Modular off-road accessory light rack

A modular light rack assembly for off-road vehicles having a plurality of individual pieces that can be selectively connected to form a substantially linear assembly for attaching a variety of headlight subassemblies. In each embodiment, there is a common left hand mounting configuration and common right hand mounting configuration, so that each piece of the modular light rack assembly having one or both of these configurations on its end or ends is selectively connectable to any other piece to form a substantially linear assembly of any desired configuration.

FIELD OF THE INVENTION

The invention relates in general to vehicle light racks mounted to off-road vehicles. More specifically, the invention relates to a modular light rack assembly having a plurality of individual pieces that can be selectively connected to form a substantially linear assembly for attaching a variety of headlight subassemblies. The light rack assembly is modular in that differently sized individual pieces are interchangeable between the end pieces. This interchangeability allows the light rack to be formed in a plurality of different configurations.

BACKGROUND OF THE INVENTION

The technology utilized in off-road vehicle racing has advanced substantially in recent years. Many off-road races require specialized lighting systems be equipped on their vehicles in order to be competitive in night racing conditions. Most manufacturers of such lighting products either sell individual headlight subassemblies requiring the purchaser to fabricate their own light rack, or sell a one size light rack housing a fixed number of headlights. However, most off-road racing vehicles today are uniquely designed, giving rise to a variety of different lighting requirements, and the one size light racks offered on the market today do not always meet these requirements. For example, one race team may desire a quantity of four 8 inch diameter headlights mounted on a rack spanning a distance of 5 feet on the front of the vehicle, while another race team may desire a quantity of six 4 inch diameter headlights mounted on a rack spanning a distance of 6 feet. Presently, a custom fabricated light rack frame would be required for each. The custom fabrication problem is further complicated since there are a variety of different headlight subassemblies to select from, and these different subassemblies come in a wide range of sizes and shapes. Thus, there is a need to provide a modular light rack assembly comprising a variety of interchangeable pieces that can be connected in a variety of different configurations to meet the individual lighting requirements of off-road racers.

BRIEF SUMMARY OF THE INVENTION

The present invention provides its benefits across a broad spectrum of vehicle light racks for off-road vehicles. Although the present invention is discussed in conjunction with high performance off-road race vehicles, it may be used for recreational off-road vehicles as well. While the description which follows hereinafter is meant to be representative of such applications, it is not exhaustive. As will be understood, the basic apparatus taught herein can be readily adapted to many uses. It is intended that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed.

It is one aspect of the present invention to provide a modular light rack capable of being assembled in a variety of configurations to meet any number of off-road vehicle lighting applications.

It is another aspect of the present invention to provide a modular light rack that is configured to maximize the visibility of the driver of an off-road vehicle when the light rack assembly is mounted on the vehicle.

It is a feature of the present invention that each piece of the modular light rack assembly is selectively connectable to any other piece of the modular light rack assembly.

It is another feature of the present invention that each piece of the modular light rack assembly has at least one end comprising a common left hand mounting configuration and/or another end having a common right hand mounting configuration, allowing each piece to be connected to any other piece.

It is still another feature of the present invention that the modular light rack assembly is selectively connected to form a substantially linear assembly to meet a variety of different off-road vehicle lighting requirements.

It is an advantage of the present invention that the substantially linear assembly establishes a low visibility profile that maximizes the visibility of the driver when the assembly is mounted to an off-road vehicle.

It is another advantage of the present invention that, with a variety of interchangeable pieces available, a multitude of different modular light rack assemblies can be provided to meet the lighting requirements of any off-road vehicle, thereby eliminating the need to custom fabricate a light rack.

