Abstract:
An improved light fixture for an inflatable structure which includes a cooling arrangement which cools the light source in a light container. The cooling arrangement including a passageway which directs a cooling fluid into and out of the interior of the canister. The cooling arrangement includes blower to direct the cooling fluid toward the light source and a diffuser to distribute the cooling fluid about the light source. The cooling arrangement also includes a temperature monitor to monitor the temperature in the light container and to activate the blower upon detecting a predetermined temperature in the light container and/or to deactivate the light source upon detecting a predetermined temperature in the light container.

Description:
This patent application is a continuation application of U.S. patent application Ser. No. 09/085,638 filed May, 27, 1998 abandoned, and incorporated herein by reference. This invention claims priority on U.S. Provisional Application Serial No. 60/047,728 filed May 27, 1997 entitled Light Cooler. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention is particularly applicable to heat dissipation arrangements for illuminating devises used to illuminate inflatable objects and will be discussed with particular reference thereto; however, the invention has broader applications and may be used to dissipate heat in a wide variety of illuminating devices. 
     In the inflatable industry, it is a particular advantage to use inflatable devices for advertising purposes due to the eye-catching nature of the inflatables. The illumination of such inflatables during the night is also advantageous since the advertising can be visually seen at night and the illumination of such inflatables enhances the visual attraction of such inflatable thereby enhancing the value of the advertising promoted by such inflatables. However, the illumination of inflatables poses several challenging problems. Lights that are normally bright enough to effectively illuminate inflatables tend to radiate large amounts of heat. The heat from such lights can cause damage to the inflatable and/or cause damage to the inflatable if the inflatable were to deflate and come in contact with the hot surface of the light. The heat generated from the light can also adversely affect the operation of the light. A significant increase in temperatures of the light can result in the light filament prematurely burning out and/or the light casing becoming damaged, thereby resulting in a failure of the light. The high temperature resulting from the light can also adversely affect the electronics operating the light, thereby resulting in control problems and ultimately the failure of the light. The high temperature produced by the light also can hamper the rapid disassembly and packaging of the illuminated inflatable. 
     As a result, there is a need and demand in the inflatable industry for an effective illuminating device for inflatables which is safe and convenient to use and overcomes the problems associated with prior illumination devices. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a light cooling system adapted to dissipate heat generated by an illumination source. The invention is particularly applicable to a light cooling system used to cool light sources for inflatables. 
     In accordance with the principles featured in the present invention, there is provided a light fixture designed to illuminate an inflatable structure. Such inflatable structures include balloons, advertising displays, recreational structures, and the like. The light fixture is designed so that it can be conveniently mounted on or within an inflatable to effectively illuminate the inflatable. The light fixture also includes several enhanced features which address the heat generation problems associated with large lumen light systems. 
     In accordance with: another feature of the present invention, the light fixture includes a light container or canister which is constructed of a semi-transparent or transparent material. One type of material is a high-impact, high heat-resistant plastic such as a polycarbonate material such as Lexan. However, other durable semi-transparent or transparent materials can be used. The durable material of the canister helps to protect the light fixture components from damage thereby increasing the life of the light fixture. The transparency of the material can be selected to control the amount of lumens generated by the lighting device. As can be appreciated, the material may be colored, have a colored coating painted or applied to the surface of the material so as to illuminate the inflatable by a particular colored light. The canister is designed to house the light source. The canister is preferably a cylindrically-shaped canister having a substantially uniform interior and exterior diameter. However, other canister shapes can be used for various types of applications. 
     In accordance with yet another feature of the present invention, the canister is sized to house other components of the light source. Preferably, the majority of the light fixture components, other than the canister and power source, are housed inside the canister. The incorporation of many of the components into the canister simplifies the installation and deinstallation of the light fixture. 
     In accordance with still another feature of the present invention, the canister is designed to allow a cooling fluid to pass through the canister so as to cool one or more components within the canister. Preferably, the cooling fluid is air and more preferably ambient air. Preferably, the canister provides a passageway to allow the cooling fluid to enter the bottom of the canister and exit out the top of the canister. As can be appreciated, the flow of the cooling fluid may be reversed and/or the cooling fluid may enter and/or exit at other areas on the canister. 
