AU2002342429A1 - An improved user assembled flashlight - Google Patents

Description

WO 03/046434 PCT/AU02/01614 1 An improved user assembled flashlight Field of the invention 5 The present invention relates to a user assembled flashlight of the type which is assembled by a user from a disassembled or collapsed state. Background to the invention 10 The present invention discloses improvements to pre-forms and attachments for user assembled and methods of assembly of such flashlights. Summary of the invention The,present invention provides a reflector assembly including a first and 15 second member, said first and second member each including formations to receive part of a lamp means so as to hold said lamp means when first and second members are connected together, said first member including attachment fonnations thereon to attach said first member to a flashlight body portion, said first and second members including reflection surfaces to form a reflector when said first and second members 20 are connected to the reflector assembly The first and second members can include a holding means to receive and hold a cover or lens. The first or second members can include a cowling to prevent side access to inside portions of said reflector assembly. 25 The first or second members can include a hinge flap, said hinge flap engaging a switch contact in use. Preferably the attachment means is at least one spigot on said first member or second member. The at least one spigot is preferably a stake which can be deformed by heating. 30 The first and second members can have mating formations thereon to interconnect said first and second members.

WO 03/046434 PCT/AU02/01614 2 If a cowling is present preferably the cowling includes strengthening ribs formed thereon. The reflector assembly can include a rearwardly directed opening through which contacts from a power source can engage terminals associated with said lamps 5 means. The lamp means can be a globe or a LED. The present invention also provides a flashlight construction including a planar body portion, a battery holder attached to said body portion, a reflector assembly and a lamp means, said reflector assembly being mounted to said body portion so that 10 contacts for a said lamp means can make electrical connection to contacts from batteries held by said battery holder. The battery holder can be a blister package member. The battery holder can include finger grip formations. The reflector can include mounting means whereby said body portion can be 15 sandwiched between said lens assembly and a backing plate. The battery holder can include a forward portion which extends from said battery holder and under said reflector assembly. The forward portion is preferably sandwiched with said body portion by said lens assembly and backing plate. Preferably the battery holder holds at least two batteries. 20 The battery holder can include an aperture adjacent a join plane between two series connected batteries. The aperture preferably receives a tab to separate positive and negative terminals of two series connected batteries. The reflector assembly can include a switch actuation means. The reflector assembly is preferably held relative to said battery holder at at 25 least two locations. The battery holder is preferably undetachably attached to said body portion. The planar body portion can be formed within a card, sheet material, or a blister card. The body portion is detachable from said card, sheet material or blister card. 30 The flashlight is preferably ready for use when said planar body portion is detached from said card, sheet material, or blister card.