These and other aspects, features, and advantages are achieved/attained in the apparatus of the present invention that comprises at least one light protector piece, a left hand piece, and a right hand piece. The light protector piece has a left connector end defining a common left hand mounting configuration, and a right connector end defining a common right hand mounting configuration. The light protector piece has an opening between the left and right connector ends to allow a light beam projected from a headlight to pass through. The left connector end of the light protector piece is selectively connectable to the right connector end of another light protector piece, and the right connector end is selectively connectable to the left connector end of another light protector piece. The left hand piece has a right mount end having the common right hand mount configuration, and the right hand piece has a left mount end having the common left hand mount configuration. The right mount end of the left hand piece is selectively connectable to the left connector end of the light protector piece, and the left mount end of the right hand piece is selectively connectable to the right connector end of the light protector piece. The light protector piece(s), the right hand piece, and the left hand piece are selectively connected, left hand mounting configuration to right hand mounting configuration, to form a substantially linear assembly.

At least one spacer piece may also be provided to establish a substantially linear assembly of a desired length. The spacer piece has a left connection end and a right connection end, the left connection end having the common left hand mounting configuration and the right connection end having the common right hand mounting configuration. The left connection end is selectively connectable to the right connector end of the light protector piece and selectively connectable to the right mount end of the left hand piece. The right connection end is selectively connectable to the left connector end of the light protector piece and selectively connectable to the left mount end of the right hand piece. When spacer piece(s) are provided, the light protector piece(s), right hand piece, left hand piece, and spacer piece(s) are selectively connected, left hand mounting configuration to right hand mounting configuration, to form the substantially linear assembly of the modular light rack.

A headlight mount member may also be provided, extending from the light protector piece(s), for mounting a headlight subassembly to the headlight mount member so that the light beam projected from the headlight subassembly passes is through the opening in the light protector piece. The headlight mount member may be integral with the light protector piece, or connected to the light protector piece with fasteners.

The left hand mounting piece and the right hand mounting piece have attachment ends for securing the light rack assembly to the off-road vehicle. In one embodiment, a first adjustment bracket is connected to the attachment end of the left hand mounting piece and a second adjustment bracket is connected to the attachment end of the right hand mounting piece. The adjustment brackets are then secured to the off-road vehicle, thereby securing the modular light rack assembly to the vehicle. The adjustment brackets may be configured to provide for the adjustment of the substantially linear assembly of the light rack assembly about a horizontal axis when the light rack assembly is secured to the vehicle.

In one embodiment, the left connector end, the left mount end, and left connection end of any spacer piece, all having the common left hand mounting configuration, comprise at least one tab. The right connector end, the right mount end, and the right connection end of any spacer piece, all having the common right hand mounting configuration, include at least one recess. In this embodiment, the tabs mate with the recesses when the light protector piece(s), right hand piece, left hand piece, and any spacer piece, are selectively connected to from the substantially linear assembly.

In another embodiment, the right connector end, the right mount end, and right connection end of any spacer piece, all having the common right hand mounting configuration, comprise at least one tab. The left connector end, the left mount end, and the left connection end of any spacer piece, all having the common left hand mounting configuration, include at least one recess. In this embodiment, the tabs mate with the recesses when the light protector piece(s), right hand piece, left hand piece, and any spacer piece, are selectively connected to from the substantially linear assembly.

In any embodiment, the light protector piece(s), right hand piece, left hand piece, and any spacer piece may interlock when selectively connected to form the substantially linear assembly. As used herein, the term “interlock” means that when the pieces are selectively connected, the resultant joint surface of these connections is flush, making the substantially linear assembly appear as a continuous single unit. As used herein, the term “selectively connectable” means that, for a given embodiment, the common left and right hand mounting configurations mate to one another, allowing the end of any piece having the common left hand mounting configuration to connect to the end of any other piece having the common right hand mounting configuration. The term “selectively connected” means that the pieces are secured together by any manner known to those skilled in the art to form a rigid structure, such as with threaded fasteners, press fit pins, rivets, or the like. The pieces may also be selectively connected together by welding, or bonding process such as brazing, as is known to those skilled in the art. As used herein, the term “each piece”, “any piece”, or “any other piece” refers exclusively to either a light protector piece, a left hand piece, a right hand piece, or a spacer piece, separately or in combination.

