Abstract:
A housing having an extrusion forming a first channel and a second channel; a lighting system in the first channel adapted to direct light away from the first channel; a mounting system in the second channel adapted to couple the extrusion to a vehicle; a first end cap including a first connector, the first end cap being coupled to a first end of the extrusion; a second end cap including a second connector, the second end cap being coupled to a second end of the extrusion; wherein the first connector and the second connector are electrically coupled to one another, and wherein the first connector and the second connector are electrically coupled to the lighting system.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates generally to providing auxiliary lighting systems. More particularly, this invention relates to auxiliary lighting systems for mobile platforms with an integral mounting system. 
         [0003]    2. Discussion of the Related Art 
         [0004]    A mounted auxiliary light typically consists of one or more light sources in a protective housing. The light sources may be of various types, for example light-emitting diode (LED), high-intensity discharge (HID) or halogen. The protective housing comes with or is configured for a mounting system that allows the external mounted light to be secured to a base. The auxiliary light is typically powered by a wired connection to a battery, for example a vehicle battery. 
         [0005]    A mounted auxiliary light is commonly used where the operator of a vehicle requires additional lighting beyond ambient lighting and lighting provided by the vehicle. For example, an off-road vehicle in a location with no exterior lights may require more lighting than that provided by the vehicle&#39;s headlights. The auxiliary light may be used in conjunction with, for example, vehicles, aircraft, watercraft, motorcycles, trailers and commercial equipment. The auxiliary light may also be used in a stationary location, for example, in an architectural use. 
         [0006]    A mounted auxiliary light may be mounted to a portion of a vehicle or other structure. Because of the variance of structures and mounting locations, it is often desirable to have an adaptable mounting system which accommodates varying mounting locations and allows the external mounted light to rotate about one or more axes. 
         [0007]    The user of a mounted auxiliary light may require a cover to, for example, protect the light or change the type of light emitted. Covers may be made of, for example, fabric or plastic and may be transparent or opaque. 
       SUMMARY OF THE INVENTION 
       [0008]    Several embodiments of the invention advantageously address the needs above as well as other needs by providing an auxiliary lighting systems for mobile platforms with an integral mounting system. 
         [0009]    In one embodiment, the invention can be characterized as a housing comprising an extrusion forming a first channel and a second channel; a lighting system in the first channel adapted to direct light away from the first channel; a mounting system in the second channel adapted to couple the extrusion to a vehicle; a first end cap including a first connector, the first end cap being coupled to a first end of the extrusion; a second end cap including a second connector, the second end cap being coupled to a second end of the extrusion; wherein the first connector and the second connector are electrically coupled to one another, and wherein the first connector and the second connector are electrically coupled to the lighting system. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The above and other aspects, features and advantages of several embodiments of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings. 
           [0011]      FIG. 1  is a perspective view of the front of the light bar system. 
           [0012]      FIG. 2  is a perspective view of the rear of the light bar system. 
           [0013]      FIG. 3  is a side view of the light bar system. 
           [0014]      FIG. 4  is a schematic wiring diagram of in-series connection of light bar systems. 
           [0015]      FIG. 5  is a schematic wiring diagram for a light combination system. 
       
    
    
       [0016]    Corresponding reference characters indicate corresponding components throughout the several views of the drawings. Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention. 
       DETAILED DESCRIPTION 
       [0017]    The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of exemplary embodiments. The scope of the invention should be determined with reference to the claims. 
         [0018]    Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. 
         [0019]    Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention. 
         [0020]    Referring first to  FIG. 1 , a perspective view of a light bar system  100  according to one embodiment of the present invention is shown. Shown is a light bar assembly  102 , including a center housing  104 , an adjustment track  106 , a right end cap  108 , a power source wiring  110 , a right receptacle  112 , a left end cap  114 , a left receptacle  116 , a front cap  118 , a front lens  120 , a light-emitting diode (LED) array  122 , and a reflector array  124 . Also shown is a mounting assembly  126 , including an adjustment bracket  128 , an adjustment bracket hole  130 , a clevis  132 , a plurality of clevis holes  134 , a pivot bolt  136 , a pivot nut  138 , a pivot washer  140 , a mounting bolt  142 , a mounting washer  144 , a mounting nut  146 , an internal wiring system  158 , a PC board, a gasket  160 , and a PC board  162 . The center housing  104  is a channel-shape, with the top and bottom of the channel forming the top and bottom of the light bar assembly  102 . It is made of extruded metal or other suitable material. In one embodiment, the center housing  104  is approximately 2-3 inches high and 3-5 inches deep. The length of the center housing  104  varies with the embodiment of the invention, but in the preferred embodiment generally varies between 6 inches and 52 inches. The back of the center housing  104  is curved and incorporates a plurality of horizontal fins. At the top and bottom of the center housing  104  are longitudinal indentations approximately ⅛″ wide and ⅛″ deep which may be used to couple an external light cover to the light bar assembly  102 . At the bottom of the back of the center housing  104 , two continuous curved horizontal ridges protrude from the center housing  104 , forming the adjustment track  106 . The front portion of the center housing  104  is shaped to hold and support the reflector array  124 , the LED array  122 , front lens  120  and the internal wiring system  148 . The gasket  162  is formed by machine and completely circles the outer edge of the front lens  120  where the inside facing outer portion of the front lens  120  lens meets with an continuous interior indentation of the light bar assembly  102 . 
         [0021]    The reflector array  124  size varies depending on the light bar variations. In general, there are one or more reflectors  148  in a row in the reflector array  124 .  FIG. 1  represents an embodiment of the invention with eight reflectors  148  in a row. Each reflector  148  has a curved conical shape and is connected at the wide end by a flat portion of the reflector array  124 , similar to the construction of an egg carton. In one embodiment, there are two horizontal reflector  148  rows stacked on top of one another.  FIG. 1  represents an embodiment of the invention with a single row in the reflector array  124 . An LED light  150  is coupled to the PC board  160  and positioned so that the LED light  150  extends through a small hole in the narrow end of the reflector  148 . The grouping of the LED lights  150  forms the LED array  122 . In front of the reflector array  124 , a thin transparent front lens  120 , made of polycarbonate or other suitable material, covers the reflector array  124 . The front lens  120  is transparent so as not to affect the photometrics of the reflectors  148 . The reflector array  124  is coupled to the PC board  160  by screws or other suitable method. The front lens  120  is coupled to the front cap  118  which frames the front lens  120  and is coupled to the top and bottom of the center housing  104 , to the left end cap  114  on the left, and the right end cap  108  on the right. The reflectors  148  in the reflector array  124  may all be of the same type, for example, spot reflectors, or a combination of types of reflectors may be used. For example, the reflector array  124  may consist of a combination of flood and spot reflectors. This allows for a variety of photometric requirements to be satisfied. The right end cap  108  covers and seals the interior of the light bar assembly  102  on the right-hand side. The right end cap  108  contains a right receptacle  112  and, in one embodiment, power source wiring  110 . In another embodiment, the power source wiring  110  may be removed from the right receptacle  112  and switched to the left receptacle  116 . A receptacle plug  152  would be placed in the right receptacle  112  for safety and to protect the internal wiring. In another embodiment, when the power source wiring  110  is coupled to the left receptacle  116 , a connecting wire  154  may be used in the right receptacle  112  to connect the light bar assembly  102  to additional light bar assemblies  102  in series. The other end of the connecting wire  154  would be connected to the receptacle of the adjacent light bar assembly  102 . The left receptacle  116  works in a similar way, and may receive either power source wiring  110 , connecting wiring  154 , or a receptacle plug  152 . The right end cap  108  is coupled to the center housing  104  with a plurality of end cap attachment screws  156 . The left end cap  114  covers and seals the interior of the light bar assembly  102  on the left-hand side. The left end cap  114  also contains the left receptacle  116 . The left receptacle  116  works in a similar way to the right receptacle  112 , and may receive either power source wiring  110 , connecting wiring  154 , or a receptacle plug  152 . 
         [0022]    The mounting assembly  126  includes the adjustment bracket  128  that is coupled to the adjustment track  106  in the back of the center housing  104 . The adjustment bracket  128  may be moved linearly along the entire length of the light bar assembly  102  to provide maximum adjustment. The bottom of the adjustment bracket  128  has an adjustment bracket hole  130  that is used to attach it to the clevis  132 . The clevis is U-shaped, with a plurality of clevis holes  134 , one in each side of the clevis. The pivot bolt  136  goes through one side of the clevis  132 , through the adjustment bracket hole  130  and through the other side of the clevis  132 , where is it secured with the pivot bolt washer  140  and the pivot bolt nut  138 . At the bottom of the U-shaped base of the clevis,  132  a threaded mounting bolt  142  extends vertically down from the base of the clevis  132 . The mounting bolt is used to mount the light bar system  100  to a support. The mounting nut  146  and mounting washer  144  are used to secure the mounting bolt  142  to the support. The adjustment bracket  128  pivots or rotates about the pivot bolt  136  location, allowing for the light bar assembly  102  to be adjusted to various angles relative to horizontal. The operation of the adjustment bracket  128  is described in more detail below. In addition, the adjustment bracket  128  may be reversed on the adjustment track  106  so that the bottom of the adjustment bracket  128  points upward. This allows for a greater range of support mounting options. 
         [0023]    Referring next to  FIG. 2 , a perspective view of the light bar system  100  is shown from the rear. Shown are the center housing  104 , the front cap  118 , the left end cap  114 , the right end cap  108 , a plurality of end cap attachment screws  156 , the adjustment track  106 , the adjustment bracket  128 , an adjustment screw  200 , the clevis  132 , the pivot bolt  136 , the mounting bolt  142 , the mounting washer  144  and mounting nut  146 . In this embodiment the right receptacle  112  is shown with the power source wiring  110 , and the left receptacle  116  is shown with the left receptacle plug  152 . 
         [0024]    Referring next to  FIG. 3 , an elevation of the right side of the light bar system  100  is shown. Shown are the front cap  118 , the right end cap  108 , the right receptacle  112 , the power source wiring  110 , the end cap adjustment screws  154 , the center housing  104 , a engagement block  300 , the adjustment bracket  128 , the adjustment bracket hole  130 , the adjustment track  106 , the adjustment screw  200 , the clevis  132 , the clevis hole  134 , the pivot bolt  136 , the pivot washer  140 , the pivot nut  138 , the mounting bolt  142 , the mounting washer  144 , the mounting nut  146 , the plurality of pivot locking pins  302  and the plurality of pivot locking depressions  304 . As described previously, the adjustment track  106  is formed by two continuous curved horizontal ridges protruding from the center housing  104 . The adjustment bracket  128  fits tightly over each leg of the adjustment track  106  and extends partly into the adjustment track  106  at the open portion of the adjustment track  106 . In the inside portion of the adjustment track  106 , the trapezoidal engagement block  300  fits in the inside of the adjustment track  106  and is bolted to the adjustment bracket  128 , locking the mounting assembly  126  in place along the adjustment track  106 . When the adjustment screw  200  is loosened, the engagement block  300  separates slightly from the adjustment bracket  128 , allowing the mounting assembly  126  to slide along the adjustment track  106 . When the mounting assembly  126  is at the desired location, the adjustment screw  200  is tightened, causing friction between the adjustment track  106  and the adjustment bracket  128  and engagement block  300 , securing the mounting assembly  126  in place. 
         [0025]    As described above, the adjustment bracket  128  pivots relative to the clevis  132  through use of the pivot bolt  136  which passes through both the plurality of clevis holes  134  and the adjustment bracket hole  130 . The pivot washer  140  has a plurality of small pivot lock pins  302  which are coupled to the inside face of the pivot washer  140 . In the preferred embodiment the pivot washer  140  has two pivot lock pins  302 , located on opposite sides of the hole of the pivot washer  140 . The pivot lock pins  302  extend through corresponding holes in the adjacent clevis  132  side and rest in the plurality of pivot locking depressions  304  of the adjustment bracket  128 . The pivot locking depressions  304  are a plurality of shallow depressions in the adjustment bracket  128  arranged in a circular pattern around the adjustment bracket hole  130 . The pivot locking depressions  304  are located so that the pivot lock pins  302  may sit in differing pivot locking depressions  304  depending on the rotation of the adjustment bracket  128  relative to the clevis  132 . When the pivot bolt  136  is tightened, the pivot lock pins  302  are engaged by the corresponding pivot locking depressions  304  and the angle of the light bar assembly  102  is locked. When the pivot bolt  136  is loosened, the pivot washer  140  may be moved outward so that the pivot lock pins  302  clear the pivot locking depressions  304 . The adjustment bracket  128  may then be rotated relative to the clevis  132  until the pivot lock pins  302  line up with alternate pivot locking depressions  304 , altering the angle of the light bar assembly  102 . When the desired angle is reached, the pivot bolt  136  is tightened, locking the angle of the light bar assembly  102 . 
         [0026]    Referring next to  FIG. 4 , a schematic wiring diagram for in-series connecting of light bar assemblies is shown. 
         [0027]    Referring next to  FIG. 5 , a schematic wiring diagram for a light combination is shown. In the embodiment where there are two rows of lighting. Each row may have a different color of LED lights  150 . Instead of lighting both rows at the same time, the light combination circuit allows for one row of lights to be illuminated while the second row of light is not. This allows for different colors of light to be illuminated separately within the same light bar assembly  102 . 
         [0028]    While the invention herein disclosed has been described by means of specific embodiments, examples and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.