Patent Publication Number: US-10775006-B2

Title: Light bar

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation Application of U.S. Ser. No. 15/856,689, filed on Dec. 28, 2017. U.S. Ser. No. 15/856,689 is a Continuation Application of U.S. Ser. No. 15/636,732, filed on Jun. 29, 2017, which claims priority under 35 U.S.C. § 119 to provisional application Ser. No. 62/396,912, filed Sep. 20, 2016. Each of these patent applications are herein incorporated by reference in their entirety. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to lights. More specifically, and without limitation, this invention relates to a light bar which is particularly well suited for use on trucks in a low-profile manner in the space above a bumper and below the tailgate. 
     BACKGROUND OF THE INVENTION 
     Vehicle lights are old and well known. Countless forms of vehicle lights exist, including: headlights, fog lights, tail lights, reverse lights, parking lights, daytime running lights, and turning lights, among countless others. Each type of light or light configuration serves its own unique purpose and provides its own unique advantages. 
     With improvements in light technology, such as the development of light emitting diodes (“LEDs”), a great variety of accessory lights have been developed. These accessory lights come in a wide array of configurations and provide their own unique functions and advantages. 
     One common form of an accessory light is known as a light bar. Light bars are designed to fit in the small space between the upper edge of the bumper and the lower edge of the tailgate of a pickup truck and include a long array of lights that are electrically connected to the electrical system of the vehicle. These light bars provide improved illumination and thereby improve visibility when breaking, turning and backing up. 
     While conventional light bars provide many advantages, they suffer from many disadvantages not solved by the prior art. Namely, the environment where light bars exist is extremely caustic. That is, the space on the back of a pickup truck between the bumper and the tailgate is a wet and dirty environment that is also exposed to road chemicals, exhaust fumes, and whatever chemicals or other contaminants drain out of the bed of the pickup truck. In addition, in this position on the exterior of the vehicle, light bars are exposed to the elements and must endure temperature extremes from the coldest of cold nights to the hottest of hot days. Due to these extreme conditions, many conventional light bars have short lives due to the combined effects of temperature extremes and infiltration of water and contaminants that lead to premature failure or short useful lives. 
     Complicating matters further, the space between the bumper and the tailgate on most trucks is extremely limited. That is, the vertical height between the top of the bumper and the bottom of the tailgate and fenders is increasingly vertically narrow. This means that the light bar must be extremely compact is size and shape otherwise it cannot be used for its intended purpose. This means that the form factor of the light bar must be extremely compact which complicates the electronic assembly of the system, heat dissipation requirements, weather proofing, installation and the overall design and configuration of the system. 
     Therefore, in view of the disadvantages in the prior art, for the reasons stated above, and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the specification, claims and drawings there is a need in the art for an improved light bar. 
     Thus, it is a primary object of the invention to provide a light bar that improves upon the state of the art. 
     Another object of the invention is to provide a light bar that has a long useful life. 
     Yet another object of the invention is to provide a light bar that can be used on practically any vehicle. 
     Another object of the invention is to provide a light bar that fits in the space between the bumper and the tailgate of most if not all pickup trucks. 
     Yet another object of the invention is to provide a light bar that is water proof. 
     Another object of the invention is to provide a light bar that is weather proof. 
     Yet another object of the invention is to provide a light bar that is can be exposed to the elements. 
     Another object of the invention is to provide a light bar that is contaminant proof. 
     Yet another object of the invention is to provide a light bar that is easily installed. 
     Another object of the invention is to provide a light bar that can be connected to practically any vehicle&#39;s electrical system. 
     Yet another object of the invention is to provide a light bar that provides multi-purpose functionality. 
     Another object of the invention is to provide a light bar that has an aesthetically pleasing appearance. 
     Yet another object of the invention is to provide a light bar that is easy to use. 
     Another object of the invention is to provide a light bar that improves safety. 
     Yet another object of the invention is to provide a light bar that includes white, yellow/amber and red lights. 
     Another object of the invention is to provide a light bar that includes breaking, backup and turning functionality. 
     Yet another object of the invention is to provide a light bar that efficiently dissipates heat. 
     Another object of the invention is to provide a light bar that is separated into electrical segments that are independently controllable. 
     Yet another object of the invention is to provide a light bar that is bright. 
     Another object of the invention is to provide a light bar that is formed of a plurality of independent lights but appears to be a single continuous light strip when illuminated due to the density of the independent lights. 
     Yet another object of the invention is to provide a light bar that can be installed without drilling into the body of the vehicle. 
     Another object of the invention is to provide a light bar that is durable. 
     Yet another object of the invention is to provide a light bar that is rugged. 
     Another object of the invention is to provide a light bar that has an intuitive design. 
     Yet another object of the invention is to provide a light bar that is formed of a minimum number of parts. 
     Another object of the invention is to provide a light bar that is relatively inexpensive to manufacture. 
     Yet another object of the invention is to provide a light bar that provides value, utility and novelty to the user. 
     Another object of the invention is to provide a light bar that has a low profile. 
     Yet another object of the invention is to provide a light bar that can be installed with adhesives and clips. 
     Another object of the invention is to provide a light bar that can be installed using adhesives. 
     Yet another object of the invention is to provide a light bar that improves safety. 
     These and other objects, features, or advantages of the invention will become apparent from the specification, claims and drawings. 
