# Patent

## Title
Composite street sign with integral electrical wiring and integrated power supply

## Abstract

A street sign assembly is fabricated from a composite material having at least one panel for displaying indicia such as street names. Electrical conductors are embedded into the panel to permit attachment and electrical coupling of an integrated power supply module, lights and other electrical devices thereto. The integrated power supply module includes a solar panel and battery in a single weatherproof enclosure that is attachable to the panel. The battery is recharged by the solar panel and power is provided from the module through electrical leads that contact the embedded electrical conductors in the panel.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation in part of U.S. patent application Ser. No. 14/830,137 filed Aug. 19, 2015, which is a continuation in part of U.S. patent application Ser. No. 14/496,325 filed Sep. 25, 2014, which claims the benefit of U.S. provisional patent application Ser. No. 61/883,502, filed Sep. 27, 2013.


BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to street signs. More specifically, street signs made from a composite material and having integral electrical wiring and an integrated power supply module.
Background & Description of the Related Art
Street signs or street name signs usually consist of rectangular panels mounted on a vertical post, each panel having a street name, either in full or a variation thereof, printed on at least one side of the panel. The sign panels may also have graphics or other ancillary notations printed on them. Street signs are commonly found at street intersections and may share mounting posts with traffic signs such as stop signs.
Street signs are often constructed of metal to provide the strength and durability necessary to withstand harsh outdoor weather conditions. Specifically, the panels are usually made out of painted aluminum and the post from painted or unpainted aluminum or steel. However, use of aluminum for street sign panels has certain drawbacks when compared to other materials. Drawbacks include increased risk of theft due to the material value, glare from unpainted or chipped surfaces, and maintenance costs. Because of these concerns, fiber reinforced polymer (also called fiber reinforced plastic) has become a popular alternative material for fabricating street sign panels.
Fiber reinforced polymer (FRP) is a durable composite material comprising a polymer material reinforced by glass, carbon, aramid or other types of fibers. FRP products are formed using a variety of manufacturing methods including a pultrusion process. Pultrusion involves pulling reinforcing fibers or matting through a vat of resin and then through a heated die where the resin undergoes polymerization encasing the fibers.
A problem with many of the street signs made and used today, whether they are made of aluminum, FRP, or some other material, is that they are difficult to read in the dark, specifically at night. For this reason street signs typically use reflective material to make their words or graphics more visible in the dark. This can be done by adding reflective vinyl or reflective paint with glass beads to the sign panels.
Relying solely on reflectivity to make a street sign visible in the dark has an obvious and significant drawback, which is that an exterior light source is required to activate the reflective element and make the sign visible. Not only must there be an exterior light source but the light must be directed at the sign and the light must be of sufficient intensity to be reflected off of the sign. There are situations where this type of light may not be available, for example pedestrians walking without a light source or inclement weather such as rain causing the intensity of light hitting the sign to decrease due to refraction by the raindrops.
What is needed in the industry is a street sign made of durable material such as FRP having an integral means for illuminating the indicia on the sign. It is known in the art to mount LED lights to a traffic sign in a manner that overlaps the sign's indicia so that the lights outline or form the shape of the indicia. A company named Sollitech (www.sollitech.com) located in Amman, Jordan currently manufactures such a product. A problem with using lights to form the shape of the indicia rather than illuminating the indicia is that characteristics of the indicia such as color will not appreciable in the dark. A better method of using lights on a sign would be to illuminate indicia with lights set away from the indicia. Also, the lights in the Sollitech signs overlay the indicia, which detracts from the aesthetics of the sign during the daytime. What is needed is a durable street sign having integral wiring and lighting with an integrated power supply module configured to provide power such that the lighting illuminates indicia rather than simply outlining or forming the shape of the indicia.
SUMMARY OF THE INVENTION
The present invention is directed to a sign fabricated from a composite material such as fiber reinforced polymer or fiberglass. The sign has at least one panel for displaying indicia such as street names, the indicia being displayed on either the front surface or back surface of the panel. The panel has a pair of electrical conductors embedded therein between the front surface and back surface that can be used to supply electricity to lights or other electrically powered devices attached to the panel. The conductors may be routed above the indicia and run continuously along the length of the panel, and accordingly lights being fed electricity from the conductors may be positioned above indicia along the length of the panel. The sign may further comprise a post for supporting the panel. A battery for providing electrical power to the electrically powered devices may be stored within the post and a solar panel may be mounted proximate the top of the post for recharging the battery.
A light that is securable to the panel may comprise a light socket body with a plug projecting from an opposite end thereof. A socket may be formed in the light socket body and a light source positioned in the socket with a pair of electrical leads extending through the light socket body and plug. The plug could be inserted through a hole in the panel such that the electrical leads are held in contact with exposed portions of the electrical conductors. When inserted in the hole, the plug would extend beyond the panel and a cap sized to be wider than the hole would be secured on the plug holding the light to the panel. Lights can be mounted in a row above indicia on the panel and the lights may project from either side of the panel to illuminate either or both sides of the panel. Also, lights may be angled toward the indicia being illuminated.
Another embodiment of the invention comprises a lighting apparatus securable to a display panel on a street sign. The lighting apparatus comprises a panel or plate that supports lights for illuminating indicia on the sign. The apparatus may have one or more flanges extending downwardly from the lighting apparatus panel. The flanges are securable to the display panel on which the apparatus is mounted. The apparatus may overhang one or more surfaces of the display panel, and each overhang may have a pair of electrical conductors embedded therein. Similar to other embodiments, the conductors can be used to supply electrical power to lights or other electrically powered devices attached to the lighting apparatus panel. Preferably, the panel and flanges are fabricated from a fiber reinforced polymer and integrally formed as a unitary structure using a pultrusion process. The lighting apparatus may include a battery and solar panel secured to the panel to provide power to the lights.
In another embodiment of the invention a sign is fabricated from a composite material such as fiber reinforced polymer or fiberglass. The sign has a first panel in a generally vertical orientation for displaying indicia such as street names on either the front surface or back surface of the panel. A second panel, configured to attach to the top of the first panel in a generally horizontal orientation comprises a pair of electrical conductors embedded therein between the top and bottom surfaces of the second panel that distribute electrical power from an integrated power supply module to lighting elements or other electrically powered devices attached to the panel. A series of receptacles formed in the second panel expose the electrical conductors embedded therein so that a power supply, lighting element, or other electrically powered device inserted into the receptacle contacts the embedded conductors and places the device in electrical communication with other devices similarly connected.
An integrated power supply module comprises a solar panel and a battery configured in a single enclosure, with the solar panel affixed to and forming the top of the enclosure with the battery positioned within the enclosure. In conjunction with internal circuitry, the solar panel is operable to charge the battery during the day. Conductive posts in electrical communication with the internal battery extend from the bottom of the power supply module. The posts are configured to insert through and mate with the receptacles in the second panel to secure the power supply to the second panel and to contact and communicate electrical power through the electrical conductors embedded in the second panel. A lip along the bottom edge of the integrated power supply module further secures the module to the second panel.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the back of a street sign made of composite material.
FIG. 2 is a front perspective view of the sign in FIG. 1.
FIG. 3 is a cross-sectional view of the post taken along line 3-3 of FIG. 2.
FIG. 4 is an enlarged portion of a sign panel having a hole formed therein to expose the conductors.
FIG. 5 is a fragmentary cross-sectional view taken generally along line 5-5 of FIG. 1.
FIG. 6 is an exploded perspective view of a light and a cap used to secure the light in a hole in a panel of the sign in contact with conductors embedded therein.
FIG. 7 is an enlarged fragmentary, cross-sectional view take generally along line 7-7 of FIG. 1.
FIG. 8 is a perspective view showing an alternate embodiment of the street sign in FIG. 1.
FIG. 9 is a cross-sectional view of the post taken along line 9-9 of FIG. 8.
FIG. 10 is a fragmentary, exploded perspective view of the embodiment of the street sign shown in FIG. 8 having a T-shaped sign panel secured to the post by a bracket.
FIG. 11 is a fragmentary, end view of the street sign shown in FIG. 8.
FIG. 12 is an end view of the bracket for mounting the T-shaped sign panel to a post.
FIG. 13 is an exploded perspective view showing a second alternate embodiment of the street sign of FIG. 1.
FIG. 14 is a cross-sectional view of the street sign's lighting assembly taken along line 14-14 of FIG. 13.
FIG. 15 is an elevation view of the lighting assembly mounted on the street sign of FIG. 13.
FIG. 16 is a front perspective view showing a third alternate embodiment of the street sign of FIG. 1.
FIG. 17 is an end view of the lighting assembly of the third alternate embodiment of the street sign of FIG. 1.
FIG. 18 is a perspective view of an integrated power supply module portion of a lighting assembly for use with a street sign in accordance with an exemplary embodiment of the present invention.
FIG. 19 is a top, partial cut-away view of the integrated power supply module of FIG. 18.
FIG. 20 is a side view of the integrated power supply module of FIG. 18.
FIG. 21 is an exploded perspective view of a street sign and lighting assembly incorporating the integrated power supply module of FIG. 18.
FIG. 22 is an end view of the lighting assembly of the street sign of FIG. 21, taken along line 22-22 of that figure.



DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, the words “upwardly,” “downwardly,” “rightwardly,” and “leftwardly” will refer to the installed position of the item to which the reference is made. The words “inwardly” and “outwardly” will refer to directions toward and away from, respectively, the geometric center of the embodiment being described and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof and words of a similar import.
Referring to the drawings in more detail, reference numeral 1 refers to a street sign with FIG. 1 showing a perspective view of the back of the sign. The sign 1 comprises a vertical post 5 and display panels 8 attached to the post. Sign 1 further comprises electrical conductors 101 and 102 embedded within each panel 8 to serve electrically powered devices such as lights 16 attached to each panel. Finally, a battery 18 is located within post 5 for powering the electrical devices. The battery is charged by solar panel 24 mounted near the top of post 5.
In the embodiment shown, post 5 is constructed of fiber reinforced polymer (FRP) or resin, which is occasionally referred to as fiberglass. Post 5 has a cross section of approximately four inches by four inches and the post is generally hollow. The height of post 5 depends on the location of the sign but a height of eight feet is typical. Post 5 must be sufficiently durable to withstand wear and tear that may be caused by weather, pedestrians or machines such as lawn mowers. Accordingly, the walls 27 of post 5 are approximately one quarter inch thick, which results in sufficient strength and durability for most applications. The wall thickness can be modified as necessary to provide durability based on the sign's environment and use. Post 5 forms the support structure for sign 1 and for a typical installation post 5 is oriented vertically and its lower end (not shown) is anchored in the ground. The lower end is usually buried at a depth of at least two feet but site conditions will dictate the appropriate depth. Also, some installations require the lower end of post 5 to be embedded in concrete within the ground for stability such as when the ground is soft or sandy. Also, post 5 may be anchored entirely in concrete instead of dirt in situations where concrete is the only surface available for mounting such as urban street corners. Post 5 has a peaked cap 28 covering its top to prevent precipitation from accumulating atop the post. It is foreseen that other cap shapes such as domes or spheres could also be used for aesthetic reasons.
Attached to post 5 proximate its upper end 30 are display panels 8. Panel 8 has a front surface 31 and a back surface 32 and indicia 33 such as street names printed on either or both surfaces 31 and 32 of the panel 8 as appropriate. There are two panels 8 shown in FIGS. 1 and 2, but any number of panels 8 may be used. Each panel 8 is constructed of FRP or fiberglass. In a preferred embodiment, post 5 and panel 8 are both formed through a pultrusion process. In a pultrusion process reinforcing fibers or matting are pulled through a vat of resin and then through a heated die where the resin undergoes polymerization. The pultruded post 5 or panel 8 can then be cut to any desired length.
As shown in FIGS. 1 and 2, each panel 8 is rectangular in shape with dimensions of approximately five inches tall, twenty four inches wide, and one eighth of an inch thick. Panel 8 is attached to post 5 by riveting the panel's mounting end 34 to post 5 using rivets. Prior to riveting panel 8 to the post, four rivet holes (not shown) are drilled in the mounting end 34. A corresponding set of four rivet holes (not shown) are drilled in the upper end 30 of post 5. Panel 8 is attached to post 5 by aligning the rivet holes on panel 8 with those on post 5 and inserting and upsetting a rivet in each hole. It is foreseen that a different quantity and configuration of rivets may be used to attach a panel 8 depending on the specific physical characteristics of post 5 and panel 8.
Alternatively, as shown in FIGS. 8 and 9, sign 1 may comprise one or more t-shaped displays or panel assemblies 35 for displaying indicia. Each display 35 has a rectangular top panel 36 oriented in a horizontal planar fashion. A downwardly extending rectangular vertical panel 37 is attached to the bottom of top panel 36. Vertical panel 37 is generally perpendicular to and extends centrally relative to top panel 36. In the embodiment shown, vertical panel 37 is located proximate the longitudinal centerline of top panel 36. It is foreseen that panel 37 could be attached to top panel 36 in other locations including an edge of top panel 36. Top panel 36 is configured to overhang or project away at least one face 38 of vertical panel 37. As shown herein, top panel 36 overhangs both faces 38 and 39 of vertical panel 37 forming first and second overhangs 40 and 41. The overhangs 40 and 41 are adapted for connecting lights thereto to illuminate the faces 38 and 39 of vertical panel 37 as will be discussed in more detail hereafter. In a preferred embodiment, vertical panel 37 and top panel 36 are formed from a fiber reinforced polymer or fiberglass and formed from a pultrusion process as a single integral member having a t-shaped cross section. It is foreseen that the panels may be fabricated from other materials and may be formed separately and various methods may be used for securing the panels together.
Display 35 is attached to post 5 using mounting bracket 43. Bracket 43 includes a mounting flange 44 and a u-shaped support 45 attached to the outer face of mounting flange 440. Bracket 43 is secured to post 5 by fastening mounting flange 44 to the wall of the post using bolts or similar fasteners. An end of vertical panel 37 is placed in support 45 and secured to the support 45 using rivets or the like. When installed, display 35 extends from post 5 in a cantilevered fashion. Bracket 43 may be constructed of FRP or fiberglass or other materials.
In the embodiment shown in FIGS. 1-3, post 5 has a panel 8 attached to its back wall 47 and a panel 8 attached to side wall 48. Panels 8 can be attached at almost any location along the exterior of post 5, however it is preferable to attach panels proximate the upper end 30 of the post so the panels are easily visible to vehicles and pedestrians.
Sign 1 further comprises an integral electrical system which includes battery 18 installed within post 5. Battery 18 may be a rechargeable twelve volt sealed lead acid battery having approximate dimensions of four inches tall, three inches wide and three inches deep. Battery 18 has two terminals, one positive and one negative, located on top of the battery. The battery is installed in battery compartment 49 which is located in the interior hollow area of post 5 proximate upper end 30 of the post.
