Mounting foot for light bar

A signaling system for mounting to an exterior surface of an emergency vehicle is provided. The signaling system includes a light bar and a pair of mounting feet. The light bar can include a plurality of signaling devices supported on and distributed along a base member and enclosed by a cover. The light bar can be secured to the mounting feet via a plurality of fasteners. The mounting feet can be connected to the emergency vehicle via roof straps. Each mounting foot can include a base, which can have a support portion, a contoured portion, and a pair of compartments; a pair of seals associated with each compartment; a pair of covers, which can be translucent, removably mounted to the base to enclose the compartments; and a roof strap secured to the base. Each compartment can house a signaling device, such as a lamp assembly.

FIELD OF THE INVENTION

This invention pertains to signaling systems for emergency vehicles and more particularly, is directed to warning light assemblies for mounting to emergency vehicles.

BACKGROUND OF THE INVENTION

Emergency vehicles such as police cars, ambulances, fire trucks, etc. typically have a signaling system including audio devices, such as sirens or speakers, and visual indicators, such as warning lights. One common type of warning light assembly for emergency vehicles is a light bar. A light bar can include a plurality of lights that are enclosed in a common housing. Different types of lights, such as stationary, strobe, oscillating, and rotating lights, as well as a speaker or siren can be packaged in a given light bar to provide a variety of different signaling options.

A light bar is typically mounted to a flat surface of the emergency vehicle, such as a roof surface, for example, using bolts that extend through the light bar to the interior of the vehicle and that can be secured thereto via washers and nuts.

Current light bar designs commonly make use of multiple, stacked lighting levels. Through the use of different levels, warning lights, such as flashing, rotating, or strobe lights are disposed in a level of their own, while other auxiliary lighting, such as takedown lights, alley lights, and directional indicators are disposed in a separate level. Through the use of this multi-level approach, devices within one level do not adversely affect the visual performance of other levels. The minimum height of a light bar using this scheme is limited based on physical limitations of the devices within each level and the stacking of each layer upon the other. Additionally, to reduce the conspicuity of a vehicle while not involved in an emergency situation, it is desired that a light bar have as low a profile as possible. The use of multi-layered light bars limits the height to which a light bar can be lowered while still maintaining adequate functionality.

SUMMARY OF THE INVENTION

The invention provides a mounting foot for use with a light bar. A signaling assembly can include a light bar and a pair of mounting feet in accordance with the present invention. The light bar can be secured to the mounting feet via a plurality of fasteners. The mounting feet can be connected to a vehicle, such as an emergency vehicle, via conventional methods, such as, roof straps. The mounting feet serve to attach and space the light bar off the roof of the vehicle while providing a platform for the mounting of components, such as, auxiliary lights, for example.

Each mounting foot can include a base, which can have a support portion, a contoured portion, and a pair of compartments; a pair of covers removably mounted to the base to enclose the compartments; and a roof strap secured to the base. A pair of seals can be associated with each compartment to seal the interior of the compartment. Each compartment can house a signaling device, such as a lamp assembly. Each cover can be made from a translucent material to allow a lamp assembly housed within the respective compartment to emit light therethrough. Each mounting foot can be disposed near the outer side edges of the roof. The contoured portion can be configured to substantially conform to the crown in the roof of the emergency vehicle to allow the mounting foot to be seated on the roof of the vehicle and to utilize more available space for the mounting of components, such as auxiliary lighting devices.

The invention allows for a reduction in the overall height of the light bar while maintaining the advantages of a multi-layered light bar. By mounting components, such as auxiliary lighting, within the light bar mounting feet, the area between the light bar and the vehicle roof fulfills the function of an auxiliary signaling layer while allowing the overall height of the light bar to be reduced.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Referring now more particularly toFIG. 1of the drawings, an illustrative signaling assembly100having a light bar100and a pair of light bar mounting feet or brackets120,122in accordance with the present invention is shown installed on a vehicle130. While the present invention is described in connection with an exemplary police car, the present invention is not limited to any particular type of vehicle. On the contrary, the present invention could be employed in any context in which it is desirable to be able to mount a light bar.

Referring toFIGS. 2-9, the signaling assembly100is shown. The mounting feet120,122are attached to the light bar110via a plurality of fasteners, such as, screws, bolts, and the like. Referring toFIG. 3, the mounting feet120,122serve to attach and space a base140of the light bar110off the roof of the vehicle while providing a platform for the mounting of components, such as, auxiliary or warning lights, for example. The mounting feet120,122are substantially identical to each other. Each mounting foot120,122includes a substantially planar support portion150upon which the base140of the light bar110can be placed in contacting engagement. Fasteners can extend through the support portion150of each mounting foot120,122and through the base140of the light bar110to secure the light bar110to the mounting feet120,122.