     SUMMARY OF THE INVENTION 
     A temperature, water and contaminant proof light bar is presented having an extruded housing with a curved cover portion and a flat back wall and flat side walls with a hollow interior. A circuit board is positioned within the hollow interior and separated into a plurality of electrical segments. The circuit board includes a row of white, a row of amber, and a row of red LEDs and is fully encapsulated with an encapsulant within the housing. The ends of the housing are enclosed by end caps. The light bar is electrically connected to the electrical system of the vehicle and is installed using a plurality of adhesively attached clips and is controlled by a control box configured to interpret the operational signals of practically any commercially available pickup truck. The light bar is also formed of a small size such that it fits practically any commercially available pickup truck. While the light bar is formed of a plurality of individual lights when illuminated the light bar appears as a single unitary light due to the brightness of the lights, the density of the lights and the manner in which the lights are illuminated. The increased visibility improves safety as well as provides an aesthetically pleasing appearance. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a perspective view of a clip for use with the vehicle light bar system presented herein, the clip is configured to attach to the body of a vehicle using adhesive and/or a fastener, the clip includes a back wall that is generally planar in shape and includes opposing arms positioned in each corner of the back wall that extend upward therefrom, the arms include a feature positioned at the outward end of opposing arms that extend toward one another, this feature is configured to grip onto the light bar when the light bar is forced between the opposing arms thereby holding the light bar within the clip, the outward ends of the arms also include a guiding surface angles toward the open interior of the clip that is configured to guide the light bar between opposing arms; 
         FIG. 1B  is an elevation view of the clip shown in  FIG. 1A , the view taken from the top surface of the clip; 
         FIG. 1C  is an elevation view of the clip shown in  FIGS. 1A and 1B , the view taken from the side surface of the clip, the view showing the arms extending upward a distance from the back wall; 
         FIG. 1 d    is an elevation view of the clip shown in  FIGS. 1A and 1B and 1C , the view taken from the end of the clip, the view showing the distance between opposing arms that extend upward a distance from the back wall; the view showing the feature positioned at the outward end of opposing arms that extend toward one another, this feature is configured to grip onto the light bar when the light bar is forced between the opposing arms thereby holding the light bar within the clip, the view also shows the guiding surface positioned at the outward ends of the arms that angles toward the open interior of the clip that is configured to guide the light bar between opposing arms; 
         FIG. 2  is an elevation schematic view of the light bar system, the view showing the light bar having three rows of LEDs, the view showing the wiring system connected to the light bar, the view showing the control box connected to the wiring system, the view showing the fuse and plug, and electrical leads connected to the light bar that are configured to connect to the electrical system of the vehicle to which the light bar is attached; 
         FIG. 3  is an elevation view of a side cut away of the assembled housing of the light bar, the view showing the housing having a back wall, opposing side walls and a cover with a pair of right angled steps that serve as features positioned between the cover and the sidewalls, the view showing the circuit board formed of a backing material, circuitry layer and LEDs positioned within the hollow interior of the housing, the view showing the ribbon wire extending below the backing material of the circuit board, the view showing the first layer of encapsulant encapsulating the outward facing surface of the circuit board including the three rows of LEDs, the view also showing the second layer of encapsulant the essentially fills all the remaining space within the hollow interior of the housing thereby fully encapsulating the circuit board and all other components positioned within the hollow interior of the housing; 
         FIG. 4  is a side elevation view of a side cut away of the assembled housing of the light bar of  FIG. 3 , the view showing the addition of the clip shown in  FIGS. 1A-1D  attached to the exterior of the housing, the view showing the features of the arms of the clip connected to and holding onto the features of the housing positioned between the sidewalls of the housing and the cover of the housing, the view showing the interior surface of the sidewalls of the arms in approximately flat and flush engagement with the exterior surface of the sidewalls of the housing, the view showing the exterior surface of the back wall of the housing in approximately flat and flush engagement with the forward surface of the back wall of the clip; 
         FIG. 5  is a perspective view of the clip of  FIGS. 1A-1D  shown in a side by side position to a portion of the housing of the light bar; 
         FIG. 6  is a perspective view of the clip of  FIGS. 1A-1D  shown partially installed on a portion of the housing of the light bar, the view showing one end of the light bar installed on the clip and one end of the light bar not installed on the clip; 
         FIG. 7  is a perspective view similar to  FIG. 6  with the portion of the housing fully installed within the clip; 
         FIG. 8  is a perspective view of the fully assembled light bar, the view showing three rows of LEDs visible through the transparent portion of the housing, a row of red LEDs, a row of white LEDs and a row of amber LEDs. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized, and that mechanical, procedural, and other changes may be made without departing from the spirit and scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled. 
     As used herein, the terminology such as vertical, horizontal, top, bottom, front, back, end, sides, and the like, are referenced according to the views presented. It should be understood, however, that the terms are used only for purposes of description, and are not intended to be used as limitations. Accordingly, orientation of an object or a combination of objects may change without departing from the scope of the invention. 
     The light bar described herein is described, as one example, for use with a pickup truck. This is by way of example only, and any use is hereby contemplated and reference to use on a pickup truck is not to be limiting. Instead, the light bar presented herein is contemplated for use in any application and may be used on any vehicle. In addition, the shape and dimensions of the light bar can be modified without departing from the spirit and scope of the invention. 
     System: 
     With reference to the figures, light bar system  10  is presented (also referred to herein as light bar  10  and/or system  10 ). The system  10  includes the component pieces of housing  12 , circuit board  14  which is separated into segments  16 , end caps  18 , encapsulant  20 , control box  22  having a microprocessor  24  and memory  26 , among other components as is described herein. The system  10  also includes one or more clips  28  that facilitate connection of the light bar  10  to a truck or vehicle  30  (not shown in detail). 
