Flashlight having a switch and an integrally molded member, and method for producing same

A flashlight adapted for use with a battery comprising:

• a housing having a front end and a rear end and an opening in a wall of the housing in fluid communication with a cavity in an outer surface of the housing;
• a bulb and a switch connected in circuit in said housing;
• a grip molded into the cavity of the housing for providing a gripping surface;
• an actuator molded into the opening of the housing for operating the switch;
• wherein the grip and the actuator are molded contemporaneously as one piece for sealing the opening of the housing.

A flashlight comprising:

• a housing member having an opening therethrough;
• a bulb, a battery and a switch connected in circuit in said housing;
• an actuator molded into the opening in the housing for operating the switch;
• wherein the actuator is molded of a material that bonds to the housing member for sealing the opening in the housing member of the flashlight.

A method of producing a flashlight housing comprising:

• obtaining a housing having a grip cavity on the outside thereof and having an actuator opening;
• placing a core inside the housing;
• placing a mold on the housing, wherein the core and the mold define a mold volume around the housing;
• injecting elastomer into the mold until elastomer fills the mold volume including the actuator opening and the grip cavity, whereby the elastomer forms a grip and an actuator molded into the housing;
• and
• removing the core and the mold.

A flashlight comprising:

• a housing having a front end, a rear end, and a wall having a cavity, and adapted for containing at least one battery;
• a head attached at the front end of the housing, the head including a reflector and a bulb positioned in said reflector;
• an electrical switch;
• an electrical circuit connecting the bulb and the switch in circuit with the at least one battery;
• a molded member molded into the cavity of the housing to provide a gripping surface on the wall thereof and an actuator for operating the switch, wherein the gripping surface and the actuator are contemporaneously molded into the housing as one piece.

A flashlight comprising:

• a housing adapted to hold a battery;
• a bulb and a switch connected in circuit in the housing;
• an actuator in the housing and movable for operating the switch;
• wherein the actuator and the housing include respective cooperating engaging features within the housing to limit the travel of the actuator relative to the housing.

A flashlight comprising:

• a housing having a head end and a tail end, and adapted for containing at least one battery;
• a head attached at the head end of the housing, the head including a bulb;
• an electrical switch having first and second switch contacts;
• an electrical circuit connecting the bulb and the electrical switch in circuit with the at least one battery;
• an actuator in the housing operably connected to move the first switch contact within a limited distance to come into and out of contact with the second switch contact;
• and
• means for moving the one of the first and second switch contacts independently of the other of the first and second switch contacts to be in continuous contact therewith and for moving one of the first and second switch contacts beyond the limited distance over which the other of the first and second switch contacts is movable to be in continuous non-contact therewith.

A flashlight adapted for use with a battery comprising:

• a housing having a front end and a rear end, having an opening in a wall of the housing and a cavity in an outer surface of the housing;
• a bulb and a switch connected in circuit in said housing;
• a grip molded into the cavity of the housing for providing a gripping surface;
• an actuator molded into the opening of the housing for operating the switch and for sealing the opening of the housing.