Lighting device including an LED chip-on-board light source and conformal lens

Patent metadata

Field	Value
Publication number	US-10295128-B2
Application number	US-201615256061-A
Country	US
Kind code	B2
Filing date	Sep 2, 2016
Priority date	Aug 1, 2016
Publication date	May 21, 2019
Grant date	May 21, 2019

Abstract

A lighting device includes: a housing configured to receive a light emitting circuit and a battery; a light emitting circuit including one or more light emitting diodes mounted to a circuit board; a translucent or transparent conformal lens formed to cover the one or more light emitting diodes; and an electrical switch for selectively energizing the light emitting diodes to produce light. The housing may be in a shape resembling a key. A method for making a lighting device includes: obtaining a circuit board having one or more light emitting devices; obtaining a housing configured to receive the circuit board; placing the circuit board in the housing; then dispensing a conformal coating material onto the circuit board; allowing the dispensed conformal coating material to spread and level; and curing the conformal coating material to form a cover on the circuit board.

First claim

What is claimed is:

1. A lighting device comprising:
a housing defining a recess configured to receive a light emitting circuit and defining a cavity configured to receive a battery;
a circuit board containing the light emitting circuit and disposed in the recess of said housing, wherein the light emitting circuit includes one or more light emitting diodes mounted to said circuit board so as to be exposed when said circuit board is disposed in the recess of said housing;
a battery disposed in the cavity of said housing;
a translucent or transparent conformal lens covering said circuit board disposed in the recess of said housing and the one or more light emitting diodes thereon, wherein said translucent or transparent conformal lens is formed in the recess to cover said circuit board and to secure said circuit board in the recess of said housing; and
an electrical switch for selectively energizing said light emitting circuit to cause said one or more light emitting diodes thereof to produce light.

2. The lighting device of claim 1 wherein said battery is a rechargeable battery, said lighting device further comprising: a connector supported by said housing to receive charging current from a mating connector that is configured to mate with said connector, wherein said connector is coupled to said rechargeable battery for providing charging current received from the mating connector to said rechargeable battery.

3. The lighting device of claim 2 wherein said connector includes a standard USB connector, a mini-USB connector, a micro-USB connector, or a lightning connector.

4. The lighting device of claim 2 further comprising:
a connector cover insertable in said housing to cover said connector; or
a connector cover tethered to said housing and insertable in said housing to cover said connector.

5. The lighting device of claim 4 wherein said connector cover includes a cover part, a base part and a tether connecting the cover part and the base part, wherein said base part is disposed in a receptacle of said housing.

6. The lighting device of claim 1 wherein said housing includes:
a main housing part defining the recess and at least a part of the cavity, and one or more covers attached to said main housing part; or
a main housing part in a shape resembling a key having a blade and a bow, the main housing part defining the recess in the blade thereof and at least a part of the cavity, and one or more covers attached to the bow of said main housing part.

7. The lighting device of claim 1 further comprising a second circuit board, wherein said second circuit board is disposed in the cavity of said housing adjacent said battery, supports said electrical switch, and is coupled to said circuit board containing the light emitting circuit.

8. The lighting device of claim 1 wherein said translucent or transparent conformal lens includes a conformal coating cured in situ covering said circuit board in the recess of said housing.

9. The lighting device of claim 8 wherein the conformal coating:
is an optically transparent or translucent material selected from the group including silicone, silicone gel, urethane, parylene, resin, acrylate resin, epoxy, potting compound, adhesive, encapsulant, casting resin, conformal coating, and a combination thereof; and
is cured by passage of time, by heat, by light, by ultraviolet light, or by a combination thereof.

10. The lighting device of claim 8 wherein the conformal coating is a colorless casting resin curable by light.

11. The lighting device of claim 1 wherein said housing defines:
a hanger loop extending outwardly therefrom; or
a hanger loop extending outwardly therefrom having a gap therein, and a gate for closing the gap in said hanger loop.

12. A lighting device comprising:
a housing defining a recess configured to receive a light emitting circuit and defining a cavity configured to receive a battery;
said housing including a main housing part defining the recess and a periphery of the cavity, and first and second covers mountable to the periphery of said housing to enclose the cavity;
a circuit board containing the light emitting circuit and disposed in the recess of said main housing part, wherein the light emitting circuit includes one or more light emitting diodes mounted to said circuit board so as to be exposed when said circuit board is disposed in the recess of said main housing part;
a battery disposed in the cavity between the first and second covers of said housing;
a translucent or transparent conformal lens covering said circuit board disposed in the recess of said main housing part and the one or more light emitting diodes thereon, wherein said translucent or transparent conformal lens covers and secures said circuit board in the recess of said main housing part; and
a switch for selectively energizing said light emitting circuit to cause said one or more light emitting diodes thereof to produce light, said switch including an electrical switch disposed in the cavity of said housing and an actuator of the electrical switch disposed in one of said first and second covers.

13. The lighting device of claim 12 wherein said battery is a rechargeable battery, said lighting device further comprising: a connector supported by said housing to receive charging current from a mating connector that is configured to mate with said connector, wherein said connector is accessible through an opening in said housing and is coupled to said rechargeable battery for providing charging current received from the mating connector to said rechargeable battery.

14. The lighting device of claim 13 wherein said connector includes a standard USB connector, a mini-USB connector, a micro-USB connector, or a lightning connector.

15. The lighting device of claim 13 further comprising:
a connector cover insertable in said housing to cover said connector; or
a connector cover tethered to said housing and insertable in said housing to cover said connector.

16. The lighting device of claim 15 wherein said connector cover includes a cover part, a base part and a tether connecting the cover part and the base part, wherein said base part is disposed in a receptacle of said main housing part.

17. The lighting device of claim 12 wherein said main housing part is in a shape resembling a key having a blade and a bow, the main housing part defining the recess in the blade thereof and the bow defining at least the periphery of the cavity, wherein said first and second covers are mounted to the bow of said main housing part.

18. The lighting device of claim 12 further comprising a second circuit board, wherein said second circuit board is disposed in the cavity of said housing adjacent said battery, supports said electrical switch, and is coupled to said circuit board containing the light emitting circuit.

19. The lighting device of claim 12 wherein said translucent or transparent conformal lens includes a conformal coating cured in situ covering said circuit board in the recess of said housing.

20. The lighting device of claim 19 wherein the conformal coating:
is an optically transparent or translucent material selected from the group including silicone, silicone gel, urethane, parylene, resin, acrylate resin, epoxy, potting compound, adhesive, encapsulant, casting resin, conformal coating, and a combination thereof; and
is cured by passage of time, by heat, by light, by ultraviolet light, or by a combination thereof.

21. The lighting device of claim 19

Assignees

• Streamlight Inc

Inventors

• Sharrah Raymond L
• Eichelberger Cleatis A

Classifications

• F21V23/06

  the elements being coupling devices {, e.g. connectors} · CPC title

• F21V5/04

  of lens shape · CPC title

• F21Y2115/10

  Light-emitting diodes [LED] · CPC title

• F21K9/90

  Methods of manufacture · CPC title

• F21V23/0414

  specially adapted to be used with portable lighting devices · CPC title