     In accordance with yet another feature of the present invention, the canister includes a top plate mounted on the top of the canister. Preferably the top plate is mounted so as to be spaced at some distance from the top edge of the canister. In one arrangement, the top plate is spaced from the top of the canister by use of brackets which are securely mounted to the top plate and the top section of the canister. However, other arrangements can be used to space the top plate from the top of the canister. As can be appreciated, the canister may include one or more openings in the top sides of the container as an alternative to or in combination with the space top plate. The space provided by the top plate can be substituted for or used in combination with slots in the top side of the canister. The top plate may also be designed to include openings. Such a top plate design allows the top plate to be spaced from or mounted on the top of the canister. The spacing of the top plate and/or openings in the top plate from the canister provides a passageway for a cooling fluid to enter or exit the canister. Preferably, the top plate is of the same material as the canister; however, other materials can be used. The top plate also has the function of reducing and/or preventing liquids or debris from inadvertently falling into the canister which may damage the light or other components of the light fixture in the canister. The openings of the canister may be covered by a mesh which allows a cooling fluid to pass through the mesh, but reduces or prevents debris, insects, liquid, etc. from inadvertently entering into the interior of the container. In one embodiment, the top plate may be or include a mesh such as a wire, plastic and/or fabric mesh. The top plate may preferably include a bracket or hook adapted to mount the top plate to an inflatable. In one embodiment, the inflatable includes a cord or chain attached to the interior of the inflatable. This cord or chain is then secured to the bracket or hook on the top plate thereby securing the light fixture in the interior of the inflatable. 
     In accordance with still yet another feature of the present invention, the illumination source of the light fixture is preferably an incandescent light source or a halide light source. Incandescent light sources typically require a larger wattage per lumen than halide light sources. If a large inflatable is to be illuminated, a halide light source is preferably used due to the lower wattage requirements and reduce amount of heat generated. Preferably, the light fixture includes a light socket adapted to be used with up to 1500 watt light sources. As can be appreciated, light sockets handling a larger wattage can be used if needed for a particular application. In one preferred embodiment, the light socket is positioned near the bottom end of the canister. In a particular embodiment, the light socket is spaced above the bottom end of the canister. 
     In accordance with another feature of the present invention, the base of the canister includes an opening adapted to allow fluid to flow into and/or out of the base of the container. The base of the canister may be mounted to the bottom end of the canister or mounted in a spaced relationship from the bottom end of the canister. Preferably, the opening in the base is positioned below the location of the light socket. In addition to or alternatively, an opening can be placed on the side of the light canister closely adjacent to the base of the light container. The opening in the base and/or sides of the canister allows fluid to enter or exit the light canister to cool the light when in operation. The base may be made of the same or a different material from the canister. As can be appreciated, the base may contain more than one opening. A mesh may be used to cover the openings in and/or form the base to prevent debris, insects, liquids and the like from entering the interior of the canister and adversely affecting the components in the canister. 
     In accordance with another feature of the present invention, the canister naturally cools the light source during operation. In one particular embodiment, the canister includes an opening at the top and bottom of the canister. These openings are preferably formed by the top plate and base of the canister. When utilizing this canister arrangement, a natural cooling action of the air about the light occurs due to the light heating the surrounding air and causing the air within the canister to rise and pass through the opening in the top of the light container. The passing of air out of the canister causes a pressure drop within the canister thereby resulting in cool air being drawn in through the base opening of the light container. As can be appreciated, such a canister design provides for natural cooling of the light in operation thereby reducing the temperature of the light and the light container during operation. 
     In accordance with another feature of the present invention, the cooling effects of the light canister can be enhanced by a fan blower positioned under the light socket to help draw air through the base of the canister and to blow the air onto the light. The blower is preferably mounted in a blower container which is designed to direct the air drawn through the base of the light container toward the light so as to maximize the cooling efficiency of the light. The blower may include a one speed or variable speed motor. In one embodiment, the blower includes a fan blade which blade is designed to draw air into the blower when the fan blade rotates. 
