COMM 393 Due: 5 April 2002
Matt Faulkner
Description Essay
Topic-Flashlights
Audience: Company Executives
The flashlight is a cylindrical black tube made of several internal and external parts, which when assembled properly create light for the user. The major external parts are the end cap, barrel, head, lens, and face cap. The major internal parts of the flashlight are the battery spring, switch assembly, lamp, and reflector (Figure 1). After proper assembly our flashlight is designed to make it easier to see in the dark. The purpose of this document is to provide insight, in order to make informed decisions of materials to use, and how to manufacture and market a better flashlight.
The internal parts (battery spring, switch assembly, lamp, and reflector)
Battery Spring: The battery spring is made of steel wire to specifications described by major engineering standards corporation and within safety safety standards set OSHA. The wire is 2 mm thick, or approximately the size used in making wire coat hangers. The battery spring keeps tension against the batteries, assembly switch, and lamp, so they all maintain contact with each other.
Switch-Assembly: The switch assembly is manufactured from a black plastic based material, similar to that of Kevlar. Kevlar as you may know is the material military helmets are made of. The internal operation of the switch is mechanical as opposed to computerized, making the part stand up to stress significantly better than computer tested switches.
Lamp: The lamp is made of high grade low cost halogen light bulbs. At the base of each lamp is a cylindrical metal ring made of aluminum, making them cheap to produce. Attached to the top of the cylindrical metal ring is a glass bulb, and contained in each bulb is a trace amount of halogen gas. Halogen gas is an inert gas meaning it has no combustive or corrosive properties. Each light bulb produces about 11000 candle power, when the flashlight is equipped with 2 D-cell batteries.
Reflector: The reflector is a cone shaped plastic polymer, which sits inside the head of the flashlight, and has a small hole in its center for the lamp to protrude through. The reflector sits neatly within the head of the flashlight. The purpose of the reflector is to funnel light from the lamp through the lens and out onto the subject.
The external parts (end cap, barrel, head, lens, and face cap)
Tail Cap: The end cap is at the handle end of the flashlight. It is typically made of the same material as the barrel and head of the flashlight, which may be plastic, or metal. It houses the battery spring, and in some models of flashlight, additional lamps, batteries, or lenses.
Barrel: The barrel is the cylindrical metal or plastic tube that houses the batteries and gives the flashlight it's shape. Attached to its bottom is the end cap and at its top end the head and lens assembly.
Head: The head of the flashlight is cylinder shaped and is sometimes tapered toward the bottom, as it butts up to the barrel. It houses the reflector. It is usually made of the same material as the end cap, barrel, and face cap. Sometimes the head is knurled, or has a rubber protective sleeve surrounding it. This aids in focusing the light beam.
Lens: The lens is a thin piece of plastic, not usually greater that the thickness of a quarter. The typical flashlight lens is flat, but sometimes they are made with reflective ridges on the bottom side to aid in focusing the light. In addition to focusing light, the lens acts as a protective cover for the lamp and helps keep debris out. The lenses are interchangeable.
Face Cap: The face cap is on the top most end of the flashlight and holds the lens in place. It is also typically made of the same material as the other external parts of the flashlight, and may have knurling on its edges. The knurling aides users when they want to replace the lens.
The flashlight above is broken down into 9 major parts, which is broken down further into internal and external parts. Most internal parts are made of plastic with few exceptions, the battery spring and electrical parts of the switch assembly. The battery spring must be metal because it acts as the ground for the batteries. The other plastic internal parts save weight and production costs over metal.
Flashlights are simple to operate and marketable to nearly everyone. Simple one button action operates the flashlight after batteries are inserted at the end-cap end of the barrel.
Audience: Engineers
The flashlight is a cylindrical black tube made of several internal and external parts, which when assembled properly will make light for the user. The light is equiped to run on 2 D-cell batteries and has 9 major parts with additional O-rings, and retaining clips as per figure 1 and described below. The major external parts are the end cap, barrel, head, lens, and face cap. The major internal parts of the flashlight are the battery spring, switch assembly, lamp, and reflector. The purpose of this document is to aid in creating a flashlight to exacting specifications as determined by the product board. The design has been tested to comply with all safety regulations of the United States and Internation Treaties.
Assembly of the following parts are held to the strictest standards according to national guidelines for consumer safety.
Tail Cap: The tail cap will be made of solid aluminum, lathed from a block of CU405 type aluminum. Knurl the edges to ensure proper grip, while keeping the bottom available for gloss paint or anodized aluminum finishing. The unfinished end of the tail cap (end toward the rest of the flashlight in Figure 1) will have a 1/4' flange with a 1/5 exterior thread, enabling it to screw into the barrel.
