Patent Publication Number: US-2023145546-A1

Title: Searchlight system for vehicle post

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of provisional application No. 62/935,734 filed Nov. 15, 2019, which is incorporated by reference in its entirety herein. 
    
    
     BACKGROUND 
     It can be desirable to mount a spotlight or searchlight to the post or pillar of a vehicle frame. For example, searchlights mounted to the A-pillar of an automobile are commonly used in law enforcement. However, many pillar-mounted searchlight systems are invasive, with installation requiring holes be drilled into and through the pillar of the vehicle body. For example, steering rods of handle-operated spotlights may extend from the interior passenger cabin through the vehicle frame post to the exteriorly-mounted spotlight. Such invasive configurations can potentially weaken the structural integrity of the pillar, which may negatively affect the pillar&#39;s crush performance in an impact event such as a rollover and thus present a safety risk. Such structural pillar modifications will also remain in the event that the searchlight system is to be uninstalled and no longer desired, thereby requiring repair in order to restore its pre-modification condition. Additionally, some searchlight mounting systems can involve a tedious process for dismounting and remounting the searchlight, for example during repair or replacement, and may not be readily compatible for use with other types of optical or sensor devices which can be advantageous depending on the user&#39;s circumstances. 
     The foregoing examples of the related art and limitations therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings. 
     SUMMARY 
     The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above described problems have been reduced or eliminated, while other embodiments are directed to other improvements. 
     The present disclosure relates to a searchlight mounting system, including a mounting assembly and a searchlight assembly, and various aspects thereof, including a method for installing such a system to a vehicle. One aspect provides for the modular exchange of searchlights with respect to a mounting assembly installed on a vehicle. Another aspect provides for a mounting assembly to mount a searchlight to a vehicle without structural modification to the A-pillar. Another aspect provides for a searchlight assembly with improved heat dissipation functionality. Another aspect is directed to ingress protection for a searchlight assembly having a head that is mounted to and rotatable relative to a pivot post. 
     In one embodiment for the modular exchange of searchlights, a searchlight mounting system comprises a mounting assembly and a searchlight assembly. The mounting assembly includes at least one bracket and an adapter, with the at least one bracket having an interior surface and an exterior surface opposite the interior surface, and the adapter projecting out from the exterior surface of the at least one bracket. The searchlight assembly includes a support arm and a head rotatably mounted with respect to the support arm, with the head carrying an optical or sensor device, and the support arm configured to attach to the adapter. The adapter comprises a first projection and a second projection which are arranged opposite the exterior surface, with a cross-sectional geometry of the first projection becoming wider as the first projection extends away from the adapter. The support arm comprises two corresponding projections at one end. The two projections of the support arm are spaced apart from each other to form a channel therebetween which is shaped to receive the first projection of the adapter. A cross-sectional geometry of this channel becomes narrower as the two projections extend away from the support arm. For example, the cross-sectional geometry of the first projection of the adapter may be trapezoidal in shape, with facing walls of the two projections of the support arm angled inward toward each other in extending away from the support arm to correspond to the trapezoidal shape of the first projection of the adapter. In this way, the first projection of the adapter and the two projections of the support arm may interface to form a dovetail joint. The second projection of the adapter may further comprise two bores configured to receive fasteners, with each bore of the second projection configured to align with a respective fastener mating bore formed in each of the two projections of the support arm. For wired embodiments, the support arm may comprise an internal conduit for which aligns with an internal conduit of the adapter, when the support arm is mounted on the adapter, for running wiring from the searchlight assembly through the adapter. The first projection of the adapter may be positioned vertically higher than the second projection of the adapter when the mounting assembly is mounted to a vehicle, such that the searchlight assembly is downwardly slidable onto adapter of the mounting assembly. 
