Abstract:
The disclosed bridge seal includes a substantially rigid bridge component and flexible gutter seal arranged to span the openings between adjacent housing modules of a modular warning light assembly such as a lightbar. The bridge seal physically connects the adjacent ends of base and dome components to each other and defines a fluid flow channel to guide water away from the area between housing modules. The disclosed bridge seal integrates discrete housing modules into a connected weather resistant enclosure having a longitudinal path for control and power distribution conductors extending the length of the lightbar.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 11/724,371, filed Mar. 14, 2007 now abandoned, the contents of which are incorporated by reference in their entirety. 
    
    
     FIELD 
     This disclosure relates generally to a modular warning light assembly for installation on vehicles. In an advantageous embodiment it is more particularly concerned with a weather sealing arrangement for a modular warning light assembly. 
     BACKGROUND 
     Warning light assemblies in the form of lightbars mounted to the exterior of a vehicle are well known in the art. Lightbars mounted to the exterior of a vehicle are exposed to the elements, including sunlight, wind, rain, ice, salt, snow, mud and the like. Internal components of the lightbar are susceptible to damage if not protected from exposure to the elements, so lightbars are typically constructed to define a substantially sealed elongated cavity to protect the internal components. Vehicle-mounted lightbars are also exposed to high wind speeds, shock, vibration and temperature extremes which make sealing between housing components problematic. 
     Lightbars having a single piece dome are relatively easily sealed, but are limited in terms of color combinations and lengths. Prior art lightbars have employed a modular approach where products of different lengths and color combinations are assembled from a unitary base and complementary dome or lens portions joined by sealed dividers. While these assemblies have proven commercially successful, they can be difficult to service and the seals between lens sections are prone to leakage. 
     There is a need for a modular warning light assembly that permits different product configurations to be assembled from standardized components to provide a substantially sealed elongated cavity. 
     SUMMARY 
     According to aspects of the disclosure, a lightbar assembly includes an extruded strength member and a plurality of housing modules arranged on the strength member. The interior of each housing module provides structures for mounting a plurality of outwardly directed lightheads and defines a longitudinal trough in which control electronics and wiring are located. Housing modules include end modules arranged at each longitudinal end of the strength member and center modules positioned between end modules and/or other center modules. End modules are configured so that an inboard end of the longitudinal trough communicates with the adjacent housing module. Center modules are configured so that both ends of the longitudinal trough communicate with adjacent housing modules. This arrangement permits control and power conductors to extend between housing modules to connect components along the length of the lightbar. 
     Each housing module includes a base and a dome that fit together to define an interior space. The base of each housing module includes an upwardly directed peripheral lip which cooperates with a downwardly directed wall of the associated dome to define a substantially enclosed interior space. At least one longitudinal end of the base and the dome are configured to define an opening communicating between the longitudinal trough of adjacent housing modules. 
     An aspect of the disclosure relates to components for sealing the longitudinal trough of the lightbar between adjacent housing modules. The disclosed structure includes a substantially rigid bridge component and flexible gutter seal arranged to span the openings between adjacent housing modules, physically connect the adjacent base and dome ends to each other and define a water proof gutter to guide water out of the area between housing modules. The disclosed arrangement integrates otherwise discrete housing modules into a connected, weather resistant enclosure having a longitudinal trough for control and power distribution conductors extending the length of the lightbar. 
     When the word “about” is used herein it is meant that the amount, dimension or condition it modifies can vary from the stated amount, dimension or condition so long as the advantages of the disclosure are realized. The skilled artisan understands that there is seldom time to fully explore the extent of any area and expects that the disclosed results might extend, at least somewhat, beyond one or more of the disclosed limits. Later, having the benefit of this disclosure and understanding the concept and embodiments disclosed herein, a person of ordinary skill can, without inventive effort, explore beyond the disclosed limits and, when embodiments are found to be without any unexpected characteristics, those embodiments are within the meaning of the term “about” as used herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       This disclosure may be better understood by reference to the following description and the accompany drawings in which: 
         FIG. 1  is a perspective view of one embodiment of a lightbar assembly with one dome removed to show the interior of the lightbar; 
         FIG. 1A  is an enlarged partial perspective view of the base sections and bridge seal of the lightbar of  FIG. 1  with all other components removed; 
         FIG. 2  is a perspective view of the lightbar assembly of  FIG. 1  with the base and internal components removed from one end of the lightbar to illustrate the relationship between the strength member and a housing module; 
         FIG. 3  is a front elevation view of the housing modules of a second embodiment of a lightbar assembly incorporating an embodiment of a bridge seal according to aspects of the disclosure; 
         FIG. 4  is a top view of the housing modules of  FIG. 3 ; 
         FIG. 5  is an end view of the housing modules of  FIGS. 3 and 4 ; 
         FIG. 6  is an exploded perspective view of the housing modules and bridge seal of  FIGS. 3-5 ; 
         FIG. 7  is an enlarged partial perspective sectional view of the housing modules and bridge seal of  FIGS. 3-6 , taken along line  7 - 7  of  FIG. 5 ; 
         FIG. 8  is an enlarged perspective view of an embodiment of a bridge component according to aspects of the disclosure; 
         FIG. 9  is an enlarged perspective view of a bridge seal according to aspects of the disclosure; 
         FIG. 10  is an enlarged perspective view of the bridge component of  FIG. 8  in functional conjunction with the bridge seal of  FIG. 9 ; 
         FIG. 11  is an enlarged, partial perspective view of the housing modules of  FIGS. 3-7  with the domes of the left end module and center module removed and the left bridge seal removed; and 
         FIG. 12  is an enlarged, partial perspective view of the housing modules of  FIG. 11  with the left bridge seal installed. 
