Abstract:
A warning light system has one or more articulated arrays of light blocks. The arrays maybe packable and lockable for transporting. In a deployed state the arrays provide variable combinations of light signals that may alert and direct oncoming traffic. The arrays are mechanically and electrically connected to a control module which controls the light blocks to provide light signals. The arrays can be deployed in a hazardous or obstructed lane without entering an unobstructed traffic lane.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 60/251,531, filed Dec. 6, 2000, the contents of which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to a warning light system, and more particularly to a device and method using one or more deployable arrays of light blocks to alert oncoming motorists to a roadway hazard. 
     Disruptions to normal traffic patterns such as disabled vehicles, obstacles on the roadway, and roadway maintenance can present serious danger to motorists and emergency personnel. Vehicular accidents increase significantly when approaching motorists receive little or no notice of such disruptions. To address this problem, emergency response and maintenance personnel are frequently provided with devices such as flares, brightly colored cones or markers, and hand-held signaling devices. These devices, however, suffer from various deficiencies. Flares generally provide only a short duration of protection. Colored cones and markers provide limited visibility, and hand-held signaling devices require a dedicated person to operate them. Additionally, these devices do not provide direction to approaching motorists on how best to avoid the approaching hazard. Also, emergency and maintenance personnel are required to place themselves at a heightened risk in order to position such devices for appropriate traffic control. 
     Various devices have been developed to overcome one or more of the above-identified problems. U.S. Pat. No. 4,827,245 to Lipman discloses a portable warning light system having a plurality of light blocks, which can be flashed sequentially to provide directional information or flashed simultaneously. Lipman discloses an internal battery allowing the device to function for an extended period of time as compared to flares. The light blocks are deployed by pulling them, with spacers, from a housing, placing operators, such as emergency or maintenance personnel, at risk during deployment. 
     U.S. Pat. No. 5,905,441 to Klee et al. discloses a hand-held visual signaling device for traffic control. This device, however, requires a dedicated person to operate it and requires the operator of the device to be positioned in or near oncoming traffic. U.S. Pat. No. 6,134,819 to McClain et al., U.S. Pat. No. 5,831,522 to Weed et al., U.S. Pat. No. 5,785,410 to Branson, Sr., and U.S. Pat. No. 5,637,513 to Weed et al. are directed to various beacon or signaling devices for traffic control. These devices, however, do not provide directional information. These devices also cover a small span, reducing their effectiveness. Additionally, emergency and maintenance personnel are required to place themselves at risk to deploy these devices. 
     A need exists for a warning light system that covers an extended span and provides directional information (sequential flashing) for maximum effectiveness and can be safely deployed by emergency and maintenance personnel. 
     SUMMARY OF THE INVENTION 
     The present invention provides a warning light system with one or more articulated arrays of light blocks. The arrays are packable and lockable for transporting. In a deployed state the arrays provide variable combinations of light signals to alert and direct oncoming traffic. The arrays are mechanically and electrically connected to each other and a control module through a hinge assembly. The control module provides electrical power and control signals to the light blocks causing the light blocks to generate light signals. In one embodiment of the present invention, the warning light system comprises two arrays separately deployable from the control module, and deployable in opposite directions. 
     An individual can deploy the arrays in a hazardous or obstructed traffic lane without entering or coming immediately proximate an adjacent unobstructed traffic lane. In one embodiment of the present invention, the first light block in each array is connected to the control module by a hinge assembly incorporating a torsion spring. A locking mechanism locks the first light block against the control module. Additional light blocks are connected to a preceding light block with a similar hinge assembly and locking mechanism holding each of the subsequent light blocks against the preceding light block. The light blocks are electrically connected to the control module by wiring. Wiring routing between light blocks may comprise electrical connectors, wires passing through a wiring channel formed in the hinge assemblies, or a hinge assembly comprising a plurality of electrically isolated hinges comprising a conductive material to which wires are connected. When the first locking mechanism is released, the first light block rotates into a line perpendicular to the control module. The subsequent light blocks, which are still locked to their respective preceding light blocks by locking mechanisms, rotate with the first light block. As each light block rotates into its deployed position a locking mechanism, locking the next light block is released, and the next light block then rotates into its deployed position. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     These and other features, aspects, and advantages of the present invention will become more fully apparent from the following description, appended claims, and accompanying drawings in which: 
     FIG. 1 shows a warning light system in a deployed state according to one embodiment of the present invention; 
     FIG. 2 shows the warning light system of FIG. 1 with one array deployed; 
     FIG. 3 shows a light block from the warning light system of FIG. 1; 
     FIG. 4 shows a warning light system with one array deployed according to one embodiment of the present invention; 
     FIGS. 5A through 5E show a deployment sequence for the warning light system of FIG. 4; and 
     FIG. 6 shows a hinge structure for the warning light system of FIG. 4 with a through-the-hinge electrical wiring channel according to one embodiment of the present invention; 
     FIG. 7 shows a sectional view of the hinge structure of FIG. 6 taken generally along axis  7 — 7 ; 
     FIG. 8 shows a portion of a partially deployed array of the warning light system of FIG. 4; and 
     FIG. 9 shows a warning light system with two arrays of light blocks deployed. 
