Integrated optic and bezel for flashlight
Disclosed in various embodiments are integrated lens and bezel systems for a flashlight or other lighting unit. Various embodiments include a housing, including a bezel portion and a body portion, a lens, wherein the lens and the bezel together comprise a single, continuous component, and a light source disposed within the housing, wherein the light source is configured to interact with the lens to provide a light beam. Some embodiments provide a mechanism for adjusting the relative positions of the light source and lens, for example to allow for focusing of the light beam. In some embodiments, the lens is continuous with just the bezel portion, whereas in other embodiments, the lens, bezel, and all or part of the body portion are formed as a single, unitary component, for instance by injection-molding or co-molding.
1. An integrated lens and housing system for a flashlight, comprising:
a housing including a front portion and a body portion,
a focusing lens comprising:
a central focusing element that directs a light beam in a desired direction; and
an annular ring portion surrounding the central focusing element, wherein the annular ring portion reflects light in a desired direction;
wherein the focusing lens and the front portion together comprise a unitary component formed from a single piece of solid, transparent material; and
a light source disposed within the housing, wherein the light source interacts with the focusing lens to provide the light beam, and wherein a distance between the focusing lens and the light source is slidably adjustable to selectably focus the light beam.
2. The integrated lens and housing system of claim 1 , wherein the front portion is configured to move relative to the body portion.
3. The integrated lens and housing system of claim 1 , wherein the front portion is configured to move relative to the body portion, and wherein movement of the front portion relative to the body portion alters a focus of the light beam.
4. The integrated lens and housing system of claim 3 , wherein the housing comprises an adjustment mechanism coupling the front portion to the body portion.
5. The integrated lens and housing system of claim 4 , wherein the front portion is slidably coupled to the body portion.
6. The integrated lens and housing system of claim 1 , wherein the housing comprises a coupling mechanism comprising one or more slidable connectors.
7. The integrated lens and housing system of claim 6 , wherein the one or more slidable connectors comprise one or more O-rings.
8. The integrated lens and housing system of claim 1 , wherein the lens, the front portion, and the body portion together comprise a single, continuous component.
9. The integrated lens and housing system of claim 1 , wherein the housing comprises a slot and a tab protruding therethrough, and wherein adjustment of a longitudinal position of the tab within the slot adjusts a focus of the light beam.
10. The integrated lens and housing system of claim 9 , wherein adjustment of the longitudinal position of the tab towards the focusing lens produces a wider light beam.
11. The integrated lens and housing system of claim 10 , wherein the slot is a longitudinal or diagonal slot.
12. The integrated lens and housing system of claim 10 , wherein adjustment of the longitudinal position of the tab away from the focusing lens produces a narrower light beam.
13. A method of making a flashlight, the method comprising:
molding a first component from a single, transparent material, wherein the first component comprises a focusing lens and a first housing member; the focusing lens comprising:
a central focusing element that directs a light beam in a desired direction; and
an annular ring portion surrounding the central focusing element, wherein the annular ring portion reflects light in a desired direction; wherein the focusing lens is configured to selectably focus the light beam into a spot beam and a flood beam;
coupling the first component to a second component, wherein the second component comprises a light source, a power source, one or more electric conduits, and a switch member, such that the distance between the focusing lens and the light source is slidably adjustable to select the spot beam or the flood beam.
14. The method of claim 13 , wherein the second component comprises a second housing member adapted to couple to the first housing member.
15. The method of claim 13 , wherein the second component is adapted to fit at least partially within the first housing member.
16. The method of claim 13 , wherein molding comprises injection-molding or co-molding.
17. The integrated lens and housing system of claim 1 wherein the distance between the focusing lens and the light source is longitudinally adjustable to selectively focus the light beam.
18. The method of claim 13 wherein the coupling of the first component to a second component is performed such that the distance between the focusing lens and the light source is longitudinally adjustable to select the spot beam or the flood beam.