     In accordance with yet another feature of the present invention, the blower includes a diffusion surface which may be positioned on the top of the fan blade. The diffuser is designed to distribute air blown by the fan blade evenly about the light source so as to efficiently cool the light source. The diffuser preferably is a plate which includes multiple openings designed to direct air through the diffuser. In one preferable embodiment, the light socket is mounted to the center of the diffuser so as to increase the efficiency and uniformity of cooling of the light source. 
     In accordance with still yet another object of the present invention, a low heat producing high lumens light source is used. A 1000 watt metal halide bulb can produce approximately 117,000 lumens and a 400 watt metal halide bulb can produce approximately 36,000 lumen. These lights require a reduced wattage as compared to an incandescent light using 1500 watts and producing only 33,000 lumens. The reduction in wattage results in less energy consumption and significantly less heat generation. As can be appreciated, lower wattage lights which produce high lumens, such as halide lights and the like can be naturally cooled without use of a blower fan. Higher wattage bulbs such as 400-1500 watt bulbs can be cooled by a relatively small blower fan. In one particular embodiment, a blower including a fan blade of approximately 4 inches in diameter is able to maintain the light fixture temperature within about 20 to 80° above ambient temperature. This temperature range allows the light fixture to be easily handled if necessary even after a long use. Furthermore, the light fixture is cooled to a sufficiently low temperature so as to reduce the chances of damage to the inflatable if the surface of the inflatable during operation and/or if the inflatable surface inadvertently comes in contact with the light container. 
     In accordance with another feature of the present invention, the light fixture may include a temperature sensor which monitors the temperature within the canister. The temperature sensor may be connected to the blower and be designed to activate the blower when a particular temperature threshold within the interior of the light container has been reached. A temperature monitor may also be connected to the blower in such a manner so as to increase or reduce the velocity of the blower in response to the monitored temperature within the container. In addition to or in alternative thereof, the temperature monitor may be connected to the light to act as a safety switch which shuts off the light when a particular temperature threshold within the light container has been reached. 
     In accordance with yet another feature of the present invention, a power source is associated with the light fixture which is adapted to generate a sufficient power source to light in a particular type of light bulb within the light fixture. For 400 and 1000 watt metal halide lights, a specially designed power source typically is used to generate enough power to energize such lights. The power source may be adapted to be plugged into a standard electrical outlet and may include a transformer or the like to convert the power from a typical electrical socket into the needed power to illuminate the light. For convenience, the transformer may be sealed in a durable container which is substantially water and/or air tight so as to reduce damage to the internal components of the transformer and may further include a handle to conveniently move the transformer to a particular location. Special quick connectors may be designed for quick attachment and detachment of the power cord from the light fixture to the transformer for ease of installation. The base of the canister preferably includes an opening to allow the power cord to enter the canister and supply the light source with power. In one embodiment the base includes a cable locking arrangement to secure the cable in place in the cable opening in the base. The cable locking arrangement prevents the wiring inside the canister from being damaged during installation and deinstallation of the light fixture. It is the primary object of the present invention to provide an illuminating source for an inflatable object. 
     In accordance with another aspect of the present invention, a light impairing material is mounted and/or positioned about the canister. The material is designed to control the amount of light radiating from the light fixture. In one particular arrangement, the material includes sections which block and/or impair the passage of light through the material. In another particular arrangement, the material causes words and/or images to be formed on the interior of the inflatable. In one preferred embodiment, the material is a plastic material mounted to be stationary and/or rotatable relative to the canister. The plastic material includes sections such as painted, dyed, laminated, colored sections which cause images to form on the interior of the inflatable when the light bulb is illuminated. As can be appreciated, the canister itself can be painted, dyed, colored or otherwise covered to form images on the interior of the inflatable. In another particular embodiment, a motor can be used to move the light impairing material about the canister. 
