Abstract:
A modular light bar having crisscross lighting in the front and rear. Each module may include two horizontal layers of lighting supported on supports connected to a longitudinal base. A wire harness is positioned within a longitudinal channel in the longitudinal base, with the harness having one end connected to quick disconnects within the modules and having another end connected to a controller. Each of the light bar module is serviceable independent of the other light bar modules, such that the support positioned within and connected to the light bar module being serviced is removable from the light bar module without accessing the other light bar modules by disconnecting the quick disconnect positioned within each light bar module being serviced.

Description:
FIELD OF THE INVENTION 
     The present invention generally relates to emergency vehicle lighting and, in particular, to a light bar for a vehicle. In particular, the invention relates to a light bar having light modules mounted in modular enclosures supported by a base. Each light module may have multiple levels of light sources. 
     BACKGROUND OF THE INVENTION 
     Emergency lighting on police or other public service vehicles has been used for many years. Generally, such lighting is mounted on the exterior (usually the roof) of the vehicle in order to provide high visibility to nearby motorists and pedestrians. Exterior mounting also minimizes the possibility that the light produced by the lighting system will adversely affect the vision of someone in the vehicle. 
     Light bars are generally the most desirable type of emergency exterior lighting because of their ability to provide a wide variety of types of illumination. Typically, the light bar is a unitary rectangular unit which spans the top of the vehicle and is supported by brackets attached to the vehicle. It is desirable that the light bar produce an intense light for maximum visibility. 
     Prior non-modular light bars have had predetermined lengths (the length of the bar generally corresponding to a width of a vehicle to which the bar is mounted). In order to size light bars for vehicles of different width and for various applications, non-modular light bars of varying length were manufactured which in turn required molds of varying size, one for each length manufactured. Frequently, each length accommodated a different number of light sources so the light source configuration was uniquely customized for each length. In addition, since prior light bars were non-modular structures, maintenance usually required that the entire light bar would have to be disassembled and reassembled. 
     Prior modular light bars have had modules of predetermined lengths but these lengths have been rather large so that only a few incremental sizes of such modular bars have been available. Sometimes modules of varying length were manufactured which in turn required molds of varying size, one for each length manufactured. Frequently, each module accommodated a different number of light sources so the light source configuration was uniquely customized for each module. 
     There is a need for a light bar configuration having varying width and having selectable light sources of differing types which can be positioned at various places within the light bar. There is also a need for a light bar having modules which can be assembled without the need for a uniquely customized light source configuration. There is also a need for a light bar having modules of smaller size, each of which can be maintained without the need for disassembling and reassembling a large portion or several modules of the entire light bar. 
     SUMMARY OF THE INVENTION 
     According to one embodiment of the invention, quick disconnects positioned within end modules, interior modules and a center module are connected between each module and a controller. A wire harness positioned within a longitudinal channel in a longitudinal base has one end connected to the quick disconnects within the modules and has another end connected to the controller. Each of the light bar modules is serviceable independent of the other light bar modules. A support positioned within and connected to the light bar module being serviced is removable from the light bar module without accessing the other light bar modules. 
     Other objects and features will be in part apparent and in part pointed out hereinafter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view, partially broken away, showing one embodiment of a light bar of the invention. 
         FIG. 2  is perspective view showing one embodiment of a light bar of the invention in which an octagonal end module is mated to a rectangular interior module with covers removed to illustrate the mounting plate. 
         FIG. 3  is similar to  FIG. 2  without the mounting plate to illustrate the position of the light modules when supported by the mounting plate. 
         FIG. 4  is a top plan view showing one embodiment of a light bar of the invention have two octagonal end modules interconnected by three rectangular interior modules. 
         FIG. 5  is a cross sectional view taken along lines  5 - 5  of  FIG. 4 . 
         FIG. 6  is a cross sectional view taken along lines  6 - 6  of  FIG. 4 . 
         FIG. 7  is a perspective view of an LED light module according to one embodiment of the invention. 
         FIG. 8  is a perspective view of a mounting plate for an octagonal end module which has be rotated 180° to illustrate the light modules and terminal strip mounted thereto, according to one embodiment of the invention. 
         FIG. 9  is a block diagram of one embodiment of a wiring configuration according to the invention. 
         FIG. 10  is a perspective view of an LED light module according to one embodiment of the invention having two horizontal rows. 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the drawings. 
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is a perspective view, partially broken away, showing one embodiment of a light bar  100  of the invention. The light bar  100  is used to generate emergency lighting and is usually mounted on a vehicle. For convenience, an arrow  102  indicates the direction of forward travel of the vehicle. The light bar  100  includes a left end module  104  and a right end module  104  which are connected to one or more interior modules  106 . Each end module has a lower section  104 L and an upper section  104 C (e.g., a cover) connected to the lower section  104 L. As an example and not by way of limitation, three interior modules  106  are shown in  FIG. 1 . In general, the number of interior modules is variable, depending in part on the width of the vehicle on which the light bar  100  is mounted and depending on the desires of the user/purchaser of the light bar  100 . 
