1. A portable light and light source adapter comprising:
a light body having an open end for receiving a light source therein, the open end exposing a face including one or more raised bosses extending axially toward the open end in an asymmetric pattern and one or more electrical connections, said light body having a cavity for receiving a source of electrical power therein and optionally including an electrical switch for selectively energizing at least one of the electrical connections;
a light source including an adapter base disposed in the open end of said light body, said adapter base having one or more raised bosses extending into the open end of said light body, said one or more raised bosses being in an asymmetric pattern that is complementary to the asymmetric pattern of the one or more raised bosses extending from the face of said light body, the one or more raised bosses extending from the face of said light body and the one or more raised bosses extending into the open end of said light body being complementary and asymmetric in that said adapter base cannot seat adjacent said face unless their complementary raised bosses are in a unique predetermined rotational relationship relative to each other for mating;
said adapter base including one or more electrical connections that are located to mate with the one or more electrical connections on the exposed face only when said adapter base is seated adjacent said face in the unique predetermined rotational relationship for mating;
whereby the orientation of said light source is uniquely predetermined relative to light body,
said light source including a source of illumination electrically connected to the one or more electrical connections of said adapter base; and
a retainer for retaining said light source disposed in the open end of said light body with said adapter base seated adjacent said face in the unique predetermined rotational relationship for mating.
2. The portable light and light source adapter of claim 1 wherein said light source comprises an elongated light bar including:
an elongated tubular transparent or translucent housing extending from said adapter base; and
a plurality of light emitting diodes disposed on an elongated support disposed in said elongated tubular housing.
3. The portable light and light source adapter of claim 2 wherein said light emitting diodes are disposed on one surface of said elongated support for directing light to the side of said tubular housing when energized.
4. The portable light and light source adapter of claim 2 wherein said elongated support includes an electrical circuit board having conductors thereon for connecting said plurality of light emitting diodes to the one or more electrical connections of said adapter base.
5. The portable light and light source adapter of claim 4 wherein said electrical circuit board includes an electronic circuit for controlling the voltage applied to andor the current flowing through said plurality of light emitting diodes.
6. The portable light and light source adapter of claim 4 wherein said elongated support includes:
an electrical circuit board having conductors thereon for connecting said plurality of light emitting diodes to the one or more electrical connections of said adapter base; and
a heat conductive member adjacent said electrical circuit board and thermally coupled thereto.
7. The portable light and light source adapter of claim 1 wherein said retainer includes a retainer ring having threads thereon for engaging threads at the open end of said light body.
8. The portable light and light source adapter of claim 1 wherein the one or more raised bosses that extend axially toward the open end of said light body in an asymmetric pattern define a curved boss over an angle of less than about 180\xb0 and wherein the one or more raised bosses of said adapter base that extend into the open end of said light body define a curved boss over an angle complementary to that of the curved boss of said light body.
9. A light source adapter for a portable light, the portable light comprising a light body having an open end for receiving a light source therein, the open end exposing a face including one or more raised bosses extending axially toward the open end in an asymmetric pattern and one or more electrical connections, the light body having a cavity for receiving a source of electrical power therein and optionally including an electrical switch for selectively energizing at least one of the one or more electrical connections;
said light source adapter comprising:
a light source including an adapter base disposable in the open end of the light body, said adapter base having one or more raised bosses for extending into the open end of the light body, said one or more raised bosses being in an asymmetric pattern that is complementary to the asymmetric pattern of the one or more raised bosses extending from the face of the light body, the one or more raised bosses extending from the face of said light body and the one or more raised bosses extending into the open end of said light body being complementary and asymmetric in that said adapter base cannot seat adjacent the face unless their complementary raised bosses are in a unique predetermined rotational relationship for mating;
said adapter base including one or more electrical connections to mate with the one or more electrical connections on the exposed face only when said adapter base is seated adjacent the face in the unique predetermined rotational relationship for mating;
said light source including a source of illumination electrically connected to the at least two electrical connections of said adapter base.
10. The light source adapter for a portable light of claim 9 wherein said light source comprises an elongated light bar including:
an elongated tubular transparent or translucent housing extending from said adapter base; and
a plurality of light emitting diodes disposed on an elongated support disposed in said elongated tubular housing.
11. The light source adapter for a portable light of claim 10 wherein said light emitting diodes are disposed on one surface of said elongated support for directing light to the side of said tubular housing when energized.
12. The light source adapter for a portable light of claim 10 wherein said elongated support includes an electrical circuit board having conductors thereon for connecting said plurality of light emitting diodes to the one or more electrical connections of said adapter base.
13. The light source adapter for a portable light of claim 12 wherein said electrical circuit board includes an electronic circuit for controlling the voltage applied to andor the current flowing through said plurality of light emitting diodes.
