Abstract:
A light bar assembly having a face component which includes a light source and a mounting member. The light bar assembly can be affixed to the surface of a structure by the mounting member to selectively light at least a portion of the structure or surrounding area thereof.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority of co-pending U.S. Provisional Application No. 60/982,890, filed Oct. 26, 2007, entitled UNIVERSAL LIGHT BAR, which is incorporated by reference herein in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    Many homeowners have looked for ways to install lights on decks, railings, stairs, fences, and a wide variety of other areas which require lighting. In the past, such lights were difficult to install and expensive to operate. In addition, such lights failed to provide sufficient illumination to satisfy current safety guidelines. 
         [0003]    Although light-emitting diode (LED) lighting currently exists in the form of “rope lighting,” drawbacks of such rope lighting include, but are not limited to, difficulty of installation and inability to light specific areas. 
       SUMMARY OF THE INVENTION 
       [0004]    An embodiment of the invention described herein provides a light bar assembly that can be easily mounted on a variety of surfaces and is capable of directing light to particular areas. The light bar assembly includes a face bar extending in a longitudinal direction and having a pair of ends, as well as at least one opening for permitting light to pass through. A lighting system mounted within the face bar comprises a circuit board extending in the longitudinal direction and having two ends as well as wires capable of carrying electric current, and at least one light source electrically connected to the wires and to the circuit board. Finally, a mounting bar extends in the longitudinal direction and has two ends, with one part forming a connecting section, and where the mounting bar is capable of being mounted to a structure. The connecting section of the face bar and the connecting section of the mounting bar are capable of being removably interconnected to each other. 
         [0005]    Another embodiment provides a light bar system comprising one or more light bar assemblies connected in series. 
         [0006]    For a better understanding of the invention, together with other and further aspects thereof, reference is made to the accompanying drawings and detailed description, the scope of the invention being set forth in the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1A  is an exploded pictorial cross-sectional view of the light bar assembly of this invention with portions thereof shown in exaggerated fashion; 
           [0008]      FIG. 1B  is a cross-sectional view of the mounting bar shown in  FIG. 1A ; 
           [0009]      FIG. 1C  is a pictorial view of the circuit board; 
           [0010]      FIGS. 2A ,  2 B,  2 C, and  2 D are cross-sectional views of various embodiments of the light bar assembly where  2 D is shown in exploded fashion; 
           [0011]      FIG. 3A  is a pictorial view of the light bar assembly of this invention mounted under a railing and connected to a power converter; 
           [0012]      FIG. 3B  is a pictorial view of the power converter as shown in  FIG. 3A ; 
           [0013]      FIG. 4  is a pictorial view of the invention mounted under a railing and shown disconnected from a power converter in order to illustrate the light bar assembly in exploded fashion; 
           [0014]      FIG. 5  is a pictorial view of an example of four light bar assemblies joined by connector plugs where two of the light bar assemblies are shown in exploded fashion; 
           [0015]      FIG. 6  is an exploded pictorial view of a light bar assembly and a connector plug; and 
           [0016]      FIG. 7  is an exploded pictorial view of a supply plug and a light bar assembly. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    The light bar assembly of the present invention provides for simplified installation and use in a wide range of applications. Its compact and aesthetically-pleasing appearance blends into a structure without being too noticeable during the daylight hours. 
         [0018]    This invention addresses shortcomings of past systems and provides a unique design capable of new and different applications. The present invention provides a light bar assembly that is exceptionally easy to reproduce, easy to install, can be adapted to many different uses and materials. The light bar assembly also allows flexibility when a user requires light at irregular or regular intervals, is virtually maintenance free, and is able to be run at very low cost. The light bar assembly is made up of a minimum of replaceable components. 
         [0019]    These and other objectives are achieved by a plurality of light sources mounted directly onto a circuit board that carries an electrical wire at one or both of its ends. The mounted light sources and circuit board are preferably embedded in a compound resistant to water and damage before being placed inside the recess of the light bar assembly. The mounted light sources can be orientated to a desired direction, which preferably would be downward to illuminate a railing, stairs, or other mounting surface for better visibility. If desired, the circuit board can also accommodate a light sensor, a rectifier, or other desired electronic components, and will preferably be able to be powered from either end. 
         [0020]    The light bar assembly is made up of at least two sections that are preferably, but not limited to, extruded plastic for lower cost. The two sections can also be made by injection molding for additional features. One of the sections, called the “face bar”, is a part containing a suitable recess, whereas the other part, called the “mounting bar”, is preferably of a modified flat shape that allows it to be mounted on a surface. 
         [0021]    The face bar, being the recessed part of the lighting system, carries the light sources, the circuit board, and electrical wires which may be connected to one or both ends of the circuit board or boards. The longitudinal edges preferably have an attaching mechanism which allows the face bar to be mated with the mounting bar. 