     Housing: 
     Housing  12  is formed of any suitable size, shape and design and is configured to house the electrical components of the light bar system  10 . In one arrangement, as is shown, housing  12  is an elongated hollow member that extends a length between opposing ends that are closed by end caps  18 . Housing  12  includes a back wall  32  that is generally flat and planar in shape when viewed from the side. The upper and lower edges of back wall  32  that extend the length of housing  12  connect to opposing sidewalls  34 . Like back wall  32 , sidewalls  34  are generally flat and planar in shape. Opposing sidewalls  34  connect at their rearward edges to the upper and lower edges of back wall  32  and extend in approximate parallel spaced alignment to one another. Sidewalls  34  extend in approximate perpendicular alignment to back wall  32 . This arrangement, with the generally planar and perpendicular alignment of the back wall  32  and side walls  34  form a generally rectangular space between the back wall  32  and opposing side walls  34 , as can be seen from the side cut away view of  FIG. 3  and  FIG. 4 . 
     The forward edges of sidewalls  34  connect to a cover portion  36  of housing  12 . In the arrangement shown, cover portion  36  has a generally smooth and curved exterior surface that connects at its upper and lower edges to the forward edges of sidewalls  34 . In the arrangement shown, cover portion  36  has a convex exterior surface, and a concave interior surface, that helps to shed water, dirt and contaminants off of the housing. However, any other size, shape and design is contemplated for use as cover portion  36 , including a flat and square shape, a peaked shape, a concave shape or any other shape. 
     In one arrangement, as is shown, one or more features  38  are positioned at the intersection or connection point between sidewalls  34  and cover portion  36 . Features  38  are formed of any suitable size, shape and design and are configured to support the engagement between and connection of clip  28  to housing  12  and to facilitate a strong and durable hold there between while also facilitating selective removal of housing  12  from clip  28 . As one example, as is shown, features  38  include a first step or ledge positioned between the exterior surface of sidewalls  34  and where cover portion  36  connects to sidewalls  34 . In this arrangement, the first step of features  38  include a small generally planar portion that extends in approximate parallel spaced relation to back wall  32  which serves as a connection point for clip  28  to hold on to and secure housing  12 . That is, in the arrangement shown, the first step of features  38  is a small generally right angle notch or step between sidewall  34  and cover portion  36  when viewed from the side as can be seen in  FIG. 3  and  FIG. 4 . Also, in the arrangement shown, a second step is also positioned just above the first step of features  38  and is configured in a similar manner. That is, in the arrangement shown, the second step of features  38  is a small generally right angle notch or step between sidewall  34  and cover portion  36  that connects at its lower or outward side to the first step of features and connects at its upper or outward side to cover portion  38  when viewed from the side as can be seen in  FIG. 3  and  FIG. 4 . In the arrangement wherein more than one step is present in features  38 , clip  28  may connect to only one of the steps or both of the steps. Any number of steps is hereby contemplated for use as features  38  such as none, one, two, three, four or more. Alternatively, any other size, shape and design for features  38  is hereby contemplated for use, such as a hook, a concave recess that is recessed inward toward back wall  32 , a protrusion or any other shaped feature  38 , which in some configurations or applications may provide a more-affirmative and durable connection between clip  28  and housing  12 . 
     The connection of back wall  32 , sidewalls  34  and cover portion  36  define a hollow interior  40  there between which houses and holds circuit board  14  therein. In one arrangement, housing  12  is formed of a single monolithic piece or extrusion and therefore the features, size and shape of housing  12  extend the length of housing  12 . Being formed of a single piece reduces the number of parts, simplifies the manufacturing process in many ways (and complicates it in other ways) and provides enhanced water proofing and contaminant protection as there are no seams or connection points for infiltration of water or contaminants into the hollow interior  30  of housing  12 . As such, the hollow interior  40  of housing  12  serves as a complete or as close to a complete shield to water and contaminants as is possible. This arrangement provides enhanced the water and contaminant protection for the components positioned within the hollow interior  40  of housing  12 . To provide further protection, the components positioned within the hollow interior  40  of housing  12  are encapsulated in an encapsulant  20  as is further described herein. Having a consistent size and shape throughout the length of housing  12  facilitates easier installation as clip  28  can be positioned along any portion of housing  12  and the components can be inserted into hollow interior  40  of housing  12  from either end and these components may be slid along the length of hollow interior  40  of housing  12  during installation. 
     In the arrangement shown, housing  12  includes a transparent portion  42  and a non-transparent portion  44 . In one arrangement, the back wall  32  and the sidewalls  34  or only the rearward portions of sidewalls  34  of housing  12  are painted with a black or dark or non-transparent paint which is placed on the exterior and/or the interior of housing  12 . Alternatively these portions of housing  12  (back wall  32  and all or a portion of sidewalls  34 ) are formed of a black or dark or non-transparent material that prevents or reduces light transmission there through. In this arrangement, the cover portion  36  and the forward portions of sidewalls  34  of housing  12  are formed of a clear, transparent, translucent or other material that allows light to be transmitted there through. In one arrangement, the color black has been tested with success as it reduces the appearance of the system  10  when installed on vehicle  30 . In the arrangement where the back wall  32  and sidewalls  34  and the cover portion  36  are formed of different colored materials, the back wall  32  and sidewalls  34  are manufactured as a single unitary piece of two different colored materials or two materials with different colors and light-transmission properties, such as a co-extrusion process or the like so as to form a single unitary and simultaneously manufactured piece without seams or other areas where water or contaminants can infiltrate the housing  12 . 
     In an alternative arrangement, housing  12  is formed multiple pieces. In one arrangement, a back portion or non-transparent portion  44 , connects to a front portion or transparent portion  42  along a connection point or seamline that is glued, welded, adhered or connected in any other way to one another. In this arrangement, the back portion or non-transparent portion  44  is formed of a black or dark or non-transparent material or is painted with a black or dark or non-transparent paint, whereas the front portion or transparent portion  42  is formed of a transparent or translucent material that allows light to be transmitted there through. In one arrangement, the back portion or non-transparent portion  44  is formed of the back wall  32  and the entirety of the sidewalls  34  which connect to the cover portion  36  at the outward ends of sidewalls  34 . In another arrangement, the back portion or non-transparent portion  44  is formed of the back wall  32  and a portion of the sidewalls  34  which connect to the cover portion  36  which includes a portion of the sidewalls  34  and as such, sidewalls  34  connect to one another along a seamline where the back portion of the sidewalls  34  are part of the nontransparent portion  44  and the forward portion of the sidewalls  34  are part of the transparent portion  42 . Any other configuration is hereby contemplated for use. 