    
    
     DETAILED DESCRIPTION 
     The present invention provides a device and method providing a warning light system that may be portable for placement a desired distance prior to a traffic obstruction, or may be mounted on a vehicle. The warning light system configured to deploy one or more arrays of light blocks for providing traffic control signals. The present invention reduces traffic-related risks to individuals, such as emergency and maintenance personnel, deploying the device. An individual carrying the warning light system of the present invention is visible to oncoming traffic, and an individual can deploy the warning light system of present invention across a hazardous or obstructed traffic lane without entering or coming immediately proximate an adjacent unobstructed traffic lane. While the following exemplary embodiments are described with two deployable arrays, it should be understood that embodiments incorporating a single deployable array and more than two deployable arrays have been contemplated and are within the scope of the present invention. 
     Referring to FIG. 1, a warning light system is provided comprising a control module  100 . The control module comprises an internal power supply, such as a battery (not shown) and control circuitry (not shown) providing intermittent power to each of a plurality of light blocks  110 A- 110 H, causing the light blocks to generate a warning light signal. The control module  100  may further comprise a connector and circuitry for charging the battery. Alternatively, the control module may comprise a connector adapted to draw power from an external power supply, such as a vehicle&#39;s battery. Two independently deployable articulated arrays of light blocks  120 , 130  are connected to the control module  100 . Each light array  120 , 130  (shown in a deployed state in FIG. 1) comprises a plurality of light blocks  110 A- 110 H. Each light block comprises one or more electrically powered lights  111 , preferably comprising one or more light emitting diodes. Alternatively, other lights such as halogen or other lamps may be used. 
     When either or both of the arrays  120 , 130  are deployed, they can be controlled by the control module  100  to flash simultaneously or in a variety of sequential patterns. For example, the lights  111  can be flashed sequentially from left to right, from right to left, or from the control module outwardly along each array. In the preferred embodiment, the warning light system provides a flashing pattern that alternates between a successive plurality of bursts of rapid simultaneous flashes adapted to maximize awareness of the signal and convey to approaching motorists a need to reduce speed (e.g., three successive bursts of bursts of five brief rapid flashes of all light blocks simultaneously), and a successive plurality of sequential flashes, adapted to indicate a desired direction of traffic flow (e.g., three repetitions of sequential flashes of the light blocks from left to right, from right to left, or in pairs from the center outward). 
     The control module  100  may further comprise a support structure  102  configured to provide physical support to the light blocks  110  when they are in a packed state (i.e., not deployed). A handle  103  may be provided to facilitate carrying the warning light system. In one embodiment, the control module further comprises a light  111 . 
     In the warning light system shown in FIG. 1, the light blocks  110  and control module  100  are interconnected by a series of rotary hinges (not shown) that constrain the facing surfaces  199  of the light blocks to remain in essentially the same plane as the array deploys. Facing surfaces  199  are those surfaces that are closest to an adjacent light block when the array is packed. Each rotary hinge is, for example, fixedly connected to the control module or the center-most of two light blocks, and the outer-most light block is able to rotate about the rotary hinge. In the foregoing example, the arrays are deployed by sequentially rotating the light blocks from the control module outward about each interconnecting rotary hinge. 