     In one embodiment, each interior module is approximately 7.5″ by 12″ in overall dimensions and each end module  104  is approximately 12″ by 18″ in overall dimensions. This embodiment has dimensions which are compatible with the size of most vehicles and provides more flexibility as compared to the larger modules of the prior art. Also, this embodiment minimizes the need for a third module such as a speaker module or spacer module in order to achieve various lengths for the overall light bar. 
     Each interior module  106  has a first left side  108  connected to a right side of the left end module  102  and also connected to a right side  110  of another interior module  106 . Thus, each interior module  106  also has a second right side  110  opposite the first left side  108  connected to a left side of the right end module  104  and connected to the left side  108  of another interior module  106 . For example, in one embodiment a separate bridge element  111  may be positioned between adjacent interior modules  106  so that the modules would be indirectly connected to each other via the bridge element  111 . Each module  106  would have an opening in its side  108 ,  110  for connected to the bridge element  111 . In this embodiment, it is also contemplated that each end module  104  may have an opening (not shown) in its side for connected to the bridge element. Alternatively, the end module  104  may have an integral bridge element (not shown) on its side for connecting to the opening in the side of the interior module  106  adjacent thereto. In one embodiment, the end modules  104  have at least eight sides and have a length measured along the direction of travel  102  which is greater than the length of the interior modules  106 . Thus, in one embodiment, both the end and interior modules properly mate to each other via an integral or separate bridge, a right side of the left end module  104  being substantially the same size (e.g., length and height) as the first side  108  of the interior module  106 . 
     Each interior module  106  has a lower section  106 L and an upper section  106 C (e.g., a cover) connected to the lower section  106 L. 
     A longitudinal base  112  such as an extruded aluminum rail is connected to the lower section  104 L of the end module  104  (e.g., via sheet metal screws, not shown) and the lower section  106 L of the interior module  106  (e.g., via sheet metal screws, not shown) for supporting the end and interior modules side by side. The base  112 , the lower section of each end module  104 L mounted on the base  112  and the corresponding upper section  104 C of each end module (connected to the lower section) together form an enclosure. Similarly, the base  112 , the lower section of each interior module  106 L mounted on the base  112  and the corresponding upper section  106 C of each interior module (connected to the lower section) together form an enclosure. In the embodiment illustrated, each interior module  106  has four sides forming a rectangular horizontal cross section and the left and right end modules  104  have substantially the same horizontal cross section and the interior modules  106  have substantially the same rectangular horizontal cross section. 
       FIG. 4  is a top plan view showing one embodiment of a light bar of the invention have two octagonal end modules interconnected by three rectangular interior modules. As shown in  FIGS. 1 and 4 , the left and right end modules  104  each have a front portion  104 F extending forward of the interior modules  106  so that light as indicated by arrow  400  emitted by the front portion of the left end module is directed toward the front portion of the right end module and visa versa (light as indicated by arrow  402  emitted by the front portion of the right end module is directed toward the front portion of the left end module). In addition, the left and right end modules  104  each have a rear portion  104 F extending rear ward of the interior modules  106  so that light as indicated by arrow  406  emitted by the rear portion of the left end module is directed toward the rear portion of the right end module and visa versa (light as indicated by arrow  408  emitted by the rear portion of the right end module is directed toward the rear portion of the left end module). As a result, light from the left end module crisscrosses with light from the right end module in both the front and rear of the light bar  100 . 
       FIG. 2  is perspective view showing one embodiment of the light bar  100  of the invention in which the octagonal end module  104  is mated to the rectangular interior module  106 , each having their upper sections  104 C,  106 C removed to illustrate a mounting plate  200 ,  202 . In particular, each end module  104  includes an octagonal mounting plate  200  which is supported by and attached to the base  112 , such as by screws (not shown). Also, each interior module  106  includes a rectangular mounting plate  202  which is supported by and attached to the base  112 , such as by screws (not shown). 
     One purpose of the mounting plates  200 ,  202  is to support modular light sources  300 ,  302 ,  304 .  FIG. 3  is similar to  FIG. 2  without the mounting plates  200 ,  202  to illustrate exemplary positions of the light modules  300 ,  302 ,  304  when supported by the mounting plate (not shown in  FIG. 3 ).  FIG. 7  is a perspective view of a six (6) LED light module  300  according to one embodiment of the invention. As illustrated in  FIG. 7 , each LED is positioned at or near a focal point of a TIR reflector and is covered by a columnating lens which directs the light in a beam or a wide angle lens which disperses the light in a wide angle.  FIG. 10  is a perspective view of a twelve (12) LED light module  310  according to one embodiment of the invention. The light source  302  is a unitary light fixture. The light source  304  is similar to the light source  300  except that it has three instead of six LEDs. 
