Warning light assembly

• US 8,939,626 B2
• Filed: 09/14/2012
• Issued: 01/27/2015
• Est. Priority Date: 09/14/2012
• Status: Active Grant

• Current Assignee: Whelen Engineering Company Incorporated
• Original Assignee: Whelen Engineering Company Incorporated
• Inventors: Grote, William F. Jr., Lyons, Jon H.
• Primary Examiner(s): HAN, JASON
• Application Number:
  US13/617,633
• Publication Number:
  US 20140078770A1
• Time in Patent Office: 865 Days
• Field of Search: 362/493, 362/111, 362/294, 362/373, 362540-549, 362/499, 362/249.01, 362/249.02, 362/473, 362/249.11
• US Class Current: 362/540
• CPC Class Codes: B60Q 1/00 Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor for lighting vehicle interior B60Q3/00
• CPC Class Codes: B60Q 1/2611 Indicating devices mounted on the roof of the vehicle
• CPC Class Codes: B60Q 1/2696 Mounting of devices using LEDs

Abstract

A warning light for attachment to a vehicle comprising a thermally conductive longitudinally extending base, a plurality of light head mount assemblies, a plurality of LED warning light assemblies, and a plurality of electronic control circuits. Said base has a pair of generally parallel longitudinal edges and a pair of ribs projecting perpendicularly from said base. Said light head mount assemblies comprise a bracket and a light head retention shoe. Said bracket has a generally planar bracket first portion and a generally planar bracket second portion oriented perpendicular to said first portion. Said light head shoe has a sole configured to engage said bracket first portion, a rib engaging portion, and a brace extending angularly therebetween. Said LED assemblies are mounted on said bracket second portion. Said dome has a main body portion, sidewalls configured to engage said edges, and end walls.

Claims

1. A warning light for attachment to a vehicle comprising:

a thermally conductive longitudinally extending base having a pair of generally parallel longitudinal edges, a pair of longitudinally extending ribs spaced laterally inwardly of said longitudinal edges and projecting generally perpendicularly from said base terminating in a distal ridge; and

wherein said pair of ribs define a center channel sized to receive at least one PC board and a plurality of arch-shaped bridges, each of said bridges having laterally opposed pairs of feet, a snap fit connector extending away from said bridge and configured to reversibly mate with a longitudinal fixation notch defined on at least one of said ribs, said laterally opposed pairs of feet each having laterally extending base engagement tabs and said base defines opposed tracks configured to receive said engagement tabs, said bridge having a PC board retention member comprising a snap working cooperatively with a nub configured to engage one of a plurality of locator holes defined on longitudinally opposed ends of said control PC board to secure said control PC board within said center channel intermediate said bridges.

2. The warning light of claim 1 further comprising;

at least one light transmissive dome secured to said longitudinal edges, wherein said bridges define a plurality of fastener receptacles and said dome defines a plurality of fastener holes, said fastener receptacles and said fastener holes configured to cooperatively engage a fastener, and wherein each of said bridges and said dome are sized such that affixing said fasteners to said fastener receptacles secures said dome to said base intermediate said longitudinal edges.

3. The warning light of claim 1, comprising;

a plurality of brackets constructed of thermally conductive material having a generally planar bracket first portion and a generally planar bracket second portion oriented generally perpendicular to said bracket first portion;

a plurality of light head retention shoes corresponding in number with said brackets, each light head shoe having a sole configured to maintain said bracket first portion in thermally conductive contact with said base, and a brace having a web and opposed sidewalls projecting generally perpendicularly from said main body, wherein said shoes are operatively retained intermediate one of said ribs and one of said longitudinal edges;

wherein said base defines a pair of longitudinally extending light head retention pockets adjacent to and oriented laterally away from said longitudinal edges and each of said ribs has a retention lip projecting laterally toward said retention pocket at a point intermediate said base and said distal ridge and defining a retention channel oriented toward said base; and

each of said shoes has a rib engaging portion laterally opposite said sole having a plurality of fingers configured to engage said distal ridge and a flexible retention member configured to reversibly engage said retention channel, said sole of each shoe configured to engage said retention pocket of said base, and said brace sidewalls extend angularly between said rib engaging portion and said sole, thereby forming a rigid structure.