     FIG. 2 shows the warning light system of FIG. 1 with one array  120  deployed, and the other array  130  packed. As shown in FIG. 2, the packed array  130  preferably rests on the support structure  102 . In one embodiment, the arrays can be locked with a locking mechanism (not shown), such as a retractable pin when in a packed state, then unlocked by withdrawing the pin with a release mechanism  104 . Supports  115  may be provided to maintain the deployed array at the height provided by the support structure  102 . 
     FIG. 3 shows an exemplary light block  110 . A light  111 , preferably comprising one or more light emitting diodes (LEDs), is mounted in one face of the light block  110  intended to be positioned in use facing oncoming traffic. As can be appreciated by those skilled in the art, lights  111  can be configured to provide light signals of various shapes and colors, and control circuitry in the control module can be used to flash lights  111  at various frequencies and for various durations. Lights  111  can be further configured to flash simultaneously or in various sequential or other orders with lights in other light blocks within a warning light system. 
     FIG. 3 shows rotary hinge  112 , about which a connected light block can be rotated to deploy an array of light blocks. Light blocks may include sequential release mechanisms (not shown) to allow the deployment to occur in a sequential manner, as may be desired to provide orderly deployment. Rotary hinge  112  is preferably hollow to provide a wiring channel for wiring between the control module and the light blocks. 
     As can be appreciated, the array illustrated in FIGS. 1-3 has particular light blocks ( 110 B,  110 D,  110 E,  110 G) that have one edge facing up when packed and a different edge facing up when deployed. These light blocks may be provided with a first instruction label  119  facing up when deployed, that provides instructions for packing the array. A second instruction label (not shown) positioned to face up when the array is packed may be provided with instructions for deploying the array. Therefore, an individual operating the warning light assembly would only see the instructions appropriate for the present state of the warning light system. 
     FIG. 4 shows another warning light system according to one embodiment of the present invention. A control module  200  is provided which comprises a power source (not shown), such as a battery, and a control circuitry (not shown) to control lights to provide various light signals including various simultaneous and sequential flashing patterns. The control module  200  may further comprise a connector and circuitry for charging the battery. Alternatively, the control module  200  may comprise a connector adapted to draw power from an external power supply, such as a vehicle&#39;s battery. Two arrays  220 , 230  of light blocks  210 A- 210 H are operably connected to the control module  200 . Array  220  is shown in a deployed state, extending from the control module  200 . Array  230 , which would deploy from the control module in the opposite direction from array  220 , is shown in a packed state (i.e., not deployed). 
     The light blocks  210 A- 210 H are connected to each other and to the control module  200  by hinges  212  comprising coaxial hollow portions or barrels (not shown). Light blocks  210  may be locked together by locking pins (not shown). The warning light system illustrated in FIG. 4 with two arrays that deploy from the control module in opposing directions increases stability of the system because each array extends a shorter distance than a system with only one array. Also, the warning light system illustrated in FIG. 4 requires fewer wires passing through any one light block than would be required in a single array of the same length (assuming one control wire per light block and a common wire) and shorter wires overall due to the shorter length of each of the arrays. 
     Referring to FIGS. 5A through 5E the arrays  220 , 230  can deploy sequentially, as shown. In FIG. 5A, the light blocks are locked together. In array  220  light block  210 H is locked to light block  210 G, light block  210 G is locked to light block  210 F, light block  210 F is locked to light block  210 E, and light block  210 E is locked to the control module  200 . In the first step of deployment, light block  210 E is unlocked from the control module  200  and pivots about a hinge  212  about ninety degrees counterclockwise (viewed from above) as shown in FIG.  5 B. As shown, the other light blocks  210 F,  210 G,  210 H remain locked and pivot with light block  210 E. As light block  210 E pivots into place, a locking mechanism (not shown) is released, unlocking light block  210 F from light block  210 E. Unlocked light block  210 F then pivots about one hundred eighty degrees clockwise (viewed from above) such that light blocks  210 E and  210 F extend essentially in a straight line which is perpendicular to control module  200 , as shown in FIG.  5 C. Light blocks  210 G and  210 H pivot with light block  210 F as shown in FIG.  5 C. As light block  210 F pivots into place, a locking mechanism (not shown) is released, unlocking light block  210 G from light block  210 F. Unlocked light block  210 G then pivots about one hundred eighty degrees counterclockwise (viewed from above) such that light blocks  210 E,  210 F, and  210 G extend essentially in a straight line which is perpendicular to control module  200 , as shown in FIG.  5 D. As light block  210 G pivots into place, a locking mechanism (not shown) is released, unlocking light block  210 H from light block  210 G. Unlocked light block  210 H then pivots about one hundred eighty degrees clockwise (viewed from above) such that light blocks  210 E,  210 F,  210 G, and  210 H extend essentially in a straight line which is perpendicular to control module  200 , as shown in FIG.  5 E. As shown in FIGS. 5A through 5E, array  230  deploys in the opposite direction that array  220  deploys and is essentially a mirror image of array  220  during each step of deployment. 