WO 03/046434 PCT/AU02/01614 3 The present invention also provides a method of constructing a flashlight said method including the step of forming a flashlight body from a blister package member and a sheet material body portion to which said blister package member is attached. The method can include the step of mounting a reflector assembly to said sheet 5 material body portion or said blister package member. The method can include the step of forming on the blister package member formations which act as finger grip formations. The step mounting said reflector can include the step of said body portion being sandwiched between said lens assembly and a backing plate. 10 The method can include the step of sandwiching a forward portion of said battery holder between said reflector assembly and a backing plate. Prior to attaching said sheet material body member to said blister package at least one battery is placed in a cavity provided by said blister package member. Prior to attaching said sheet material body member to said blister package at 15 least one battery contact is placed in a cavity provided by said blister package member. The method can include the step of placing a tab between adjacent positive and negative terminals of said two series connected batteries. The method can include the step of forming said sheet material body portion as 20 part of a sheet of cardboard, polymeric sheet material, or a blister card. The method can also include the step that the blister package member is attached to said sheet material body portion, before said sheet material body portion is detached from said sheet of cardboard, polymeric sheet material or blister card. The sheet material body portion is preferably contained in a larger sheet of 25 material and said sheet material body portion must be detached from said larger sheet to enable said flashlight to be used. Brief description of the drawings 30 Embodiments of the present invention, will now be described, by way of example only, with reference to the accompanying drawings in which: WO 03/046434 PCT/AU02/01614 4 Figure 1 illustrates a front perspective view of an assembled reflector, globe and lens assembly; Figure 2 illustrates an underneath perspective view of the assembly of Figure 1; 5 Figure 3 illustrates an exploded view of the components of Figure 1; Figure 4 illustrates an upper perspective view of the reflector assembly top piece; Figure 5 illustrates an underneath perspective view of the piece of Figure 4; Figure 6 illustrates an upper front perspective view of the reflector assembly 10 lower piece; Figure 7 illustrates a rear perspective view of the piece of Figure 6; Figure 8 illustrates a cross-section through a vertical plane of the assembly of Figure 6; Figure 9 illustrates a front elevation of a contact member to interconnect the 15 positive terminal of a globe with a positive terminal of a battery; Figure 10 illustrates a plan view of the contact of Figure 9; Figure 11 illustrates a side elevation of the contact of Figure 9 and Figure 12 illustrates a right side elevation of the contact of Figure 9; Figure 13 illustrates a negative contact in plan view; 20 Figure 14 illustrates a front elevation of the contact of Figure 13; Figure 15 illustrate a left side view of the contact of Figure 13 and Figure 16 illustrates a right side view of the contact of Figure 13 and Figure 16 illustrates a right side view of the contact of Figure 13; Figure 17 illustrates an upper perspective view of a battery holder; 25 Figure 18 illustrates an underneath perspective of the battery holder of Figure 17; Figure 19 illustrates a right side elevation of the holder of Figure 17; Figure 20 illustrates a tab for use with the holder of Figures 17 to 19; Figure 21 illustrates steps 1 to 6 in the assembly procedure; 30 Figure 22 illustrates steps 7 through 12 of the assembly procedure; Figure 23 shows a completed assembly of the items of Figures 1 to 20; WO 03/046434 PCT/AU02/01614 5 Figure 24 is a perspective view of the underneath side of the assembly of Figure 23; Figure 25 illustrates a cross-section through a vertical plane through the assembly of Figure 23; 5 Figure 26 illustrates an alternative reflector assembly; Figure 27 illustrates an alternative backing plate for use with the lens assembly of Figure 26; Figure 28 illustrates another flashlight formed on a cardboard pre-form and detachable therefrom; 10 Figure 29 illustrates a detailed cross section of a portion of Figure 25; Figure 30 illustrates a perspective view of an alternative reflector assembly; Figure 31 illustrates an exploded view of the reflector assembly of Figure 30; Figure 32 illustrates a cross section through the reflector assembly of Figure 30; 15 Figure 33 illustrates a plan view of blister package member; Figure 34 illustrates a front elevation of the blister of Figure 33; Figure 35 illustrates a right side elevation of the blister of Figure 33; Figure 36 illustrates a rear elevational of the blister of Figure 33; Figure 37 illustrates an exploded view of the components and a preform with 20 some modified features; Figure 38 illustrates a cross section through the assembly of Figure 37; and Figure 39 illustrates a side elevation of the assembled components of Figure 37. 25 Detailed description of the embodiments Illustrated in Figures 1 to 8 is reflector assembly 10 and its component parts. While the reflector assembly 10 can be pre assembled I as indicated in Figures 1 to 8, in use as illustrated in Figures 21 and 22 the assembly is done as part of the overall 30 assembly of a preform for a user assembled flashlight. The reflector assembly 10 is comprised of a top piece 12 and a lower piece 14 which are joined together by means of downwardly protecting barbed lugs 16 which WO 03/046434 PCT/AU02/01614 6 engage upwardly opening rectangular apertures 18 on a flange the lower piece 14. The lugs 16 and apertures 18 co-operate so that once the upper and lower pieces 12 and 14 are interconnected they are difficult to separate without breakage. Before the upper and lower pieces 12 and 14 are interconnected, a front cover 5 or lens 20 is positioned in a three sided semi-circular groove 22 at the front of the lower piece 14. Further a lamp 24 having a flange 26 is placed inside a three sided semi-circular groove 28 at an intermediate location. In the lower piece 14 once the lens or cover 20 and globe 24 are located in their respective grooves, the upper piece 12 can be interconnected to the lower piece 10 14 with the corresponding grooves 22' and 28' on the upper piece 12 completing the encapsulation of the rim of the lens 20 and the flange 26 of the lamp 24. As can be seen from Figures 1 to 8, the lower piece 14 includes at its lower periphery a flat edge 40 which is the terminus of an extension piece 41, which extends away from the rim of the reflector. The lower edge 40 allows the lower piece 14 to sit 15 on a flat surface in a stable orientation. As can be seen also in Figure 2, the lower piece includes two spigots 42 whose purpose is to secure the lower piece 14 to a cardboard preform and will be discussed in more detail below. The base of the lower piece 12 includes a hinged flap 30 which has two 20 upwardly projecting guides 34 extending therefrom. The flap 30 is adjacent an aperture 36 in the rear face 38 of the lower piece 14. The aperture 36 receives a front end of the negative contact 130 of the Figures 13 to 16. The parabolic surfaces of revolution can have a highly reflective coating to serve as a reflector surface. As an alternative a reflective parabolic or other shaped 25 insert can be utilised and captured within the reflector assembly 10. The top piece 12 includes a left and right side cowling 48 which extends downwardly from the top piece 12 to prevent access to the inner portions of the reflector assembly from the sides thereof. The cowlings 48 on the top piece results in the reflector assembly 10 once assembled having only two openings to gain access to 30 the internal portions, namely a rearwardly directed opening 50 and the lower rearwardly directed opening 36.

