Supplemental lighting element

A supplemental lighting element (10) for a vehicle includes a circuit board (27) including at least one illuminator thereon, a housing having an optical element (12) in register with the at least one illuminator on the circuit board (27) and a heat sink (22) positioned between the circuit board (27) and the heat sink (22).

BACKGROUND

This invention relates to lighting and illumination fixtures for, in one non-limiting example, a vehicle. In one of its aspects, the disclosure relates to a lighting fixture with multiple light-emitting diode (LED) light sources. In another of its aspects, the disclosure relates to a light assembly of one or more light sources and housing components.

SUMMARY OF INVENTION

In one aspect, aspects of the disclosure relate to a supplemental lighting element for a vehicle includes a circuit board including at least one illuminator thereon, a housing having an optical element in register with the at least one illuminator on the circuit board and a peripheral wall enveloping a periphery of the circuit board, the housing having at least one inwardly-extending leg having a retainer thereon, a heat sink having at least one recess in alignment with the at least one inwardly-extending leg on the peripheral wall of the housing, and a thermal pad positioned between the circuit board and the heat sink.

DETAILED DESCRIPTION

Aspects of the disclosure can be implemented in any environment, apparatus, or method for illuminating or providing illumination. In one non-limiting example configuration, aspects of the disclosure can be included as lighting element or supplementary lighting element for a vehicle. For example, one non-limiting aspect of the disclosure can be utilized to provide active visual illumination, such as visual or lighting warnings, to attract the attention of motorists and pedestrians to the vehicle's presence or approach. While a “vehicle” is described, aspects of the disclosure can be applied to any vehicles, including, but not limited to, emergency vehicles (e.g. fire trucks, ambulances, law enforcement vehicles, or the like), construction vehicles (e.g. cars, trucks, construction equipment, bulldozers, cranes, or the like), land-based vehicles (pedestrian automobiles, motorbikes, all-terrain vehicles, or the like), sea-based vehicles (boats, barges, or the like), or air-based vehicles (aircraft, blimps, balloons, or the like). Non-limiting examples of vehicles can include, for instance, cars, trucks, semi-trucks, cargo carriers, boats, aircraft, and trains. Furthermore, as used herein, a vehicle does not need to include an independent propulsion system, and can include, for example, train cars, barges, trailers, or semi-trailers. In addition to vehicles, non-limiting aspects of the disclosure can also be included in stationary illumination applications, such as signage, security lighting, or the like.

While “a set of” various elements will be described, it will be understood that “a set” can include any number of the respective elements, including only one element. As used herein, the terms “axial” or “axially” refer to a dimension along a longitudinal axis described. The terms “fore” or “forward” refers to a vector in the direction of illumination of a lighting element, while the terms “aft,” “backward,” or “rear” used in refers to a direction opposite to the vector in the direction of illumination of the lighting element, or toward the rear lighting element.

As used herein, the terms “radial” or “radially” refer to a dimension extending between a center longitudinal axis described, an outer circumference, or a circular or annular component described.

All directional references (e.g., radial, axial, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise) are only used for identification purposes to aid the reader's understanding of the disclosure, and do not create limitations, particularly as to the position, orientation, or use thereof. Connection references (e.g., attached, coupled, connected, and joined) are to be construed broadly and can include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to each other. The exemplary drawings are for purposes of illustration only and the dimensions, positions, order and relative sizes reflected in the drawings attached hereto can vary.

FIG. 1illustrates a lighting element assembly10in accordance with various aspects described herein. Non-limiting aspects of the disclosure can be included wherein the lighting element assembly10is a primary lighting element or a supplemental lighting element, for instance, for a vehicle or another device as described above. As used herein, a “primary” lighting element can include a primary illuminator, such as room lighting, or automobile headlamps, while a “supplementary” lighting element can include non-primary illuminators, including, but not limited to, accessory lighting, light bars (e.g. for emergency or non-emergency vehicles), warning lighting, perimeter lighting, notification lighting, or the like.

The lighting element assembly10can include at least one optical element12, illustrated as a first optical element14and a second optical element16. Non-limiting aspects of the disclosure can be included wherein the first and second optical elements14,16can be formed or molded as a single, continuous optical element12, or can be separately formed as distinct optical elements14,16and adjoined, assembled, coupled, attached, fixed, or the like. As shown, the at least one optical element12can include a top portion (for example, the first optical element14portion) having a substantially ovate, planar surface. Also as shown, the at least one optical element12can include a side portion (for example, the second optical element16) having a peripheral wall encircling the top portion while the contours transition from the substantially planar surface of the top portion to a sidewall surface that is substantially perpendicular to the top planar surface. Not limiting dimensional aspects of the lighting element assembly10can include an assembly that is less than or equal to 10 millimeters tall (e.g. 9 millimeters, or as measured from the base of the peripheral wall to the top planar surface), between, or less than, 76.2 millimeters to 101.6 millimeters along a major body axis of the assembly10, and less than or equal to 25.4 millimeters wide along a minor body axis of the assembly10.