     In one embodiment for mounting a searchlight to a vehicle without structural modification to the A-pillar, a mounting assembly comprises at least one bracket and an adapter. The bracket has an interior surface opposite an exterior surface, with the interior surface configured to face toward the vehicle when installed. The adapter projects out from the exterior surface of the bracket and is configured to attach to the searchlight. The bracket comprises projections which extend out from the interior surface, with a first bore formed into each projection from the exterior surface. Each projection has an end wall opposite the interior surface with a second bore formed through the end wall, the first bore being larger in diameter than the second bore. Fasteners having a head and a shank insert into the projections. The head is larger in diameter than the second bore, while the shank is smaller in diameter than the second bore. Openings are formed in a trim cover of the vehicle which covers the A-pillar to receive the projections of the bracket, but otherwise no structural modification of the A-pillar of the vehicle itself is necessary. During installation of the mounting assembly onto the A-pillar, fasteners are inserted into the first bore at the exterior surface of the at least one bracket, through the second bore at the end wall of each projection. The fasteners are anchored into either existing fastener mating holes of the A-pillar or into clip nuts, whereby the fasteners are then tightened against a contact surface provided by the end walls of the projections. The clip nuts, as part of the mounting assembly where the A-pillar does not have fastener mating holes, are positioned underneath the trim cover and receive the shanks of the fasteners. For example, the clips nuts may be mounted onto a metal base piece of the vehicle between the pillar and trim piece, such as in vehicles having such a base piece welded onto the A-pillar for attachment of the trim piece thereon. The at least one bracket may comprise a shell construction with the interior surface defining a cavity for running wiring from the searchlight to the vehicle. For example, the adapter may have an internal conduit for running wiring from the searchlight to the cavity defined by the interior surface of the at least one bracket. The at least one bracket may extend along the A-pillar down to a windshield cowling area of the vehicle. In some embodiments, the adapter is a separate component secured to the bracket. For example, the interior surface of the bracket may comprise an interface surface adjacent a bracket opening therethrough, with the adapter having a mounting collar with a wider geometry than the rest of the adapter and bracket opening, such that the adapter extends through the bracket opening in projecting out from the exterior bracket surface, and the mounting collar of the adapter is coupled to the interface bracket surface. In which case, the mounting collar and/or the interface surface may include a collar conduit for running wiring across the mounting collar. In some embodiments, the at least one bracket comprises an upper bracket and a lower bracket, and the adapter projects out from the exterior surface of the upper bracket. In some embodiments, the at least one bracket and the adapter are formed together as a single component. Such a single-piece construction of the bracket and adapter may or may not have a separate lower bracket depending on the embodiment. 
     In one embodiment directed to heat exchange, a searchlight assembly comprises a head including at least one housing shell, a heat sink, a heat sink ring gasket, and an optical device. The at least one housing shell houses one or more internal components of the head, and the heat sink is coupled to the at least one housing shell. The heat sink comprises a heat sink ring having a first mating surface, a second mating surface opposite the first mating surface, and an exterior surface extending between the two mating surfaces. The heat sink ring gasket is positioned between the first mating surface and the at least one housing shell to provide a water-resistant seal therebetween. An outer surface of the head is formed, at least in part, by the exterior surface of the heat sink ring and the at least one housing shell. The outer surface of the head is exposed to an outside environment, whereby the heat sink ring is in direct thermal communication with the outside environment. It is preferable that the heat sink be made of a material with high thermal conductivity. For example, the heat sink may be made of aluminum. The at least one housing shell may generally be made of a molded material, such as plastic or aluminum. The heat sink may further comprise a plurality of cooling fins facing the internal components of the head within the at least one shell. A bezel may be provided which abuts the second mating surface of the heat sink ring, and configured to outwardly secure an optical device within the head. The heat sink ring may be coupled to the at least one housing shell via fasteners which extend through the heat sink ring and mate into bosses of the at least one housing. In some embodiments, the fasteners couple the bezel to the second mating surface of the heat sink ring as well. 