WO 03/046434 PCT/AU02/01614 7 The assembly illustrated in Figures 1 through to 8 will be described occurs once the spigots 42 have passed through the pre-form and through a backing plate and then secured by heat deformation to the pre-form as will be described later. Illustrated in Figures 17 to 19 is the blister pack 70 for use with the lens 5 assembly 10 previously described. The blister pack 70 is manufactured, pressed or blow moulded from a thin layer of polymeric or plastic material and comprises a base 72 from which extends a battery holder cavity formation 74, which effectively provides a cavity in which to receive batteries and other components. 10 The length of the cavity formation 74 allows two batteries to be placed in series in longitudinal alignment within cavity formation 74. The battery holder cavity formation 74 includes four raised projections 76, 78, 80 and 82 with strengthening ribs 84, 86 and 88 interconnecting them. The strengthening rib 86 includes a laterally oriented tapering formation 90 15 which has an aperture 92 through the upper surface thereof. The purpose of the aperture 92 is to receive a T-shaped separator 200, as illustrated in Figure 20, whereby the leg 202 of the T-shape can be inserted into the aperture 92 so as to separate the adjacent positive and negative terminals of batteries located inside the cavity formation 74. The cross piece 204 of the T-shape member 200 provides a grip for a 20 user to pull out the T-shape member 200 immediately prior to use. The rear end of the battery holder formation 74 includes a part cylindrical end formation 94 and an upside down T-portion 96 in which is received the rear end 132 of the negative contact 130 of Figures 13 to 16. At the forward end of the cavity formation 74 is a front wall 98 which has a 25 cut-out 100 at the base thereof. The cut-out 100 allows the negative contact 130 of the Figures 13 to 16, to pass under the wall 98 to engage the flap 30 so that the front end 134 of the negative contact 130 can be used to contact the cylindrical body of the lamp 24 to thereby close a circuit between the lamp and batteries. Adjacent the wall 98 is an aperture 102 which is located on an upwardly facing 30 segment 103 of the cavity formation 74. The aperture 102 allows the positive contact 150 of Figures 9 through to 12 to be inserted into the cavity formation 94 so as to WO 03/046434 PCT/AU02/01614 8 make contact with the positive terminal of the forward battery and ultimately to provide a contact with the positive terminal of the lamp 24. A shaped cut-out 104 is provided in the base 72 extending forwardly away from the base of the wall 98. This cut-out 104 allows the flap 30 on the reflector 5 assembly 10 to push directly against the front end 134 of negative contact 130 of Figures 13 to 16. Forward of the cut-out 104 are two locator apertures 106 through which can pass the spigots 42 (see Figure 2) on the reflector assembly 10 (further detail of this will be provided with respect to the description of Figures 21 through to 23). 10 At the very front end of the blister pack 70 is a pentagonal, bendable front piece 108 which is hingedly connected to the base 72 by hinge members 110. Between hinge members 110 is an aperture 112 so as to reduce the amount of force required to bend the front piece 108 relative to the base 72. The front piece 108 also includes an aperture 114 which has a profiled or shaped rim 116. The profiled rim 116 extends 15 downwardly away from the base 72 as seen in the side elevation of Figure 19. The profile of the profiled rim 116 provides strength to the rim, and as will be discussed later, provides an internal frame for an aperture through the cardboard pre-form, through which light will be emitted from the reflector assembly 10. Illustrated in Figures 21 and 22 is the method of assembly of a lighting product 20 to be assembled by a user. The steps in the product assembly process are indicated by a number in a circle next to the respective images in Figures 21 and 22. Step 1: the blister 70 is placed in a heat press dye. Step 2 two double A sized batteries 256 and 257 are placed inside the blister 20 with battery 256 having its positive terminal against the front wall 98 of the blister 25 70 and the battery 252 having its positive terminal in a contact with the negative terminal of battery 256. Step 3: the negative battery contact 130 (of figures 13 through to 16) is positioned such that the rear terminal 132 is inserted into the blister 70 into the space provided by the upside down T-shaped portion 96 (see Figure 17). The front end 134 30 protrudes through the aperture 104 and also passes through the cut-out 100. Step 4: a blister card is placed over the blister 70 and is located relative to the blister pack 70 by means of the profiled rim 116 protruding through a similarly sized WO 03/046434 PCT/AU02/01614 9 hole in the blister card 70. Once aligned, the blister pack 70 and the blister card 140 are heat sealed together. Step 5: the security tab 200 is then inserted into the aperture 92 in the blister 70 in order to electrically isolate the positive end of battery 252 and the negative end 5 of the battery 256. Step 6: the reflector assembly lower piece 14 is placed onto the pre-form by the spigots 42 passing through the two holes 106 in the base 72 of the blister 70 as well as two aligned pre-cut holes in the blister card 140 so as to protrude through both the base 72 and the blister card 140. 10 Step 7: a holding plate 142 is then placed adjacent to the other side of blister card 140 and over the ends of the spigots 42 and heat applied to the terminii of spigots 42 so as to rivet the reflector plate 142, blister card 140, base 72 and reflector lower 14 together. By this means the base 72 and the blister card 140 are sandwiched between the lower piece 14 and the reflector plate 142. 15 Step 8: the positive contact is then pushed into place into the blister 70 by pushing the lower portion 152 through the aperture 102 until such time as the detent end 154 has passed through the aperture 102 (see Figure 29). At this point the detent end 154 will then spring backwards in a rearward direction relative to the blister 70 preventing the positive contact 150 from being able to be withdrawn from the aperture 20 102. The detent 154 rests against an inside surface of the upwardly facing segment 103 of blister pack 70. When the lower piece 14 is placed on the blister card 140, the straight lower edge 40 on the lower piece 14 lies flat against the plane of the blister card 140. 25 Step 9: a bulb 24 is positioned into the reflector lower piece 14 by the flange 26 being positioned within the groove 28 of the lower piece 14. Step 10: the lens or cover 20 is then positioned inside the groove 22 on the lower piece 14. Step 11: reflector upper piece 12 in then snapped into location on the reflector 30 lower piece 14 by the lugs 16 passing through apertures 18. Step 12: requires the addition of a double-sided tape strip 160 to the edge of the pre-form as indicated at step 12 in Figure 22. The end 164 of the double-sided tape WO 03/046434 PCT/AU02/01614 10 strip 162 is such that there is no adhesive under the end 164 to allow for easy lift off of the backing strata of the double-sided material. By these steps 1 to 12 a pre-fonn with blister pack 70 and lens assembly 10 is produced as illustrated in Figures 23 and 24 and in cross-section in Figure 25. 5 If desired the tab 200 can be added at step 2 or step 3, instead of at step 5 as indicated above. As can be seen from Figure 25, the tab 200 is in place separating the positive terminal 250 of battery 252 from the negative terminal 254 of the rear battery 252. It can also be seen from Figures 25 and 29 that the forward end 134 of the negative 10 contact 130 has its lowest portion 136 resting against the inside surface of the flap 30 between the guides 32 and 34. Figures 25 and 29 also illustrate that the rounded and conical positive terminal 260 of the globe 24 sits snuggly into a curved recess 262 on the positive contact 150. The recess 260 on the positive terminal 150 helps to prevent the terminal 260 from 15 moving downward during use. As can be seen from Figure 23, the rear portion 300 and front portion 302 have a series of tabs 304 and 306 integrally formed thereon. Each of the tabs 304 have an undercut portion 308 on one side only whilst the tabs 306 have two undercuts 310 and 312. The tabs 304 and 306 when the pre-form is folded and assembled into a flashlight 20 will pass through the apertures 404 (which receive tabs 304 and aperture 406 which receive tabs 30. Undercuts 308 have the undercuts oriented such that they face or open outwardly away from the lines 113 and 115 where the portion 300 and 302 are folded. In order to create a flashlight from the pre-form of Figures 23 and 24, a user separates the top portion 350 of the blister card away from the pre-form and the base 25 352, then the user folds end portions 300 and 302 to a vertical orientation and then folds sides 354, 355 so that the tabs 304 and 306 pass through the holes 404 and 406. Then the sides 356, 357 and 358 are folded so as to position the tabs 304 and 306 through the apertures 404 and 406. Finally, the backing strata 160 is peeled off to reveal the double-sides tape and then the wall 358 is adhered to the upper surface of 30 the wall 354. With this construction the formations 76 to 88 act as reinforcing or supports for the planar sides 354, 357 and 358 to give the resultant flashlight the look and feel of a regular flashlight.