14. The light source adapter for a portable light of claim 12 wherein said elongated support includes:
an electrical circuit board having conductors thereon for connecting said plurality of light emitting diodes to the one or more electrical connections of said adapter base; and
a heat conductive member adjacent said electrical circuit board and thermally coupled thereto.
15. The light source adapter for a portable light of claim 9 further comprising:
a retainer for retaining said light source disposed in the open end of the light body with said adapter base seated adjacent the face in the unique predetermined rotational relationship for mating.
16. The light source adapter for a portable light of claim 15 wherein said retainer includes a retainer ring having threads thereon for engaging threads at the open end of said light body.
17. The light source adapter for a portable light of claim 9 wherein the one or more raised bosses that extend axially toward the open end of the light body in an asymmetric pattern define a curved boss over an angle of less than about 180\xb0 and wherein the one or more raised bosses of said adapter base that extend into the open end of said light body define a curved boss over an angle complementary to that of the curved boss of said light body.
18. A portable light and light source adapter comprising:
a light body having an open end for receiving a light source therein, the open end having an exposed a face including one or more features in an asymmetric pattern and one or more electrical connections, said light body having a cavity for receiving a source of electrical power therein and optionally including an electrical switch for selectively energizing at least one of the electrical connections;
a light source for emitting light in a predetermined direction relative to said light body and including an adapter base disposed in the open end of said light body, said adapter base having one or more features complementary to the features of said light body in an asymmetric pattern that is complementary to the asymmetric pattern of the one or more features of the face of said light body, the one or more raised bosses extending from the face of said light body and the one or more raised bosses extending into the open end of said light body being complementary and asymmetric in that said adapter base cannot seat adjacent said face unless their complementary features are in a unique predetermined rotational relationship for mating;
whereby said light source when disposed in said light body can emit light in the predetermined direction relative to the light body.
19. The portable light and light source adapter of claim 18 wherein said adapter base includes one or more electrical connections that are located to mate with the one or more electrical connections on the exposed face only when said adapter base is seated adjacent said face in the unique predetermined rotational relationship for mating.
20. The portable light and light source adapter of claim 18 wherein said light source includes a source of illumination electrically connected to the one or more electrical connections of said adapter base for emitting light in the predetermined direction.
21. The portable light and light source adapter of claim 18 further comprising a retainer for retaining said light source in the open end of said light body with said adapter base seated adjacent said face in the unique predetermined rotational relationship for mating.
22. The portable light and light source adapter of claim 21 wherein said retainer includes a retainer ring having threads thereon for engaging threads at the open end of said light body.
23. The portable light and light source adapter of claim 18 wherein said light source comprises an elongated light bar including:
an elongated tubular transparent or translucent housing extending from said adapter base; and
a plurality of light emitting diodes disposed on an elongated support disposed in said elongated tubular housing for emitting light in the predetermined direction.
24. The portable light and light source adapter of claim 23 wherein said light emitting diodes are disposed on one surface of said elongated support for directing light to the side of said tubular housing when energized.
25. The portable light and light source adapter of claim 23 wherein said elongated support includes an electrical circuit board having conductors thereon for connecting said plurality of light emitting diodes to the one or more electrical connections of said adapter base.
26. The portable light and light source adapter of claim 25 wherein said electrical circuit board includes an electronic circuit for controlling the voltage applied to andor the current flowing through said plurality of light emitting diodes.
27. The portable light and light source adapter of claim 23 wherein said elongated support includes:
an electrical circuit board having conductors thereon for connecting said plurality of light emitting diodes to the one or more electrical connections of said adapter base; and
a heat conductive member adjacent said electrical circuit board and thermally coupled thereto.
28. The portable light and light source adapter of claim 18 wherein the one or more features of said light body include one or more raised bosses that extend axially toward the open end of said light body in an asymmetric pattern define a curved boss over an angle of less than about 180\xb0 and wherein the one or more features of said light source include one or more raised bosses of said adapter base that extend into the open end of said light body define a curved boss over an angle complementary to that of the curved boss of said light body.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
What is claimed is:
1. In a method of spin forming a cylindrical sheet metal workpiece, to form a sheet metal connector ring for sheet metal ducting, by using a mandrel that has an open center, a generally radial forming surface surrounding the open center, and an outer diameter, wherein a first end portion of the workpiece is positioned in the open center of the mandrel, and is secured to the mandrel, and a second end portion of the workpiece projects axially outwardly from the center opening in the mandrel and has an outer end part, and wherein the mandrel and the workpiece are spun together about a common spin axis and the second end portion of the workpiece is progressively stretched in diameter and moved radially outwardly along the generally radial forming surface of the mandrel by a first forming tool, the improvement comprising;
rotating the mandrel and workpiece and using the first forming tool to stretch the second end portion of the workpiece and move it radially outwardly on said radial forming surface until the outer end part of the second end portion of the workpiece becomes spaced generally axially from the radial forming surface substantially at the outer diameter of the mandrel;
continuing to rotate the mandrel and the workpiece and moving a second forming tool against the outer end part of the second end portion of the workpiece, and using said second forming tool to curl the outer end part radially inwardly and move it substantially against an adjoining radial part of the second end portion of the workpiece that is in contact with the radial forming surface on the mandrel; and
removing the formed workpiece from the mandrel to serve as a connector ring having a radial flange at a first end and a cylindrical flange at a second end, wherein said radial flange has an outer marginal portion with a rounded outer edge.