     In another embodiment directed to ingress protection, the searchlight assembly comprises a head and a pivot post. The head includes an optical device, at least one housing shell, and at least one internal housing insert. The pivot post at least partially extends into the head. The head is mounted to the pivot post in a vertically pivotable manner whereby a lower edge of the at least one housing shell is spaced apart from the pivot post for clearance space. The at least one housing shell houses one or more internal components of the head. An internal housing surface of the housing shell comprises insert piece fittings which project from the internal housing surface. The insert piece fittings are shaped to receive and retain the internal housing insert. The internal housing insert is positioned within the insert piece fittings and interfaces with the internal housing surface, whereby the at least one internal housing insert completes a physical partition between the pivot post within the head and the one or more internal components of the head. Both the at least one housing shell and the at least one internal housing insert may be made of a molded material, such as plastic or aluminum. In some embodiments, sealant or adhesive is provided along contact points between the housing shell(s) and the internal housing insert(s). One or more rubber or elastomer seals may also be provided along contact points between the housing shell(s) and the internal housing insert(s). In some embodiments, the head further comprises at least one cradle structure for mounting the one or more internal components of the head, and the at least one internal housing insert interfaces with the at least one cradle structure in completing the physical partition. In which case, sealant or adhesive may be provided along contact points between the cradle structure(s) and the internal housing insert(s) as well. One or more rubber or elastomer seals may also be provided along contact points between the cradle structure(s) and the internal housing insert(s). In some embodiments, the at least one internal housing insert comprises two internal housing inserts, and the two housing inserts interface with each other in completing the physical partition. Again, sealant or adhesive may be provided along contact points between the two housing inserts. Likewise, one or more rubber or elastomer seals may also be provided along contact points between the two housing inserts. 
     Accordingly, a method for installing a searchlight system to a vehicle may comprise the steps of: forming openings in a trim cover for a pillar of the vehicle; arranging a mounting assembly of the searchlight system on the trim cover, the mounting assembly comprising a mounting bracket having counterbores or countersinks which extend between an exterior surface of the mounting bracket and an interior surface of the mounting bracket, wherein the interior surface faces the trim cover when the mounting bracket is arranged on the trim cover; securing the mounting bracket to the trim cover by tightening fasteners inserted into the counterbores or countersinks from the exterior surface of the mounting bracket, whereby the fasteners are anchored into fastener mating holes of the pillar of the vehicle or into clip nuts underneath the trim cover; and mounting a searchlight assembly to the mounting bracket, wherein an adapter projects from the exterior surface of the mounting bracket, and the searchlight assembly is configured to removably couple to the adapter. The counterbores or countersinks may be formed through projections which project from the interior surface of the mounting bracket, wherein the projections are inserted through the openings of the trim cover when the mounting bracket is arranged on the trim cover. In some embodiments, the mounting bracket comprises a shell construction defining a cavity, and after the step of securing the mounting bracket to the trim cover, wiring is run from the searchlight assembly through the adapter of the mounting bracket and into the cavity which is formed between the trim cover and the interior surface of the mounting bracket. In which case, the wiring may then be run from the cavity between the trim cover and mounting bracket to a windshield cowling area of the vehicle and then through into the interior cabin of the vehicle. In some embodiments, the mounting bracket comprises an upper mounting bracket and a lower mounting bracket, with the upper mounting bracket carrying the adapter, and the upper mounting bracket being secured to the trim cover before the lower mounting bracket is secured to the trim cover. In which case, the lower mounting bracket may be arranged between the upper mounting bracket and the windshield cowling area of the vehicle, and wiring run from the searchlight assembly through the upper bracket and into the interior cabin of the vehicle before the lower mounting bracket is secured to the trim cover. In some embodiments, during the step of mounting the searchlight assembly to the mounting bracket, the adapter of the mounting bracket and the searchlight assembly interface to form a dovetail joint. The searchlight assembly may also be slid downward onto the adapter of the mounting bracket. In some embodiments, fasteners used to secure the mounting bracket to the trim cover may be the original pillar fasteners that came with the vehicle. Where the fasteners are anchored into clip nuts, rather than existing fastener mating holes of the pillar, the clip nuts may be mounted onto a metal piece of the vehicle between the pillar and trim cover, for example, such as in vehicles having such a base piece welded onto the A-pillar for attachment of the trim cover thereon. 