WO 03/046434 PCT/AU02/01614 11 Illustrated in Figures 26 and 27 is a further improvement to the reflector assembly 10 whereby the side cowlings 48 include spigots 49 extending from a lower surface thereof, whilst the rear portion of the lower piece 14 includes apertures 51 therethrough. The reflector holding plate 142 includes two leg extensions 143 which 5 have apertures 145 therethrough, which can receive the spigots 49. In this way, the rear of the reflector assembly 10 is held securely to the rear of the lower piece 14, preventing any movement with respect thereto. Illustrated in Figure 28 is a flashlight 600 formed on a cardboard base. However, unlike the flashlight preform of previous figures, the flashlight 600 is 10 simply formed onto a blister card 140. To operate the flashlight 600 can be simply removed from the card by separating the base 143 of the flashlight 600 from the blister card 140 and removing the tab 200. In this version, the formations 76, 78, 80, 82, 84, 86 and 88 act as finger grip formations 303 allowing the operator to activate the switch of the flashlight 600 by pushing onto the flap 30 with their thumb. In this 15 embodiment the formations 76 to 88 will project in a generally downward direction in use. Another embodiment of a user assembled flashlight is disclosed in Figures 30 to 39 with Figures 30 to 32 being directed to a modified reflector assembly 500, Figures 33 to 36 to a modified blister 550, Figures 37 to 39 to an exploded view of the 20 components and a modified sheet material body 600. These will be described in more detail below. Illustrated in Figures 30 through 32 is a reflector assembly 500 which is similar to the reflector assembly 10, with like parts being like numbered. The reflector assembly 500 differs from the reflector assembly 10 in that 25 several features of improvement are present. The lens assembly 500 has the cowlings 48 on the top piece 12 secured to the bottom piece 14 by means of clips or barbs 502 (only one of which is illustrated in Figure 32 the other being on the inside surface of the opposite side cowling) which clip into recesses 504 on the underside of the lower piece 14. Whereas one of the four 30 barbed lugs 16 of the reflector assembly 10 remain in the reflector assembly 500 being only that barbed lug 16 which is closest to the lens 20. By spacing the securement WO 03/046434 PCT/AU02/01614 12 between the lower piece 14 and the top piece 12, the lens assembly 500 will have a greater level of rigidity by comparison to the reflector assembly 10. Extending in a rearward direction from the rear of the top piece 12 is a hook 506. This hook 506 will pass through an aperture 552 (see Figure 33) which is on a 5 forward facing surface of the forward most castellation on the blister 550. The hook 506 will assist in preventing the separation of the reflector assembly 500 from blister 550. If desired, there can be included a shoulder which is spaced from the barb of the hook 506, to provide a groove into which the aperture 552 can be located, which will prevent movement of the top piece 12 towards, or away from the blister 550. Without 10 such a shoulder, the hook 506 only prevents movement of the top piece 12 away from the blister 550. Extending upwardly from the top piece 12 is a cuneiform support surface 508 which has a similar appearance to the castellations on the blister 550. The support member 508 provides additional support for the sheet material body which will form 15 around the reflector assembly 500 and the blister 550. The lens assembly 500 includes a locating rim 510 which is formed as a skirt 512 on the top piece 12 and as a skirt 514 on the lower piece 14. As can be seen from Figure 31 the skirt 514 is tapered, that is, in the regions 516 at the join line of the lower piece 14 the skirt 514 extends away from the lens 20 by a greater distance than 20 in the region 518 at the bottom of the skirt 514. In contrast, the rim 510 as formed by the skirt 512 is of a substantially constant width. The tapered nature of the skirt 514 on the bottom half of the rim 510 is such that when the front face 602 (see Figure 37) of the flashlight sheet material body 60 is 25 folded up to the reflector assembly 500 and the circular aperture 604 therethrough, can be more easily located over the rim 510. If desired at the periphery of the rim 510, a continuous or discontinuous flange can be provided at right angles to the rim 510, over which the aperture 604 will pass. Such a flange or flanges will help to retain the front face 602 in position on the rim 30 510. Another important difference between the reflector assembly 10 and the reflector assembly 500 is that the reflector assembly 500 has a downwardly extending WO 03/046434 PCT/AU02/01614 13 rear plate 520. This rear plate will be sandwiched between two sections of a contact 522. The contact 522 replaces the contact 150 of Figure 22. The contact 522 has a forward portion 524 which will engage the positive terminal of a lamp or globe 24. Once the contact 522 is in place on the plate 520, the assembled reflector assembly 5 500 can be positioned adjacent the blister 550 which will contain the batteries with the lower portion and face 526 of the contacts 22 making contact with the positive terminal of the closest battery in the blister 550. As illustrated in Figure 32, the termination of the cowlings 48 include an elongated rib 530. The ribs 530 together with the spigots 42 will pass through cut-outs 10 606, 608 and 610 of Figure 37 to thereby pass through the sheet material body 600 allowing the ribs 530 and spigots 42 to be welded to a backing plate 700 as illustrated in Figure 38. The backing plate 700 is an inverted U-shape whereby the legs 702 of the U will engage and be welded to the ribs 530 while the elongated ribs 542 will engage 15 and be welded to a central portion 704 of the backing plate 700. The U shaped bight 703 on plate 700 provides a stop or locator to accurately position the palm side of a thumb or finger therein so as to activate the ON switch. The spigots 42 of reflector assembly 10 have been replaced by an elongated rib 542 which passes through the aperture 606 and can thus also be welded to the backing 20 plate 700. By sonically welding the ribs 530 and ribs 542 to backing plate 700 the reflector assembly 500 is mounted at three spaced apart locations to the sheet material body 600, thus providing a relatively rigid sub-assembly. The sheet material body 600 differs from previously described embodiments in that the central panel 615 is of a different width to the other panels 616, 617, 618 and 25 619. That is, the body forms an irregular pentagon whereas previous embodiments had formed a regular pentagon. By providing the panel 615 with a greater width the assembled flashlight is such that if placed to rest on a flat surface on any one of sides 616, 617, 618 or 619 the weight of the batteries and other components located adjacent to panel 615 will force the flashlight to rotate so that the panel 615 is at the 30 bottom whereby the batteries and other components are in an equilibrium position. This rotatability or ability to find an equilibrium position is also assisted by means of the tabs 304 and 306 on the end faces 602 and 300 being rounded.