Battery compartment 49 is accessed through opening 50 on the front wall 46 of post 5. Opening 50 is generally concealed by cover 51 unless battery 18 is being replaced or the sign's electrical system is being serviced. Cover 51 is held in place over opening 50 by screws 52 which are routed through screw holes in the cover and threadingly engaged with threaded receivers 55. Threaded receivers 55 are located in tabs or brackets 56 which are riveted to the interior surface of the front wall 46 of post 5 at the top and bottom of opening 50 and extend toward the center of opening 50. In addition to receiving screws 52, brackets 56 serve as stops for cover 51 so that it does not fall through opening 50 and into battery compartment 49. Cover 51 is sized to fit snugly within opening 50 so that the cover 51 is flush with the exterior surface of front wall 46. A handle or pull (not shown) may be provided on cover 51 to assist in removal of the cover from the sign.
Battery 18 sits in battery compartment 49 on a platform 60. Integrally attached to the back of platform 60 is a mounting flange 67 extending downward at a right angle from the platform 60. Mounting flange 67 is placed against the interior surface of back wall 47 and riveted thereto so that platform 60 is horizontal within compartment 49. Mounting flange 67 has two rivet holes (not shown) aligned horizontally. Corresponding rivet holes (not shown) are located on the back wall 47 proximate the lower end of battery compartment 49 which generally aligns with the bottom of opening 50. Mounting flange 67 is attached to the back wall 47 by aligning the rivet holes in flange 67 with the corresponding holes on back wall 47 and inserting and upsetting a rivet in each hole. It is foreseen that a different quantity and configuration of rivets may be used to attach mounting flange 67 depending on the physical characteristics of post 5 and the weight being supported by flange 67. Care must be taken so that the rivets do not interfere with the mounting of a panel 8. Platform 60 is sized so that its width is slightly smaller than the width of opening 50 thus allowing the platform to be inserted through opening 50 for installation in compartment 49. When mounted on back wall 47, platform 60 extends away from the back wall 47 and across the battery compartment 49 to within approximately one half inch of opening 50.
The solar panel 24 for the electrical system of sign 1 is mounted proximate the top of post 5. Solar panel 24 comprises a collection of interconnected photovoltaic modules which are designed to convert solar energy or sunlight into electricity. Solar panel 24 generates electricity to charge battery 18 when the panel is exposed to sunlight. Therefore, for optimal operation of the solar panel 24, sign 1 should be mounted in a location which maximizes the amount of sunlight solar panel 24 receives. If sign 1 is mounted in an area that does not receive ample sunlight, such as in a tunnel or a heavily shaded area, solar panel 24 may not generate sufficient electricity to recharge battery 18.
Solar panel 24 is connected electrically to battery 18 through wiring 68. The electrically positive wire 68 attaches to the positive terminal on battery 18, and the electrically negative wire 68 attaches to the negative terminal on battery 18. The wires are routed from solar panel 24 to battery 18 through a wire opening 69 in post 5. The wire opening 69 is sealed with caulk or other weatherproofing to prevent moisture from entering the battery compartment 49.
Solar panel 24 is attached to post 5 by a bracket 70. Bracket 70 attaches to the lower back portion of solar panel 24 and also to post 5 above opening 50. Bracket 70 is attached to post 5 by riveting the mounting flange 72 of the bracket 70 to the post 5. Riveting is performed using a procedure similar to the steps of riveting a panel 8 or mounting flange 67. Typically four rivets oriented in a rectangular configuration are sufficient to attach and support solar panel 24 to post 5, however additional rivets may be used if necessary based on the weight of the solar panel. A supporting member or central web 74 of bracket 70 extends away from mounting flange 72 toward a panel engaging flange 75. The panel engaging flange 75 attaches to the lower back surface 76 of solar panel 24 by screws or other fasteners. As mentioned above it is desirable to maximize the amount of sunlight solar panel 24 receives, therefore the solar panel is typically tilted upward when mounted on post 5.
The electrical system of sign 1 also comprises a photocell switch (not shown) that is integral to solar panel 24 that automatically switches on and off electrical power from battery 18 to lights 16 based on ambient light proximate the sign. The photocell switch uses a light sensor 81 to identify the amount of ambient light around the sign, and when a predetermined level of ambient light is reached the switch activates or deactivates lights 16 as necessary. When light sensor 81 senses that it is sufficiently dark to require lights 16, the switch closes to allow battery 18 to provide power to the lights. When sensor 81 senses that it is sufficiently light outside and lights 16 are not needed, the photocell switch opens to stop battery 18 from providing power to the lights. The electrical system of the sign is designed such that, in general, during the daylight hours the lights 16 are off and the solar panel 24 generates electricity to charge battery 18, and during the nighttime hours battery 18 dispenses its charge to power lights 16.
As best seen in FIG. 4, electrical conductors 101 and 102 may be embedded in and run the length of panel 8. Similarly, two pairs of electrical conductors 101 and 102 are preferably embedded in and run the length of top panel 36 on opposite sides thereof. The conductors 101 and 102 are preferably flattened and generally form an elongated cuboid. The conductors 101 and 102 carry low voltage DC current to power electrical apparatus such as lighting, speakers, weather sensors and the like mounted to panel 8 or top panel 36. In the preferred embodiment the conductors 101 and 102 are flattened so that the conductors are taller than they are wide relative to a vertically oriented panel in which they are embedded. The wire may also be referred to as a flattened wire or conductor and the wire does not have to be truly rectangular in cross-section. It is to be understood that the wire could have planar, parallel front and rear surfaces with rounded upper and lower edges. It is also foreseen that the wire could have an ovate cross-section. Using flattened wires 101 and 102 reduces the size of any bulges or the like formed by displacement of fiberglass material around the conductors 101 and 102.