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements or features common to the figures.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring toFIGS. 1-2, a modular light rack assembly is shown generally by number10in accordance with a first embodiment of the present invention. The modular light rack assembly10illustrated inFIGS. 1-2is an exemplary configuration of the preferred embodiment comprising three light protector pieces12two spacer pieces14, a left hand piece16, and a right hand piece18. Also shown are two adjustment brackets20, one connected to left hand piece16and the other to right hand piece18. The modular light rack assembly10in this example is configured to mount three headlight subassemblies22. It is to be appreciated that the modular light rack assembly of the present invention can be configured to mount one headlight subassembly, or as many as needed, to meet individual off-road lighting requirements.

The individual components of the modular light rack assembly10of the first embodiment are shown inFIG. 2. For each light protector piece12there is a corresponding headlight mount member24which is connected to its corresponding light protector piece12with fasteners26. The spacer pieces14are connected to the light protector pieces12with fasteners28. The left hand and right hand pieces,16and18respectively, are attached to their adjacent light protector pieces12with fasteners30. The attachment brackets20are connected to the left hand and right hand pieces,16and18respectively, with fasteners32and corresponding nuts34.

Referring toFIG. 3, a substantially linear assembly36of the first embodiment of the present invention modular light rack assembly10ofFIGS. 1-2is shown. The substantially linear assembly36is formed when the light protector pieces12, left hand piece16, right hand piece18, and spacer pieces14are connected with fasteners28and30. It is to be appreciated that the substantially linear assembly36has a substantially low visibility profile compared to prior art light racks which have upper and lower frame members that extend above and below the headlight subassemblies. This substantially low visibility profile maximizes the visibility of the driver of an off-road vehicle particularly when the light rack assembly is mounted on the front of the vehicle above the level of the hood.

InFIG. 4the substantially linear assembly36ofFIG. 3is shown unassembled. Each light protector piece12has a left connector end indicated by numeral38, and a right connector end indicated by numeral40. Each light protector piece12has an opening, identified by numeral42, between the left and right connector ends,38and40respectively, to allow a light beam projected from a headlight to pass through. The left connector end38defines a common left hand mounting configuration and the right connector end40defines a common right hand mounting configuration. It is to be appreciated that, for each embodiment, the end of any piece having the common left hand mounting configuration is selectively connectable to the end of any piece having the common right hand mounting configuration. The left hand piece16has a right mount end44having the common right hand mounting configuration and is therefore selectively connectable to the left connector end38of any light protector piece12. The right hand piece18has a left mount end46having the common left hand mounting configuration and is therefore selectively connectable to the right connector end40of any light protector piece12.

Additionally, each spacer piece14has a left connection end identified generally by numeral48and a right connection end identified generally by numeral50. The left connection end48has the common left hand mounting configuration and is therefore selectively connectable to the right connector end40of any light protector piece12, and also selectively connectable to the right mount end44of the left hand piece16. The right connection end50has the common right hand mounting configuration and is therefore selectively connectable to the left connector end38of any light protector piece12, and also selectively connectable to the left mount end46of the right hand piece18. As can be appreciated by those skilled in the art, any combination of light protector pieces, and if desired, spacer pieces, can be selectively connected between the left hand and right hand pieces16and18to form a substantially linear assembly of any desired configuration and length. For example, referring toFIG. 11, a substantially linear assembly36of an alternate configuration is shown comprising four light protector pieces12selectively connected between left hand and right hand pieces16and18. In the configuration shown inFIG. 11, there are no spacer pieces used in the substantially linear assembly36. As those skilled in the art will appreciate, selectively connecting light protector pieces12together without a spacer piece in-between would not be possible but for the left connector end38having the common left hand mounting configuration and the right connector end40having the common right hand mounting configuration, thereby allowing the left connector end38of one light protector piece12to be selectively connectable to any right connector end40of another light protector piece12.

In the all embodiments shown, the opening42is shown having a circular shape for ease of illustration. It is to be appreciated that opening42may be configured to any size and shape, according to the present invention, to accommodate any headlight subassembly configuration. For example, an opening42for a circular headlight subassembly having a diameter of about 4.0 inches may be a circular opening having a diameter of about 4.5 inches, and an opening42for a circular headlight subassembly having a diameter of about 8.0 inches may be a circular opening having a diameter of about 8.5 inches. Accordingly, a rectangular opening may also be configured to accommodate a rectangular headlight subassembly, if desired. Hence, the size and shape of the opening42of every light protector piece is configured to conform to a particular shape and size of a particular headlight subassembly. This allows the modular light rack assembly10to accommodate a variety of different headlight subassemblies in one light rack.