     The foregoing embodiments and aspects thereof may be practiced independently or combined with any other embodiments and aspects thereof according to the present disclosure. In addition to the aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the accompanying drawings forming a part of this specification. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following description is provided on the basis of example embodiments with reference to the appended figures, wherein: 
         FIG.  1 A  shows a front perspective view of a vehicle&#39;s left A-pillar with trim cover; 
         FIG.  1 B  shows the vehicle A-pillar of  FIG.  1 A  without the trim cover, with underlying components in exploded view; 
         FIG.  2    shows the trim cover of  FIG.  1 A  with openings formed therein; 
         FIG.  3    shows a front perspective view of a searchlight system mounted on the trim cover of  FIG.  2   ; 
         FIG.  4    shows a left side view of the searchlight system and trim cover of  FIG.  3   ; 
         FIG.  5    shows a right side view of the searchlight system and trim cover of  FIG.  4   ; 
         FIG.  6    shows a front side view of the searchlight system and trim cover of FIG.  3 ; 
         FIG.  7    shows a back side view of the searchlight system and trim cover of  FIG.  6   ; 
         FIG.  8    shows a front perspective view of the mounting assembly of  FIG.  3   ; 
         FIG.  9    shows the mounting assembly of  FIG.  8    without the adapter; 
         FIG.  10    shows a bottom perspective view of the mounting assembly of  FIG.  8   ; 
         FIG.  11    shows the mounting assembly of  FIG.  10    without the adapter and fasteners; 
         FIG.  12    shows a top rear perspective view of the adapter of  FIG.  8    without the brackets; 
         FIG.  13    shows a bottom front perspective view of the adapter of  FIG.  12   ; 
         FIG.  14    shows a bottom front perspective view of the searchlight assembly of  FIG.  3   ; 
         FIG.  15    shows a detail view of box  15  of  FIG.  14   ; 
         FIG.  16    shows a back side perspective view of the searchlight assembly of  FIG.  14   ; 
         FIG.  17    shows a detail view of box  17  of  FIG.  16   ; 
         FIG.  18    shows a back perspective view of the searchlight assembly of  FIG.  14   ; 
         FIG.  19    shows the searchlight assembly of  FIG.  18    connected to the adapter of the mounting assembly; 
         FIG.  20 A  shows a front perspective view of another vehicle&#39;s left A-pillar with trim cover; 
         FIG.  20 B  shows the vehicle A-pillar of  FIG.  20 A  without the trim cover; 
         FIG.  21    shows the trim cover of  FIG.  20 A  with openings formed therein; 
         FIG.  22    shows a rear view of the trim cover of  FIG.  21   ; 
         FIG.  23    shows a detail view of box  23  of  FIG.  22   ; 
         FIG.  24    shows the trim cover of  FIG.  21    with another embodiment of the mounting assembly; 
         FIG.  25    shows a front perspective view of the mounting assembly of  FIG.  24   ; 
         FIG.  26    shows a bottom perspective view of the mounting assembly of  FIG.  25   ; 
         FIG.  27    shows the mounting assembly of  FIG.  26    with clip nuts; 
         FIG.  28    shows the detail view of  FIG.  23    with the mounting assembly and clip nuts installed on the trim cover; 
         FIG.  29    shows a side view of a fastener and clip nut of the mounting assembly; 
         FIG.  30    shows a left side perspective view of the searchlight assembly of  FIG.  3    with the left housing shell omitted; 
         FIG.  31    shows a right side perspective view of the searchlight assembly of  FIG.  3    with the right housing shell omitted; 
         FIG.  32    shows a front perspective view of the pan/tilt drive mechanism components of the searchlight assembly of  FIGS.  31  and  32    with the pivot post component moved to the right; 
         FIG.  33    shows a side perspective view of the support arm of the searchlight assembly of  FIGS.  31  and  32   ; 
         FIG.  34    shows a bottom perspective view of the pivot post component of  FIG.  32   ; 
         FIG.  35    shows a left side perspective view of the head of the searchlight assembly of  FIG.  30    with the left housing shell and pan/tilt drive mechanism components omitted; 
         FIG.  36    shows a left side view of the head of  FIG.  35   ; 
         FIG.  37    shows an exploded view of the head of  FIG.  36   ; 
         FIG.  38    shows a front side view of the searchlight assembly of  FIG.  3   ; 
         FIG.  39    shows the searchlight assembly of  FIG.  38    with the outer lens cover omitted; 
         FIG.  40    shows the searchlight assembly of  FIG.  39    with the reflector omitted; 
         FIG.  41    shows the searchlight assembly of  FIG.  40    with the LEDs and LED mounting bracket omitted; 
         FIG.  42    shows a front perspective view of the reflector and LED mounting bracket of  FIGS.  39  and  40   ; 
         FIG.  43    shows a rear perspective view of the reflector and LED mounting bracket of  FIG.  42    with LED circuit board and LEDs mounted to the mounting bracket; 
         FIG.  44    shows a bottom front perspective view of the reflector and LED mounting bracket of  FIG.  42   ; 
         FIG.  45    shows a left side perspective view of a right housing shell with insert piece installed; 
         FIG.  46    shows the right housing shell and insert piece of  FIG.  45    with the insert piece moved off to the left. 