Access to the conductors or wires 101 and 102 for electrically connecting an electrical apparatus thereto is accomplished by forming holes 103 through panel 8 or top panel 36 with the holes 103 extending between the two conductors 101 and 102 and exposing a sufficient portion of the conductors 101 and 102 to form an electrical connection thereto with conductors on the apparatus to be installed. The number of holes 103 can vary depending on the type and quantity of apparatuses being connected to panel. The apparatus to be installed may include lights 16 of the type disclosed in my prior U.S. Pat. No. 7,810,277, the disclosure of which is incorporated herein by reference. A typical sign installation may comprise a row of lights 16 proximate the top of panel 8, the lights 16 spaced apart at two and a half inch intervals. If indicia 33 are on both sides of panel 8, the lights 16 in the row may be arranged in an alternating fashion such that every other light 16 illuminates one side of the panel (as shown in FIGS. 1 and 2). A typical panel 8 may have seven to eleven lights 16 mounted thereon. Other quantities and arrangements of lights 16 are foreseen depending on the size and application of the sign 1.
For T-shaped displays 35, holes are formed in each overhang 40 and 41 of the top panel 36 between parallel spaced conductors 101 and 102. Lights 16 are mounted on top panel 36 on opposite sides of vertical panel 37 to shine downward and illuminate indicia 33 on both sides of the vertical panel 37.
Battery 18 supplies electrical power to the conductors 101 and 102 respectively using a power supply clip 113 and cap 114 (see FIG. 3) assembly similar to that shown in U.S. Pat. No. 7,810,277. Electrical wires or leads 115 are connected between solar panel 24 and conductors 101 and 102. Electrical power supplied by battery 18 to conductors 101 and 102 is routed through solar panel 24 so that the photocell switch can start or stop power to the conductors depending on the amount of ambient light present.
The power supply clip 113, as shown in FIGS. 3 and 9, includes a plug or plug shaft 117 and a face plate or plug flange 118 sized for insertion in one of the holes 103 to frictionally engage the portion of the panel surrounding the hole 103. The plug 117 is generally square in cross-section. Two bores 124 extend through the face plate 118 and plug 117 of clip 113.
An exposed portion of each lead 115 is bent back over and across an outer surface of the plug 117 and preferably at least up to a rear surface 130 of the face plate 118f. The plug 117 is inserted in one of the holes 103 with the plug 117 oriented so that the exposed ends of leads 115 engage the conductors 101 and 102 so that the exposed ends of the leads 115 are pressed against and held in electrical contact with the conductors 101 and 102.
One of the caps 114 (of the type shown in FIGS. 5-7) is securable over the end of the plug 117 to help further secure the clip 113 in place on panel 8 or top panel 36. The cap 114 used for the power supply clip 113 may also be used for securing the lights 16 to panel 8 or top panel 36. Reference is therefore made to the drawings showing the lights 16 for details regarding the caps 114. Each cap 114 includes a receiver 133 which is square in cross-section and sized to receive the plug 117 in a friction fit. It is to be understood that a wide variety of other means could be utilized to connect electrical leads to the conductors 101 and 102 to supply electricity thereto. For example, the electrical connection may be made at the end of each panel 8 or 35.
The lights 16, an example of which is best seen in FIGS. 5-7, are constructed in a fashion similar to the clip 113. Each light 16 includes a body 135 including a plug or plug shaft 137 which projects rearwardly from a face plate or flange 138. The plug 137 is sized for insertion in one of the holes 103 to frictionally engage the portion of the panel surrounding the hole 103. The plug 137 is generally square in cross-section and includes a base 139 with a pair of rearwardly projecting legs or prongs 140 separated by a groove 141. Two bores 143 and 144 extend through the face plate 138 and plug 137 of light body 135. The bores 143 and 144 extend through base 139 of the plug 137 and open into the groove 121.
A bulb socket 146 is formed on faceplate 138 on a side opposite the plug 137, a light bulb 147 is secured within the socket 146 and a lens 148 covers the bulb 147 and socket 146. Electrical leads 149 and 150 extend from the light bulb 147 and through bores 151 and 152 in the in the face plate 138 and plug shaft 137 and back around sides of the plug 137 for engagement with the electrical conductors 101 and 102 when the plug 137 is inserted in one of the holes 103 in panel 8 or top panel 36. An exposed portion of each lead 149 and 150 is bent back over and across an outer surface of the plug base 139 and at least up to a rear surface 154 of the face plate 138. The plug 137 is inserted in one of the holes 103 with the plug 137 oriented so that the exposed electrical leads 149 and 150 engage the conductors 101 and 102 to form an electrical contact with the conductors 101 and 102.
A cap 114 is securable over the end of the plug 137 of each light 16 to help further secure the lights 16 in place on panel 8 or top panel 36. The cap 114 receiver 133 is sized to receive the plug 137 in a friction fit. The plug 137 preferably includes a groove 155 formed along the side of one of the legs 140. A mating guide or tongue 157 is formed in the cap receiver 133. The tongue 157 in cap receiver 133 extends into the aligned groove 155 formed in the leg 140 of plug 137 in a friction fit to further assist in securing the cap 114 to the plug 137.
The light bulb 147 may be of a variety of types including incandescent or LED. The shape of the socket 146 and lens 148 may also vary and it is foreseen that the light could be mounted above the sign 1, with flexible leads connected to conductors 101 and 102 through a clip such as clip 113 or through a rigid mount.
The light bulb 147 and lens 148 for each light 16 may be angled relative to the face plate 138 and mounted on panels 8 or 36 so as to angle toward and direct light toward indicia 33 on front and rear faces 31 and 32 of panel 8 or front and rear faces of panel 36. Overhangs 40 and 41 also reflect light downward across front and rear faces 38 and 39 to enhance illumination of the indicia 33 thereon.