     FIG. 6 shows a side view of a hinge  212  separated and illustrated without hinge pins for clarity. Hinge  212  comprises a first section  213  attached, for example to light block  210 F and a second section  214  attached, for example to light block  210 G. First section  213  and second section  214  each comprise a plurality of intermittent cylinders (i.e., barrels)  215 . When hinge  212  is assembled for use, the cylinders  215  of the first section  213  and the second section  214  all have a common axis such that they form a continuous opening and one or more hinge pins (not shown) are driven into the opening allowing the hinged joint to rotate about the pin. Deploying force can be provided, for example, by springs, such as torsional springs (not shown). The springs can be positioned on the hinge pins (not shown) providing torque in the direction of deployment for each particular hinge to provide the power for deployment. 
     In one embodiment, illustrated in FIG. 6, the hinge pins (not shown) do not extend to the center-most portion of the center-most cylinders  215 A,  215 B. An opening extends from center-most cylinder  215 A to light block  210 G, and another opening extends from center-most cylinder  215 B to light block  210 F forming a wire channel comprising communicating portions of the openings in center-most cylinders  215 A and  215 B and the openings extending into the attached light blocks  210 F and  210 G. Wires connecting the control module ( 200  in FIG. 4) to the lights  211  pass through the wire channels, experiencing twisting of up to about one hundred eighty degrees which provides less stress than acute bending of the wires. The wire channel reduces the risk of wires being frayed, nicked, or cut by external objects. The wire channel also provides some measure of protection from the external environment as hinge pins substantially block the outer opening of the center-most cylinders  215 A and  215 B. 
     FIG. 7 shows a sectional view of the hinge in FIG. 6 taken along line  7 - 7 ′ in FIG.  6 . First section  213  and second section  214  of hinge  212  are attached to light block  210 F and light block  210 G respectively for the hinge illustrated. First section and second section may be attached by any of a variety of techniques, which would be apparent to those skilled in the art. For example, hinge screws  216  can pass through first and second sections  213  and  214  and through-holes in light blocks  210 F and  210 G and be fastened to hinge plates  217 . 
     FIG. 7 also illustrates a locking mechanism, comprising a pivoting locking pin  271 , and release mechanism, comprising a release knob  272 , that may be used to provide a sequential deployment of the light blocks  210 . In the exemplary embodiment, locking pin  271  is pivotally attached to light block  210 G at a pivot point  273 . The locking pin includes a catch  275  extending beyond light block  210 G and configured to catch on a lip (not shown) in the subsequent light block (not shown). Locking pin  271  can be held in a locked position (i.e., with catch  275  restraining the lip of the subsequent light block) by a spring  274 . Locking pin  271  further includes a tail  276  on the opposite end of pivot point  273  from the catch  275 . It should be understood that alternative locking mechanisms and release mechanisms, which would be apparent to one of skill in the art, may be substituted respectively for the locking pin and release knob illustrated and described within the scope of the present invention. 
     As light block  210 G pivots into line with light block  210 F, a release knob  272  disposed on the edge of light block  210 F nearest light block  210 G in a deployed state, contacts tail  276  of locking pin  271  through an opening in second section  214  and the end of light block  210 G. Release knob  272  exerts force on tail  276  pivoting locking pin  271 . As locking pin  271  pivots about pivot point  273  catch  275  disengages the lip of the subsequent light block, unlocking it and allowing it to pivot into line with light sections  210 F and  210 G. By providing a release knob  272  and a locking pin  271  at each hinge  212  in both arrays of a warning light system, the arrays will deploy sequentially. Each light block will be unlocked, allowing it to rotate into a line perpendicular to the control module as the previous light block finishes rotating into the line perpendicular to the control module. 