     
    
    
     Before explaining the selected embodiments, it is to be understood that the present disclosure is not limited in application to the details of the particular arrangements shown and is capable of other embodiments. While certain embodiments are illustrated in reference to the figures, it is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than limiting. Also, the terminology used herein is for the purpose of description and not of limitation. 
     DETAILED DESCRIPTION 
     As used herein, the terms “front”, “forward” and the like refer generally to the normal direction of travel of an automobile having a searchlight system according to the present disclosure, while the terms “rear”, “back” and the like refer generally to the opposite or reverse direction. 
       FIG.  1 A  shows the left A-pillar of an automobile with a trim cover  10 . These types of covers are also generally referred to as windshield, pillar or side trim pieces or moldings. The automobile in the depicted embodiment is a 2012-2019 Ford Explorer. The cover  10  snaps onto and covers a base trim piece  15  which is secured via fasteners  25  (e.g. bolts) to the A-pillar of the automobile frame (see  FIG.  1 B ). The A-pillar  5  in this type of construction includes threaded mating holes  30  for receiving the fasteners  25  which secure the base piece  15  thereto. When these components are assembled, the cover  10  gives a finished aesthetic appearance to the automobile exterior. 
       FIG.  2    shows the trim cover  10  of  FIG.  1 A  with openings  20  introduced for installing a searchlight system according to the present disclosure. As discussed in more detail below, the openings  20  in the cover  10  are aligned with the fastener holes  30  in the A-pillar  5 . It should be appreciated that the specific location and arrangement of the openings  20  may be different depending on the automobile model. 
       FIGS.  3 - 7    show a searchlight system  100  mounted on the trim cover  10 . The system  100  comprises a mounting assembly  200  and a searchlight assembly  300 . As discussed in more detail below, the searchlight assembly  300  comprises a support arm  310 , a pivot post  320 , and a head  330 . 
     Referring also now to  FIGS.  8 - 13   , the mounting assembly  200  comprises one or more brackets  210 ,  212  and an adapter  230 . Each bracket  210 ,  212  has an interior surface  214 , which faces in the direction of the automobile frame when installed, and an exterior surface  216 , which faces away from the automobile when installed. Each bracket  210 ,  212  has a shell construction which forms a cavity bounded by the interior surface  214 . This cavity provides clearance space between the brackets  210 ,  212  and the cover  10  for running wiring (not shown). 
     The brackets  210 ,  212  have projections  218  extending out from the interior surface  214 . The projections  218  are inserted into the openings  20  of the cover  10  during installation. A bore  220  is formed into each projection  218  from the exterior surface  216  of the brackets  210 ,  212 . The diameter of the bore  220  is sized to allow passage of the head of the fastener  226 . Each projection  218  has an end wall  222  on its side opposite the interior surface  214 . The end wall  222  has a bore  224  sized to allow passage of the shank of the fastener  226 , but not the head of the faster  226 , and therefore provides a contact surface for tightening the fastener  226 . Therefore, bore  224  is smaller in diameter than bore  220  and together they form a counterbore (or countersink) within the projection  218 . In this way, the fastener  226  may be inserted into the bore  220  at the exterior surface  216 , then through the bore  224  of the end wall  222  of each projection  218 —which extend through the openings  20  of the trim piece  10 —into the fastener receiving hole  30  of the A-pillar  5 , and then tightened against the contact surface provided by the end wall  222  to securely couple the brackets  210 ,  212  to the A-pillar  5  and trim pieces  10 ,  15 . 
