Always ready, from the basement to the backyard

Technical Description Report

Date: June 3, 2011 To: H. Willison, CEO From: Jigar Mehta, Sr. Technical Head Subject: Technical Description of Rayovac Value Plus Flash Light I am Jigar Mehta, Sr., technical head of Rayovac, taking this opportunity to provide you with a detailed technical report about our upcoming product Rayovac Value Plus. Under your guidance and support, this report is prepared for the customer in a very customer friendly manner. This report focuses on three main parts: General Description, Parts Description and Rayovac flashlights Operating Description.

General Description
Definition: Rayovac Value Plus is a hand-held, lightweight, portable, easy to use flashlight. It
is basically a battery-operated device used for illumination.

Purpose: Need a light when the power goes out? Going camping? Or want to have some fun
with shadow puppets? From emergencies to family fun and from the basement to the backyard, Rayovac makes all-purpose flashlights you need for both indoor and outdoor use.

Overall description:
1) The flashlight is 8 inches long, with a diameter of two inches at the head of the flashlight, reducing to 1 inch in diameter at battery compartment. 2) The net weight of the flashlight is two pounds and the overall material used for outer casing is hard plastic for a secure handgrip. 3) The body of the flashlight is cylindrical in shape, matte black with orange edges, and powered by two 4.5volts D-sized batteries. The sketch of a flashlight is shown in Figure (i).

H.Willison, June 6, 2011, page 2

Figure (i)

Parts Description
The flashlight consists of two major parts:

1) Head section 2) Body section

The internal components of the Rayovac Flashlight are shown in Figure (ii)

Figure (ii)

H.Willison, June 6, 2011, page 3

1) Head section:
The head section consists of bulb assembly, reflector, lens, connector and bulb holder. When everything is assembled, the bulb assembly is 2 inches long and the rest of the section is 6 inches long. The bulb assembly completes the flashlight by screwing into the end. The parts of the head section are explained below:

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 bulb to stick out through. The material used is plastic polymer.

Bulb
The glass bulb is the light source for the flashlight and is fused onto a metal base with flanged base. The bulb is made of high-grade low cost halogen.

Connector
Connector is of black plastic and its end is connected with a gold strip.

Lens
Lens is a thin, clear plastic located in front of flashlight.

Definition

Material

It is made up of hard plastic to combine head and base section. The connector establishes the connection between the reflector and the bulb to the battery power source. It is used to allow joining with the bulb and reflector.

Purpose

The purpose of a reflector is to funnel light from the bulb through the lens and out onto the subject.

The purpose of a bulb is to act as a light source when flashlight is turned ON.

The lens is made with reflective ridges on the inner side to help focus the light. The main purpose is for the protection of bulb.

Uses

The reflector enhances the light produced by the battery-powered bulb.

To produce a visible light when needed.

A plastic lens is used so that the bulb is safe under minor accidents.

H.Willison, June 6, 2011, page 4

Diagram

2) Body section:
The body section consists of a switch, two D-size batteries, spring and copper strip. The parts of the body section is explained below:

Switch
Switch controls the ON/OFF transition of the flashlight and is designed to activate by placing thumb on it.

Batteries
Batteries are the power source for the flashlight. There are two D-size batteries incorporated in flashlight. The material used for Dsize batteries is carbonzinc.

Spring
Spring is a steel wire used to support the batteries from both ends.

Strip
A copper strip of metal that is located throughout the flashlight, make the electrical connection.

Definition

Material

The switch assembly is manufactured from a black plastic based material. Lights rely on ON/OFF switch to make connection between battery terminals and base of a bulb.

Battery spring is made of steel wire and is 2mm thick.

The material used is copper.

Purpose

The purpose of a battery is to provide a power for the bulb to glow.

The purpose of a thin spring is to make electrical connection between various parts.

When switch is ON/OFF, strip provides connection/ disconnection ; thus turning ON/OFF flashlight.

 By pushing switch upward, light turns ON and sliding it downward turns the light OFF. The D-size batteries used lasts for a longer duration.

H.Willison, June 6, 2011, page 5

Uses

Spring is used to keep tension against the batteries, switch and bulb to maintain contact with everyone.

Without the use of a copper strip; there would be no electricity generated inside the flashlight.

Operating Description
How all components work together?
When switch slides in forward direction, copper strip makes contact with battery and powers ON the flashlight. When activated, bulb glows by emitting light in a particular direction. Light reflects off of the reflector and directs the light rays creating a steady beam of light. When switch slides in downward direction, copper strip breaks contact with battery and powers OFF the flashlight. All of the above components must be placed in a correct order for proper function of the flashlight.

Maintenance
Rayovac Flashlight is the most affordable tool available in the market. The materials and components used to manufacture flashlights are economical. Hence, proper maintenance and care should be taken while operating. Here are a few tips for long-lasting flashlight: If you are not using flashlight for a long period, remove the batteries from the battery compartment. Keep the battery contacts clean and avoid contact with liquid. Replace your batteries every 6 months. Taking care of your flashlight really isnt a rocket science. The procedure will take less than 5-10minutes. Time well spent.

Limitations
Limited lifespan of a flashlight. Limited range and coverage of a flashlight. Bulb filaments can be broken due to high heat. Flashlight fades light without prior warning. Flashlight consumes more power and may cause batteries discharge quickly.

 Flashlights are not waterproof. Dropping from more than 5 feet, can damage the flashlight.

H.Willison, June 6, 2011, page 6

When fully assembled, the Rayovac Flashlight is a sturdy easily held portable tool providing light, sufficient for both indoor and outdoor purposes. As this report is written in a very userfriendly manner, I hope customers will find it useful in better understanding of a flashlight.