An additional embodiment of the invention is shown in FIGS. 13-15. The figures illustrate a lighting apparatus or assembly 200 which can be secured to a sign display panel 201. The sign display 201 is attached to post 5 in a similar fashion to the t-shaped display 35 in FIGS. 8-12. The assembly 200 comprises a rectangular support plate or panel 203 oriented in a horizontal planar fashion over the sign display 201, with a solar panel 224 and battery 218 mounted to the plate's top surface, which power the lights 16 to illuminate the sign 201. As seen in FIGS. 13 and 14, a longitudinal channel 210 is formed between two flanges 212 extending downwardly from the underside of panel 203. Channel 210 is generally perpendicular to panel 203 and oriented proximate the longitudinal centerline of panel 203. Channel 210 is adapted to receive the upper edge of sign display panel 201. Other mounting means including alternative configurations of flanges 212 or channels 210 are also possible.
Assembly 200 may be secured to panel 201 by fastening or bonding flanges 212 to display panel 201. This can be done using fasteners such as rivets or threaded fasteners, or by using an adhesive or other permanent bond. Depending on the material used to fabricate assembly 200 and panel 201 it may also be possible to weld flanges 212 to panel 201.
Panel 203 is configured to overhang at least one of surfaces 213 or 214 of sign display panel 201. Surface 213 is a front surface or face of display panel 201 and surface 214 is a back surface or face of display panel 201. When assembly 200 is secured to display panel 201, the configuration of panel 203 and display panel 201 is similar to the configuration for vertical panel 37 and top panel 36 on the t-shaped display 35 as shown in FIGS. 8 and 10. Panel 201 extends downward from panel 203 in a generally perpendicular fashion. As shown in FIG. 13, panel 203 may overhang both surfaces 213 and 214 of panel 201 to form first and second overhangs 215 and 216. Preferably, panel 201 is centrally located below panel 203. However, it is foreseen that panel 203 may also be configured to overhang only one surface or face of panel 201. As discussed in more detail below, overhangs 215 and 216 are adapted to support lights 16 which can illuminate surfaces 213 and 214.
Panel 203 and flanges 212 are preferably constructed from a fiber reinforced polymer or fiberglass although other materials such as plastic, rubber, and metal may be used. Panel 203 and flanges 212 may be integrally formed as a unitary structure using a pultrusion process as previously described. It is foreseen that the panel 203 and flanges 212 may also be formed separately from one another and be secured together using fasteners or bonding methods known in the art.
As shown in FIGS. 13-15, lighting assembly 200 further comprises an electrical system which includes a battery 218 secured to panel 203. Battery 218 may be housed in a weatherproof enclosure or it may have a weatherproof construction. Battery 218 is located on panel 203 in a location that is convenient for maintenance such as on the top surface of the panel 203. Battery 218 is preferably rechargeable but a non-rechargeable battery may also be used. If a rechargeable battery 218 is used, it may be desirable to include a recharging device on assembly 200 such as solar panel 224.
Solar panel 224 comprises a collection of interconnected photovoltaic modules which are designed to convert solar energy or sunlight into electricity. Solar panel 224 generates electricity to charge battery 218 when the panel is exposed to sunlight. Therefore, for optimal operation of the solar panel 224, lighting assembly 200 should be mounted in a location which maximizes the amount of sunlight solar panel 224 receives and solar panel 224 should be mounted on top of panel 203. If lighting assembly 200 is mounted in an area that does not receive ample sunlight, such as in a tunnel or a heavily shaded area, solar panel 224 may not generate sufficient electricity to recharge battery 218.
As shown in FIGS. 13 and 15, solar panel 224 is connected electrically to battery 218 through wiring 230. Wiring 230 can be routed from solar panel 224 to battery 218 atop panel 203 in weatherproof sheathing. Wiring 230 may be secured to panel 203 using a wiring management system known in the art, or in some circumstances it may not be necessary to secure wiring 230 to panel 203. Solar panel 224 and battery 218 may be secured to panel 203 using fasteners or adhesives.
The electrical system of lighting assembly 200 further comprises a photocell switch (not shown) that is integral to solar panel 224 that automatically switches on and off electrical power from battery 218 to lights 16 based on ambient light proximate the assembly 200. The photocell switch uses a light sensor 235 to identify the amount of ambient light around the assembly 200, and when a predetermined level of ambient light is reached the switch activates or deactivates lights 16 as necessary. When light sensor 235 senses that it is sufficiently dark to require lights 16, the switch closes to allow battery 218 to provide power to the lights. When sensor 235 senses that it is sufficiently light outside and lights 16 are not needed, the photocell switch opens to stop battery 218 from providing power to the lights. The electrical system of the assembly 200 is designed such that, in general, during the daylight hours the lights 16 are off and the solar panel 224 generates electricity to charge battery 218, and during the nighttime hours battery 218 dispenses its charge to power lights 16.
Power supply devices other than battery 218 and solar panel 224 may be used to power lights 16. For example, assembly 200 may get electrical power from an emergency generator, a wind turbine, or a connection from a municipal power supply grid.
As best seen in FIG. 17, electrical conductors 101 and 102 may be embedded in and run the length of panel 203 similar to the t-shaped display 35 (shown in FIGS. 10 and 11). Two pairs of electrical conductors 101 and 102 are preferably embedded in and run the length of panel 203 on overhangs 215 and 216. It is also foreseen that only one or neither of the overhangs may have a pair of conductors 101 and 102. The conductors 101 and 102 carry low voltage DC current to power electrical apparatus such as lights, speakers, weather sensors and the like as described above with respect to a t-shaped display 35. Panel 203 may be referred to as conductive panel 203.
Access to the conductors or wires 101 and 102 for electrically connecting an electrical apparatus thereto is accomplished by forming holes 103 through panel 203 with the holes 103 extending between the two conductors 101 and 102 and exposing a sufficient portion of the conductors 101 and 102 to form an electrical connection thereto with conductors on the apparatus to be installed. The number of holes 103 can vary depending on the type and quantity of apparatuses being connected to panel. As shown in FIGS. 4-7 and 13-15, the holes 103 are capable of receiving a power supply clip 113 or an illuminating member such as light 16 similar to the T-shaped display 35. A cap 114 is used to secure the power supply clip 113 and lights 16 to panel 203.