Referring toFIG. 4, attachment to the vehicle can be accomplished through conventional means, for example, through the use of hooks or fasteners through the mounting feet into the vehicle roof. InFIG. 4, the first mounting foot120includes a connecting bracket or roof strap160secured thereto by a fastener162. Referring toFIG. 5, each fastener162can be secured to the respective mounting foot120,122by extending through a transversely extending attachment rib164. The support portion150of each mounting foot120,122includes a plurality of holes170therein for receiving a respective fastener to attach the base140of the light bar110to the mounting feet120,122.

Referring toFIGS. 10-18, the first mounting foot120is shown. It will be understood that the description of the first mounting foot120is applicable to the second mounting foot122, as well. Referring toFIGS. 10 and 18, outer corners180,181of the mounting foot120can each include a respective compartment184,185for receiving therein one or more electrical components, such as a lighting device, for example. A respective cover188,189encloses each compartment184,185. The covers188,189can be produced from a transparent material or an opaque material, for example. In the illustrative embodiment, the first cover188is translucent, being blue, and the second cover189is opaque. In other embodiments, the cover can be constructed from a different colored material or a clear material, for example. Constructing the cover from an opaque material can be desired, for example, in embodiments where the particular compartment does not house a lighting device.

Referring toFIG. 11, the first and second covers188,189are secured to a base200of the mounting foot120via a plurality of fasteners202, such as screws, for instance. Referring toFIG. 12, the connecting bracket160extends from an outer end210of the mounting foot120. The supporting portion150of the mounting foot120is disposed at an inner end212of the mounting foot120. Referring toFIG. 13, the base200includes a curved cutout218for accommodating the connecting bracket160to allow the connecting bracket160to extend from the outer end210of the mounting foot120.

Referring toFIGS. 14-16, the mounting foot120includes a pair of seals230,231for each compartment184,185thereof. The first and second seals130,131can cooperate with the covers188,189to respectively seal the interior of each compartment184,185and to provide a seal between the mounting foot120and the vehicle. Referring toFIG. 18, two signaling devices in the form of lamp assemblies250,252can be attached to the mounting foot120. These lamp assemblies are capable of being adjusted over a horizontal angle254of about 110 degrees and then locked in position through the use of a screw, for example. The lamp assembly252can also be moved over a vertical angle256of about 10 degrees, measured between a point substantially parallel to the primary plane of the mounting foot and a point downward therefrom.

In other embodiments, the use of colored lighting that serves a secondary warning function could also be used. The invention is also not limited to the use of the described signaling device. LED or discharge (strobe) sources along with their associated lenses or reflectors could also be employed, for example. The signaling device can have a visual signaling feature and/or an aural signaling feature.

Referring toFIGS. 19-28, the base200of the mounting foot is shown. Referring toFIG. 19, the base200includes the support portion150, a contoured portion260, and the first and second compartments184,185. The contoured portion260extends between the supporting portion150and the compartments184,185. The contoured portion260is configured to dispose the compartments184,185in predetermined, spaced relationship with the supporting portion150and with each other.

Referring toFIG. 26, the second compartment185is shown. The first compartment is substantially a mirror image of the second compartment184. The second compartment includes a pair of cover mounts280,281that extend from a sidewall284and a bottom286of the compartment185. The sidewall284and the bottom286meet at an edge288that is curved. The compartment185includes an opening292, disposed substantially at the edge288, for allowing electrical wires, for example, to extend therethrough. The compartment185includes a signaling device mounting system296which includes a plurality of mounting points for allowing the signaling device to be pivotally connected to the base200such that the signaling device can rotate about at least two axis.

The mounting system includes a mounting dimple298having an opening300therethrough. The mounting dimple298presents a convex surface302to the bottom286of the compartment185. The surface302can be configured to substantially conform to a housing of the signaling device. The signaling device can pivot both horizontally and vertically with respect to the base200of the mounting foot about the mounting dimple298. The mounting system296can include a curved slot306, a mounting boss308, and a pair of lands310,311. The mounting dimple298can be disposed within a recess314.