In another non-limiting aspect of the disclosure, at least one of the first or second optical elements14,16can be adjoined, or the like, during the forming process. For example, the first optical element14can be formed, molded, manufactured, or the like, and can then be adjoined, or the like, during the forming, molding, manufacturing, or the like, of the second optical element16. Non-limiting aspects of the disclosure can also be included wherein the compositions, colors, additives, tintings, attenuation, dopings, or physical properties or characteristics can be the same or dissimilar between the first and second optical elements14,16. In yet another non-limiting aspect of the disclosure, at least one of the first or second optical elements14,16can be formed or molded from a flexible, optical-grade silicon material.

FIG. 2illustrates an exploded view of the lighting element assembly10. As shown, the lighting element assembly can further include an electronics board portion20, a thermally conductive heat sink portion22, and an optional adhesive pad24. In this sense, the heat sink portion22is positioned between the electronics board portion20and the optional adhesive pad24. The electronics board portion20can further include, but is not limited to a circuit board27, such as a printed circuit board (PCB), supporting at least one illuminator and supporting circuitry28. In the non-limiting illustrated example, the at least one illuminator can include a set of light-emitting diodes (LEDs)26, and the supporting circuitry28can include controller modules configured to operate the set of LEDs26, power electronics for converting, regulating, or supplying appropriate power levels to the LEDs26, and the like. As shown, non-limiting aspects of the disclosure can be included wherein the entire set of the LEDs26, or a subset thereof, are positioned or located along a common axis, a common plane, or a common two-dimensional array. Non-limiting aspects of the electronics board portion20or the circuit board27can be include wherein the electronics board portion20, the circuit board27, or a substrate thereof can be rigid or flexible.

Non-limiting aspects of the circuit board27can also include a set of mountings29configured to receive a corresponding or matching set of fasteners. Non-limiting examples of fasteners can include mechanical fasteners, screws, nails, rivets, or the like, to enable or provide for physical attachment or coupling of the electronics board portion20or the lighting element assembly10to a mounting surface, such as the surface of a vehicle (not shown). In another non-limiting example, the mechanical fasteners can enable or provide for physical attachment or coupling of the electronics board portion20to the heat sink portion22. In yet another non-limiting example, a set of more than one mechanical fasteners can be utilized, wherein, for example, a first mechanical fastener enables or provides for physical attachment or coupling of the electronics board portion20to the heat sink portion22, while a second mechanical fastener is utilized to mount the lighting element assembly10to a mounting surface. In the aforementioned example, the first and second mechanical fasteners can be different fasteners (e.g. a rivet and a screw). For ease of understanding, the fastener has been generically illustrated as a set of screws35.

The electronics board portion20can also include a set of electrical connectors, shown as conductive wires30, for electrically coupling at least one of the circuit board27, the supporting circuitry28, or the LEDs26to a power source or a controller module configured to operate the like. While a set of conductive wires30are illustrated, non-limiting aspects of the disclosure can be included wherein as few as two conductive wires30are included (e.g. power and ground), or, for example, three conductive wires30are included (e.g. power, ground, common control signal configured or generated for controlling the set of LEDs26).

Non-limiting aspects of the heat sink portion22can include a thermally conductive material, such as a metal, metal alloy, or the like, selected for thermally conductive properties. In another non-limiting aspect, the heat sink portion22can be rigid or flexible. During illumination operations, the LEDs26can generate an amount of heat that can be thermally conducted, for instance, via the circuit board27, to the heat sink portion22. Non-limiting configurations of the heat sink portion22can also include a first aperture or opening32sized, shaped, contoured, keyed, or the like, to receive or enable the set of conductive wires30to pass through the first opening32. In another non-limiting configuration of the heat sink portion22, a set of second openings34can be provided that are sized, shaped, contoured, keyed, or the like, to receive or enable the set or a subset of the screws35to pass through.