4. The warning light of claim 3, wherein said sole is generally planar and oriented generally parallel to said base and has a leading edge and a plurality of toes projecting from said sole along said leading edge, said bracket first portion has a stepped configuration such that a ledge extends generally perpendicular between first and second generally planar steps, said ledge and first and second steps defining a plurality of engagement slots configured to receive said toes, and wherein said sole maintains said first step in generally flat thermally conductive contact against said base said leading edge abuts said bracket ledge providing a retentive force on said bracket first portion in a direction laterally toward said longitudinal edge of said base and said toes extend through said slots and engage said retention pocket.

5. The warning light of claim 4, wherein said first step has a plurality of laterally projecting retention pocket engaging extensions configured adjacent said engagement slots, and wherein said leading edge maintains said engaging extensions in said retention pocket.

6. The warning light of claim 3, wherein said plurality of brackets and light head retention shoes are juxtaposed along an entire length of each longitudinal edge such that said plurality of LEDs provide an unbroken pattern of light along said entire length.

7. The warning light of claim 6, wherein light heads configured at longitudinal ends of said base have a bracket third portion adjacent to and extending angularly away from said bracket second portion and oriented generally transverse to said bracket first portion.

8. A warning light for attachment to a vehicle comprising:

a generally planar thermally conductive longitudinally extending base having a pair of generally parallel longitudinal edges and a pair of longitudinally opposed ends;

at least one light transmissive dome having a generally planar main body portion oriented generally parallel to said base, longitudinally opposed inner and outer ends, and sidewalls contiguous with and extending generally perpendicularly from said generally planar main body portion terminating in a bottom edge, said main body portion defining a shallow longitudinally extending dome channel, wherein said outer terminal end has an end wall contiguous with and extending generally perpendicularly from said main body portion and terminating in a bottom edge, said end wall oriented contiguous with and generally transverse to said sidewalls;

a longitudinally extending panel sized to be received in said dome channel;

wherein said longitudinal edges define a longitudinally extending dome-securing channel configured to receive said bottom edge of said sidewalls such that said light transmissive dome is longitudinally slideable along said base between said inner and outer ends, and wherein longitudinally sliding said dome along said base until said bottom edge of said end wall is configured adjacent one of said longitudinally opposed ends of said base defines an interior cavity;

a plurality of LED warning light assemblies installed in said interior cavity of the warning light;

a plurality of mounting assemblies for fixing said LED warning light assemblies in the interior cavity of the warning light; and

a plurality of control circuits for selectively energizing the LED warning light assemblies.

9. The warning light of claim 8, wherein a bottom wall projects laterally inwardly from and generally perpendicular to said sidewalls at an end opposite said dome main body portion, said sidewall bottom edge is disposed on said bottom wall at an end laterally opposite said sidewall, wherein said dome-securing channel is configured to receive said sidewall bottom edges.

10. The warning light of claim 9, wherein said sidewall bottom edges have an interrupted rail projecting away from said bottom wall and a longitudinally extending lip configured adjacent said interrupted rail projects away from said bottom wall.

11. The warning light of claim 8, wherein at least two light transmissive domes are slideable along said base, said inner ends are oriented towards one another, and wherein said inner ends are received in a dome coupler attached to said longitudinal base edges said dome coupler having an I-beam configuration when viewed in longitudinal section and having a configuration substantially identical to said inner ends of said domes, and wherein said base, domes, and bridge seal define said interior cavity.

12. The warning light of claim 11, wherein each side of said I-beam of said dome coupler includes a wipe seal having a configuration substantially identical to said dome coupler for providing a weather-resistant connection to said inner ends of said dome, and said end wall bottom edge defines a plurality of holes configured to cooperate with fasteners to longitudinally secure said domes to a plurality of fastener receptacles defined on said base.