     Circuit Board: 
     Circuit board  14  is formed of any suitable size, shape and design and is configured to house a plurality of light emitting diodes  46  (“LEDs”) thereon and facilitate selective illumination of the LEDs  46 . In one arrangement, as is shown, circuit board  14  is formed of a backing material  48  and a circuitry layer  50 . 
     Backing material  48  is formed of any suitable size, shape and design and serves to provide support to circuitry layer  50  as well as serve heat dissipation purposes. In one arrangement, backing material  48  is formed of a metallic material, such as aluminum, copper, an aluminum alloy, a copper alloy, or any other metallic material, rigid material and/or material the provides for support and/or heat dissipation. In an alternative arrangement backing material  48  is formed of a non-metallic material. 
     Backing material  48  provides structural support for circuitry layer  50  as well as heat dissipation. That is, when circuitry layer  50  is connected to backing material  48  and backing material  48  is formed of a material with a high coefficient of diffusivity (such as aluminum, an aluminum alloy, copper, a copper alloy, or another alloy material) backing material  48  helps to absorb and diffuse heat generated by LEDs  46 . To maximize space utilization within the hollow interior  40  of housing  12 , backing material  48  is relatively thick, and substantially thicker than circuitry layer  50 , and backing material  48  fits within the hollow interior  40  of housing  12  within relatively close and tight tolerances. In the arrangement shown, when viewed from the side, backing material  48  is generally rectangular in shape with an opposing back wall and forward wall that approximate the size of or are slightly the size of the interior surface of back wall  32  of housing  12  and are positioned in approximate parallel planar spaced relationship with one another; and similarly backing material  48  has a pair of opposing sidewalls that extend a portion of the interior surface of sidewalls  34 . The width of backing material  48  is slightly smaller than the width between the interior surfaces of opposing sidewalls  34  of housing  12  so as to facilitate insertion of backing material  48  into the hollow interior  40  of housing  12 . The height of backing material  48  is smaller than the height of the interior surfaces of sidewalls  34  so as to provide room for ribbon wire  63  behind backing material  48  as well as to provide room for circuitry layer  50  and LEDs  46  on top of backing material  48 . Maximizing the size of backing material  48  within the hollow interior  40  of housing  12 , while providing ample room for the other components of the system  10  maximizes heat diffusion and structural rigidity provided by backing material  48 . 
     Circuitry layer  50  is formed of any suitable size shape and design and provides the electrical connection between the electrical components of the system  10 . In one arrangement, circuitry layer  50  includes the electrical leads and traces that connect and interconnect the electrical components of system  10  including LEDs  46 , ribbon wire  63  and control box  22 . Circuitry layer  50  may be formed of multiple layers itself so as to provide electrical isolation between the many electrical leads therein. 
     While backing material  48  and circuitry layer  50  are described as separate components in one arrangement they may be formed as a single component, or alternatively they may be formed of separate components. That is, circuitry layer  50  may be manufactured separately and then applied to backing material  48 . Alternatively, circuitry layer  50  may be formed onto and/or into backing material  48 . 
     Circuit board  14  is formed of any suitable size shape and design and is configured to house, hold and provide the electrical connections for LEDs  46 . In the arrangement shown, circuit board  14  includes three rows of densely packed LEDs  46  that extend a length or the entire length between end caps  18  within the hollow interior  40  of housing  12 , including a row of amber LEDs  46 A, a row of white LEDs  46 W and a row of red LEDs  46 R. In the arrangement shown, the white LEDs  46  are positioned in the middle with the red and amber LEDs  46  positioned on opposite sides of the row of white LEDs  46 , however any other configuration is hereby contemplated for use. 
     To provide independent control of various portions of light bar system  10 , circuit board  14  is electrically separated into a plurality of segments  16 . Segments  16  allow for independent control of each segment. In the arrangement shown, light bar  10  is separated approximately down its middle at a seamline  54  into two separate segments  16 , such as a driver&#39;s side segment  16  and a passenger side segment  16 . Segments  16  can be independently illuminated as well as simultaneously illuminated. Separating light bar  10  into driver side and passenger side segments  16  allows the control box  22  to illuminate the entire length of light bar  10  for breaking and backing up, as well as illuminating only one segment  16  for the turning signal. While only two segments  16  are shown, any number of segments  16  are hereby contemplated for use. 
     To reduce the appearance of the light bar  10  when installed, the exterior facing surface  55  of circuit board  14  is a dark or black color. This dark or black color reduces the visibility of the light bar  10  when installed thereby improving the aesthetic appearance of the light bar  10 . 
     Endcaps &amp; Wiring: 
     End caps  18  are formed of any suitable size, shape and design and serve to close the hollow interior  40  of housing  12  at its outward ends. In one arrangement, one end cap  18  allows the passage of wiring  56  there through whereas the opposite end cap  18  does not have wiring  56  passing there through and as such this end cap  18  simply closes the opposite end of housing  12  from the wiring end cap  18 . To continue with the low-profile appearance theme of the light bar  10 , in one arrangement, end caps  18  are formed of a black material, like the back portion or non-transparent portion  44  of housing  12 . End caps  18  are friction fit as well as sealed within the hollow interior  40  of housing  12  so as to prevent water and contaminants from entering hollow interior  40 . End caps  18  are sealed into housing  12  by any manner, method or means such as gluing, adhering, welding, heat shrinking, taping, wrapping and/or any combination thereof or the like. 