As shown, the optional adhesive pad24can include a corresponding set of second openings34, aligned with the openings34of the heat sink portion22for receiving or enabling the set or a subset of the screws35, as described. Non-limiting configurations of the optional adhesive pad24can also include a third aperture or opening36sized, shaped, contoured, keyed, or the like, to receive or enable the set of conductive wires30to pass through the third opening36. Aspects of the disclosure are envisioned wherein the set of openings34are aligned or arranged based on the aforementioned mechanical fastener configurations or locations.

FIG. 3illustrates a cross-sectional view of the lighting element assembly10taken along line ofFIG. 1(i.e. along the minor body axis of the lighting element assembly10). As shown, the optical element12or the first optical element14is positioned above the LED26such that the optical pathway of light emitted from the LED26is directed through the top substantially planar surface of the optical element12or the first optical element14. In this sense, the optical element12or the first optical element14is in register with the LED26. As shown, non-limiting configurations of the optical element12or the first optical element14can further include shaping38, contours, angling, or the like configured to enable the focusing of light emitted from the LED26to concentrate, reach, or the like a predetermined target or predetermined pattern. The optical element12or the first optical element14can also include a set of first legs46configured to define, structurally space, or resiliently enable or maintain a predefined focal spacing between the LED26and at least one of the optical element12, the first optical element14, or the shaping38. In a further non-limiting aspect, the arrangement of LEDs26with shaping38is especially favorable when the materials for optical element12are physically non-rigid or flexible. For example, aspects of the disclosure can be included wherein the first legs46provide for, enable, or maintain self-alignment, registration, physical supportive means, or a combination thereof between the circuit board27and the shaping38or optical element12.

As shown, the lighting element assembly10can further include a thermally conductive and electrically insulative portion such as a thermal pad80, positioned between the circuit board27and the heat sink portion22to electrically insulate the circuit board27from the heat sink portion22. Non-limiting aspects of the thermal pad80can include a pre-formed solid or flexible material, such as silicon, configured to aid or enable the conduction of heat away from the electronics board portion20. In another non-limiting aspect, the thermal pad80can be an incompressible element or material. In this sense, heat generated by the LEDs26can be thermally conducted via the circuit board27, through the thermal pad80, to the heat sink portion22.

In another non-limiting aspect of the disclosure, the optical element12or the second optical element16can define a peripheral wall42, as described herein. As shown, at least a portion of the peripheral wall42can extend rearwardly past at least one of the circuit board27or the heat sink portion22. Non-limiting aspects of the disclosure can be included wherein the at least a portion of the peripheral wall42can further extend rearwardly past at least a portion of the optional adhesive pad24. In this sense, the circumference of the peripheral wall42envelops a periphery of the circuit board27, and defines at least a portion of a housing (including the optical element12, the first optical element14, or the second optical element16) for the lighting element assembly10.

The optical element12or the second optical element16can also include at least one second inwardly-extending leg40having a retainer41. The heat sink portion22can further include at least one third outwardly-extending circumferential leg44having a recess43sized, shaped, contoured, keyed, or the like to mate, match, or otherwise interact with the retainer41of the second leg40. In this sense, the retainer41and the recess43are configured, sized, shaped, or the like, to be in alignment with, or to be received within each other when the lighting element assembly10is assembled. WhileFIG. 3illustrates only a single cross-sectional view, non-limiting aspects of the disclosure can be included wherein the retainer41or the second leg40extends along the entire inner surface of the entire peripheral wall42, or a set of portions thereof. Likewise, non-limiting aspects of the disclosure can be included wherein the recess43or the third leg44extends along the entire periphery of the heat sink portion22, or for example, along a corresponding or matching set of periphery portions aligned with the retainer41.

As shown, at least one of the optical element12, the second optical element16, or the heat sink portion22can be sized such that a set of gaps48can be formed between the heat sink portion22and the circuit board27, or between at least an aligned portion of the second leg40and third leg44, when the optical element12or the second optical element16is placed around the circuit board27. While a gap48is illustrated between the thermal pad80and the heat sink portion22, aspects of the disclosure can be included wherein the gap48can exist between the circuit board27and the thermal pad80(e.g. the thermal pad80is coupled with the heat sink portion22instead of the circuit board27), or gaps48can exist both above and below the thermal pad80.

Non-limiting aspects of the disclosure can also be included wherein at least one of the optical element12, the first optical element14, or the second optical element16can include an additive (schematically illustrated as dotted box49). Non-limiting example additives49can include compositions, coloring elements, visible or non-visible spectrum light attenuation or attenuating elements, tinting elements, doping elements, or illuminative enhancement elements, such as a phosphoric element. The additive49can be evenly dispersed or selectively positioned or located on or within the optical element12. As described herein, aspects of the disclosure can be included wherein the first optical element14and the second optical element16can include dissimilar additives49. For instance, in one non-limiting configuration, the optical element12or the first optical element14can include no additives49, or additives49selected or configured to enable transparency or a predetermined amount of translucency. In this sense, the optical element12or the first optical element14can be configured to allow a significant portion of illumination from the LED26to traverse through the optic.