         [0022]    The mounting bar is capable of being affixed to a surface by various means and has along its longitudinal edges a suitable mating mechanism adapted to accept the face bar. The mounting bar can optionally provide a suitable longitudinal recess in front or on its back that can carry and secure electrical wiring for connecting together a plurality of light bar assemblies. 
         [0023]    The light bar, assembled as described, can optionally be closed at both ends by a supply plug, a connector plug, or other suitable component that can also incorporate a method of attaching an adjoining light bar assembly. In one embodiment, one or both ends of the light bar assembly are hollow, thus providing a suitable space for at least one such suitable component, protected from view and the elements. 
         [0024]    The mounting bar can also be used as a stand-alone part to carry the electrical wire hidden and secured, or it can be used together with an empty face bar, without a light source and circuit board therein, to provide a uniform and matching bar assembly, one section of which would be lighted and the other section would be used to carry the electrical wire within its empty recess. In that embodiment, the empty bar can be used to hide all wiring and its ends can also be shaped into a chamfer or other shape that would allow a uniform bar to go around the perimeter of a structure, such as a hexagon, although it is not limited to this shape. 
         [0025]    Each time an additional light bar is used, a connection with an electrical wire is required. Provided for this purpose is a commercially existing connector that does not require wire ends to be stripped. 
         [0026]    In one embodiment, a supply plug may be used to connect a power converter to the first or last light bar. The supply plug is preferably molded to the end of an electrical wire that can then be cut at the power converter end and attached to the power converter by a pair of fasteners, preferably hidden, without the need for electrical connectors. 
         [0027]    The power supply of the power converter is preferably shaped in such a way, although not limited thereto, so as to fit under the cover of an outdoor electrical outlet. In that case, a light sensor controlling the entire installation could be provided on a separate tail of suitable length connected to the power converter, so that the light sensor could be placed away from the covered power supply. Alternatively, the supply plug could incorporate a light sensor. 
         [0028]    Many other combinations and shapes are possible, formed of either extruded plastic, injection molding, or otherwise shaped, and made up of one or several shapes, examples of which are illustrated in the drawings. There are also different methods for mounting the light bar, depending on the shapes chosen or the requirement of mounting to a horizontal or vertical surface. 
         [0029]    Reference is now made to the drawings provided herein, and initially to  FIGS. 1A and 1B  which illustrate light bar assembly  1  made up of a face bar or component  2  and a mounting bar or component  3 . The face bar  2  may be channel-shaped and may have at least one hole or opening  4  which is preferably shaped in such a way as to match the diameter of a light source  5 , which could be, but is not limited to, an LED, and may be chamfered  6  in such a way as to allow the light generated to freely radiate into the desired direction  7 . In addition, a transparent or colored cap may be provided to cover the opening and to color the light. A hollow area  8  generated by the shape of the face bar  2  is dimensioned to contain a circuit board  9  which may be in the form of a printed circuit board onto which at least one light source  5  is mounted by its contacts  10 . In the embodiment, the space  12  contained between the circuit board  9  and the lower surface  11  of the face bar may be filled with epoxy or any other commercially suitable filler material. This ensures that all electrical components and the circuit board  9  are protected against moisture or damage and also ensures that the face bar  2  is strengthened. 
         [0030]    A suitable attaching system such as a snapping mechanism is provided in the form of a longitudinal recess and upstanding element  13  on the face bar  2  that is joinable with another attaching system, such as, for example, a longitudinal recess  14  on the mounting bar  3 . By not filling the upper part of the face bar  2  with filler, it is ensured that the face bar  2  can deform sufficiently for the two parts of the longitudinal recesses  13  and  14  to engage and hold. 
         [0031]    If so desired, the mounting bar  3  can have an additional longitudinal recess  15  into which an electrical wiring  16  can be pressed and secured. A further groove  17  could optionally be provided to locate and secure mounting screws, nails or other fasteners  18 , and the shape of groove  17  can match the shape of a fastener head  19  for additional security. In another embodiment, the back of the mounting bar  3  can be coated with a double sided tape  20  or other adhesive to affix the mounting bar  3  to a desired surface with or without the use of additional fasteners. 
         [0032]    With reference to  FIG. 1C , at each end of the circuit board  9  is a pair of electrical wires  21  and a pair of electrical wires  22  which can be connected to the circuit board  9  to provide power to a light source  5 , and also provide an electrical connection to adjoining light assemblies  1  by means of a suitable commercially available snap connector  23  that preferably allows connection of wires without stripping their insulation. Although a single circuit board  9  is shown in  FIG. 1C , a series of circuit boards may be utilized with at least one light source connected thereto to form a series of “mini circuit boards” electrically connected together by the wires. Such “mini circuit boards” allow the face bar  2  and mounting bar  3  to take on various configurations. Any other suitable connector, such as co-axial connectors or standard connectors could also be used for this purpose. 
         [0033]    With reference to  FIGS. 2A-2D , wherein  FIG. 2D  is shown in exploded fashion, different shapes and combinations are given for the light bar assembly  1 . As shown in  FIG. 2A , an embodiment of the light bar assembly could be made up of two interlocking angled components  24 . 