     Wiring  56  exiting one end of housing  12  electrically connects to control box  22  and includes a fuse  58  before electrically connecting to a plug  60 . Plug  60  is formed of any suitable size, shape and design and in one arrangement is formed of a conventional four-way trailer plug that electrically connects to the electrical system of many standard vehicles  30 . However any other form of plug is hereby contemplated for use as is directly wiring the wiring  56  of light bar  10  into the wiring system of vehicle  30 . 
     In one arrangement, wiring  56  also includes one or more signal leads  62 . Signal lead  62  is an electrical lead that is configured to be electrically connected to electrical system of vehicle  30 , and more specifically a reverse light lead, a left turn signal lead, a right turn signal lead or another electrical lead of vehicle  30 . In combination, plug  60  and signal lead(s)  62  are configured to receive power and operational signals from vehicle  30  and provide operational signals to light bar  10 . That is, as a user operates vehicle  30 , the lights in the back of the vehicle  30 , where light bar  10  is positioned, are controlled in various ways. That is, when the user presses the brake pedal, the brake lights of the light bar  10  illuminate until the brake pedal is released; when the user engages a turn signal, the appropriate turn signal of the light bar  10  periodically flashes until the turn signal is disengaged; when the user places the vehicle  30  in reverse, the reverse lights of the light bar  10  illuminate until the vehicle  30  is removed from reverse; when the user turns the hazard lights on, the brake lights of the light bar  10  flash until the hazard lights are turned off, and so on. Signal lead  62 , as well as the other wires of wiring  56 , are configured to receive and transmit the operational signals to the light bar  10  so that light bar  10  can illuminate appropriately and in coordination with the lights of vehicle  30 . 
     In the arrangement wherein the light bar  10  is formed of two segments  16 , a ribbon wire  63  extends outward from an end of each segment  16 . That is, a ribbon wire  63  connects to the first segment  16  and extends outward through the end cap  18  that allows passage of the ribbon wire  63  there through. A second ribbon wire  63  extends under the circuit board  14  of the first and second segment  16  and electrically connects to the end of second segment  16  opposite first segment  16 . This ribbon wire  63  also extends out the same end cap  18  such that both wires extend out of the same end of housing  12 . In the arrangement shown, ribbon wire  63  includes six wires, or three pairs of wires, one pair for each color of LED  46  (white LED  46 W, red LED  46 R, and amber LED  46 A). As depth of the system  10  is important to maintain the low profile nature of the system  10 , to minimize the depth of the system, only two segments  16  are used and therefore only one layer of ribbon wire  63  extends below the segments  16 . Having the ribbon wire  63  extend out of the outward ends of the segments  16  allows the circuit boards  14  and backing material  48  and circuitry layer  50  connect to one another in flush alignment with one another at seamline  54  in flush and flat engagement with little to no gap there between. This allows for practically seamless illumination between opposing segments  16  and makes it practically impossible to distinguish between the opposing segments  16  as the spacing of the LEDs  46  is maintained across the seamline  54 . That is, the seamline  16  does not disturb the continuous spacing of LEDs  46  from one segment  16  to the other segment  16 . In fact, the seamline  54  is itself hard to see when light bar  10  is inspected. 
     Control Box: 
     System  10  includes a control box  22 . Control box  22  is formed of any suitable size, shape and design and is configured to receive operational signals from the electrical system of vehicle  30 , interpret these signals and output operational signals that control operation of light bar  10 . Control box  22  includes a microprocessor  64  and memory  66  among other components. Microprocessor  64  is any device which receives informational signals, interprets these signals, and outputs information or commands based on instructions stored in memory  66 . Memory  66  is any form of an informational storage device or system, such as RAM, flash memory, a hard drive, or the like. Information or instructions in the form of software, code, firmware or the like are stored on memory  66  and is accessible to microprocessor  64 . Microprocessor  64  and memory  66  may be formed of a single unitary device, separate but electrically connected devices, or a plurality of separate but electrically connected devices. 
     Since light bar  10  is configured to be installed on practically any vehicle  30 , microprocessor  64  and memory  66  are programmed to interpret signals from multiple types of vehicles and output the appropriate operational signals. That is, in one arrangement, microprocessor  64  and memory  66  are programmed to detect or determine what type of vehicle they are connected to and then determine the appropriate operational signal to output based on what operational signals are received as input. In this way, the use of control box  22  and microprocessor  64  and memory  66  allows for seamless utilization of a single light bar  10  for multiple makes and models of vehicle  30  without the need to program or reprogram the microprocessor  64  and memory  66  for each vehicle  30 . This increases the speed and ease of installation and use. 
     Clip: 
     Clip  28  is formed of any suitable size, shape and design and is configured to connect housing  12  to vehicle  30 . In one arrangement, as is shown, clip  28  has a back wall  100  that extends between opposing end walls  102  and opposing sidewalls  104 . Back wall  100  has a generally flat forward face  106  and a generally flat rearward face  108  that form planes that extend in approximate parallel spaced relation to one another. Opposing sidewalls  104  extend in approximate parallel spaced relation to one another, and opposing end walls  102  extend in approximate parallel spaced relation to one another. As such, sidewalls  104  and end walls  102  extend in approximate perpendicular alignment to one another thereby forming a generally rectangular member. 