In another non-limiting configuration, the optical element12or the second optical element16can include additives49selected or configured to enable transparency, a predetermined amount of translucency, a predetermined amount of opacity, or coloring of the optic. For example, the optical element12or the second optical element16can be configured to be at least partially opaque and to be color-matched to correspond with a mounting surface, such as a wall or body of a vehicle. In this sense, the optical element12, the first optical element14, or the second optical element16can be configured or selected such that the additives49enable a “blending in” or a “concealing” quality of the light element assembly10relative to the mounting surface. Stated another way, the light element assembly10can be selectively configured to reduce the visibility of the light element assembly10relative to the mounting surface or vehicle. In on non-limiting example, a reduced visibility light element assembly10can improve the concealment of a law enforcement vehicle.

FIG. 4illustrates a cross-sectional view of the lighting element assembly10taken along line IV-IV ofFIG. 1(i.e. along the major body axis of the lighting element assembly10). As shown, non-limiting aspects of the disclosure can include the circuit board27having a plurality of grouped LED26sets, such as a plurality of 3 LEDs per grouping. Each of the plurality of grouped LED26sets can be aligned with a corresponding depending partial conical portion, or bulbous portion50, of the optical element12or the first optical element14. In this sense, the bulbous portion50defines a cavity52containing a set of the grouped LEDs26.

FIG. 5illustrates a zoomed cross-sectional view of a grouping of LEDs26ofFIG. 4. Non-limiting aspects of the disclosure can be included wherein each LED26in a grouping of LEDs26are the same, or emit a substantially similar colored light or illumination. Additional non-limiting aspects of the disclosure can be included wherein at least a subset of the LEDs26in a grouping emits different colored light or illumination. For example, the grouping of LEDs can include a first LED54, a second LED56, and a third LED58. In a non-limiting first aspect, all the LEDs54,56,58can emit white light. In a non-limiting second aspect, all LEDs54,56,58can emit red light. In a non-limiting third aspect, the first LED54can emit a first color, such as red, while at least one of the second or third LEDs56,58can emit a second color, such as white. In yet another non-limiting fourth aspect, the first LED54can emit a first color, such as red, the second LED56can emit a second color, such as white, and the third LED58can emit a third color, such as blue.

While only a single set of grouped LEDs26is illustrated, non-limiting aspects of the disclosure can be included wherein the same LEDs26(i.e. same colors of LEDs26, or grouping of similarly-colored LEDs26) of each grouping are controllably illuminated at the same time. For instance, all red LEDs26can be configured to operate simultaneously under a first control condition such that the lighting element assembly10only produces red light. In another example configuration, a first set of LEDs26can be configured to operate in an alternating flashing pattern with a second set of LEDs26to, for instance, flash red and white light from the lighting element assembly10.

FIG. 6illustrates a cross-sectional view of the lighting element assembly10similar toFIG. 3, therefore like parts are identified with like numerals. A difference betweenFIG. 3andFIG. 6is thatFIG. 6illustrates a view wherein the lighting element assembly10has been fastened, coupled, or attached to a mounting surface62, such as a vehicle. In one non-limiting aspects of the disclosure, a fastener (not shown) can be utilized to restrain, bias, fix, or compress the circuit board27toward the mounting surface62. As a result of the compressive force of the circuit board27toward the mounting surface62, the peripheral wall42of the optical element12or the second optical element16is compressed toward the mounting surface62. Since the peripheral wall42is a flexible material, the compressive force of the peripheral wall42toward the mounting surface62can form a weather-tight seal, preventing moisture, debris, and the like from accessing the interior of the lighting element assembly10. In another non-limiting configuration of the disclosure, the compressive force between the circuit board27toward the mounting surface62can be provided or enabled by way of the optional adhesive pad24. In this configuration, for example, the mechanical fasteners can connect the heat sink portion22with the circuit board27, as described herein.

In another non-limiting aspects of the disclosure, the compressive force of the circuit board27toward the mounting surface62, the peripheral wall42of the optical element12or the second optical element16is compressed toward the mounting surface62can effectively or operably close or eliminate the gap48(i.e. as shown and described with respect toFIG. 3) between the heat sink portion22, the thermal pad80, and the circuit board27. In another non-limiting configuration of the disclosure, the compressive force between the circuit board27toward the mounting surface62can be provided or enabled by way of the optional adhesive pad24.