     It should be appreciated that the length of the projection  218  from the interior surface  214  (in conjunction with the depth of the cavity formed by the shell construction of the brackets  210 ,  212 ) determines how close the fastener contact surface of the end wall  222  is positioned relative to the fastener receiving hole  30  of the A-pillar  5 . In embodiments where the original A-pillar fasteners are to be reused in installing the mounting assembly  200  (i.e. fasteners  25  are fasteners  226 ), the length of each projection  218  should permit a secure connection whereby the fastener  226  sufficiently extends into the fastener receiving hole of the A-pillar. In other embodiments, for example if longer replacement fasteners are to be used as fasteners  226  in installing the mounting assembly  200 , the length of the projections  218  may be reduced or the projections  218  omitted altogether (in which case the exterior surfaces  216  of the brackets may provide the fastener contact surface and the size of the openings  220  reduced to allow passage of the fastener shank, but not the fastener head). 
     The depicted embodiment includes separate upper and lower brackets  210 ,  212 . With this configuration, the upper bracket  210  may be mounted first, and any wiring of the searchlight assembly  300  may then be run before the lower bracket  212  is installed. The wiring can be run down into the windshield cowling area and through the firewall (which typically has apertures) separating the engine compartment from the passenger compartment. In this way, the searchlight assembly  300  may be controlled by a user within the passenger cabin. The lower bracket  212  largely serves a cosmetic/protective function in covering the wiring, rather than a structural function in supporting the searchlight assembly  300 . It should be appreciated that other embodiments may instead include only one bracket or more than two brackets, which additionally may differ in extent along the A-pillar. 
     In the depicted embodiment, the adapter  230  is provided as a separate component from the brackets  210 ,  212 . The adapter  230  comprises a mounting collar  232  which has a wider geometry than the remainder of the adapter  230 . In this way the adapter  230  may be inserted through an opening  234  of the bracket  210 , whereby the mounting collar  232  contacts a corresponding interface surface  236  provided on the interior surface  214  of the bracket  210  and is coupled to the bracket  210  via fasteners  238 . This approach may be advantageous for fabrication purposes given the relatively complicated structure of the adapter  230  in the depicted embodiment. However, it should be appreciated that the adapter  230  and the bracket  210 , or brackets  210 ,  212 , may instead be produced as a single-piece in other embodiments. Further, the specific design of the mounting collar  232  and interface surface  236 , including the number and position of fasteners  238 , may be modified and therefore different from the depicted configuration in other embodiments. 
     When coupled to bracket  210 , the adapter  230  projects outward from the exterior surface  216  of the bracket  210  and provides a structure for connecting the searchlight assembly  300  to the mounting assembly  200 . On its free side opposite the bracket  210 , the adapter  230  comprises a first projection  240  and a second projection  242 . In the depicted embodiment, the projection  240  has a trapezoidal shaped cross section, wherein the base of the projection  240  becomes wider as the projection  240  extends away from adapter  230 , although other geometries may also be used (e.g. a bulb shaped cross section). The second projection  242  includes two bores configured to receive fasteners  244  in the direction of the first projection  240 . The fasteners  244  are arranged on each side of an internal conduit  246  of the adapter  230 . The internal conduit  246  provides a passage for running wiring from the interior of the searchlight assembly  300  through to the internal-facing side of the mounting assembly  200 . The adapter mounting collar  232  and/or interface surface  236  may also include a conduit  248  for this purpose. 