     A pair of opposing arms  110  are connected to each end of clip  28 . Arms  110  are connected to sidewalls  104  and extend upward a distance from forward face  106 . The outward edge of arm  110  is in planar alignment with sidewall  104 . The outward end of arm  110  is in alignment with end wall  102  and extends inward a distance therefrom. Arms  110  include a locking feature  112  positioned at their outward most end. Locking features  112  are formed of any suitable size, shape and design and are designed to engage and lock housing  12  into clip  28 . In one arrangement, locking features  112  are formed of a step or ledge or hook that matingly engage the feature  38  or step in the exterior surface of housing  12  positioned at the intersection of cover portion  36  and sidewalls  34 . In the arrangement shown, when clip  28  is viewed from the and end  102 , locking features  112  on opposing arms  110  extend inward and over the forward face of back wall  100  a distance. Accordingly, to facilitate locking engagement, arms  110  extend upward from forward face  106  approximately the same distance as sidewall  34  of housing  12 . 
     To further facilitate a firm, durable and strong connection between clip  28  and housing  12 , arms  110  are slightly biased inward toward one another. This causes the distance between the outward ends of arms  110  to be slightly narrower than the width of housing  12 . As such, when housing  12  is placed between opposing arms  110  and locked into place an inward force is applied on housing  12  by arms  110 . This helps to hold housing  12  within clip  28 . This also helps to keep engagement between locking feature  112  of arm  110  and the feature  38  of housing  12 . 
     Due to the slight inward bias of the arms  110  of clip  28 , the outward most ends of arms  110  include a curved or angled guiding surface  114 . Guiding surface  114  helps to guide the housing  12  into the space between opposing arms  110 . In the arrangement shown, guiding surface  114  curves or angles inward from the upper most end of arms  110  down to the step of locking feature  112 . This causes the upper ends of guiding surface  114  to be wider than the width of back wall  32  of housing  12 , while the lower end of guiding surface  114  is narrower than the width of back wall  32  of housing  12 . This causes the arms  110  to flex or bend outward as the light bar  10  is forced within the clip  28 . 
     The rearward face  108  of back wall  100  is flat and thereby provides maximum surface area for connection to the body of vehicle  30 . This allows for the use of an adhesive, such as a double sided tape or foam or gel to be positioned between the rearward face  108  of clip  28  and the body of vehicle  30 . Using adhesive eliminates the need to put screws or bolts into the body of vehicle  30 , simplifies the installation process, speeds the installation process, eliminates the need to use tools to install the clips  28  and provides a durable installation. 
     Despite that the installation process that uses adhesives instead of drilling and screwing, back wall  100  includes an opening  116  therein that facilitates reception of a screw or other fastening device therein if the installer chooses to use a fastener. In one arrangement, to ensure the head of the screw does not protrude, the opening  116  is countersunk. That is, the walls of the opening angle inward as they extend from forward face  106  to rearward face  108 . 
     Installation and Use: 
     The system  10  is installed by first placing adhesive on the rearward face  108  of a plurality of clips  28 . In one arrangement, the clips  28  are then adhered to the body of vehicle  30 . Once the clips  28  are installed on the vehicle  30 , the housing  12  is aligned with the clips  28  and the housing  12  is forced into the clips  28 . Alternatively, the clips  28  are installed onto the housing  12  and then the housing  12  and clips  28  are simultaneously installed onto the body of the vehicle  30 . 
     When the housing  12  is forced into the clips  28 , the back wall  32  of housing  12  engages the upper or outward end of the guiding surface  114  of arms  110  of clips  28 . As the guiding surfaces  114  angle inward and because the arms  110  are angled slightly inward, force is applied causing the arms  110  to elastically bend outward as the housing  12  is forced downward between opposing arms  110 . The arms  110  continue to bend outward until the ledge or step of features  112  of clip  28  passes or engages the step or features  38  of housing  12 . At this point the locking features  112  of arms  110  engage or lock onto the step or features  38  of housing  12  thereby locking the housing  12  within the clip  28  with a strong and durable connection. In this position, the flat back wall  32  of housing  12  is in flat and flush engagement with the forward face  106  of the flat back wall  100  of clip  28 . In this position, the exterior surface of sidewalls  34  of housing  12  are in flat and flush engagement with the interior faces of arms  110  of clip  28 . In this position, the lower surface of features  112  in the end of arms  110  are in flat and flush locking engagement with the upper surface of the features  38  of the housing  12 . 
     Once the housing  12  is installed, the plug  60  and signal lead  62  are connected to the electrical system of the vehicle  30 . Once electrically connected, the control box  22  and microprocessor  64  and memory  66  receive power and operational signals from the electrical system of the vehicle  30 . The microprocessor  64  interprets these signals according to the instructions stored in memory  66  and outputs operational signals that control operation of the light bar  10 . 
     Dimensions: 
     In one arrangement, to ensure that the system  10  fits practically every commercially available pickup truck, in one arrangement, the light bar system  10  comes in two lengths, 60 inches or 48 inches. The use of these two lengths facilitates use on practically all commercially available pickup trucks. Any other length is hereby contemplated for use. The light bar has a depth approximately ⅜ of an inch without the clip  28  and approximately ½ of an inch with the clip  28  installed. The light bar  10  has a height of approximately ⅝ of an inch without the clip  28  and ¾ of an inch with the clip  28  installed. In one arrangement, the clips  28  are approximately 3 and ¼ inches long. Any other depth and/or width is hereby contemplated for use. 
     Method of Manufacture: 
     In one arrangement, the system  10  is manufactured in the following manner. 
     The housing  12  is extruded of a clear plastic material and the back wall  32  and the rear portions of the sidewalls  34  (nontransparent portion  44 ) are painted with a dark or black color. Alternatively, the housing  12  is extruded and the nontransparent portion  44  is extruded of a nontransparent material whereas the transparent portion  42  is extruded of a transparent material. 
     Next, the circuit board  14  is formed in segments  16 . This is accomplished by installing the LEDs  46  onto the circuitry layer  50  and then installing the LEDs  46  and circuitry layer  50  on the backing material  48 . Once the LEDs  46  are installed onto the circuit board  14  a first layer  120  of encapsulant  20  is laid over the LEDs  46  and the exterior facing surface  55  of circuit board  14 . 