     It is a principal object of the present invention to provide an illumination source for an inflatable structure. 
     It is another object of the present invention to provide an illuminating system which includes a light cooling system to dissipate the heat generated by the illuminating system. 
     It is yet another object of the present invention to provide an illuminating system which can be conveniently mounted on or within an inflatable structure. 
     It is still yet another object of the present invention to provide an illuminating system which can generate one or more colors thereby illuminating an inflatable in a particular color. 
     It is another object of the present invention to provide an illuminating system which is durable and lightweight. 
     It is still another object of the present invention to provide an illuminating system which is designed to naturally cool the light source. 
     It is still yet another object of the present invention to provide an illuminating system which directs a cooling fluid about a light source to thereby efficiently and effectively cool the lighting source. 
     It is yet another object of the present invention to provide an illuminating system which includes a diffuser to direct a cooling fluid substantially uniformly about the lighting source to thereby efficiently and effectively cool the lighting source. 
     It is still another object of the present invention to provide an illuminating system which includes a light source that produces a high quantity of lumens, low heat generation and low wattage usage. 
     It is another object of the present invention to provide an illuminating system which prevents unwanted materials from entering into the interior of the light system. 
     It is still another object of the present invention to provide an illuminating system including a blower to direct cool air onto the light source. 
     It still yet another object of the present invention to provide a light system which monitors the temperature of the light source and adjusts the rate of cooling of the light source and/or deactivates the light source upon detecting a certain temperature. 
     It is still yet another object of the present invention to provide a power source for the lighting system which is durable and can be easily assembled and dissembled from the light source. 
     These and other objects and advantages will become apparent to those skilled in the art upon reading and understanding the following detailed description of the various embodiments of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Reference may now be had to the drawings, which illustrate various embodiments that the invention may take in physical form and in certain parts and arrangements of parts wherein; 
     FIG. 1 is a perspective view of the light system of the present invention; 
     FIG. 2 is an enlarged perspective view of the top edge of the light system shown in FIG. 1; 
     FIG. 3 is an exploded perspective view of the top section of the light system shown in FIG. 1; 
     FIG. 4 is an exploded perspective view of the bottom section of the light system shown in FIG. 1; and 
     FIG. 5 is an exploded perspective view of the fan housing shown in FIG.  1 . 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the preferred embodiment of the invention only and not for the purpose of limiting the same, FIGS. 1-5 illustrate a light system  10  which is designed to illuminate an inflatable structure. Light system  10  includes a canister  20  which is cylindrical in shape and includes side wall  22 , a top edge  24  and a bottom edge  26 . Canister  20  is made of a transparent material made of a durable high impact, high heat resistant material such as a polycarbonate material. Referring now to FIGS. 1-3, a circular top plate  40  is connected to the top portion of canister  20 . Top plate  40  is spaced from top edge  24  of canister  20  and is connected to canister  20  by the use of top brackets  50 . Top brackets  50  include a plurality of bracket holes  52  to adjust the distance top plate  40  is secured from the top edge  24  of canister  20 . The space between top edge  24  and top plate  40  defines a top opening  46 . Top brackets  50  are connected to the interior surface of side wall  22  by bracket screws  54  being inserted through bracket holes  52  of top bracket  50  and into openings  28  of side wall  22  of canister  20 . Bracket screws  54  are secured in place by clip nuts  57  which are clipped to the ends of brackets  50 . Similarly, top brackets  50  are connected to top plate  40  by inserting bracket rivets  55  through bracket hole  52  and into bracket openings  42  of top plate  40 . Bracket rivots  55  are secured by washer  59 . Top plate  40  is preferably a transparent material which is similar in composition to the material used in canister  20 . 
     Top plate  40  includes a hook opening  44  adapted to receive the end of hook  150 . Hook  150  is secured into hook opening  44  of top plate  40  by the use of a washers  151 ,  152 ,  153  and a hook bolt  154  which is threaded onto the end of hook  150 . Connected to the eye of hook  150  is lock clip  158  to hook  150 . Lock clip  158  is designed to be clipped to a hook, chain or other fastening area on an inflatable thereby attaching light system  10  to an inflatable. 