2. The method of claim 1, further comprising using the second forming tool to press the outer end part of the second end portion of the workpiece flat against the adjoining radial part of the second end portion of the workpiece.
3. The method of claim 1, further comprising providing a first forming tool that includes a roller having a center axis; mounting the first forming tool for free rotation of the roller about its center axis; providing the roller with a convex face; placing the roller inside the second end portion of the workpiece, with its convex face directed towards the second end portion of the workpiece; and moving the roller along a radial path that is within a plane that includes the spin axis of the mandrel and the center axis of the roller, whereby as it moves the roller progressively stretches the second end portion of the workpiece and progressively forces it against the generally radial forming surface on the mandrel.
4. The method of claim 3, comprising providing a support arm for the first forming tool; pivotally connecting a lower end of the support arm to a support, for pivotal movement about a pivot axis that extends perpendicular to the center axis of the roller; mounting the roller onto the support arm at a location spaced from said pivot axis; and swinging the support arm about the pivot axis to place the roller inside of the second end portion of the workpiece and in position to contact the second end portion of the workpiece and stretch it and force it against the radial forming surface of the mandrel as the roller is being moved along said radial path.
5. The method of claim 1, comprising mounting the mandrel for rotation about a spin axis that extends substantially vertically, placing the generally radial forming surface in a plane that extends substantially horizontally.
6. The method of claim 5, further comprising providing a first forming tool that includes a roller that has a substantially horizontal center axis; mounting the roller for free rotation about its center axis; providing the roller with a convex face; placing the roller inside the second end portion of the workpiece, with its convex face directed towards the second end portion of the workpiece; and moving the roller along a path that extends radially of the mandrel and workpiece, progressively stretching the second end portion of the workpiece and progressively forcing it against the generally radial forming surface on the mandrel, as said roller moves along said workpiece.
7. The method of claim 6, comprising providing a support arm for the roller; pivotally connecting a lower end of the support arm to a support frame, for pivotal movement about a substantially horizontal pivot axis that extends perpendicular to the center axis of the roller; mounting the roller on the support arm at a location spaced from and above said pivot axis; and swinging the support arm about the pivot axis to place the roller inside the second end portion of the workpiece and in position to contact the second end portion of the workpiece and stretch it and force it against the radial forming surface of the mandrel as the roller is moved radially along the workpiece.
8. The method of claim 7, comprising moving the support for the support arm for moving the support arm and the roller relative to the second end portion of the workpiece.
9. The method of claim 1, comprising mounting the first forming roller for movement towards and away from the generally radial forming surface on the mandrel; and spring biasing the roller towards the radial forming surface.
10. The method claim 1, comprising providing a second forming tool that includes a roller that has a center axis and a cam surface surrounding the center axis; and moving the second forming tool so as to contact the outer part of the second end portion of the workpiece, and move it radially inwardly and axially towards an adjoining radial part of the second end portion of the workpiece that is in contact with the radial forming surface on the mandrel.
11. The method of claim 10, comprising mounting the roller of the second forming tool on a movable support, for rotation about the center axis of said roller, and moving the support towards the mandrel and workpiece to move the cam surface of the roller against the outer end part of the second end portion of the workpiece.
12. The method claim 11, comprising providing a support in the form of a swing arm; mounting one end of the swing arm for rotation about a swing axis; mounting the roller on an opposite end of the swing arm for rotation about an axis that is parallel to the swing axis; and swinging the swing arm towards the mandrel and workpiece to move a cam surface of the roller against the outer end part of the second end portion of the workpiece.