The light bulb 147 and lens 148 for each light 16 may be angled relative to face plate 138 and mounted on panel 203 so as to angle toward and direct light toward indicia 33 on front and rear surfaces 213 and 214 of the panel 201. Overhangs 215 and 216 also reflect light downward across front and rear surfaces 213 and 214 to enhance illumination of the indicia 33 thereon.
A third embodiment of the invention is shown in FIGS. 16 and 17. The third embodiment comprises a lighting apparatus or assembly 300 that is the same as the embodiment shown in FIGS. 13-15 except that it comprises only a single flange 212 functioning as a mounting means and no longitudinal channel 210. Lighting apparatus 300 may be secured to panel 201 by fastening or bonding flange 212 to display panel 201. This can be done using fasteners such as rivets or threaded fasteners, or by using an adhesive or other permanent bond. Depending on the material used to fabricate assembly 300 and panel 201 it may also be possible to weld flange 212 to panel 201.
A fourth embodiment of the invention is depicted in FIGS. 18-22. The fourth embodiment is similar to the embodiments described with respect to FIGS. 13-17, including a first panel having indicia, a second panel attachable to the first having embedded electrical conductors and configured to receive lighting elements and other electrically powered devices, and a vertical post to support the sign assembly, but further includes an integrated power supply module configured to attach to the second panel and operable to provide power to the sign assembly as will now be described.
Looking first to FIGS. 18-20, an integrated power supply module in accordance with an exemplary embodiment of the present invention is depicted generally by reference numeral 400. Power supply module 400 comprises a box-shaped enclosure 402, having generally square-shaped top and bottom panels 404, 406 positioned in parallel, spaced apart relationship. The top and bottom panels 404, 406 are connected to each other by four rectangular walls 408, 410, 412, 414 which extend between the outer edges of the corresponding sides of the top and bottom panels. The connected panels and walls form an interior cavity in which a battery, circuitry, and power connection posts are positioned as will be described in more detail below.
As best seen in FIGS. 18 and 20, the lower edge of side walls 408 and 410 each extend slightly below the junction of the respective wall with the bottom panel 406, with an inwardly facing lip 420, 422 protruding from each corresponding lower edge. The extended lower edge and protruding lip form an L-shaped projection extending along the lower edge of each side wall and defining a slot 424, 426 along the lower edge of each between the bottom panel 406 and the L-shaped projection. As will be described in more detail below, the slots 424 426 are configured to conform to the thickness of the second panel of the sign assembly such that the power supply module is secured to the second panel when the slots are placed or snapped into place on the second panel.
Preferably enclosure 402 is sealed and weathertight, with the edges of the top and bottom panels 404, 406 sealed to the corresponding edges of the side walls by welding, gluing, or other adhesion methods known in the art. Most preferably, the panels and walls are made of a composite material, such as FRP.
As best seen in FIG. 18, in the embodiment depicted, the top panel 404 preferably includes a solar panel 428 extending over substantially the entire top surface of the panel. Solar panel 428 preferably comprises a plurality of photovoltaic modules wired in conjunction, with each photovoltaic module operable to convert solar energy into electrical power.
It should be understood that while the exemplary embodiment depicts a single solar panel 428 covering the entire enclosure and integrated with the top panel 404, other configurations of solar panels or photovoltaic modules are contemplated by the present invention. For example, the top panel 404 may be a separate piece with one or more separate solar panels attached to that piece, or the one or more solar panels may include a backing plate that is used as the top panel 404 of the enclosure. Similarly, while the solar panel 428 is depicted as extending over substantially the entire top area of the enclosure, other configurations of solar panels extending less than the entire top area may be used.
Looking to the cutaway view of FIG. 19, it can be seen that a battery 430, control circuitry 432, and connection points to conductors extending into power connection plugs 434, 436 are positioned within the inner cavity of the enclosure, beneath the top panel 404 and solar panel 428. Internal electrical wiring connects between the battery, the control circuitry, and the power connection posts to allow the flow of electrical power between those components.
Battery 430 is preferably a rechargeable type battery, such as a nickel cadmium (NiCad), lithium, or lead-acid battery as is known in the art. Control circuitry 432 preferably regulates the charging of the battery 430 from the electrical power generated by the solar panel 428.
Looking to FIGS. 18-20 in conjunction, it can be seen that the power connection plugs 434, 436 extending from the bottom of the power supply module are essentially identical in configuration and operability to the plugs extending from the bottom of the previously described light assembly of FIG. 6, the plug being generally square in cross-section and including a base with a pair of downwardly projecting legs or prongs separated by a groove. Two electrical leads extend through bores in the center of the plug, extending downwardly from the interior of the power supply module, with the leads wrapping back up along opposite sides of the plug. Thus, two conductive leads are exposed along the front and back sides of each projecting power connection plug.
In a manner similar to that previously described with respect to the embodiment of FIGS. 4 through 7, the power connection plug is configured to insert into the holes or receptacles formed in the second panel, with the conductive leads on the power connection plugs contacting the exposed internal conductors in the panel accessible in the receptacles. Thus, plugging the power supply module into receptacles on the second panel causes the electrical power from the module (e.g., from the solar panel and/or the battery) to be communicated through the conductive leads on the power connection plugs to the electrical conductors embedded in the second panel. The electrical power from the power supply module is thus communicated along those embedded conductors and is available to any light or device plugged in to other receptacles on the second panel.