Referring toFIG. 29, the first seal230can include a plurality of cutouts and openings to substantially conform to the interior of the compartment of the mounting foot in which it is disposed. The first seal230can be made from any suitable material. Referring toFIG. 30, the second seal231is shown. The second seal231can be configured to substantially conform to the perimeter of the compartment with which it is associated. The second seal231can be made from the same material as the first seal or from a different material.

Referring toFIGS. 31-35, an illustrative signaling device350is shown. The signaling device350shown inFIGS. 31-35is the same as the first and second signaling devices250,252shown inFIG. 18. The signaling device350is in the form of a lamp assembly. The lamp assembly350includes a housing352, a light source354, a connector356, a cap358, an o-ring360, a lens362, and a retainer ring364.

Referring toFIGS. 36-43, the lamp housing352is shown. The lamp housing352includes a generally concave recess370disposed at a bottom372thereof. Referring toFIG. 43, the recess370has a boss374extending therefrom. The boss374includes an opening376extending therethrough. Referring toFIG. 39, the lamp housing352includes a pair of fins380,381each having an elongated slot384and an opening386. Referring toFIG. 41, the lamp housing352is generally hollow. The concave recess370can be operably arranged with one of the mounting dimples298of the base200of one of the mounting feet, such as the mounting dimple298shown inFIG. 28.

Referring toFIG. 42, the lamp housing352includes a groove390extending around a perimeter392of a front opening394. The groove390is configured to accommodate the retainer ring such that the retainer ring can be disposed within the groove390with a portion of the retainer ring extending into the front opening394from the groove390around the perimeter392. With the retainer ring disposed in the groove390, the retainer ring can act to retain the lens, the o-ring, and a portion of the light reflector between the retainer ring and a shoulder396of the housing352.

As illustrated inFIG. 44, the light source354is molded with a light bulb receptacle400for receiving a light bulb402, which can be integrally molded together. In the illustrated embodiment, the receptacle400is formed to receive and retain two connection pins404,405, which form electrical connection with the light bulb402. Referring toFIG. 45, the connector356includes wires410,411for supplying electrical power to the light bulb. The wires410,411can be connected to the pins via push-on connectors, for example. Referring toFIGS. 46 and 47, the cap358is generally hollow and is provided to encircle the connector. The cap358includes a pair of grommets314,315to accommodate the wires of the connector. The cap358can be constructed from a material, such as rubber, for example, to provide a seal around the wires of the connector. The cap358can be sized such that the cap is retained around the connector via a friction fit. In other embodiments, different lights sources can be used, such as one or more LEDs, for example.

Referring toFIG. 48, the o-ring360is shown. The o-ring360can be made from any suitable material, such as, any suitable elastomer, for example. In some embodiments, the o-ring360can be made from silicone. Referring toFIG. 49, the lens362is shown. The lens362can be made from any suitable translucent or transparent material, such as borosilicate glass, for example. The lens362can be clear or be colored. Referring toFIG. 50, the retainer ring364is shown. The retainer ring364is the shape of an annulus with a portion removed therefrom. The retainer ring can be constructed from any suitable resiliently flexible material, such as metal for instance. The cutout portion of the retainer ring364allows the retainer ring to be flexed to reduce the size of an outer perimeter420thereof to allow the retainer ring to fit through the front opening of the lamp housing. The resiliently flexible nature of the retainer ring364allows the retainer ring to return to its original shape once the retainer ring364is aligned with the groove of the lamp housing.

Referring toFIGS. 51-59, the second cover189of the mounting foot is shown. The second cover189is a mirror image of the first cover188shown inFIG. 10. The second cover189is opaque whereas the first cover188is translucent. It will be understood that the second cover is similar to the first cover in other respects. As such, the description of the second cover189is applicable to the first cover188as well. Turning toFIG. 52, the cover189is shaped to substantially conform to the perimeter of the second compartment of the mounting foot to thereby enclose the compartment. The second cover189includes a pair of mounting holes430,431which are arranged such that the mounting holes430,431can be substantially aligned with the first and second cover mounts280,281of the mounting foot base200, shown inFIG. 26.

Referring toFIG. 59, the first mounting hole430of the cover189is shown. The second mounting hole of the cover189is substantially similar to the first mounting hole430. The first mounting hole includes a counterbore436and an opening438extending through a base440of the counterbore436.

Referring toFIG. 54, the cover189includes a notch444in a rear end wall446. When the cover189is mounted over the second compartment185of the mounting foot, the notch444is substantially aligned with the opening292of the compartment185, as shown inFIG. 26. Referring toFIGS. 56 and 57, the cover189includes a dome portion450. Referring toFIG. 58, the cover189includes a lip452which can extend about a perimeter454of the second compartment185, as shown inFIG. 15. At least a portion of the lip452can overlap the perimeter454.