     Referring now to FIGS. 1 and 4, canister  20  also includes a circular base plate  60  which is secured to the bottom edge  26  canister  20 . Base plate  60  is a transparent material similar in composition to the composition used in canister  20 . As shown in FIG. 1, base plate  60  is secured to canister  20  so that the base plate substantially abuts against bottom edge  26  of canister  20 . Base plate  60  is secured to canister  20  by the use of bottom brackets  70 . Bottom brackets  70  include bracket holes  72  which are designed to be aligned with bottom bracket openings  30  on canister  20  and bracket opening  62  on base plate  60 . Bracket rivots  74  are inserted through bracket holes  72  and into openings  30  on canister  20  and opening  62  on base plate  60  and secured in place by washers  75  thereby securing base plate  60  to canister  20 . 
     Referring now to FIGS. 4 and 5, base plate  60  includes a base opening  66  positioned substantially in the center of base plate  60 . Base plate  60  also includes a power cord opening  64  positioned adjacent to base opening  66 . As shown in FIG. 5, power cord opening  64  provides an opening whereby power cord  130  can be inserted through base plate  60 . A cord lock  132 , lock bolt  133 , nut  137  and compressor  135  are designed to be threaded into cord opening  64  and to lock power cord  130  in position relative to base plate  60  so as to prevent power cord  130  from moving within cord opening  64 . 
     As shown in FIGS. 1 and 4, a light bulb  80  is positioned in the interior of canister  20 . Light bulb  80  is designed to provide illumination when supplied with power. Preferably light bulb  80  is a metal halide light. The type of metal halide light and the operation of metal halide light are well known in the art and will not be described further. As shown in FIG. 1, light bulb  80  is secured into place in light socket  90 . In one arrangement, light bulb  80  is screwed into light socket  90 . Light socket  90  is in turn secured to the top of diffuser  100 . As shown in FIG. 1, light socket  90  is positioned substantially in the center of diffuser  100 . 
     Diffuser  100  includes a plurality of diffuser openings  102 . As shown in FIG. 1, diffuser openings  102  are arcuate in shape and are positioned about, light socket  90  at various intervals from the peripheral edge of the diffuser  100 . Diffuser  100  includes mount openings  104  which openings are aligned with top openings  118  on blower housing  110 . 
     Blower housing  110  includes a central cavity wherein a motor  114  and a fan  116  are positioned therein. Blower housing  110  also includes mount openings  112  used to secure blower housing  110  to the inner surface of base plate  60 . A lower diffuser  170  having a plurality of arcuate openings  172  is positioned over opening  66 . Lower diffuser  170  is secured to base plate by mount openings  174 . Mount screws  106  are inserted through mount openings  174  and washers  107  to secure lower diffuser  170  to the bottom of base plate  60 . Mount screws are designed to pass through mount openings  112  of housing  110  to securing housing  110  to the bottom interior of base plate  60 . Washers  109  and nuts  111  securing the housing in place relative to base plate  60 . Mount screw  106  also secures diffuser  100  to the top of housing  110  by passing through three washers  113  and through mount openings  104  of diffuser  100 . Washers  115  and bolts  117  securing diffuser  100  in place. 
     Attached to the side of canister  20  is a temperature monitor  120 . Temperature monitor  120  is mounted to canister  20  by rivots  119  passing through openings  23  in side  22  and being secured in place by washer  121 . Temperature monitor  120  is connected to wire  122  from power cord  130 . Wires  124  and  126  from power cord  130  provide energy to motor  114  and wires  122  and  123  from power cord  130  provide energy for light bulb  180 . Wire  125  is connected between light socket  90  and temperature monitor  120 . Wire  129  from light socket  90  is connected to wire  123  by clip  127 . 
