Rugged lighting system

A new and innovative, rugged lighting system is provided. The problem of achieving a lighting system that optimizes ruggedness, luminosity, energy and thermal efficiency, versatility, and unbundling of key components is solved. Embodiments of the present invention include a rugged lighting system comprising a housing unit with a body with integrally formed back, sides, and a front with an opening to provide access to the interior of the housing unit; a first lens configured to substantially cover the opening; a first lens bezel configured to removeably attach to the housing unit over the first lens; a second lens configured for placement over the first lens; and a second lens bezel configured to removeably attach to the housing unit over the first lens bezel. Various embodiments further include a light module within the housing unit with a light emitting diode (LED) mounted to an electronics module having a printed circuit board for operating the LED.

BACKGROUND OF THE INVENTION

Many industries require vehicles to operate continually, day and night, in harsh conditions. The mining industry is one such example. Operators are often required to work in dark and/or nighttime conditions on heavy vehicles. Lighting in these circumstances is paramount. Today, traditional lighting technology is being surpassed by LED lighting because of the latter's energy and thermal efficiency, not to mention increased brightness. Despite the adoption of this technology, a number of technological deficiencies exist in current LED lighting products for mining and large industrial applications. For example, many products are not sufficiently constructed to withstand the extreme and varied environments encountered. Thus, LED lighting systems and their internal electronic componentry are susceptible to impact and moisture, among other environmental hazards. Also, the componentry of many LED lighting products is not unbundled, and often, damage to one element requires replacement of the entire unit at high cost. Additionally, current LED lighting products do not allow for customization and versatility in beam features and control or power usage and regulation. In any event, there is great need for innovation to achieve a lighting system that optimizes ruggedness, luminosity, energy and thermal efficiency, versatility, and unbundling of key components.

SUMMARY OF THE INVENTION

In accordance with the above, a new and innovative, rugged lighting system is provided. The problem of achieving a lighting system that optimizes ruggedness, luminosity, energy and thermal efficiency, versatility, and unbundling of key components is solved. Embodiments of the present invention include a rugged lighting system comprising a housing unit with a body with integrally formed back, sides, and a front with an opening to provide access to the interior of the housing unit; a first lens configured to substantially cover the opening; a first lens bezel configured to removeably attach to the housing unit over the first lens; a second lens configured for placement over the first lens; and a second lens bezel configured to removeably attach to the housing unit over the first lens bezel. Various embodiments further include a light module within the housing unit with a light emitting diode (LED) mounted to an electronics module having a printed circuit board for operating the LED.

These and other aspects of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT

The present invention in its various embodiments, some of which are depicted in the figures herein, is a rugged lighting system.FIG. 1depicts the outside of one embodiment of a fully assembled, rugged lighting system100.

Referring now toFIG. 2, an exploded perspective view of a rugged lighting system100with various components is shown. In preferred embodiments, the system100is comprised of a first lens207, second lens202, and housing unit209with LED array214.

The first lens207is removeably attachable to the front of the housing unit209. In certain embodiments, the means for removable attachment of the first lens207is a first lens bezel204configured to overlap a portion of the perimeter of the first lens207. Depending on the embodiment, the first lens bezel204may be either permanently affixed to or separable from the first lens207. In the illustrated embodiment, this first lens bezel204is separable and shaped as a key to precisely fit the housing unit209. In various embodiments, the first lens bezel204may incorporate grommets, seals, or o-rings to optimize sealing against the moisture and elements that may be found in outdoor environments. Thus, the first lens207and first lens bezel204are configured to seal an LED array214and corresponding electronics.

The first lens bezel204may have one or more first apertures205for directly receiving bolts, such that the bolt heads rest within the first lens bezel204when placed therein, thereby facilitating removeable attachment of the first lens bezel204and the first lens207to the housing unit209. In the illustrated embodiment, the first lens bezel204has two such apertures in each of its four corners. The first lens bezel204may also have one or more second apertures206for indirectly receiving bolts, such that the bolt head does not rest within the first lens bezel204, thereby facilitating removable attachment of other components (e.g.,201,202), first to the first lens bezel204, first lens207and then, second, to the housing unit209. In the illustrated embodiment, the first lens bezel204has one such aperture in each of its four corners.