     
    
    
     DETAILED DESCRIPTION 
     The disclosed bridge seal is a sub-assembly that is illustrated in the context of a warning light assembly known in the art as a lightbar. The internal components of the disclosed lightbars are fully described in U.S. patent application Ser. No. 11/724,371, filed Mar. 14, 2007, the contents of which are incorporated by reference in their entirety. Since most of the internal components of the disclosed lightbar are not directly relevant to the disclosed bridge seal, they are omitted from the Figures. 
     Referring to the embodiments illustrated in the drawings and particularly  FIGS. 1 and 2 , a lightbar  10  includes a longitudinally extending strength member  12 , two or more housing modules  14 , lightheads  16 , electronics  18  and associated conductors (not shown). The lightbar  10  is typically secured to a vehicle by a mounting foot assembly (not shown) that engages channels  20  on the bottom of the strength member  12  to secure the lightbar  10  to a vehicle in a manner well known in the art. See for example U.S. Pat. No. 6,845,893, the disclosure of which is incorporated herein by reference in its entirety. 
     The exemplary lightbars  10  comprise an elongated strength member  12  which supports a plurality of housing modules  14 . The disclosed strength member  12  is an aluminum extrusion, but other suitably rigid components may be compatible with the disclosed lightbars. The length of the strength member  12  and the size and number of housing modules  14  permit construction of many lightbar configurations from a limited number of standardized components. The housing modules  14  include end modules  22  configured to fit over the ends of the strength member  12  and center modules  24  which mount between the end modules  22  as shown in  FIGS. 3 and 4 . The term “inboard” when used in this application refers to a location between the ends of the lightbar. For example, the inboard end of the end module  22  illustrated in  FIGS. 1 and 2  is the end facing the viewer, with the housing module end facing away from the viewer being the “outboard” end. 
     The lightbar embodiment of  FIGS. 1 and 2  includes two end modules  22  and no center module. The lightbar embodiment of  FIGS. 3 and 4  includes one center module  24  between the end modules  22 . Center modules  24  may be added to extend the length of the lightbar  10  as desired. The disclosed lightbar embodiments include one size of end module  22  and one size of center module  24 . It is contemplated that more than one size end module  22  and more than one size center module  24  may be provided to allow a greater variety of lightbar configurations. Generally speaking, the lightbars illustrated and discussed in this application are constructed to be installed in a horizontal orientation with the domes  28  above the bases  26  and the strength member beneath the housing modules  22 . References to direction in the specification and claims should be interpreted in view of the described or claimed components as they are positioned in the intended installed orientation. 
     Each housing module  14  includes a base  26  and a dome  28 . As best illustrated in  FIG. 2 , the underside of each base  26  is configured to receive ribs  30  extending upwardly from the strength member  12 . The resulting base configuration defines a longitudinal trough  31  in the center of each base  26 . The trough is aligned with the longitudinal axis of the lightbar  10 , providing a convenient location for routing power and control conductors and securing control electronics  18 , as illustrated in  FIG. 1 . 
     As best shown in  FIG. 1A , each base  26  also includes an upwardly directed peripheral lip  32  provided with a seal  34  on the outside surface of the lip  32 . In the disclosed embodiment, the seal  34  is an extruded elastomer, plastic, or rubber seal that is adhesively bonded to the lip  32  of the base  26 . In the illustrated embodiments, the lip  32  and seal  34  extend around the periphery of the base  26 , except a central portion of the inboard end walls  36  of the base. The seal  34  is configured to be compressed between the lip  32  of the base  26  and the peripheral walls  38  of the dome  28 . Other seal configurations may be suitable, such as applying the seal to the dome  28  rather than the base  26 . Co-molded seals are also a known equivalent. 
     The base  26  and dome  28  components are preferably molded plastic parts comprised of a polymeric material, for example polycarbonate. In the disclosed embodiments, the base  26  is opaque plastic while the dome  28  is clear or tinted transparent plastic. The peripheral walls  38  of the domes may include optical features  40  (best seen in  FIG. 1 ) for spreading light generated by lightheads  16  secured within each housing module  14 . The peripheral wall  38  of each dome is configured to overlap the upstanding lip  32  of each base and include features to engage the inside surface of the lip  32  to maintain the seal  34  in compressed relationship between the base  26  and dome  28 . 
     As described above, the base  26  and dome  28  of each housing module  14  are configured to define a substantially sealed interior space to protect the internal components of the lightbar  10  from the elements. However, the inboard end wall  36  of each base  26  defines a generally U-shaped opening  42  that allows control and power delivery conductors to connect various internal components distributed among the several housing modules  14 . Electronics  18  may be located in the longitudinal trough  31  and conductors for control and power distribution are routed along the longitudinal trough  31  and through the aligned openings  42  in the inboard end walls  36  of adjacent bases  26 . 
       FIG. 1A  illustrates the inboard ends of the bases  26  of adjacent housing modules with the domes and other internal components removed for clarity. As shown in  FIGS. 1 ,  1 A,  2  and  6  each base  26  includes an inboard end wall  36 . In the disclosed embodiment the end walls  36  extend inwardly from the peripheral lip of the base, increasing in height as it progresses toward the longitudinal axis of the lightbar. The center of each end wall  36  defines a U-shaped opening  42  which cooperates with the U-shaped openings  42  of an adjacent base end wall  36  to define a path communicating between adjacent housing modules  14 . In the disclosed embodiment, the strengthening ribs  30  of the strength member  12  at least partially enclose the space between adjacent housing modules  14  from below. 
     The present disclosure relates particularly to a bridge seal  44  configured to traverse the gap between adjacent housing modules at the location of the openings  42  which provide a path connecting adjacent housing modules  14 . The disclosed bridge seal  44  includes a bridge  46  and gutter seal  48  configured to span the space between adjacent housing modules  14  to prevent penetration of the elements from above. As best shown in  FIGS. 1 and 2 , the gutter seal  48  is configured to traverse the highest part of the end walls  36  of adjacent housing modules  14  and extend downwardly and outwardly along the end walls  36  to meet the peripheral lip  32  of the adjacent bases  26 .  FIG. 2  clearly illustrates the relationship between the upwardly projecting ribs  30  of the strength member  12  and the sloped configuration of the end walls  36  and gutter seal  48 . In the disclosed embodiment, the strength member  12  spans the gap between housing modules from below, while the bridge  46  and gutter seal  48  span the gap between adjacent housing modules  14  from above. The bridge seal  44  is configured to guide fluid (water) away from the region between housing modules with the assistance of gravity. 
     The illustrated embodiment of a bridge seal  44  includes a bridge  46  and a complementary gutter seal  48  which cooperate to span the openings  42  in the inboard end walls  36  of adjacent bases  26 . The bridge  46  and gutter seal  48  components of the disclosed bridge seal  44  are illustrated in  FIGS. 8-10 . As shown in  FIG. 8 , the bridge  46  is generally I-shaped and constructed of substantially rigid plastic such as polycarbonate or polystyrene. The bridge  46  includes side walls  50  and a bottom  52  which define a channel  54 . Each end of the bridge  46  is configured to provide a mechanical connection between the inboard end walls  36  adjacent bases  26  as shown in  FIGS. 1A ,  11  and  12 . The upper edges of the side walls  50  of the bridge  46  each define a slot  53 . These slots  53  are configured to receive and retain ears  55  integrally extending from the gutter seal  48  as shown in  FIG. 10 . 