The outer dimensions of the square power connection plugs are preferably sized to conform to the square shape of the receptacles formed in the second panel. Thus, the power connection plugs preferably frictionally engage with the walls of the receptacle such that the power connection plugs secure the power supply module in place when plugged in to the receptacles while simultaneously the electrical leads of the power connection plugs contact the embedded wiring in the receptacle to communicate electrical power throughout the panel.
Looking to FIG. 20, in a manner to the cap previously described with respect to the embodiment of FIG. 5, a semicircular cap 440, 442 is configured to snap over the lower end of each power connection plug to protect the post and secure it within a hole or receptacle of the second panel of the street sign assembly. Preferably the caps are made from a resilient, weather resistant material such as a plastic or composite material.
In alternative embodiments the integrated power supply module may include a photocell and circuitry operable to switch on or off the flow of electrical power from the battery and/or the solar panel to control the charging of the battery and to limit the usage of the battery to times in which the ambient light is at a level low enough to warrant lighting of the street sign assembly. The photocell is preferably attached to an external portion of the enclosure with wiring extending into the interior cavity. Most preferably, the control circuitry 432 within the module monitors the photocell and regulates the flow of electrical power accordingly. Thus, the photo cell allows the control circuitry to switch on or off the power to the power output posts so that any lighting elements connected to the street sign light assembly are only provided with power when required based on the ambient light level. For example when the ambient light is below a predetermined level, such as at night or during cloudy or stormy weather, no power would be provided to the lights. In other alternative embodiments the predetermined level of light at which power is switched is adjustable by a user via a potentiometer or other control in communication with the control circuitry.
As just described, it can be seen that the integrated power supply module, including the solar panel 428, battery 430, control circuitry 432, internal electrical wiring, and the electrical lead portions of power connection plugs 434, 436 are all in electrical communication with each other such that electrical power generated by the solar panel is used to charge the battery. The battery then provides electrical power to the power output posts, which in turn provide electrical power to the embedded conductors in the second panel of the street light assembly as will now be described.
Looking to FIGS. 21 and 22, in a manner similar to that described with respect to the embodiment of FIGS. 13 through 17, a street sign assembly in accordance with an exemplary embodiment of the present invention includes a sign assembly 450 comprised of a first vertically oriented panel 452 having indicia 453 thereon and a second horizontally oriented lighting panel 454 attached to the top of the first panel. The entire T-shaped sign assembly is constructed and configured in a manner similar to that previously described with respect to the various embodiments shown and described in FIGS. 8-12 and FIGS. 13-17.
In this embodiment, the second panel 454 includes two pairs of embedded electrical conductors 456, 458 running within the panel proximate each outer edge, in the manner as previously described. A series of holes or receptacles formed along each edge of the panel allow access to the embedded conductors, exposing a sufficient portion of each conductor to allow an electrical connection to be formed between the conductor and a lighting element, electrical accessory, or power supply post inserted into the receptacle. The number of holes or receptacles can vary depending on the length or size of the panel, or can vary depending upon the desired lighting capability of the panel.
As shown in FIG. 21, an integrated power supply module 400 is mounted to the top of panel 454, with the power connection plugs extending downwardly and through two of the holes formed along opposite edges of the panel. With the integrated power supply 400 module thus placed, the electrical leads of each power connection plug contact the exposed portion of the embedded electrical conductors in the receptacle so that the power supply module supplies electrical power to those conductors.
Thus, as seen in FIG. 22, a cross-sectional view taken along line 22-22 of FIG. 21, the integrated power supply module 400 is mounted atop the lighting panel 454, with the power connection plugs 434, 436 extending through two of the receptacles in the panel. The lower end of each plug 434, 436 is covered by a corresponding cap 440, 442, which serve to protect the post and electrical leads from the elements and to further secure the module to the panel. The slots at opposite sides of the of the power supply module, formed by the extended lower edges of side walls 408, 410 and the protruding lips 420, 422 secure the edges of the power supply module to the edges of the lighting panel 454 to further secure the integrated power supply module 400 in place on the panel.
With the integrated power supply module 400 thus secured to the lighting panel, a plurality of lighting elements 460 are inserted into other holes in the panel 454 in the manner previously described, and the lighting panel 454 is secured to the first panel 452 as previously described.
Thus assembled, the solar panel 428 of the integrated power supply module captures sunlight and converts it to electrical power which is used to charge the internal battery of the module. The electrical power from the battery communicates through the electrical leads in the power connection plugs and to the embedded electrical conductors in the panel, and to the lighting elements which illuminate the panel 452 and the indicia 453 thereon. The sealed integrated power supply module protects the battery and internal circuitry from the weather and elements, and can be easily snapped on to, or off of, the lighting panel to allow replacement with a new module and/or maintenance of the existing module.
It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown.