Referring toFIGS. 5-8, adjustment brackets20and their connection with the left and right hand pieces,16and18respectively, are shown. The left hand and right hand pieces,16and18, each comprise attachment ends, generally identified by numeral52, for securing the light rack assembly to an off-road vehicle. In this embodiment, the attachment ends52comprise a lower mounting hole54and a upper mounting hole56. Adjustment brackets20comprise a pivot hole58and adjustment slot60. Fasteners32and nuts34connect the lower mounting hole54of both brackets16and18with the pivot hole58of their corresponding adjustment bracket20, and the upper mounting hole56of both brackets16and18with the adjustment slot60of their corresponding adjustment bracket20. As shown, each adjustment bracket20has a coupling end62for securing the light rack assembly to an off-road vehicle. As is commonly known in the art, coupling end62is typically clamped to a tubular frame member of the off-road vehicle with fasteners not shown, or welded directly to the tubular frame member.

Referring toFIG. 9, the substantially linear assembly36is shown with the left and right hand pieces,16and18respectively, connected to the adjustment brackets20, illustrated inFIGS. 5-8. A horizontal axis64is established between the pivot holes58of both adjustment brackets20, allowing the modular light rack assembly10to be adjusted about the horizontal axis64by loosening and tightening fasteners32and nuts34. With coupling ends62secured to the vehicle, the light rack assembly10can be adjusted about the horizontal axis64. This allows for the vertical adjustment of the direction of the beams of light of the headlight subassemblies22, shown inFIG. 1, to a desired position.

It is to be appreciated that adjustment brackets20need not be used to secure the modular light rack assembly10to a vehicle. For example, the left hand and right hand pieces16and18can attach the modular light rack assembly10to the vehicle by attachment ends52, if desired. In addition, attachment ends52may be connected in conjunction with linear actuators to allow vertical adjustment of the direction of the beams of light of the headlight subassemblies while the vehicle is in motion, as disclosed in U.S. Pat. No. 7,249,875 to Roach et al. Alternatively, attachment ends52need not comprise upper mounting hole56and lower mounting hole54, but may comprise a single mount hole to secure the modular light rack assembly10to the vehicle, if desired.

FIG. 10shows a preferred manner of mounting a headlight subassembly20so that the light beam projected from the headlight subassembly passes through the opening in the light protector piece12. As is well known in the art, a headlight subassembly20is a preassembled unit typically comprising a light housing, headlight reflector, bulb, light retainer ring, lens, ballast, and wiring as discussed in U.S. Pat. No. 7,249,875 to Roach et. al. InFIG. 10, the headlight mount member24is connected to the light protector piece12with fasteners26that pass though holes66of the light protector piece12and engage threaded holes68in the headlight mount member24. The headlight subassembly20has a threaded mount end70that is inserted in through hole72of the headlight mount member24. The headlight subassembly20is secured to the headlight mount member24with a mounting nut74that engages threaded mount end70. Alternatively, headlight mount member24may be integrally formed with the light protector piece12or welded or brazed to the light protector piece, if desired.

Referring back toFIG. 3, the substantially linear assembly36formed by selectively connecting the light protector pieces12, right hand piece18, left hand piece16, and spacer pieces14, appears as a continuous single unit. In this embodiment, each piece interlocks with the adjacent piece that it is selectively connected to, providing a resultant joint surface that is flush, making the substantially linear assembly36appear as a continuous single unit. It is preferred that each piece interlocks to form a substantially linear assembly36that appears as a continuous single unit, although it is not required. The resultant joint surface of each connected piece need not be flush. All that is required is that each piece having the common left hand mounting configuration on one end mate with the end of any other piece having the common right hand mounting configuration. Hence, for each embodiment, the common left hand mounting configuration and the common right hand mounting configuration are integrally related, so that each piece is selectively connectable to any other piece, left hand mounting configuration to right hand mounting configuration, to form the substantially linear assembly36.