     Transformer  140  provides the required power to light bulb  80  and motor  114 . The end of power cord  130  includes a connector  160  to allow an operator to easily connect and disconnect the end of power cord  130  from transformer  140 . Connector  160  includes two plugs  162 ,  164  which form a positive connection to the four wires in power cord  130 . A latch  166  is designed to secure the two plugs together. The end of plug  164  includes a quick connect  142  which is designed to be easily secured to transformer  140 . Transformer  140  also includes a source power cord  144 . Source power cord  144  includes a quick connect  142  to enable an operator to quickly connect and disconnect one end of the power cord  144  from transformer  140 . The other end of power cord  144  is designed to be plugged into a standard electrical outlet. Transformer  140  also includes a handle  146  to allow an operator to easily carry and position transformer  140  to a desired location. Transformer  140  also includes a casing  148  designed to protect the components of the transformer from adverse ambient conditions. The general components of transformer  140  which produce the desired voltage and current to energize light bulb  80  and motor  114  are well known in the art and will not be further described. 
     In one particular embodiment, canister  20  is constructed out of a low weight, high impact, high heat resistant Lexin. Top plate  40  is mounted approximately one inch above the top edge  24  of canister  20 . Top plate  40  is also made of Lexin. The top plate is designed to act as a rain shield to prevent moisture from entering the interior of canister  20  thereby preventing moisture to come in contact with light bulb  80  which could in turn cause damage to light bulb  80 . Base plate  60  is also made of Lexin and has a blower housing  110  mounted to the interior surface of the base plate. The fan  116  within blower housing  110  is a four inch diameter blade impeller. The fan is designed to draw air through lower diffuser  170  and base opening  66  and force air through diffuser openings  102  of diffuser  100  to cool light bulb  80  during operation. The air upon passing light bulb  80  is then expelled from canister  20  by passing through top opening  46 . This arrangement has been found to maintain the temperature of the canister so that it is cool enough to be handled with human hands even after a long duration of operation. Typically the temperature of the canister is merely 40° above ambient temperatures which the light bulb is energized. The temperature monitor  120  is used to monitor the temperature within the canister and to deactivate light bulb  80  upon detection of the temperature above a predetermined level by breaking the circuit between wires  122  and  125 . The deactivation of the light bulb prevents canister  20  from becoming too hot if the fan should fail to operate or if the inflatable deinflates and comes in contact with canister  20  thereby plugging up base opening  66  and/or top opening  46 . In one design, temperature monitor  120  shuts down light bulb  80  when the temperature of canister  20  is detected to be 50-80° above ambient temperature. The light bulb is a 400 watt metal halide bulb or a 100 watt metal halide bulb. The 400 watt bulb is designed to produce 36,000 lumens (FLC-400) and the 100 watt bulb is designed to produce 117,000 lumens (FLC-1000). 
     In another embodiment, the light system  10  includes the design as mentioned above. The light system further includes the temperature monitor  120  to be wired to motor  114  to thereby activate motor  114  when a threshold temperature within canister  20  is reached and/or to deactivate motor  114  when the temperature within canister  120  falls below a threshold temperature. In a further embodiment, motor  114  is a variable speed motor whereby the speed of the rotating fan is a function of the detected temperature within canister  20 . 
     In a further embodiment, light system  10  includes a mesh which is positioned about top opening  46  and/or base opening  66 . The mesh is designed to prevent debris, insects or other unwanted materials from inadvertently entering into the interior of canister  20  and adversely affecting one or more of the internal components in canister  20 . The mesh may be made up of a fabric, plastic and/or wire material and connected to canister  20  by bolts, screws, adhesive, tacks, brackets, bands or the like. Mesh is air permeable so as not to adversely affect the flow of air into and/or out of canister  20 . 
     The invention has been described with reference to a preferred embodiment and alternates thereof, it is believed that many modifications and alterations of the embodiment disclosed will readily suggest itself to those skilled in the art upon reading and understanding the description of the invention in combination with the drawings. It is intended to include all such modifications and alterations insofar as they come within the scope of the present invention.