     FIG. 8 shows three light blocks  210 F,  210 G, and  210 H of a partially deployed array. Light block  210 F has already pivoted into a line perpendicular to the control module (not shown). Light block  210 G is in the process of pivoting about hinge pin  212 A into a linear alignment with light block  210 F. Locking pin  271  locks light block  210 H to light block  210 G. Catch  275  of locking pin  271  restrains lip  282  in light block  210 H, preventing light block  210 H from pivoting about hinge pin  212 B. 
     The pivoting force in the exemplary embodiment is provided by a spring mechanism  281 , such as a torsion spring. As light block  210 G pivots, release knob  272  on light block  210 F contacts locking pin  271  causing it to pivot. As locking pin  271  pivots, catch  275  releases lip  282  and light block  210 H is able to pivot about hinge pin  212 B. In one embodiment of the present invention, release knobs  272  may comprise an elastomeric material which provides damping of the torsion of deployment as each light block pivots into its deployed position. Damping may alternatively be provided using a viscous fluid or other means as would be known to those skilled in the art. 
     FIG. 9 shows a deployed warning light system, as it would appear to oncoming traffic according to one embodiment of the present invention. Two arrays  220 , 230  of light blocks extend in opposite directions from a control module  200 . Each light block  210 A- 210 H comprises a light  211 . Lights  211  preferably comprise at least one light emitting diode (LED) which are set to flash simultaneously to attract the attention of oncoming motorists or sequentially to provide directional information, such as to bear left, to oncoming motorists. In one embodiment, the lights alternate between simultaneous flashing and sequential flashing. Each light is wired to the control module  200 . In one embodiment the wires pass through a wire channel as described above and shown in FIG.  6 . Alternatively, a hinge joint  300  including a plurality of separate hinges comprising electrically conductive material can electrically connect the wiring between the light blocks and the control module. Because the control module is in the center of the light blocks, fewer wires are used in each direction than would be required in a single array having the same number of lights. Therefore, fewer electrically isolated hinges (i.e., one for each wire) can provide the necessary electrical connections between adjacent light blocks. Each of the wires from the control module  200  is connected by a mechanical or soldered connection or both to a separate one of the hinges in hinge joint  300 . Each hinge is also connected to a wire in the first light block  210 D or  210 E. Likewise, the subsequent hinge joints are each wired to the adjacent light blocks. 
     To provide visibility of operators, such as emergency or maintenance personnel, while positioning the warning light system of the present invention, a safety light  301  can be provided on the control module. The safety light  301  is preferably disposed on the end of the control module  200  such that it is visible to oncoming traffic while the warning light system is being carried. In one embodiment, the safety light  301  is connected to a switch that is activated through the a carrying handle  302 , such that the safety light either turns on or begins to flash when the warning light system is lifted by the handle  302 . The safety light may include a non-flashing light and lens such that it is usable as a flashlight. The safety light may alternately or additionally include a non-flashing light capable of illuminating a work area. 
     In one embodiment, the warning light system of the present invention may further comprise one or more function indicator lights disposed on the warning light system such that it is visible in a direction opposite oncoming traffic when the warning light system is in a deployed state. 
     The present invention provides several advantages over current warning light systems. The control module with arrays deployable in opposite direction allows the control module to be located away from channeled traffic. Even if an end light block (e.g., the light block closest to traffic) were to be damaged by traffic, the electronics located in the control module and the remaining light blocks could continue to function. Furthermore, a light block can be repaired or replaced more readily and at a lower cost than the control module. Also, the central control module requires fewer and shorter wires in each array. Additionally, an operator can deploy either or both arrays more safely, because the operator is not required to enter or be immediately proximate an unobstructed traffic lane. Operator safety is further enhanced by deployment of the arrays, whereby the arrays can be rapidly deployed under their own power from the control module. 
     It will be understood that various changes in the details, materials, and arrangements of the parts which have been described and illustrated above in order to explain the nature of this invention may be made by those skilled in the art without departing from the principle and scope of the invention as recited in the following claims.