In yet another non-limiting aspect of the disclosure, the compressive force (via compression toward the mounting surface62, or via compression of the circuit board27and the heat sink portion22) can effectively or operably close or eliminate the gap48between at least an aligned portion of the second leg40and third leg44. In yet another non-limiting aspect of the disclosure, the compressive force can effectively or operably close or eliminate all of the gaps48described herein. Since at least the second leg40can be a flexible material, the compressive force toward the mounting surface62, or between the circuit board27and the heat sink portion22, can form a weather-tight seal, preventing moisture, debris, and the like from accessing the interior of the lighting element assembly10. At least one of the compressive seal between the mounting surface62and the peripheral wall42, between the heat sink portion22and the circuit board27, or between at least an aligned portion of the second leg40and third leg44can prevent access to the circuit board27.

FIG. 7illustrates a non-limiting zoomed cross-sectional view of the lighting element assembly10, wherein the circuit board27is fixed or fastened relative to the heat sink portion22by way of a mechanical fastener, illustrated as a rivet90. As shown, the fastening or fixing of the circuit board27relative to the heat sink portion22can provide the compressive force described herein to close the gap48between the circuit board27, the heat sink portion22, the thermal pad80, or a combination thereof.

FIG. 8illustrates another non-limiting aspect of the disclosure wherein a lighting element assembly110can be fastened to a vehicle100surface, such as a car side wall or door102, by way of another fastener, such as a clip mount160. As shown, the clip mount can provide the aforementioned compressive force to form the compressive seals described herein.

FIG. 9illustrates another non-limiting aspect of the disclosure, wherein a set of lighting element assemblies210can be fastened to a vehicle200surface, such as along a windshield202, or along a predefined mounting line of the vehicle200, to define a lighting assembly, such as a light bar.

Many other possible embodiments and configurations in addition to that shown in the above figures are contemplated by the present disclosure. For example, one non-limiting aspect of the disclosure can be included wherein an additional sealing element, such as a flexible material, adhesive, sealant, or the like, can be received into or proximate to at least one of the retainer41or the recess43, or between the peripheral wall42and a mounting surface62, to provide or improve the weather-proof seal described herein.

The embodiments disclosed herein provide a vehicle lighting assembly. One advantage that can be realized in the above embodiments is that the above-described aspects have superior size and durability advantages over conventional lighting fixtures. The flexible silicon optical elements provide for improved durability, or are more resistant to chips, cracks, or dulling, compared with similarly configured and sized polycarbonate type lens. The aforementioned configurations further provide for a thermally coupled heat sink that can be further connected with a vehicle mounting surface, further enabling increased heat removal or cooling capabilities compared with conventional configurations. Yet another advantage of the above-described aspects is that the lighting element assembly includes no sharp edges, allowing the lighting element assembly to meet state, local, or federal guidelines relating to smooth outer surface requirements.

Yet another advantage of the described assembly is that the optical elements allow for selective doping, tinting, or coloring of the housing to provide reduced visibility, or increased concealment of the assembly, compared with conventional lighting elements. Reduced visibility, or increased concealment can result in more effective vehicle utilization, such as for law enforcement. Reduced visibility or increased concealment is further enabled by a lower overall height of the lighting element assembly, as described. Yet another advantage of the described assembly is that the mounting of the lighting element assembly can provide for at least one weather-tight seal, preventing moisture or debris from entering the assembly, or interfering with the electronics such as the circuit board or LEDs. The interference of weather can increase maintenance efforts, or prematurely reduce the expected operating life of the assembly or subcomponents.

Yet another advantage of the described assembly is that the assembly allows for or enables a set of multi-colored LEDs to be included, as well as conformity of controlling operations for the multi-colored LEDs. By enabling multi-colored, controllable LEDs, a single lighting element assembly can effectively function as a set of different, single-colored lighting assemblies. Yet another advantage of the described assembly is that the assembly allows for or enables the molding of the housing or optical elements into shapes not otherwise possible with traditional engineering thermoplastics. Another advantage is the integrated single piece12with short optical profile height of the full assembly relative to the mounting surface62.

To the extent not already described, the different features and structures of the various embodiments can be used in combination with each other as desired. That one feature cannot be illustrated in all of the embodiments is not meant to be construed that it cannot be, but is done for brevity of description. Thus, the various features of the different embodiments can be mixed and matched as desired to form new embodiments, whether or not the new embodiments are expressly described. Combinations or permutations of features described herein are covered by this disclosure.