Light bar and method for making

• US 20070242472A1
• Filed: 03/31/2006
• Published: 10/18/2007
• Est. Priority Date: 03/31/2006
• Status: Active Grant

• Current Assignee: Federal Signal Corporation
• Original Assignee: Federal Signal Corporation
• Inventors: Fleszewski, Vince, Gergets, Paul, Mostello, Allan
• Granted Patent: US 7,476,013 B2
• Time in Patent Office: Days
• US Class Current: 362/493
• CPC Class Codes: B60Q 1/2611 Indicating devices mounted on the roof of the vehicle
• CPC Class Codes: B60Q 1/52 for indicating emergencies
• CPC Class Codes: F21S 41/00 Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps reversing lights F21S43/00
• CPC Class Codes: F21S 41/148 the main emission direction of the LED being perpendicular to the optical axis
• CPC Class Codes: F21S 41/151 arranged in one or more lines
• CPC Class Codes: F21S 41/285 Refractors, transparent cover plates, light guides or filters not provided in groups F21S41/24-F21S41/28
• CPC Class Codes: F21S 41/321 the reflector being a surface of revolution or a planar surface, e.g. truncated
• CPC Class Codes: F21S 41/323 the reflector having two perpendicular cross sections having regular geometrical curves of a distinct nature
• CPC Class Codes: F21S 43/13 characterised by the type of light source
• CPC Class Codes: F21S 43/14 Light emitting diodes [LED]
• CPC Class Codes: F21S 43/15 Strips of light sources
• CPC Class Codes: F21S 43/195 Details of lamp holders, terminals or connectors
• CPC Class Codes: F21S 43/31 Optical layout thereof
• CPC Class Codes: F21S 43/37 Attachment thereof
• CPC Class Codes: F21S 45/10 Protection of lighting devices cooling of lighting devices F21S45/40; waterproofing of lighting devices F21S45/50
• CPC Class Codes: F21S 45/47 Passive cooling, e.g. using fins, thermal conductive elements or openings
• CPC Class Codes: F21V 23/04 the elements being switches safety devices F21V25/00
• CPC Class Codes: Y10T 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A light bar is described that is of a modular construction based on one or more large circuit boards that are populated with light beam assemblies and then fastened to an interior space of the light bar housing. Keys that automatically align the light beam assemblies on each of the boards precisely control placement of the assemblies on the board. In turn, each of the boards is keyed to the interior of the light bar housing so that when the board is fastened to the housing the light beam assemblies are automatically registered into alignment with the lenses in the housing so that the beams from the assemblies are properly oriented. The light bar is inexpensive to fabricate and can be assembled quickly and reliably, yet it provides for a high degree of customization, which is a requirement in the emergency vehicle lighting industry.

Claims

1. A light bar comprising:

at least one circuit board with keys in its surface that assist attaching the circuit board to two or more light beam assemblies such that the keys pilot the attachment of the one or more light beam assemblies to the circuit board to register each of the one or more assemblies on the circuit board at a predetermined position;

each of the one or more light beam assemblies including keys complementing at least some of the keys in the at least one circuit board such that engagement of the complementing keys registers the assembly at the predetermined position on the board; and

a housing including keys complementing at least some of the keys in the circuit board such that engagement of the complementing keys registers the circuit board to the housing so that each of the one or more light beam assemblies attached to the circuit board is automatically aligned with lens in the housing.

2. The light bar of claim 1 where the complementing keys include one or more pairs of mating holes and posts.

3. The light bar of claim 1 wherein the complementing keys including one or more pairs of holes in the at least one circuit board and the one or more light beam assemblies, where each pair align to receive a fastener attaching a light beam assembly to the at least one circuit board.

4. The light bar of claim 1 wherein the keys on the at least one circuit board are for two or more light beam assemblies.

5. The light bar of claim 1 wherein the keys for each location on the at least one circuit board is for alternative types of the one or more light beam assemblies such that the keys at each location pilot and register a selected one of the alternative types of assemblies to the predetermined position on the circuit board associated with the selected type.