13. In a method of spin forming a cylindrical sheet metal workpiece, to form a sheet metal connector ring for sheet metal ducting, by using a mandrel that has an open center, a generally radial forming surface surrounding the open center, and an outer diameter, wherein a first end portion of the workpiece is positioned in the open center of the mandrel, and is secured to the mandrel, and a second end portion of the workpiece projects axially outwardly from the center opening in the mandrel and has an outer end part, and wherein the mandrel and the workpiece are spun together about a common spin axis and the second end portion of the workpiece is progressively stretched in diameter and moved radially outwardly along the generally radial forming surface of the mandrel by a forming roller, the improvement comprising:
mounting the mandrel for rotation about a substantially vertical spin axis with its generally radial forming surface in a substantially horizontal plane;
mounting the forming roller for rotation about an axis that is in a common radial plane with the spin axis of the mandrel;
providing the roller with a convex face and a periphery;
placing the roller inside the second end portion of the workpiece, with its convex face directed radially outwardly towards the second end portion of the workpiece and its periphery directed downwardly;
spring biasing the roller downwardly when it is inside the second end portion of the workpiece, to place its periphery initially below the level of the radial forming surface;
spinning the mandrel and the workpiece around the spin axis of the mandrel;
moving the roller radially outwardly of the mandrel and its convex face against the second end portion of the workpiece, so as to radially stretch the second end portion of the workpiece as the roller moves radially outwardly;
positioning the periphery of the roller where it will press the second end portion of the workpiece against the generally radial forming surface as it moves radially outwardly,
whereby as the roller moves radially outwardly its contact with the second end portion of the workpiece will move the roller upwardly against the spring bias, allowing the second end portion of the workpiece to move radially outwardly along the radial forming surface, between the periphery of the roller and the radial forming surface; and
continuing the radial outward movement of the roller against the second end portion of the workpiece at least until a predetermined amount of the second end portion of the workpiece is against the radial forming surface below and behind the roller and a remainder of the second end portion of the workpiece is forwardly of the roller against its convex face.
14. The method of claim 13, comprising rotating the mandrel and using the roller to stretch the second end portion of the workpiece and move it radially outwardly on said radial forming surface until the outer end part of the second end portion of the workpiece becomes spaced generally axially from the radial forming surface substantially at the outer diameter of the mandrel;
continuing to rotate the mandrel and the workpiece and moving an edge forming tool against the outer end part of the second end portion of the workpiece and using said tool to curl the outer end part radially inwardly and substantially against an adjoining part of the second end portion of the workpiece that is in contact with the radial forming surface on the mandrel; and
removing the formed workpiece from the mandrel to serve as a connector ring having a radial flange at a first end and a cylindrical flange at a second end, wherein said radial flange has a double-thickness outer marginal portion with a rounded outer edge.
15. The method of claim 13, comprising providing a support in the form of a swing arm; mounting one end of the swing arm for rotation about a generally vertical swing axis; mounting the edge forming roller on the swing arm for free rotation about an axis that is parallel to the swing axis; and swinging the swing arm towards the mandrel and workpiece to move a cam surface on the edge forming roller against the outer end part of the second end portion of the workpiece whereby the outer end part of the second end portion of the workpiece is moved radial inwardly and substantially against the adjoining part of the second end portion of the workpiece that is in contact with the radial forming surface on the mandrel.
16. A sheet metal connector ring for connecting adjoining ends of two duct sections together or for connecting an end of a duct section to a flat wall surface, comprising:
a cylindrical insertion flange sized to be received within an end portion of a section of sheet metal ducting;
a radial mating flange extending radially outwardly from one end of the insertion flange to an outer edge, said mating flange having an annular, single thickness, inner portion and an annular, double-thickness outer portion; and
said double-thickness outer portion having a laterally rounded outer edge and an inner edge that is spaced radially inwardly from the outer edge on the side of the mating flange that is opposite the insertion flange, said inner edge forming an inner boundary for the double-thickness, outer portion of the mating flange.
17. A connection between adjoining ends of two duct sections, comprising:
a first duct section having an end portion;
a second duct section having an end portion;
a sheet metal connector ring for each duct section, each connector ring comprising:
a cylindrical insertion flange sized to be received within an end portion of a section of sheet metal ducting;
a radial mating flange extending radially outwardly from one end of the insertion flange to an outer edge, said mating flange having an annular, single thickness inner portion and an annular, double-thickness outer portion; and
said double-thickness outer portion having a laterally rounded outer edge and an inner edge that is spaced radially inwardly from the outer edge on the side of the mating flange that is opposite the insertion flange, said inner edge forming an inner boundary for the double-thickness outer portion of the mating flange;
wherein the insertion flange of one a first of the connector rings is telescopically received in the end portion of the first duct section and the insertion flange of the second connector ring is telescopically received within the end portion of the second duct section;
said radial mating flanges of the two connector rings confronting each other with their double-thickness outer portions substantially touching each other and with a space being formed axially between the single thickness inner portions of the two connector rings, radially inwardly of the inner edges of the double-thickness outer portions of the mating flanges;
a seal ring in said space contacting the inner portions of the mating flanges;
fasteners connecting the end portions of the duct sections to the insertion flanges; and
fasteners connecting the mating flanges of the two connector rings together.