Referring toFIGS. 12 and 13, the common left hand mounting configuration and the common right hand mounting configuration of the first embodiment are shown, exemplified by two adjacent light protector pieces12to be selectively connected. This is the preferred common left hand and right hand mounting configuration of the present invention. Hence, the modular light rack assembly10shown inFIG. 1is a configuration that is exemplary of the preferred embodiment of the present invention. Referring back toFIGS. 12 and 13, each light protector piece12has a left connector end38defining a left hand mounting configuration and a right connector end40defining a right hand mounting configuration. For ease of illustration, only the left connector end38of the left most light protector piece12and only the right connector end40of the right most light protector piece12are shown. The left connector end38has one tab76and the right connector end has one recess78that mate when the two light protector pieces12are selectively connected, as shown inFIG. 13. This type of mating relationship is known as a lap joint. Through holes80are provided in the left connector end38and threaded holes82are provided in the right connector end40. When the two light protector pieces12are selectively connected, as shown inFIG. 13, fasteners28are inserted into the through holes80and engage threaded holes82to secure the light protector pieces12together. Stated in the alternative, the right connector end40has one tab84while the left connector end38has one recess86that mate when the two light protector pieces12are selectively connected.

It is to be appreciated that the common left hand mounting configuration and the common right hand mounting configuration shown inFIGS. 12 and 13of the left connector end38and right connector end40, also apply to the left connection end48and right connection end50respectively of any spacer piece14utilized in the first embodiment. Further, the right mount end44of the left hand piece16of the first embodiment also has the same common right hand mounting configuration, and the left mount end46of the right hand piece18of the first embodiment also has the same common left hand mounting configuration. This allows for any combination of light protector pieces12and spacer pieces14to be selectively connected between a left to hand piece16and a right hand piece18to form a substantially linear assembly36of any desired configuration.

Referring now toFIGS. 14 and 15, an alternate embodiment of the common left hand mounting configuration and the common right hand mounting configuration of the present invention are shown, exemplified by two adjacent light protector pieces12to be selectively connected. In this embodiment, the right connector end40has two tabs88, and the left connector end38has two recesses90and one tab92that mate when the two light protector pieces12are selectively connected, as shown inFIG. 15. This type of mating relationship is a variant of a lap joint and a tongue and groove joint. Through holes94are provided in tabs88of the right connector end40and threaded holes96are provided in tab92of the left connector end38. When the two light protector pieces12are selectively connect, as shown inFIG. 15, fasteners28are inserted into the through holes94and engage threaded holes96to secure the light protector pieces12together. As with the first embodiment, in this embodiment the left mount end46(not shown) of the right hand piece18(not shown) has the common left hand mounting configuration of this embodiment, and the right mount end44(not shown) of the left hand piece16(not shown) has the common right hand mounting configuration of this embodiment. Furthermore, the left connection end48(not shown) and right connection end50(not shown) of any spacer piece14(not shown) used in this embodiment also respectively have the common left hand mounting configuration and the common right hand mounting configuration of this embodiment. In this embodiment, as well as the first embodiment, any combination of light protector pieces12and spacer pieces14can be selectively connected between a left hand piece16and a right hand piece18to form a substantially linear assembly36of any desired configuration.

Referring now toFIGS. 16 and 17, another alternate embodiment of the common left hand mounting configuration and the common right hand mounting configuration of the present invention are shown. In this embodiment, the right connector end40has two tabs98and the left connector end38has two tabs100. Tabs98and tabs100mate when the two light protector pieces12are selectively connected, as shown inFIG. 17, leaving an aperture identified generally by numeral106. This type of mating relationship is another variant of a lap joint and a tongue and groove joint. Through holes102are provided in tabs98and threaded holes104are provided in tabs100so that when the two light protector pieces12are selectively connected, fasteners28are inserted into the through holes102and engage threaded holes104to secure the light protector pieces12together. As with the other embodiments, in this embodiment the left mount end46(not shown) of the right hand piece18(not shown) has the common left hand mounting configuration of this embodiment, and the right mount end44(not shown) of the left hand piece16(not shown) has the common right hand mounting configuration of this embodiment. Furthermore, the left connection end48(not shown) and right connection end50(not shown) of any spacer piece14(not shown) used in this embodiment also respectively has the common left hand mounting configuration and the common right hand mounting configuration of this embodiment. In this embodiment, as well as the other embodiments, any combination of light protector pieces12and spacer pieces14can be selectively connected between a left hand piece16and a right hand piece18to form a substantially linear assembly36of any desired configuration.