Battery Spring: The battery spring is made of steel wire to specifications described by the Major Engineering Standards Corporation and within safety standards set by the Occupational Safety and Health Administration (OSHA). The wire is to be 2 mm thick, formed in a cone shape with now fewer than 10 windings. The height of the spring will be 1 1/2" with a wound diameter of
1-7/16".
Switch-Assembly: No manufacturing of the switch assembly is required. This part has been subcontracted out to our specifications and is currently in stock in the warehouse.
Barrel: The barrel is the cylindrical metal or plastic tube that houses the batteries. Each barrel is 1 9/16" in diameter as per Figure 1 specifications in the lower right hand corner of the figure. Both ends of the barrel will have a 1/5 thread to accept the tail cap at one end and the head at the other. The head end must have 1 1/2 inches of exterior threading to allow for focusing. The tail cap end must have 1/4" of interior threading to accept the tail cap.
Lamp: No manufacturing of flashlight lamps is needed due to subcontracting for this particular part. The current lamps are rated at 11000 candle power using 2 D-cell batteries. Ensure you notify Quality Control if lamps fail to meet this specification.
Head: The head of the flashlight is cylinder shaped and will be tapered at the edge adjacent to the barrel. Ensure the circumference in a 1" wide path is knurled into the head in a "X" pattern. Manufacture the bottom edge of the head in a 2" diameter with a 1/5 thread, to accept the top of the barrel.
Reflector: The reflector is a cone shaped plastic polymer, which sits inside the head of the flashlight, and has a small hole in its center for the lamp to protrude through. The reflector sits neatly within the head of the flashlight. The purpose of the reflector is to funnel light from the lamp through the lens and out onto the subject. The inside of the cone will have a shiny chrome look to it to project and focus light emitting from the lamp.
Lens: The lens is a round, 1/16" thick, round film of plastic designed to focus light and protect the reflector, lamp, and other interior parts of the flashlight.
Face Cap: The face cap is on the top most end of the flashlight and holds the lens in place. Manufacture the face plate with a 2 inch diameter opening at the bottom with a 1/5 thread. It is also typically made of the same material as the other external parts of the flashlight, and may have knurling on its edges
The main exterior parts to include the end cap, barrel, head, and face cap will all be manufactured frm CU405 aluminum. The finishing of all exterior edges will be various colors of anodizing and/or gloss paint schemes to be determined after marketing tests are conducted. Leave all exterior surfaces polished aluminum until further notice.
During assembly of the flashlight ensure all parts according to the parts list are together. Just as in figure 1 start assembly from left to right. All rubber O-rings are included in a subcontract and will not have to be redesigned by this company.
The flashlight above is broken down into 9 major parts and 6 minor parts. After assembly the flashlight operates as follows. As the user depresses the button a ground is created between the switch assembly, the positive end of the batteries, and the lamp. This simultaneous action of battery, switch, and grounding causes the lamp to emit light through the reflector and out the lens.
Audience: Potential Customers
Our flashlights, able to stand up to the test of time and your hardest punishment come preassembled from the best parts possible. All exterior metal parts are constructed from C405 aluminum, the same type and strength used in airplane siding. All internal parts were gathered from around the country from the finest craftsmen. This simple to use 3 piece design was created to provide years of use.
- Key features of the 3 piece design are the solid cut end piece. Perfect for Emergency Services, Police, and Fire Department use. For the household user, the end cap comes in handy as a spare light bulb holder.
- The barrel is knurled to prevent slippage in wet environments or when a little more grip or leverage is needed.
- The adjustable head/lens holder comes fully adjustable to focus the beam into a fine beam or wide enough to serve as a portable room light.
- Simple one button operation
Additional Features:
- Long lasting halogen light bulbs
- Fully tested waterproof to 100 feet
- 5 colors
- Lowest cost per candle power1
- 5 light densities available for varied tasks
1 Independent testing done by Firebug Industries
Sources
MagLight Industries. http://63.95.44.10/product_anatomy.asp?psc=2DCELL&m=anatomy
I chose the styles of presentation above for each of the specific audiences based on the following:
Company Executives: In my opinion company executives who are the decision makers need enough easily understood words and great detail to determine if they want to manufacture a product. I went into detail of most parts, with exception to the minor parts. These parts although functional will not help the overall focus of the essay. They need to understand a bit more than the customer who received little technical information, but information that will help to sell the flashlight and convey quality craftsmanship.
Engineers received most/all important information to successfully build a flashlight. Their description was provided with little use of subjective words, but rather words that depicted exactness of size, shape, and color. Aesthetics should be unimportant to the engineer as their area of focus should be building and designing the flashlight.
Customers need different and less technical information than either business executives or engineers, so I focused their attention on what the flashlights were made of; their material and construction processes. A target of the last part was ease of use and simplicity in design. Few or no technical terms were used in the description for ease in understanding.
*Some names and processes were simplified or guessed at, to simply convey a point about the flashlight, and not to promote any specific product. No research was done for this project other than to edit the above photos.
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