6. The light bar of claim 5 wherein the keys for each location pilot and register either a light beam assembly for a solid state light source or for a gas-filled tube light source.

7. The light bar of claim 1 wherein the at least one circuit board is an thermally conductive circuit board that both communicates control signals to the one or more light beam assemblies and sinks heat generated by the assemblies.

8. The light bar of claim 1 wherein the at least one circuit board is two or more circuit boards each connected to another by a wiring harness.

9. The light bar of claim 1 wherein LEDs in the one or more light beam assemblies provide light sources for the assemblies and the LEDs are mounted directed to the at least one circuit board.

10. The light bar of claim 1 including a controller for the one or more light beam assemblies comprising solid state components mounted directly to circuit board.

11. The light bar of claim 1 wherein all of the one or more light beam assemblies are mounted to the at least one circuit board and each of the one or more circuit boards is positioned in the housing such that its planar surface is oriented substantially horizontally when the light bar is mounted in an operational position.

12. The light bar of claim 1 wherein the one of more circuit boards includes an angled portion for either structural support or for properly orienting the one of the light beam assemblies to direct associated one or more light beams through lens in the housing.

13. The light bar of claim 1 wherein the at least one circuit board is at least two circuit boards mounted in the housing to be substantially side-by-side and co-planar.

14. The light bar of claim 9 wherein the controller includes a wireless connection to a source of commands remote from the light bar.

15. The light bar of claim 1 including a power source for the one or more light beam assemblies mounted within the housing such the assemblies operate without requiring power from a source external to the light bar.

16. The light bar of claim 1 wherein the at least one circuit board attaches to the housing so that the one or more light beam assemblies are oriented upside down such that, when viewed from above, a backplane of the at least one circuit board is visible and effectively shields an interior space of the housing with includes the one or more light beam assemblies.

17. A light bar made by the process of

(a) populating a circuit board with two or more light sources by registering each of the light sources to a predetermined location on the circuit board and then fastening the light source to the circuit board at the predetermined location;

(b) placing the circuit board in a housing of the light bar; and

(c) registering the circuit board to the housing with respect to one or more references, which align each of the light sources on the circuit board with a lens in the housing.

18. The process of claim 17 wherein populating the light sources includes selecting each light source from a group of different types of light sources.

19. The process of claim 17 wherein the group of different types of light sources includes two or more of the following types:

LEDs, halogen lamps, high intensity discharge (HID) lamps, lasers, strobe lamps, incandescent lamps and light engines.

20. The process of claim 17 including populating another circuit board with one or more light sources by registering each of the light sources to a predetermined location on the circuit board and then fastening the light source to the circuit board at the predetermined location;

placing said another circuit board in the housing; and

, connecting a wiring harness between the said another circuit board and the circuit board.

21. The process of claim 20 including placing the circuit board and the said another circuit board in the housing such that their planar surfaces substantially share a common horizontal plane.

22. The process of claim 17 wherein the circuit board is an aluminum circuit board.

23. The process of claim 17 wherein populating the circuit board with one or more light sources includes fastening LEDs to the circuit board in predetermined locations such that the board both provides power to the LEDs and sinks heat generated by the LEDs.

24. The process of claim 23 including registering a reflector to a predetermined location on the circuit board and fastening the reflector to the circuit board at the predetermined location to cooperate with one or more of the LEDs so as to generate a light beam passing through a lens of the housing.

25. The process of claim 17 including populating the circuit board with the one or more light sources includes selecting light sources of different color.

26. The process of claim 25 wherein light sources of different color are commonly configured to each alternatively fit in one of the predetermined locations.

27. The process of claim 17 including adding a wireless receiver within the housing for receiving remotely generated commands controlling the two or more light sources.

28. The process of claim 17 including physically attaching a power source to the light bar for providing power to the two or more light sources.

29. The process of claim 28 wherein the power source is a solar cell.

30. The process of claim 28 wherein the power source is a fuel cell.

31. The process of claim 28 wherein the power source includes an energy storage device.