device comprising:
a generally hollow handle;
a one-piece, generally tubular illumination casing connected to the handle at one end and having an integral end portion distal from the handle and an integral side portion extending from the handle end to the distal end portion, the end portion and side portion defining an interior space;
the side portion having a taper such that the illumination casing has a smaller diameter at the end portion than at the handle end;
the one-piece, generally tubular illumination casing being molded of a high-strength, substantially light-transmissive material;
a printed circuit board having a base portion mounted in the handle and an elongate portion sized to be inserted into the interior space; and
a plurality of LEDs mounted to the elongate portion of the printed circuit board for providing illumination through the illumination casing.
15. The light device of claim 14 , wherein the taper of the casing side portion and the high-strength, substantially light transmissive material are selected to provide the illumination casing with strength sufficient to withstand a compression force of about 500 to about 2000 pounds per square inch.
16. The light device of claim 15 , wherein the illumination casing tapers from a diameter of about 1 inch at the handle end down to a diameter of about 0.70 inch at the end portion and wherein the high-strength, substantially light-transmissive material is selected from the group consisting of polycarbonate and acrylic plastics.
17. The light device of claim 14 , wherein the illumination casing tapers from a diameter of about 1 inch at the connection to the handle down to a diameter of about 0.70 inches at the end portion.
18. The light device of claim 14 , wherein the high-strength, substantially light-transmissive material is selected from the group consisting of polycarbonate and acrylic.
19. The light device of claim 14 , wherein the casing has a central longitudinal axis and a shoulder wall portion adjacent the handle end extending transverse to the casing axis for providing optimizing resistance to compression forces at the larger diameter handle connection.
20. The light device of claim 14 , wherein the printed circuit board has proximal and distal ends and a majority of the plurality of LEDs being substantially equally spaced along the printed circuit board with a pair of distal LEDs being more closely spaced than the other LEDs for providing concentrated illumination at the distal end.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/766,514 US20100238654A1 (en) | 2005-03-11 | 2010-04-23 | Work Light |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/077,682 US7306349B2 (en) | 2005-03-11 | 2005-03-11 | Work light |
US12/001,468 US7703966B2 (en) | 2005-03-11 | 2007-12-11 | Work light |
US12/766,514 US20100238654A1 (en) | 2005-03-11 | 2010-04-23 | Work Light |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/001,468 Continuation US7703966B2 (en) | 2005-03-11 | 2007-12-11 | Work light |
Publications (1)
Publication Number | Publication Date |
---|---|
US20100238654A1 true US20100238654A1 (en) | 2010-09-23 |
Family
ID=46329917
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/001,468 Expired - Fee Related US7703966B2 (en) | 2005-03-11 | 2007-12-11 | Work light |
US12/766,514 Abandoned US20100238654A1 (en) | 2005-03-11 | 2010-04-23 | Work Light |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/001,468 Expired - Fee Related US7703966B2 (en) | 2005-03-11 | 2007-12-11 | Work light |
Country Status (1)
Country | Link |
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US (2) | US7703966B2 (en) |
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US20120188756A1 (en) * | 2009-05-27 | 2012-07-26 | Jameson Llc | Portable led tube light |
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US10551042B2 (en) * | 2017-12-22 | 2020-02-04 | Southwire Company, Llc | Multipurpose adaptable work light |
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Also Published As
Publication number | Publication date |
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US20080130277A1 (en) | 2008-06-05 |
US7703966B2 (en) | 2010-04-27 |
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Legal Events
Date | Code | Title | Description |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |