Abstract:
A spotlight assembly (10) has inner and outer hemispherically shaped mounting members (20, 21) fixed to the roof (R) of a vehicle (A). Inner and outer movable frames (12, 14) are mounted on the fixed mounting members (20, 21) for relative rotative and tilting movements upon actuation of a handle (78). A lamp unit (16) is mounted on outer movable frame (14) about horizontal pivots (90, 91) from linkages (106, 50, 51). The tilting movement of handle (78) results in a tilting movement of lamp unit (16) around three times the angular movement of handle (78) to permit lamp unit (16) to be easily folded to a protected retracted position as shown in FIG. 3. The spotlight assembly (10) is easily installed on the roof (A) by first securing the inner and outer fixed hemispherically shaped mounting members (20, 21) to the roof (R), then mounting an upper movable subassembly on the outer mounting member (20) with an operating shaft (43) extending through the opening in the roof, and next mounting the lower movable subassembly on the inner mounting member (21) with the operating shaft (43) being received in an interfitting telescoping position for actuation by a handle (78).

Description:
FIELD OF THE INVENTION 
     This invention relates to a spotlight assembly for vehicles and method of installation, and more particularly to such a spotlight assembly including a lamp unit having a low profile particularly if the spotlight is not in use. 
     BACKGROUND OF THE INVENTION 
     Heretofore, spotlights have been mounted on vehicles, such as police cars and other emergency vehicles. Various types of mounting means have been used heretofore, such as a mounting member extending from the front corner post of the vehicle body. It is desirable to have a minimal projecting height from the top or roof of the vehicles as damage may occur from various sources, such as low overhead structures, for example. 
     My prior U.S. Pat. No. 4,725,238 dated Feb. 16, 1988, shows a bracket for mounting a spotlight on the roof of a car with manual means on the inside of the roof for controlling the positioning of the spotlight. The lamp or spotlight unit is secured to the movable outer frame or socket assembly for movement therewith and is not mounted for any movement relative to the outer socket assembly. Thus, the lamp or spotlight unit is limited in its tilting movement to a total movement of around 45 degrees and may not be moved to a retracted position projecting a minimal height or distance from the roof of the vehicle so that it may be protected by the socket assembly. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a spotlight assembly especially adapted for mounting on the roof of a vehicle, such as a police car or emergency vehicle, for example, and having a lamp or spotlight unit adapted to be selectively moveable between a retracted position with the spotlight facing generally in a vertical direction and a predetermined projected position with the lamp unit being positioned to project a light beam in a desired direction including a downward direction with as much as a 30 degree declination. In the retracted position of the lamp unit, the spotlight projects a minimal height or distance above the roof of the vehicle and is protected by fairing or shrouding in a forward direction. 
     It is necessary to mount the spotlight unit for both a tilting movement and a rotating movement. The mounting means includes a fixed hemispherically shaped mounting member on inner and outer sides of the roof, and a movable frame having a concave socket member fitting over each of the fixed hemispherically shaped mounting members. The lamp unit is mounted on the movable outer frame and linkage between the lamp unit and movable outer frame permits rotation of the lamp unit with the movable outer frame and permits tilting of the lamp unit in a vertical plane. The linkage permits a relatively small movement of the actuating handle in a vertical plane to result in a relatively large movement of the spotlight unit in a vertical plane thereby to permit the lamp unit to be easily moved to a retracted position closely adjacent the roof of the vehicle. A lever actuated cam mechanism on the handle sets the drag in the ball and socket assembly to effectively &#34;lock&#34; the unit in any position the user desires. A depressible button on the handle permits the user to easily &#34;unlock&#34; the unit for free movement. 
     It is an object of this invention to provide such a spotlight assembly having a lamp unit mounted for unlimited rotation and for tilting movement in a vertical plane with a relatively small movement of an actuating handle resulting in a relatively large movement of the lamp unit in a vertical plane. 
     Another object is the provision of a translucent glare control fairing to protect the lamp unit when in a retracted position and to reduce glare when the lamp unit is in a projected position by filtering a low portion of the beam. 
     It is a further object of this invention to provide a spotlight assembly including a lamp unit for mounting on the roof of a vehicle with the lamp unit having a minimal projecting height from the roof particularly in an inoperable position of the spotlight assembly. 
     It is another object of this invention to provide a mounting assembly for mounting a lamp unit or the like on the roof of a vehicle with the spotlight assembly being controlled by actuating means inside the vehicle movable between locked and unlocked positions. 
     An additional object is to provide a method of installing a spotlight assembly on the roof of a vehicle in a simple and quick manner. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective of the spotlight assembly comprising the present invention shown mounted on the roof of an automobile, such as a police vehicle for example; 
     FIG. 2 is an enlarged side elevation of the spotlight assembly of FIG. 1 with the lamp unit in a projected operable position; 
     FIG. 3 is an enlarged side elevation similar to FIG. 2 but showing the lamp unit in a retracted position closely adjacent the roof of the vehicle; 
     FIG. 4 is an enlarged cross sectional view of the spotlight assembly taken generally along line 4--4 of FIG. 1 and showing the fixed hemisphere members and movable frames thereon mounting the spotlight unit for tilting and rotative movements with the lamp unit shown in an operable projected position; 
     FIG. 5 is an enlarged cross sectional view similar to FIG. 4 but showing the lamp unit tilted downwardly in a vertical plane from the position of FIG. 4; 
     FIG. 6 is an enlarged sectional view taken generally along line 6--6 of FIG. 4; 
     FIG. 7 is a top plan taken generally along line 7--7 of FIG. 6 with certain portions broken away; 
     FIG. 8 is a section taken generally along line 8--8 of FIG. 7; and 
     FIG. 9 is a section taken generally along line 9--9 of FIG. 8. 
    
    
     DESCRIPTION OF THE INVENTION 
     Referring to the drawings for a better understanding of this invention, and more particularly to FIGS. 1 and 2, an automobile is shown A having a roof R on which a spotlight assembly generally indicated at 10 and comprising the present invention is mounted. Spotlight assembly 10 includes an inner movable frame generally designated 12 on the inner side of roof R and an outer movable frame 14 on the upper or outer side of roof R. A spotlight unit or lamp unit generally indicated at 16 is mounted on outer movable frame 14 for tilting and rotative movements as will be explained further. 
     As shown more particularly in FIGS. 4-9, fixed hemispheres or hemispherical shaped mounting sections are shown generally at 20 and 21 having central collar bores 32, internal flanges 33, external flanges 34, and internal flange bores 35. Press fit insert studs 24 extend through flange 33 of hemisphere 20, through receiving holes in roof R, and through flange 33 of hemisphere 21 for securing hemispheres 20, 21 to roof R. An elastomeric retaining ring 25 attached to flange 33 of hemisphere 21 in frictional contact with insert studs 24 retains hemisphere 21 with trim boot 22 during installation without fasteners. Elastomeric trim boot 22 adapts to a range of depths between the underside of roof R and internal headliners for the roof. An intermediate adhesive gasket 23 sandwiched between hemisphere 20 and roof R serves the dual purpose of a weather seal and a retainer for hemisphere 20 during installation. 
     Mounted for rotative and tilting movements on fixed hemispherical mounting sections or members 20 and 21 are the outer movable frame 14 on the outer side of roof R and the inner movable frame 12 on the inner side of roof R. Outer movable frame 14 is generally comprised of upper frame member 41, upper concave polymer shell 40, translucent fairing 42, and control shaft or rod 43. Frames 12 and 14 are connected to each other by a splined shaft or rod 43 extending through internal flange bores 35 of hemispherical sections 20 and 21. Outer movable frame 14 includes a lower tilting section having an intermediate concave polymer shell 40 forming a socket in frictional contact relation with fixed hemisphere 20 and similar outer concave frame section of member 41. Threaded fastener 44 secures splined shaft 43 to frame member 41 for movement therewith. 
     The translucent fairing or housing member 42 formed of a plastic material such as a polycarbonate material, for example, is secured to and extends in a rearward direction in conjunction with frame member 41 and has a pair of side arms or extensions 51 also mated with frame extensions 50. Frame and fairing extensions 50 and 51 clamp together to provide seats for bearings 47 at opposing ends of each extension. Bearings 47 connect to pivots 90 of lamp unit 16 to permit pivoting of lamp unit 16 about a horizontal axis. Fairing member 42 acts to protect lamp unit 16 particularly in the retracted position shown in FIG. 3 from flying debris or the like from a position forwardly of vehicle A. Fairing member 42 fits in close proximity with lamp unit 16 when in the retracted position to protect from fouling due to ice or road debris from a position forwardly of vehicle A. Translucent fairing member 42 also serves to filter the lower portion of the spotlight beam thereby reducing glare that might limit the visibility of the driver of vehicle A. 
     An upper non-tilting frame section over the lower tilting frame section 41 includes an upper concave member 101 and an intermediate concave bearing member 105. An inner thimble or sleeve 100 is mounted for relative rotative movement within bore 32 of hemisphere 20 and receives a pair of female threaded electrical contact lugs 102. Male electrically conductive, threaded fasteners 104 within insulating washers 103 provide a mechanical and electrical union between upper concave member 101 and inner thimble 100 with its electrical contact lugs 102. This assembly is referenced 117. Elongate slots 52 in frame 41 and corresponding elongate slots 53 in concave polymer shell 40 allow upper frame assembly 14 to tilt freely relative to non-tilting assembly 117. Contact between the convex planar surface of frame 41 and concave surfaces of members 101 and 105 assure that assembly 117 is slaved to all rotational movements of upper movable frame 14. Concave bearing 105 and thimble 100 are formed of a high lubricity polymer material to allow sufficient clamping force to be exerted by fasteners 104 to prevent exterior moisture from reaching slots 52 and 53 without incurring excessive drag between the tilting motions of frame member 41 and shell 40 in relation to non-tilting assembly 117. 
     Concave member 101 and concave bearing member 105 of assembly 117 provide a pivoting bearing seat for linkage member 106 at pivot 115 as illustrated in FIG. 4. Generally U-shaped linkage 106 has opposed ends mounted for pivotal movement at pivots 91 about a horizontal axis on opposed bosses of lamp unit 16. Tilting motion of upper movable frame 14 raises lamp unit 16 about pivots 90 into its operable position. The linkage between non-tilting assembly 117 and pivots 91 on lamp unit 16 effects a mechanical advantage on lamp unit 16 causing it to tilt on pivots 90 at approximately a three to one relationship to the 45 degree tilting action of upper frame member 41. By varying the distance between pivots 90 and pivots 91 on lamp unit 16 the mechanical advantage of the tilt action in lamp unit 16 can be proportionally increased or decreased. 
     Lamp unit 16 has a pair of halogen bulbs 83 therein adjacent parabolic reflectors 92 and protected by tempered glass lens 87 over the face of lamp unit 16. Suitable halogen bulbs may be purchased as H3-100 bulbs from Osram, Newburgh, N.Y. As shown particularly in FIGS. 8 and 9, bulb 83 is secured to bulb carrier 82 by suitable spring clips (not shown) so that the bulb element 93 is precisely aligned with the axis 94 of parabolic reflector 92. Bulb carrier 82 receives threaded adjusting screw 84 which passes through counteracting spring 85. Manually adjusting the screw moves the bulb element 93 inward or outward along axis 94 to focus the reflected light beams to converge at variable distances. Defocusing the beam serves to disperse the light beams, thereby providing a more generalized flood lighting as may be desired under certain applications. Mounting halogen bulb 83 at a perpendicular attitude to axis 94 serves to align bulb element 93 with axis 94 to optimize the convergence of the light beams. This mounting attitude further allows the implementation of parabolic reflector 92 with a shorter focal length than would otherwise be practical and therefore increasing the efficiency of the optical set to reflect and focus a greater percentage of the emitted light of bulb 83. This mounting attitude further serves to permit such focus travel within a relatively shallow lamp body 80. The integration of reflector and lamp boy in unit 80 serves to further reduce depth and weight in lamp unit 16. The relatively shallow lamp unit 16 is significant to minimizing the retracted profile of the entire upper assembly of frame 14 and lamp unit 16. Lamp module 81 with bulb carriers 82 and bulbs 83 may be separated from lamp body 80 by removing two threaded fasteners for servicing or replacement of bulbs 83. 
     For tilting and rotating lamp unit 16, lower movable frame 12 comprises a handle assembly 78 which may be manually gripped by an operator of the vehicle A. Handle assembly 78 has an intermediate concave shell 60 between a lower handle frame 61 and fixed hemispherical mounting section 21. Handle assembly 78 is connected to splined shaft 43 by an interfitting splined receiver or socket 67 which receives the splined end of shaft 43 in a telescoping relation. A fastener 66 secures shaft 43 and receiver 67 together for movement with handle assembly 78. Manually depressible lever 62 is mounted at one end of handle frame 61 for relative pivotal movement about pivot axis 70 and has a button 72 thereon for fitting within opening 75 in handle frame 61. The other end of lever 62 is pivotally mounted at 73 to an overcenter link member 63 pivotally mounted at 74 to cam 64 fitting between the convex surface 77 of handle frame 61 and a cam follower 65 about threaded fastener 66. Cam 64 has a bearing surface 69 adjacent convex surface 77 and cam follower 65. In an inoperable locked position shown in FIG. 4, link member 63 is in an overcenter position with pivot 73 being overcenter with respect to pivots 70 and 74 to releasably hold handle 78 in this position. Cam 64 is urged by lever 62 tightly between cam follower 65 with its associated threaded fastener 66 and convex surface 77 to hold convex shells 40 and 60 in tight frictional contact with adjacent fixed hemispherical mounting sections 20 and 21. 
     When it is desired to tilt or rotate lamp unit 16, button 72 is manually depressed inwardly to move pivot 73 past a dead center relation with respect to pivots 70 and 74 and move cam 64 out of camming relation with cam follower 65 thereby to unlock handle 78 for manual actuation. In this position as illustrated in FIG. 5 handle 78 may be rotated or tilted to impart a corresponding movement to lamp unit 16 since tight frictional contact between fixed hemispherical sections 20, 21 and adjacent concave polymer shells 40, 60 has been released. FIG. 5 shows lamp unit 16 tilted downwardly by handle 78 with members 40 and 41 moving in vertical plane relative to concave member 101 and U-shaped link 106. FIG. 3 shows lamp unit 16 tilted to the rearmost, retracted position to provide a low profile and protect lamp unit 16. FIG. 3 would normally be an inoperable position unless it was desired to direct a beam of light in a generally vertical upward direction. The positioning of pivots 90 and 91 on lamp unit 16 provides a mechanical advantage with the tilting movement of handle 78 in a vertical plane resulting in a tilting movement of lamp unit 16 in a vertical plane around three times the movement of handle 78. 
     To provide electrical energy to bulbs 83, a pair of electrical leads or wires 37 from a source of electrical energy in automobile A are connected to fixed rings 26 as shown in FIG. 6. Associated contacting, rotatable rings 27 are in contact with respective conducting probes 118 of electrical contact lugs 102 and conducting threaded fasteners 104. Leads 107 from conducting threaded fasteners 104 extend to female quick connect terminals in lamp module 81 and a grounding point in same. Electrical energy is conducted from female quick connect terminal to male terminal on the lead 95 from bulb 83. Bulb 83 is grounded to bulb carrier 82, focus adjusting fastener 84, spring 85, and thereto lamp module 81. 
     The installation of general spotlight assembly 10 on vehicle A may be accomplished by drilling appropriate holes in roof R corresponding to internal flange bore 35, insert studs 24, and lead wires 37. With bundled lead wires 37 and insert studs 24 extending through their respective holes in roof R, adhesive gasket 23 retains upper hemisphere 20. Lower hemisphere 21 with trim boot 20 is subsequently pressed on insert studs 24 from the underside of roof R and held in place by frictional contact with insert studs 24 and retainer 25. Factory assembled upper frame 14 with lamp unit 16 can be then installed with splined shaft 43 extending through internal flange bore 35 and electrical probes 118 being aligned and contacting rotatable rings 27. The handle assembly 78 is mated with externally splined shaft 43 being inserted within internally splined shaft receiver 67 and retained by threaded fastener 66. The removal of threaded fastener 66 allows the entire spotlight assembly to be rapidly removed from vehicle A for servicing or transfer to another vehicle if necessary without the removal of any other threaded fasteners. 
     By forming fixed hemispherical mounting sections 20, 21 and concave shells 40, 60 of a high lubricity polymer material such as a glass filled nylon material, the requirement for lubricants is eliminated and a waterproof non-icing service life is provided. 
     While a preferred embodiment of the present invention has been illustrated in detail, it is apparent that modifications and adaptations of the preferred embodiment will occur to those skilled in the art. Specifically, such functions as bulb focus, variable tension locking, and free rotating electrical conduction could be selectively eliminated in the development of lower cost commercial embodiments. Conversely, the herein described manual bulb focusing could be automated for remote, electrical control by the user within vehicle A. Also, lamp unit 16 may have utility with other types of spotlight assemblies, such as being mounted on a vehicle utility body or the like and actuated without utilizing a lower handle assembly. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention as set forth in the following claims.