         [0034]    In yet another embodiment, as shown in  FIG. 2B , a face bar  2  is rotated in such a way as to allow a mounting bar  3  to be mounted on the top, thus allowing the light bar assembly to be mounted in a vertical direction  28 . By employing a differently shaped face bar  2  and mounting bar  3 , a combination of horizontal or vertical mounting could be accomplished. 
         [0035]    In another embodiment, as shown in  FIG. 2C , a shaped component  25  can optionally incorporate a support  26  on which circuit board  9  rests. 
         [0036]    In addition to the at least one hole  4  for the light source  5 , the face bar  2  can also incorporate a horizontal through-hole  27  and/or a vertical through-hole on mounting bar  3  to accommodate selected fastener  18  for either horizontal or vertical mounting options. 
         [0037]    In yet another embodiment, as shown in  FIG. 2D , the face bar  2  has a different profile that allows a top snapping mechanism  29  to be engaged first before rotating  30  and pushing a lower snapping mechanism  31  into place. More specifically, the embodiment shown in  FIG. 2D  utilizes an upstanding element fitting within a recess as snapping mechanism  29  and a recess and upstanding element in conjunction with a recess as snapping mechanism  31 . The snapping mechanism on the face bar  2  and mounting bar  3  may be interchanged as well within the concept of attaching the upper snapping mechanism  29  in place with rotating the face bar  2  so as to engage snapping mechanism  31 . In addition, opening  4  may be located within either the bottom segment of face bar  2  or the side segment of face bar  2  to permit the light bar assembly to be mounted horizontally or vertically. The unused opening  4  would be closed if one light source is utilized. It may also be possible to use two perpendicularly disposed light sources (not shown), if desired. 
         [0038]    With reference to  FIG. 3A , a typical arrangement of light bar assemblies  1  is shown. A power converter  32  is shown with a rear view in  FIG. 3A  and a front view in  FIG. 3B  with an optionally incorporated optical sensor  33  and is capable of being plugged into a power supply or of being battery operated. The power converter  32  may include screw-type lugs  35  or another equivalent wire connector at its protected back, onto which an electrical wire  36  powering the light bar assembly  1  is attached. In one embodiment, a snap connector  23  connects the first light bar assembly  1  to a pair of electrical wires  36  (positive and negative) coming from the power converter  32 . Such an arrangement allows long electrical wires  36  to be cut to size by the installer because the cut ends will be attached to the screw-type lugs  35 . A further embodiment includes a supply plug  37  and is shown in  FIG. 7 . 
         [0039]    With reference to  FIG. 4 , the mounting bar  3  is attached to the surface of a railing by means of fasteners  18  (shown in exploded fashion), double sided tape  20 , or similar means. The face bar  2  mates with the mounting bar  3 . A snap connector  23  connects the power converter  32  to the first light bar assembly  1 , providing power for the light sources. The face bar and mounting bar  3  may be various lengths and number according to the set-up to be utilized. 
         [0040]    With reference to  FIG. 5 , further mounting bars  3  can be installed in line with the first such mounting bar  3  until the section is completed. A first face bar  2  is then snapped onto the mounting bar  3  at the location desired for light. In addition, a single elongated mounting bar  3  may accommodate more than one face bar  2 , if desired. After connection has been completed, a connector plug  39 , as shown in  FIGS. 5 and 6 , is pushed into the hollow end  38  of either adjacent light bar assembly  1 , before the two assemblies are tightly pushed together. The connector plug  39  has a hole through which electrical wires may pass. 
         [0041]    Any space that does not require lighting can optionally be covered with an empty face bar  40  that is shaped identically to face bar  2 , but does not contain any electrical components. If a distance between light bar assemblies  1  or between sections has to be bridged, a suitable electrical wire  41  can be used, either left open or covered by the space bar  40 . In either situation, electrical wire  41  is connected to the last used light bar assembly  1  and the first used light bar assembly  1  of a new section by means of snap connector  23 . 
         [0042]    With reference to  FIG. 7 , a further embodiment is shown to provide power to the light bar assembly  1 . A supply plug  37  which connects to a converter/power source can be mated with an end of a light bar assembly  1 . The supply plug  37  can optionally incorporate an optical sensor, timing device, or other technology to control power to the light bar assembly  1 . 
         [0043]    Although the invention has been shown as a light bar assembly used for a deck railings, many other applications exist for the invention, such as steps, overhangs, fencing and more, many of which are regulated by code which requires appropriate lighting. 
         [0044]    Further, while the present invention has been described above in terms of various embodiments, it is to be understood that the invention is not limited to these disclosed embodiments and is also capable of a wide variety of further and other embodiments within the spirit and scope of the appended claims. It is intended that the scope of the invention should be determined by those of skill in the art relying upon the disclosure in this specification and the attached drawings.