     As best illustrated in  FIG. 11 , the upper portion of each end wall  36  defines a plurality of spaced slots  56  and a ledge  58  generally perpendicular to the vertical orientation of the end wall  36 . In the illustrated embodiment, the ledge  58  extends about the entire periphery of the base  26 , including the U-shaped opening  42  in the end wall  36  as shown in  FIG. 7 . The ledges  58  on the inboard ends of adjacent bases  26  abut each other to define the spaced relationship between housing modules  14  as shown in  FIGS. 1A ,  11  and  12 . The slots  56  in the upper edge of the end walls  36  are configured to receive and retain the ears  55  integrally extending from the upper edge of the gutter seal  48 . The slots  53 ,  56  in the upper edges of the bridge  46  and end walls  36 , respectively, engage the ears  55  of the gutter seal  48  to provide alignment and mechanical engagement with the gutter seal  48  to retain the otherwise flexible gutter seal  48  in a predetermined position with respect to the bridge  46  and end walls  36  of adjacent bases  26 .  FIGS. 1A ,  2 ,  7  and  12  illustrate the gutter seal  48  and bridge  46  in their installed positions. 
     The bridge  46  is configured to span the U-shaped openings  42  in the end walls of adjacent bases  26  and mechanically engage portions of the end walls  36  of adjacent bases  26  as shown in  FIG. 11 . As shown in greater detail in  FIG. 8 , the bridge  46  includes spaced walls  50  and a connecting bottom  52  that define a channel  54 . An arm  60  extends from the end of each bridge wall  50 . Advantageously, each arm  60  is parallel to, and outwardly offset from, each bridge wall  50 . A tongue  62  extends from each end of the bridge bottom  52 . The tongue  62  and outwardly offset arms  60  define two spaced apart slots  64  which receive portions of the end walls  36  as shown in  FIG. 11 . When the bridge  46  is disposed between adjacent bases  26 , each bridge tongue  62  is supported on a step formed in the adjacent end wall ledges  58  so that the channel  54  in the bridge is aligned with the abutting ledges  58  of the bases  26  to form a location to receive the gutter seal  48 . 
     One embodiment of a gutter seal  48  is shown in  FIG. 9 . Typically, the gutter seal  48  is molded from an elastomeric polymer. The gutter seal  48  comprises spaced walls  70  and a connecting base  72  that define a gutter channel  74 . Ears  55  project outwardly from the wall outside surface at regularly spaced intervals complementary with the slots  53 ,  56  in the bridge walls  50  and base end walls  36 , respectively. The inside surface of the gutter seal walls  70  advantageously comprise one or more inwardly projecting sealing ribs  76 . The gutter seal  46  is configured with a central portion and downwardly inclined portions attached to each side of the central portion. This configuration fits the shape of the raised central portion of the base end walls  36 , the installed bridge  46  and the sloping portions of the end walls. The gutter seal  48  is received in the channel  54  defined by the bridge  46  and supported by the abutting ledges  58  of adjacent bases  26 . The ears  55  projecting from the sides of the gutter seal  48  are received in the slots  53 ,  56  defined by the bridge walls  50  and end walls  36  respectively. 
     The inboard end walls  78  of the domes  28  have a configuration complementary to the configuration of the base inboard end walls  36  as shown in  FIGS. 1 and 2 . The bottom edges of adjacent dome inboard end walls  78  are received in the gutter channel  74  defined by the gutter seal  48  as shown in  FIG. 7 . The raised central portion of the gutter seal  48  and the downwardly sloped configuration of the inclined portions promote drainage of any water or precipitation away from the openings  42  defined in the end walls of the bases  26 . 
     During assembly, when all the components have been secured within the bases  26  one dome  28  is placed over each base  26  to complete the module  14 . The modules  14  are longitudinally arranged end to end relationship. Adjacent dome inboard end walls  78  are retained within the gutter seal channel  74 . Thus, the disclosed embodiment provides a continuous gasket interface between the inner surface of the dome peripheral walls  38  and end walls  78  and the outer surface of the base section peripheral lip  32  and end walls  36 . Each dome  28  will be secured to the base  26 , for example by screws (not shown) passing through the dome  28 . 
     With the above arrangement the interior of the lightbar is sealed from exposure to the elements. However, communication between the base sections in the lightbar is maintained via the aligned openings  42  under the bridge seal  44 . 
     The disclosed bridge seal  44  includes a bridge component  46  described as “rigid” and a gutter seal component described as “flexible.” It will be understood that the terms rigid and flexible as used in this application are relative terms and encompass a range of values. It will also be understood that no material is completely rigid and the plastic material of the bridge component  46  is flexible to a limited extent. Further, the bridge seal  44  is disclosed in the form of a two component embodiment. It will be understood that the two components may be combined into a single component or further divided into additional components without departing from the scope of the appended claims. 
     While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto. Accordingly, it is understood that the present embodiments have been described by way of illustration and not limitation.