WO 03/046434 PCT/AU02/01614 14 As the tabs 304 and 306 maintain some resiliency or springiness due to the flexure of the sheet material after being bent, these tabs 304 and 306 also help to maintain the flashlight in a non-equilibrium position unless the flashlight is put down at first instance with the panel 615 on a flat surface. 5 By the flashlight once assembled finding an equilibrium position with the panel 615 being on the base, accidental activation of the ON-switch cannot occur. Previous embodiments utilised double sided tape to join the panel 619 to the panel 617, however it has been advantageous to provide a series of tabs 620 along the outside edge of panel 619 which can pass into slot 622 formed between the panel 617 10 and the outer flap 624. The blister 550 of Figures 33 to 36 is similar to the blister 70 of Figures 17 to 19, with like parts being like numbered. The main differences include that the blister material and features forward of the wall 98 have been removed making the blister 550 simpler. The blister 550 is thus 15 not staked and held to the sheet material body 600 by means of the reflector assembly 500, it is only secured to the sheet material body 600 directly. Another difference is that the contact between the positive terminal of the forwardmost battery passes through an aperture 102 on the blister 70, whereas for the blister 550 this has been further simplified with the positive terminal of the 20 forwardmost battery passing through aperture 99 (see Figure 34) and extending proud of the wall 98. This has been achieved by also making the width 577 of the battery cavity of blister 550 smaller from the width of the battery cavity of blister 70. This arrangement simplifies the mounting and preassembly of the positive contact 522 onto the reflector assembly 500. 25 By forming the flashlight with a sheet material body a ready vehicle is provided whereby the print or appearance can be easily changed from one batch to another so as to be attractive to different market segments. It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or 30 evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.