13. The warning light of claim 12, wherein said feet each have laterally extending base engagement tabs and said base defines laterally opposed tracks configured to receive said engagement tabs.

14. The warning light of claim 8, wherein said base has a pair of longitudinally extending ribs spaced laterally inwardly of said longitudinal edges and projecting generally perpendicularly from said base defining a center channel sized to receive at least one control PC board and a plurality of arch-shaped bridges, each of said bridges having laterally opposed pairs of feet, a snap fit connector extending away from said bridges configured to reversibly mate with a longitudinal fixation notch defined on at least one of said ribs, a PC board retention member disposed on said bridges comprising a snap working cooperatively with a nub configured to engage one of a plurality of locator holes defined on longitudinally opposed ends of said control PC board to secure said control PC board within said center channel intermediate said bridges.

15. The warning light of claim 14, wherein said dome and said panel define a plurality of through holes sized to receive a plurality of fasteners, said through holes and fasteners sized to cooperate with a plurality of dome fastener receptacles which project generally perpendicularly from said bridges to secure said dome and said insert to said base intermediate said edges.

16. The warning light of claim 8, wherein said plurality of light head mounting assemblies each comprises a bracket constructed of thermally conductive material having a generally planar bracket first portion and a generally planar bracket second portion oriented generally perpendicular to said bracket first portion, and a light head retention shoe having a sole configured to maintain said bracket first portion in thermally conductive contact with said base, and a brace having a web and opposed sidewalls projecting generally perpendicularly from said main body, wherein said shoes are operatively retained intermediate one of said ribs and one of said longitudinal edges, and wherein said LED warning light assemblies are mounted to said bracket first portion.

17. The warning light of claim 16, wherein said base defines a pair of longitudinally extending light head retention pockets adjacent to and oriented laterally away from said longitudinal edges and each of said ribs terminates in a distal ridge, said ribs have a retention lip projecting laterally toward said retention pocket at a point intermediate said base and said distal ridge and defining a retention channel oriented toward said base;

and

each of said shoes has a rib engaging portion laterally opposite said sole having a plurality of fingers configured to engage said distal ridge and a flexible retention member configured to reversibly engage said retention channel, said sole of each shoe configured to engage said retention pocket of said base, and said brace sidewalls extend angularly between said rib engaging portion and said sole, thereby forming a rigid structure.

18. The warning light of claim 17, wherein said sole is planar and oriented generally parallel to said base and has a leading edge and a plurality of toes projecting laterally from said sole along said leading edge, said bracket first portion has a stepped configuration such that a ledge extends generally perpendicular between first and second generally planar steps, said ledge and first and second steps defining a plurality of engagement slots configured to receive said toes, and wherein said sole maintains said first step in generally flat thermally conductive contact against said base said leading edge abuts said bracket ledge providing a retentive force on said bracket first portion in a direction laterally toward said longitudinal edge of said base and said toes extend through said slots and engage said retention pocket.

19. The warning light of claim 18, wherein said first step has a plurality of laterally projecting retention pocket engaging extensions configured adjacent said engagement slots, and wherein said leading edge maintains said engaging extensions in said retention pocket.

20. The warning light of claim 17, wherein said plurality of brackets and light head retention shoes are juxtaposed along an entire length of each longitudinal edge such that said plurality of LEDs provide an unbroken pattern of light along said entire length.

21. The warning light of claim 20, wherein light heads configured at longitudinal ends of said base have a bracket third portion adjacent to and extending angularly away from said bracket second portion and oriented generally transverse to said bracket first portion.

22. The warning light of claim 17, wherein the flexible retention member is a cantilevered snap fit connector.

23. The warning light of claim 22, wherein the cantilevered snap fit connector is a u-shaped cantilevered snap fit connector.