In some embodiments, the cover can be what is sometimes referred to as a “hot mirror” wherein the cover allows visible light to pass through it but reflects back inwardly infrared light so as to diminish the amount of heat transferred outwardly. With such a cover, it can be possible to locate a lamp housed within it closer to materials which would otherwise be susceptible to melting and/or damage from heat.

Referring toFIGS. 60-62, the connecting bracket or roof strap160is shown. The roof strap160can be made from cold-rolled steel, for example, and provided for securing each of the mounting feet to the roof of the vehicle130, as shown inFIG. 1. A first end460of the strap160can be secured under a rain gutter of the vehicle and a second end461of the strap160can be secured to the respective mounting foot by way of a bolt458, for example, through the roof strap160and the strap mounting hole470of the mounting foot120, as shown inFIG. 17.

Referring toFIG. 63, another embodiment of a light bar810is shown. The light bar810can be substantially similar to the light bar shown and described in U.S. Pat. No. 5,884,997 to Stanuch et al., which issued on Mar. 23, 1999. In other embodiments of the signaling assembly, the light bar can be similar to the light bar shown and described in U.S. Pat. No. RE36,245 to Stanuch et al., which issued on Jul. 6, 1999. In yet other embodiments, the signaling assembly can include a light bar commercially available from Federal Signal of Oak Brook, Ill., such as one form the group including multi-level light bars, such as those marketed under the trade names VISTA Strobe, VISTA Halogen, and CUDA Spectre™, v-shaped light bars, such as those marketed under the trade names Premium Vision®, Smart Vector®, and Vector®; and single-level light bars, such as those marketed under the trade names Jetstream, JetStrobe Plus, Arjent™, Raydian™, and StreetHawk®, for example.

The light bar810shown inFIG. 63is a multi-level light bar and has a housing822with a generally elliptical shape and a plurality of lights disposed inside the housing. The light bar810can be mounted on the emergency vehicle by means of the mounting feet, with the lengthwise direction of the light bar transverse to the forward direction of the vehicle.

In the illustrated embodiment, the light bar810has three sections, including a left side section826, a right side section828, and a center section830. Another center section can be added to the light bar to allow incorporation of more lights in the light bar. Each section of the housing has a set of interfitting upper and lower shells which form a closed container. Thus, the housing includes upper shells832,834,836, and the corresponding lower shells838,840,842. The upper shells join the respective lower shells at a seam which surrounds the light bar. The lights in the light bar810are arranged in two tiers, one above the seam and one below the seam, to provide a variety of warning functions.

The upper and lower shells of each section interfit to form a substantially sealed container for protecting light fixtures mounted therein from the elements in the environment. The shells are preferably molded of a substantially transparent, high-impact plastic material, such as polycarbonate, for example, and are preferably clear, although they may be colored, or certain portions of the shells may be made opaque to prevent light emission in certain selected directions.

FIG. 63shows the basic structural components of the light bar810without the lights mounted therein. As illustrated, the housing includes three sections828,830,826with upper shells832,834,836and lower shells838,840,842, respectively. The lower shells838,840,842of the three sections are rigidly secured to a structural support member for structural support. In the illustrated embodiment, the structural support is an extruded beam844which has a length shorter than the overall length of the light bar. The beam844can be made from any suitable metal, such as, aluminum, for example. The structural rigidity of the light bar is further enhanced by the use of interlocking ribs846disposed on the opposing sides of adjacent lower shells.

The light bar can have a modular construction which is achieved by the use of trays with cells for mounting lights. As illustrated inFIG. 63, the side sections826,828have side trays850,848, respectively, disposed therein in the recesses of the lower shells838,842around the ends of the beam844. The center section830has a front tray852and a rear tray854disposed in the recesses in the lower center shell840on the two sides of the beam844. The trays are preferably molded of plastic.

The trays848,852,854,850are attached to the respective lower shells838,840,842. Each tray848,852,854,850can include a plurality of vertical dividers which define an associated plurality of light cells (indicated by arrows inFIG. 63) for receiving standardized light fixture components, for example. The thickness of the trays is such that the tops856,858,860,862of the trays when mounted in the lower shells have a height that substantially matches that of the seam of the housing. The tops of the trays separate a lower tier of lights which is below the seam from an upper tier of lights above the seam. The tops of the trays also provide a platform for mounting lights on the upper tier.