WO 03/046434 PCT/AU02/01614 15 The foregoing describes embodiments of the present invention and modifications, obvious to those skilled in the art, can be made thereto, without departing from the scope of the present invention.

Claims (52)

1. A reflector assembly comprising a first and second member, said first and second member each including formations to receive part of a lamp means so as to hold said lamp means when said first and second members are connected together, 5 said first member including attachment formations thereon to attach said first member to a flashlight body portion, said first and second members including reflection surfaces to form a reflector when said first and second members are connected

2. A reflector assembly as claimed in claim 1, wherein said first and second members include a holding means to receive and hold a cover or lens. 10

3. A reflector assembly as claimed in claim 1 or 2 wherein said first or second member include a cowling to prevent side access to inside portions of said lens assembly.

4. A reflector assembly as claimed in any one of claims 1 to 3 wherein said first or second members include a hinge flap, said hinge flap engaging a switch contact in 15 use.

5. A reflector assembly as claimed in any one of claims 1 to 4 wherein said attachment means is at least one spigot on said first or said second member.

6. A reflector assembly as claimed in any one of claims 1 to 5 wherein said at least one spigot is a stake which can be deformed by heating. 20

7. A reflector assembly as claimed in any one of claims 5 or 6, wherein there are three spigots.

8. A reflector assembly as claimed in any one of claims 5 to 7 wherein said at least one spigot is elongated so as to provide an elongated contact surface.

9. A reflector assembly as claimed in any one of claims 1 to 8 wherein said first 25 and second members have mating formations thereon to interconnect said first and second members.

10. A reflector assembly as claimed in claim 3 wherein said cowling includes strengthening ribs formed thereon.

11. A reflector assembly as claimed in any one of claims 1 to 10 wherein said lens 30 assembly includes a rearwardly directed opening through which contacts from a power source can engage terminals associated with said lamp means. WO 03/046434 PCT/AU02/01614 17

12. A reflector assembly as claimed in any one of claims 1 to 11 wherein said lamp means is a globe or an LED.

13. A reflector assembly as claimed in any one of claims 1 to 12, further including a member extending away from said assembly in a direction lateral to a direction that 5 light will be emitted from such reflector when in use.

14. A reflector assembly as claimed in claim 13, wherein such member can assist in supporting a body portion which will surround said reflector assembly.

15. A reflector assembly as claimed in any one of claims 1 to 14, wherein an annular skirt extends away from the reflector assembly. 10

16. A reflector assembly as claimed in claim 15, wherein said skirt has a tapered construction to assist in locating a body portion around said skirt.

17. A reflector assembly as claimed in claim 16, wherein said tapered construction is located on one of said first or second members.