24. A warning light assembly comprising:

a thermally conductive longitudinally extending base having a longitudinal edge defining a longitudinal channel having a slot-shaped opening facing away from said longitudinal edge, a floor between said slot-shaped opening and an upstanding rib spaced laterally inward from said longitudinal channel, a longitudinally extending retention pocket defined between said rib and longitudinal channel;

a bracket constructed of thermally conductive material, said bracket having a configuration complementary to said retention pocket and including a bracket upstanding portion, a bracket base portion configured to engage said floor in thermally conductive contact, and a bracket forward extension projecting into said slot-shaped opening, a bracket intermediate portion extending between said upstanding portion and said base portion defining at least one aperture aligned with said slot-shaped opening;

a plurality of light emitting diodes mounted to said bracket upstanding portion in thermally conductive relation thereto; and

a shoe having a sole configured to engage the base portion of said bracket, a toe arranged to extend through said aperture into said longitudinal channel, said shoe including a retainer laterally opposite said toe and positioned to engage said upstanding rib,

wherein said bracket is intermediate said shoe and said base, with the toe of said shoe extending through said aperture into said longitudinal channel and said retainer engaging said upstanding rib so that said shoe retains said bracket to said base in a fixed longitudinal position relative to said base and said sole exerts downward force on said bracket base portion to enhance thermal contact between said bracket base portion and said floor whereby heat generated by said plurality of light emitting diodes is transmitted to said base.

25. The warning light assembly of claim 24, wherein said base is constructed of metal and has a substantially constant cross section.

26. The warning light assembly of claim 24 further comprising;

at least one light-transmissive dome secured to said longitudinal edges, wherein said base is symmetrical and includes a pair of longitudinal edges defining a pair of longitudinal channels with inward facing slot-shaped openings and a pair of upstanding ribs, said pair of upstanding ribs defining a center channel along a longitudinal center line of said base.

27. The warning light assembly of claim 26, wherein said ribs define a center channel sized to receive at least one control PC board and a plurality of arch-shaped bridges, each of said bridges having laterally opposed pairs of feet, at least one snap fit connector extending away from said bridge and configured to reversibly mate with a longitudinal fixation notch defined on at least one of said ribs, each of said bridges having at least one PC board retention member comprising a snap working cooperatively with a nub configured to engage one of a plurality of locator holes defined on longitudinally opposed ends of said control PC board to secure said control PC board within said center channel intermediate said bridges.

28. The warning light assembly of claim 27, wherein said bridges define a plurality of fastener receptacles and said dome defines a plurality of fastener holes, said fastener receptacles and said fastener holes configured to cooperatively engage a fastener, and wherein each of said bridges and said dome are sized such that affixing said fasteners to said fastener receptacles secures said dome to said base intermediate the longitudinal edges.

30. The warning light assembly of claim 24, wherein said upstanding rib terminates at a distal ridge above said floor and includes a shoe engagement feature complementary to said retainer so that when said retainer is engaged with said shoe engagement feature, said shoe and bracket are retained in a substantially fixed longitudinal position relative to said base.

31. The warning light assembly of claim 30, wherein said shoe engagement feature comprises a retention lip projecting laterally toward said longitudinal edge and said retainer is configured to engage said lip.

32. The warning light assembly of claim 31, wherein said retainer is flexible and biased toward said upstanding ridge so that insertion of said toe through said aperture and pivoting of said shoe downwardly moves said retainer past said lip where it is engaged beneath said lip.

33. The warning light assembly of claim 32, wherein the retainer is a cantilevered snap fit connector.

34. The warning light assembly of claim 33, wherein the cantilevered snap fit connector is a u-shaped cantilevered snap fit connector.

35. The warning light assembly of claim 24, wherein said plurality of brackets and shoes are juxtaposed along an entire length of the longitudinal edge such that said plurality of LEDs provide an unbroken pattern of light along said entire length.

29. The warning light of claim assembly 27, wherein said laterally opposed pairs of feet each have laterally extending base engagement tabs and said base defines opposed tracks configured to receive said engagement tabs.