     The light source module  300  includes a bracket  700  having a horizontal leg  702  and a vertical leg  704 . The horizontal leg  702  is connected to an underside of the mounting plate  200 , such as by screws (not shown). The vertical leg  704  supports at least two (and preferably three or six) of a plurality of light emitting elements such as light emitting diodes (LED)  706 . In one embodiment, as shown in  FIG. 10 , a light module may include two horizontal rows. Thus,  FIG. 10  illustrates a light source module  310  having a light source bracket and a plurality of 12 light emitting elements on the light source support forming at least two different horizontal levels of lighting. 
     In one embodiment, the brackets  700  are connected to and support the LEDs such that heat generated by the LEDs to transferred to the brackets  700 . In addition, the brackets are in heat exchange relationship with the mounting plate  200  so that heat absorbed by the brackets is transferred to the mounting plate. Thus, heat from the LEDs is transferred to the brackets and heat absorbed by the brackets from the LEDs is transferred to the mounting plate. 
     In one embodiment, it is contemplated that the light module  300  as shown  FIG. 7  or the light module  310  as shown in  FIG. 10  may include at least one red LED  706 R and at least one blue LED  706 B which may be simultaneously energized by a controller. In one embodiment, each row of modules  300  and  310  would have three (3) red LEDs contiguous to each other and three (3) blue LEDs contiguous to each other. In another embodiment, the red and blue LEDs would alternate with each other so that a row would be red, blue, red, blue, red and blue. In yet another embodiment of the module  310 , one row would be red and one row would be blue. Other alternative patterns will be apparent to those skilled in the art. Generally, it is contemplated that the number of red LEDs equal the number of blue LEDs. However, certain red LEDs may have more intensity than certain blue LEDs so that more blue LEDs than red LEDs may be used, and visa versa. In each embodiment, the one or more red LEDs  706 R and the one or more blue LEDs  706 B when simultaneously energized would generate light which appears to be white light to an remote observer (not shown). 
       FIG. 5  is a cross sectional view taken along lines  5 - 5  of  FIG. 4  illustrating the light modules  300 ,  302  and  304  within the end module  104 .  FIG. 6  is a cross sectional view taken along lines  6 - 6  of  FIG. 4  illustrating the light modules  300  and  304  within the interior module  106 . 
       FIG. 8  is a perspective view of a mounting plate for an octagonal end module which has be rotated 180° to illustrate the light modules and terminal strip mounted thereto, according to one embodiment of the invention. (terminal strip;  FIG. 8 ) In one embodiment, a terminal strip  800  is positioned on each mounting plate  200 ,  202 . The plurality of light emitting diodes on the brackets on each particular mounting plate are electrically connected by wires  802  to the terminal strip  800 . In addition, a wire harness  804  connects the terminal strip  800  to the controller to selectively energize each of the plurality of light emitting diodes. 
     In one embodiment, it is contemplated that the controller would be positioned within one of the modules and connected to the light sources via the harness connected to the terminal strips  800 . Thus, the controller selectively energizes the light sources to generate one or more emergency warning signals. Preferably, the wire harness may be positioned within a channel in the base  112  so that one end of the harness is connected to the light sources via the terminal strip  800  and the another end of the harness is connected to the controller. As shown in  FIG. 8 , the harness would include a quick disconnect  806  between each module and the controller. Thus, if a mounting plate of a particular module needs to be removed from the light bar  100  for repair or revision, the quick disconnect  806  allows the mounting plate to be disconnected and replaced without the need to open or access any other modules other than the particular module. 
       FIG. 9  is a block diagram of one embodiment of a wiring configuration according to the invention. In one embodiment, it is contemplated that a multiple of the light sources of the modules  300 ,  302 ,  304  are connected to a common circuit via the terminal strip  800 , the harness  804  and the quick disconnect  806 . In one embodiment, each LED module  300 ,  302 ,  304  would have its own dimmer circuit  902  and a control lead from each dimmer circuit  902  would be connected to the terminal strip  800 . The dimmer circuits could be optionally used in this embodiment. For example, the dimmer circuit would be connected to controller via the terminal strip  800  and the quick disconnect  806  when the ability to dim the LEDs is desired. Alternatively, there may be various types of controllers and the dimmer circuit would only be connected to certain controllers. As another alternative, it may be desirable that only certain modules are dimmed, in which case only those dimmer circuits of the modules to be dimmed would have their control lead connected to the controller via the terminal strip  800  and quick disconnect  806 . 
     The common circuit is then connected to a flashing circuit  902  responsive to a controller  904  for simultaneously flashing the multiple light emitting diodes. A remainder of the harness  906  including the dimmer control (if it will be used) is directly connected to the controller  904  so that the controller selectively energizes the light sources. As shown in  FIG. 9 , the flasher  902  is illustrated as a separate component. However, it is also contemplated that the flashing function may be integral with the controller. In this case, the controller  904  would have certain ports which are connected to the common circuit to flash its sources wherein the controller  904  would have other ports which would selectively energize the light sources connected thereto. 
     Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. 
     When introducing elements of the present invention or the preferred embodiments(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. 
     In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained. 
     As various changes could be made in the above constructions, products, and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.