18. A reflector assembly as claimed in any one of claims 15 to 17, wherein said 15 skirt includes a flange at a periphery thereof to locate a body portion inboard of said flange.

19. A flashlight construction including a planar body portion, a battery holder attached to said body portion, a reflector assembly and a lamp means, said reflector assembly being mounted to said body portion so that contacts for said lamp means can 20 made electrical connection to contacts from batteries held by said battery holder.

20. A flashlight construction as claimed in claim 19 wherein said battery holder is a blister package member.

21. A flashlight construction as claimed in any one of claims 19 or 20 wherein said battery holder includes finger grip formations. 25

22. A flashlight construction as claimed in any one of claims 19 to 21 wherein said lens assembly includes mounting means whereby said body portion can be sandwiched between said lens assembly and a backing plate.

23. A flashlight construction as claimed in any one of claims 19 to 14 wherein 22 said battery holder includes a forward portion which extends from said battery holder 30 and under said reflector assembly.

24. A flashlight construction as claimed in claim 23 wherein said forward portion is sandwiched with said body portion by said lens assembly and a backing plate. WO 03/046434 PCT/AU02/01614 18

25. A flashlight construction as claimed in any one of claims 19 to 24 wherein said battery holder holds at least 2 batteries.

26. A flashlight construction as claimed in claim 25 wherein said battery holder includes an aperture adjacent a join plane between two series connected batteries. 5

27. A flashlight construction as claimed in claim 26 wherein said aperture receives a tab to separate positive and negative terminals of two series connected batteries.

28. A flashlight construction as claimed in any one of claims 19 to 27 wherein said reflector assembly includes a switch actuation means.

29. A flashlight construction as claimed in any one of claims 19 to 28 wherein said 10 reflector assembly is held relative to said battery holder at at least one location.

30. A flashlight construction as claimed in claim 29 wherein said reflector assembly is held relative to said battery holder at at least two locations.

31. A flashlight construction as claimed in any one of claims 19 to 29 wherein said reflector assembly has a rearwardly extending member to engage said batter holder. 15

32. A flashlight construction as claimed in claim 31 wherein said member is a barb.

33. A flashlight construction as claimed in claim 32 wherein said battery holder includes an aperture to receive and hold said barb.

34. A flashlight construction as claimed in any one of claims 19 to 33 wherein said 20 battery holder is undetachably attached to said body portion.

35. A flashlight as claimed in any one of claims 19 to 34 wherein said planar body portion is formed within a card, sheet material, or a blister card.

36. A flashlight as claimed in claim 35 wherein said body portion is detachable from said card, sheet material or blister card. 25

37. A flashlight as claimed in any one of claims 35 or 36, wherein said flashlight is ready for use when said planar body portion is detached from said card, sheet material or blister card.

38. A method of constructing a flashlight said method including the step of forming a flashlight body from a blister package member and a sheet material body 30 portion to which said blister package member is attached. WO 03/046434 PCT/AU02/01614 19

39. A method of constructing a flashlight as claimed in claim38, further including the step of mounting a reflector assembly to said sheet material body portion or said blister package member.

40. A method of constructing a flashlight as claimed in any one of claims 37 to 39, 5 wherein said method includes a step of forming said blister package member with formations which act as finger grip formations.

41. A method of constructing a flashlight as claimed in any one of claims 39 or 40, wherein said method includes a step of forming said reflector assembly with a formation which can act as a finger grip formation. 10

42. A method of constructing a flashlight as claimed in any one of claims39 to 41 wherein the step of mounting said reflector assembly includes sandwiching said body portion between said reflector assembly and a backing plate.

43. A method of constructing a flashlight as claimed in any one of claims 38 to42, wherein method includes the step of sandwiching a forward portion of said battery 15 holder between said reflector assembly and a backing plate.

44. A method of constructing a flashlight as claimed in any one of claims 38 to 43, wherein prior to attaching said sheet material body portion to said blister package member there is included a step whereby at least one battery is placed in a cavity provided by said blister package member. 20

45. A method of constructing a flashlight as claimed in any one of claims 38 to 44, wherein prior to attaching said sheet material body portion to said blister package member there is included a step whereby at least one battery contact is placed in a cavity provided by said blister package member.

46. A method of constructing a flashlight as claimed in any one of claims 38 to 45 25 wherein said reflector assembly is assembled so as to provide a contact between a terminal of a lamp means and a battery terminal.

47. A method of constructing a flashlight as claimed in any one of claims 38 to 46, wherein said method includes the step of placing a tab between adjacent positive and negative terminals of said two series connected batteries. 30

48. A method of constructing a flashlight as claimed in any one of claims 38 to 47, wherein said sheet material body portion is initially formed as part of a sheet of cardboard, polymeric sheet material, or a blister card. WO 03/046434 PCT/AU02/01614 20

49. A method of constructing a flashlight as claimed in claim 44, wherein said blister package member is attached to said sheet material body portion, before said sheet material body portion is detached from said sheet of cardboard, polymeric sheet material or blister card. 5

50. A method of constructing a flashlight as claimed in any one of claims 38 to 49, wherein said sheet material body portion is contained in a larger sheet of material and said sheet material body portion must be detached from said larger sheet to enable said flashlight to be used.