     Encapsulant  20  is formed of any flowable material that seals the LEDs  46  and circuit board  14 . In one arrangement, encapsulant  20  is a flowable material when initially applied that later cures to a non-flowable material. In one arrangement, encapsulant  20  is a flowable plastic material that is transparent or translucent. In one arrangement, while the encapsulant  20  is initially flowable, it hardens to a rigid, semi-rigid, flexible or rubber-like material. 
     Next, the separate segments  16  are connected together by aligning the adjacent segments  16  in end-to-end engagement thereby forming seamline  54  there between and then an adhesive is laid over the rearward face of the circuit board  14 , such as a glue, paste, tape, double sided tape or the like. This using an adhesive such as a double sided tape, gel or the like holds the two segments  16  together while also provides for adhesion of ribbon wire  63  to the back of circuit board  14  as well. 
     Since both segments  16  have ribbon wire  63  extending outward from an end of the segment  16 , and it is desirable to have wires only coming out one end of the housing  12 , the ribbon wire  63  of one segment  16  is folded around and onto the back of circuit board  14  such that both ribbon wires  63  extend out of the same end of system  10 . In this position, the adhesive holds the folded ribbon wire  63  in place on the back of circuit board  14 . 
     Now that both ribbon wires  63  extend outward from the same end of circuit board  14 , the combined and assembled circuit board  14  formed of both segments  16  is slid into the hollow interior  40  of housing  12  through an open end of the housing  12  until the assembled circuit board  14  is fully installed within the hollow interior  40  of housing  12 . 
     Once fully installed, an end cap  18  is positioned over each end. Once installed, the end caps  18  are sealed in place. 
     Next, to fully encapsulate the housing  12 , the housing  12  is vertically aligned, so as to help the bubbles flow out of the hollow interior  40  of the housing  12  and a second layer  122  of encapsulant  20  is injected through the lower end cap  18  and into the remaining air-space within the hollow interior  40  of housing  12 . This encapsulant  20  fills most if not all of the voids and spaces within the hollow interior  40  thereby providing an additional contaminant and water proofing barrier. In one arrangement, this second layer  122  of encapsulant  20  is over-flowed, that is more encapsulant  20  is forced into the hollow interior  40  of the housing  12  such that the excess escapes out the opposite end of the housing  12  and in doing so, excess air bubbles are forced out of the hollow interior  40 . The encapsulant  20  is left to cure over time. Once cured the light bar  10  is ready for use. 
     When encapsulant  20  is properly injected within the hollow interior  40  of housing  12 , the second layer  122  of encapsulant  20  fills all of the air space left within the hollow interior  40  of housing  12 . In one arrangement, the second layer  122  surrounds all portions of the circuit board  14  and engages the entire exterior surface of the circuit board  14  as well as engages the entire interior surface of the hollow interior  40  of housing  40 . By filling all of the air space within the hollow interior  40  of housing  12  after the circuit board  14  has been inserted within the hollow interior  40  this prevents any water or contamination from getting into the hollow interior  40  by filling this space already. In addition, even if water or contaminants did get into the hollow interior  40  of housing  40  this water and/or contaminants would not be able to get to the circuit board  14  itself as the circuit board  14  is fully encapsulated within the second layer  122  of encapsulant  20 . In addition, the LEDs  46  are also encapsulated by the first layer  120  or encapsulant  20  thereby providing a second layer of protection. This these first and second layers  120 ,  122  of encapsulant  20  are protected by being housed within the sealed housing  12  thereby protecting the encapsulant  20  from exposure to water and contaminants not to mention physical contact and abuse. By forming the housing  12  out of a single continuous extrusion, this prevents water or contaminants from getting into housing  12  except for the ends which are covered by end caps  18  that are sealed in place and then sealed again with second layer  122  of encapsulant  20 . In way, a light bar system  10  is provided that is extremely durable and practically impenetrable. 
     Chip-On-Board LEDs: 
     In one arrangement, LEDs  46  are what are known as Chip-On-Board LEDs. COB LED technology describes the mounting of a bare LED chip in direct contact with the substrate to produce LED arrays. It is a method of LED packaging which has a number of advantages over traditional surface mount technologies such as the use of “T-pack” and Surface mount LEDs. 
     Due to the small size of the LED chip, Chip-on-Board technology allows for a much higher packing density than surface mount technology. This results in higher intensity &amp; greater uniformity of light for the user. 
     COB light source can save about 30% cost in the application, mainly lie in LED package cost, light engine production costs and the secondary light distribution costs, which is of great significance for many applications. In performance, through the rational design and micro-lens molding, a COB light module can avoid the defects of point and glare light and other deficiencies of prior art LEDs. COB modules make the production of lighting simpler and more-convenient, and reduce costs effectively. In production, existing technology and equipment can support high yield and large-scale COB module manufacturing, assembly and installation. As such, the use of COB LEDs provides many advantages including brighter illumination and an appearance of a single continuous light instead of a plurality of individual lights. 
     Control Box Algorithm and Operation: 
     One problem associated with adding a light bar  10  having red, white and amber LEDs  46  is that a break light signal and a turn signal from the vehicle&#39;s electrical system is indistinguishable, but it is desirable for the light bar  10  to illuminate the amber LEDs  46 A on the appropriate segment  16  of the light bar  10  for a turn signal while it is desirable to illuminate the red LEDs  46 R of both segments  16  for a break light. In addition, to provide the maximum visibility and safety, it is desirable to illuminate both the red LEDs  46 R of a segment  16  and the amber LEDs  46 A when the breaks are applied while the turn signal is on. Yet, again, in many applications, the break and turning signals are indistinguishable from one another as they merely appear as power to a line through plug  60 . 