Referring now toFIGS. 18 and 19, yet another alternate embodiment of the common left hand mounting configuration and the common right hand mounting configuration of the present invention are shown. In this embodiment, the right connector end40has two offset tabs108, and the left connector end38has two offset recesses110. As shown inFIG. 19, offset tabs108and offset recesses110mate when the two light protector pieces12are selectively connected. This type of mating relationship is a variant of a lap joint, and more aptly described as an offset lap joint. One through hole112is provided in the left connector end38and another through hole114is provided in the right connector end40of the light protector pieces12. One threaded hole116is provided in the left connector end38and another threaded hole118is provided in the right connector end40of the light protector pieces. When the two light protector pieces12are selectively connected, through hole114aligns with threaded hole116and through hole112aligns with threaded hole118, and fasteners28engage these alignments and secure the light protector pieces12together. As with all the embodiments, in this embodiment the left mount end of the right hand piece and the left connection end of any spacer piece has the common left hand mounting configuration of this embodiment, and the right mount end of the left hand piece and the right connection end of any spacer piece has the common right hand mounting configuration of this embodiment. Hence, in this embodiment, any combination of light protector pieces12and spacer pieces14can be selectively connected between a left hand piece16and a right hand piece18to form a substantially linear assembly36of any desired configuration.

Referring now toFIGS. 20 and 21, still yet another alternate embodiment of the common left hand mounting configuration and the common right hand mounting configuration of the present invention are shown. In this embodiment, the right connector end40has two tabs120and the left connector end38has one tab122that mate when the two light protector pieces12are selectively connected. This type of mating relationship is a combination of a finger joint and dowel joint. Press fit bores124are provided in tabs120and tab122that align to allow press fit dowels126to be driven into the aligned bores to secure the two light protector pieces12, when the two light protector pieces are selectively connected, as shown inFIG. 21. As with all previous embodiments, in this embodiment the left mount end of the right hand piece and the left connection end of any spacer piece has the common left hand mounting configuration of this embodiment. Further, the right mount end of the left hand piece and the right connection end of any spacer piece has the common right hand mounting configuration of this embodiment. Again, any combination of light protector pieces12and spacer pieces14can be selectively connected between a left hand piece16and a right hand piece18to form a substantially linear assembly36of any desired configuration.

FIGS. 12-21, exemplify a number of embodiments of the present invention having alternative common left and right hand mounting configurations. It is to be appreciated that, according to the present invention, a multitude of alternative common left hand and right hand mounting configurations can be achieved. It is envisioned that variations of lap joints, finger joints, tongue and groove joints, dove joints, mortise and tenon joints, bridle joints, scarf joints, dowel joints, and the like, may be used, singularly or in combination, to establish a multitude of alternative common left hand and right hand mounting configurations, all in accordance with the present invention. All that is required is that a particular common left hand mounting configuration and common right hand mounting configuration be integrally related, so that each piece is selectively connectable to any other piece, left hand mounting configuration to right hand mounting configuration, to form a substantially linear assembly of any desired configuration.

What has been described are preferred embodiments of a modular light rack assembly adapted to be mounted to an off-road vehicle in which modifications and changes may be made without departing from the spirit and scope of the accompanying claims. Although a number of embodiments have been described above in detail, those skilled in the art will appreciate that numerous modifications are possible without materially departing from the novel teachings and advantages of the subject matter described herein. Other modifications, substitutions, changes, and omissions may be made in the design and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present invention.