51. A method of constructing a flashlight as claimed in claim 48 or 49, wherein 10 said flashlight is ready for use after said sheet material body portion is detached from said sheet of cardboard, polymeric sheet material or a blister card.

52. A method of constructing a flashlight a claimed in any one of claims 48 to 50, wherein once detached, said sheet material body portion is foldable around said reflector assembly and said blister packing member to fornn a flashlight body. WO 03/046434 PCT/AU02/01614 21 AMENDED CLAIMS [received by the International Bureau on 28 April 2003 (28.04.03); original claims 1-24 replaced by new claims 1-24; orginal claims 25-52 unchanged.] 1. A flashlight reflector assembly comprising a first and second member, said first and second member each including formations to receive part of a lamp means so as to hold said lamp means when said first and second members are connected 5 together, said first member including attachment formations thereon to attach said first member to a flashlight body portion, said first and second members including reflection surfaces to form a reflector when said first and second members are connected 2. A flashlight reflector assembly as claimed in claim 1, wherein said first and 10 second members include a holding means to receive and hold a cover or lens. 3. A flashlight reflector assembly as claimed in claim 1 or 2 wherein said first or second member include a cowling to prevent side access to inside portions of said lens assembly. 4. A flashlight reflector assembly as claimed in any one of claims 1 to 3 wherein 15 said first or second members include a hinge flap, said hinge flap engaging a switch contact in use. 5. A flashlight reflector assembly as claimed in any one of claims 1 to 4 wherein said attachment means is at least one spigot on said first or said second member. 6. A flashlight reflector assembly as claimed in any one of claims 1 to 5 wherein 20 said at least one spigot is a stake which can be deformed by heating. 7. A flashlight reflector assembly as claimed in any one of claims 5 or 6, wherein there are three spigots. 8. A flashlight reflector assembly as claimed in any one of claims 5 to 7 wherein said at least one spigot is elongated so as to provide an elongated contact surface. 25 9. A flashlight reflector assembly as claimed in any one of claims 1 to 8 wherein said first and second members have mating formations thereon to interconnect said first and second members. 10. A flashlight reflector assembly as claimed in claim 3 wherein said cowling includes strengthening ribs formed thereon. 30 11. A flashlight reflector assembly as claimed in any one of claims 1 to 10 wherein said lens assembly includes a rearwardly directed opening through which contacts from a power source can engage terminals associated with said lamp means. WO 03/046434 PCT/AU02/01614 22 12. A flashlight reflector assembly as claimed in any one of claims 1 to 11 wherein said lamp means is a globe or an LED. 13. A flashlight reflector assembly as claimed in any one of claims 1 to 12, further including a member extending away from said assembly in a direction lateral to a 5 direction that light will be emitted from such reflector when in use. 14. A flashlight reflector assembly as claimed in claim 13, wherein such member can assist in supporting a body portion which will surround said reflector assembly. 15. A flashlight reflector assembly as claimed in any one of claims 1 to 14, wherein an annular skirt extends away from the reflector assembly. 10 16. A flashlight reflector assembly as claimed in claim 15, wherein said skirt has a tapered construction to assist in locating a body portion around said skirt. 17. A flashlight reflector assembly as claimed in claim 16, wherein said tapered construction is located on one of said first or second members. 18. A flashlight reflector assembly as claimed in any one of claims 15 to 17, 15 wherein said skirt includes a flange at a periphery thereof to locate a body portion inboard of said flange. 19. A flashlight construction including a planar body portion, a battery holder attached to said body portion, a reflector assembly and a lamp means, said reflector assembly being mounted to said body portion so that contacts for said lamp means can 20 made electrical connection to contacts from batteries held by said battery holder. 20. A flashlight construction as claimed in claim 19 wherein said battery holder is a blister package member. 21. A flashlight construction as claimed in any one of claims 19 or 20 wherein said battery holder includes finger grip formations. 25 22. A flashlight construction as claimed in any one of claims 19 to 21 wherein said lens assembly includes mounting means whereby said body portion can be sandwiched between said lens assembly and a backing plate. 23. A flashlight construction as claimed in any one of claims 19 to 14 wherein 22 said battery holder includes a forward portion which extends from said battery holder 30 and under said reflector assembly. 24. A flashlight construction as claimed in claim 23 wherein said forward portion is sandwiched with said body portion by said lens assembly and a backing plate. AlIKlrlI O-U Cl-IJT IAITTIfI - 4l