     To accomplish this functionality, and separate the turn signals from break signals, microprocessor  64  and memory  66  of control box  22  use an algorithm that is capable of determining whether a signal is a break signal or a turn signal and from this determination the control box  22  illuminates the appropriate segment(s)  16  of light bar  10  and the appropriate color(s) of LEDs  46 . 
     More specifically, in one arrangement, control box  22  receives power and four electrical operational signals from the electrical system of the vehicle  30 . These four operational signals are: (1) a tail light signal (which is a low power signal on both the right tail light lead and the left tail light lead), (2) a reverse light signal, (3) a left blinker/brake signal, and (4) a right blinker/brake signal. 
     The reverse signal is simply a pass through signal. That is, when the reverse signal is received, the white LEDs  46 W of both segments  16  are illuminated. Similarly, the tail light signal (meaning that the tail lights of the vehicle are to be illuminated at a low level, such as when the headlights are on) is also a pass through signal. That is, when the tail light signal is received, the red LEDs  46 R of both segments  16  are illuminated, at a low illumination level. As such, there is essentially no need to perform processing on the reverse light signal and/or the tail light signal. 
     However, processing is required to determine whether a signal is a turn signal or a break signal. The algorithm processes three functions passed along in two wires; left turn signal which is represented as a blinking signal on the left signal lead; right turn signal which is represented as a blinking signal on a right signal lead; and brake signal which is represented as a solid or continuous signal simultaneously present on both the left and right signal leads. The right and left turn signals are mutually exclusive, but the brake signal can be present at any time for any duration. 
     The software algorithm uses memory of the current state and the recent past state of the right signal lead and the left signal lead to determine what function is most likely active at a point in time. That is whether it is a break signal or a turn signal. The algorithm observes the rate at which a turn signal is flashing to estimate when the next signal should arrive, and the algorithm acts accordingly if that signal either does or does not arrive. The software contains a state machine to take care of most situations, and also employs timers to keep certain states from running too long. 
     In addition, the algorithm adapts to the speed of the turn signal for each vehicle, so that if a nondeterministic state is incorrectly determined, the function only lasts the minimum time necessary. This reduces the time that an erroneous output is displayed (an output that may not be in sync with the vehicle). For example, a brake released at just the right time may activate an errant turn signal, e.g. flash of the amber LEDs  46 A of a segment  16 . This functionality adds to the universal nature of the light bar. 
     As such, the control box  22  extrapolates these four electrical operational signals from the electrical system of vehicle  30  into the following functions using an algorithm:
         Break Light: The control box  22  detects a simultaneous solid high-intensity illumination on both the right signal lead and the left signal lead. The control box  22  outputs a high intensity illumination on both segments  16  of red LEDs  46 R.   Breaks Applied and Right Turn Signal Active: The control box  22  detects a constant signal on left turn signal lead and intermittent signal on the right turn signal lead. The control box  22  outputs a high intensity illumination on both segments  16  of red LEDs  46 R while simultaneously outputting a flashing illumination of the amber LEDs  46 A on the right segment  16  of light bar  10 .   Breaks Applied and Left Turn Signal Active: The control box  22  detects a constant signal on right turn signal lead and intermittent signal on the left turn signal lead. The control box  22  outputs a high intensity illumination on both segments  16  of red LEDs  46 R while simultaneously outputting a flashing illumination of the amber LEDs  46 A on the left segment  16  of light bar  10 .   No Break Applied and Right Turn Signal Active: The control box  22  does not detect a signal on the left turn signal lead while detecting an intermittent signal on the right turn signal lead. The control box  22  outputs a flashing illumination of the amber LEDs  46 A on the right segment  16  of light bar  10 .   No Break Applied and Left Turn Signal Active: The control box  22  does not detect a signal on the right turn signal lead while detecting an intermittent signal on the left turn signal lead. The control box  22  outputs a flashing illumination of the amber LEDs  46 A on the left segment  16  of light bar  10 .   Hazards: Detecting hazards is equivalent to detecting a break light signal. That is, the control box  22  detects a simultaneous solid high-intensity illumination on both the right signal lead and the left signal lead. The control box  22  outputs a high intensity illumination on both segments  16  of red LEDs  46 R. In one arrangement, a timer function is used to detect the periodic illumination on both the right signal lead and the left signal lead and microprocessor  64  determines that this continued cycling of this signal is indeed a hazard signal and the microprocessor  64  instead illuminates that amber LEDs  46 A until the periodic cycling ceases.       

     From the above discussion and the accompanying drawings and claims it will be appreciated that the light bar system and method of use and method of manufacture presented offers many advantages over the prior art. That is, the handlebar mounted tool system and method of use presented; improves upon the state of the art; has a long useful life; can be used on practically any vehicle; fits in the space between the bumper and the tailgate of most pickup trucks; is water proof; is weather proof; can be exposed to the elements; is contaminant proof; is easily installed; can be connected to practically any vehicle&#39;s electrical system; provides multi-purpose functionality; has an aesthetically pleasing appearance; is easy to use; improves safety; includes white, yellow/amber and red lights; includes breaking, backup and turning functionality; efficiently dissipates heat; is separated into electrical segments that are independently controllable; is bright; is formed of a plurality of lights but appears to be a single continuous light strip when illuminated; can be installed without drilling into the body of the vehicle; is durable; is rugged; has an intuitive design; is formed of a minimum number of parts; is relatively inexpensive to manufacture; provides value, utility and novelty to the user; has a low profile; can be installed with adhesives and clips, among countless other improvements and advantages. 
     It will be appreciated by those skilled in the art that other various modifications could be made to the device without parting from the spirit and scope of this invention. All such modifications and changes fall within the scope of the claims and are intended to be covered thereby. It should be understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application.