The second lens202is also removeably attachable to the housing unit209. The second lens202is configured for placement over the first lens207when the system100is assembled. The means for removable attachment of the second lens202is a second lens bezel201configured to overlap the perimeter of the second lens202. Again, depending on the embodiment, the second lens bezel201may be either permanently affixed to or separable from the second lens202. In the illustrated embodiment, the second lens bezel201is shaped as a key to precisely fit over the first lens bezel204. In various embodiments, the second lens bezel201may incorporate grommets, seals, or o-rings to further optimize sealing against moisture and elements.

The second lens bezel201may have one or more first apertures203for directly receiving bolts, such that the bolt heads rest within the second lens bezel201when placed therein. In the illustrated embodiment the position of these apertures203correspond to the position of the first lens bezel second apertures206, such that bolts pass through the second lens bezel201and the first lens bezel204, thereby facilitating removable attachment of the second lens202and second lens bezel201to the housing unit209. In the illustrated embodiment, the housing unit209has one or more apertures208,215into which bolts may be tightened to accomplish this. The second lens bezel201has one such aperture in each of its four corners in the illustrated embodiment.

Thus configured, the first lens207and first bezel204provide primary protection for the LED array214and internal electronics relating thereto. The second lens202and second bezel201provide a secondary and additional level of protection. Advantageously, if either lens is damaged, fogged, or otherwise requires maintenance or replacement, the unbundled nature of the lenses allows for such without having to replace other components. Moreover, in various embodiments, lenses may incorporate features resulting in numerous optical permutations depending on the desired function. For example, either first207and/or second202lenses may incorporate one or more of: (a) opaqueness or tinting to tone down brightness; (b) varying thickness or patterning for beam control or alteration; and (c) coloration to color the beam.

In various embodiments, the housing unit209is integrally formed of metal or other high strength material. The housing unit209may incorporate fins211on its top and/or back in order to dissipate heat generated by the LED array214and electronics. The housing unit209may also have a mounting unit210with a positioning feature212allowing for beam-adjustable mounting of the housing unit209on a vehicle or other surface.

The housing unit209also has an external power means213. This external power means213may be wired in such away as to provide for hi power or low power settings depending on which or how connectors on the external power means213are connected with the connectors to the power supply. For example, external power means213may have multiple power connections such that power could be applied to a certain connection point (pin) causing the light to illuminate in its high power mode. Similarly, power could be applied to an alternate connection point in external power means213causing the light to illuminate in its low power mode.

Referring now toFIG. 3, a side, cross-section of a rugged lighting system100is shown. The first lens207and first lens bezel204are shown attached to the housing unit209. The second lens202and second lens bezel201are shown attached to the first lens207, first lens bezel204, and housing unit209. Thus configured, the system provides two layers of protection, as well as optimal versatility and feature permutations from having two separate lenses. In various embodiments, both layers of protection are environmentally sealed and integrated to have the external appearance of a singular configuration.

Moreover, as noted fromFIG. 3, the housing unit209is ruggedly constructed of relatively thick metal. The housing unit209may be integrally constructed.

In preferred embodiments, the LED array214is located within the housing unit209and configured to optimize brightness, while minimizing energy usage and thermal output. The system may, for example, incorporate Cree® CXA LED Arrays to achieve these ends. However, any number of LED arrays214, or for that matter, light components that achieve these same purposes may be used without departing from the scope of the invention.

In various embodiments, the system may also incorporate electronics to operate the LED array214. These electronics may be, for example, one or more circuit boards located within the housing209and connected to the LED array214and/or external power means213. Operations may include, but are not limited to, detecting heat and powering down to prevent thermal damage to the system. Specifically, powering down does not include powering off; rather, the system is configured to scale down or optimize power usage for existing ambient temperatures in order to prevent thermal damage to the system.

Certain embodiments of the invention may also include a “piggy-back” bracket, onto which AC/DC power supply may be mounted in order to allow the system to alternatively run on AC power. The system may also include a “photo eye” or light sensor, capable of detecting daylight and/or nigh time conditions. Accordingly, the light is capable of automatically turning on or off according to preset sensitivity levels. This enables the system to achieve reduced energy consumption and adds longevity. In operation, a user can allow a user to selectively turn the light on, e.g., at fifteen (15) minutes prior to sundown, or five (5) minutes prior to sundown, etc.

Thus configured, embodiments of the present invention provide a rugged lighting system for use in a variety of applications. The problem of achieving a lighting system that optimizes ruggedness, luminosity, energy and thermal efficiency, versatility, and unbundling of key components is solved.