## Claims

1. A sign comprising:
a first panel for displaying indicia, said first panel having a first surface and a second surface, said indicia displayed on said first surface;
a second panel securable to said first panel such that said first panel extends below said second panel in a generally perpendicular fashion;
a pair of electrical conductors embedded in said second panel, an illuminating member electrically coupled to said pair of electrical conductors for illuminating said indicia on said first panel; and
an integrated power supply module comprising a solar panel and a battery in communication with a pair of electrical leads, said electrical leads in communication with said pair of electrical conductors to provide power to said illuminating member;
wherein said second panel comprises at least one receptacle allowing access to at least one of said embedded electrical conductors, and wherein said integrated power supply module includes at least one extending plug having an electrical lead in communication with said battery, said plug configured to mate with said receptacle so that power is communicated from the electrical lead to the at least one of said embedded electrical conductors.

2. The sign as in claim 1 further comprising a photocell operable to switch power from said battery.

3. The sign as in claim 1 wherein said integrated power supply module comprises first and second slots configured to receive and engage opposite edges of said second panel to secure said module to said second panel.

4. The sign as in claim 3 further comprising a cap attached to and covering an end of said extending plug.

5. The sign as in claim 1 wherein said second panel includes at least one downwardly extending flange to which said first panel may be secured.

6. The sign as in claim 5 wherein said second panel and said flange are integrally formed as a unitary structure.

7. The sign as in claim 5 comprising two flanges extending downwardly from said second panel presenting a channel for receiving said first panel.

8. The sign as in claim 1 wherein said second panel is fabricated from fiber reinforced polymer.

9. A lighting apparatus securable to a display panel on a street sign comprising:
a conductive panel having first and second electrical conductors embedded within said conductive panel, said electrical conductors having exposed portions;
an illuminating member securable to said conductive panel, said illuminating member contacting said first and second electrical conductors and receiving electrical power through at least one of said conductors;
a flange extending downwardly from said conductive panel, said flange adapted to be secured to the display panel on the street sign such that the display panel extends below said conductive panel in a generally perpendicular fashion;
an integrated power supply module secured to said conductive panel for powering said illuminating member, said integrated power supply module comprising an enclosure, a solar panel, a battery, control circuitry, and at least one electrical lead in communication with said battery, said electrical lead configured to engage with one of said embedded electrical conductors; and
wherein said conductive panel comprises at least one receptacle allowing access to at least one of said embedded electrical conductors, and wherein said at least one electrical lead extends along a power connection plug extending from said power supply module, said plug configured to mate with said receptacle such that said electrical lead is secured in electrical contact with at least one of said embedded electrical conductors.

10. The lighting apparatus as in claim 9 further comprising two of said flanges extending downwardly from said conductive panel presenting a channel for receiving the display panel.

11. The lighting apparatus as in claim 9 wherein said conductive panel and said flange are fabricated from a fiber reinforced polymer, and said conductive panel and said flange are integrally formed as a unitary structure.

12. The lighting apparatus as in claim 10 wherein said illuminating member comprises a light socket body with a plug projecting from an opposite end thereof; a light socket is formed in said light socket body and a light source is positioned in said light socket with a pair of electrical leads extending through said light socket body and said plug; said pair of electrical leads held in electrical contact with said exposed portions of said first and second electrical conductors.

13. The lighting apparatus as in claim 10 further comprising a cap securable on said plug opposite said light socket body.

14. The lighting apparatus as in claim 9 wherein said at least one receptacle comprises a plurality of receptacles.