     As seen in  FIGS.  14 - 19   , the side of the support arm  310  of the searchlight assembly  300  which interfaces with the adapter  230  of the mounting assembly  200  comprises projections  312 . The projections  312  are spaced apart from one another. The space between the projections  312  is configured to receive the projection  240 . Thus, the space between the projections  312  forms a channel having a cross section corresponding to the shape of the adapter projection  240 , wherein the width of this channel becomes narrower as the projections  312  extend away from the support arm  310 . In the depicted embodiment, the facing walls of the projections  312  are angled inward to match the trapezoidal shape of the first adapter projection  240 . Each of the support arm projections  312  may further comprise a threaded fastener mating bore  314 . As seen here, the support arm  310  also has an internal conduit  316  which provides a passage for running wiring. When the searchlight assembly  300  is installed on the mounting assembly  200  (described below), the conduits  246 ,  316  are aligned to form a single passage therebetween enclosed by the adapter/support arm projections  240 ,  242 ,  312 . In other embodiments, wiring from the searchlight assembly  300  may be run directly outside, such as through aperture  317  formed on the bottom side of the support arm  310  (see  FIG.  14   ), rather than internally through the mounting assembly  200 , preferably with a protective covering to prevent damage to such exterior wiring extending between the searchlight assembly  300  and the vehicle ingress point. 
     In attaching the searchlight assembly  300  to the mounting assembly  200 , the searchlight assembly  300  is slid onto to the mounting assembly  200 , whereby the first projection  240  of the adapter  230  is moved into the space between the projections  312  of the support arm  310  until the second projection  242  of the adapter  230  abuts the projections  312 . In this way, a dovetail joint is formed between the adapter projection  240  and arm projections  312 . It is preferable if the first adapter projection  240  is arranged above the second adapter projection  242  when the mounting assembly  200  is installed on an automobile. In this case, the searchlight assembly  300  is slid downward onto the adapter  230  until the arm projections  312  are supported against gravity by the second adapter projection  242 , which provides a strong attachment in combination with the dovetail mating between the first adapter projection  240  and arm projections  312 . Once the supporting arm  310  is positioned on the adapter  230 , the fasteners  244  may be inserted through the second adapter projection  242  into the threaded fastener mating bores  314  of the arm projections  312 , and then tightened against the contact surface provided by the second adapter projection  242  to further secure the attachment between the searchlight assembly  300  and the mounting assembly  200 . Wiring for the searchlight assembly  300  may be run through the mounting assembly  200  before mounting, and pulled taut as the support arm  310  is slid onto the adapter  230  to avoid wire damage during installation. 
     With this attachment, the searchlight assembly  300  may be readily exchanged with respect to the mounting assembly  200  in a modular manner. For example, it may be desirable to uninstall a particular searchlight assembly for repair or to replace it with another searchlight assembly fitted with a different type of optical or sensor system (e.g. light emitting diodes (LEDs), halogen lamps, high-intensity discharge (HID) lamps, cameras, infrared devices, heat sensitive devices, etc.). The mounting assembly  200  can remain installed on the automobile, ready for use with any searchlight assembly  300  configured to mate with the adapter  230 . Therefore, such a modular system  100  may realize substantial benefits in terms searchlight interchangeability and installation time/effort. 
       FIGS.  20 A and  20 B  shows another arrangement of the left A-pillar of a vehicle. The vehicle here is a 2020 Ford Explorer. Here, the A-pillar  5  does not comprise mating holes  30 . Rather, the base piece  15  is a metal piece welded onto the A-pillar  5 . The base piece  15  has openings  35  for attachment of the trim piece  10 . The trim cover  10  with the openings  20  introduced for installing a searchlight system according to the present disclosure is shown in  FIG.  21   . As seen in  FIGS.  22  and  23   , the rear side of the trim cover  10  has fittings  40  for snap fasteners (not shown) which couple into the openings  35  of the base piece  15 .  FIGS.  24 - 26    show another embodiment of a mounting assembly  200  according to the present disclosure for this A-pillar arrangement. The above descriptions regarding the previous embodiment, including the attachment of the mounting assembly  200  and the searchlight assembly  300 , apply here unless otherwise specified and are therefore not repeated. This mounting assembly  200  has a one-piece construction, with the bracket  210  and the adapter  230  produced as a single component. In addition to not having a separate bracket piece  212 , this mounting assembly  200  also illustrates another possible arrangement of the bracket  210  with adapter  230  with respect to size, extension and positioning. Referring now to  FIGS.  27 - 29   , the mounting assembly  200  further comprises clip nuts  250 . The clip nuts  250  couple to the fasteners  226 . The clip nuts  250  provide the mating or anchoring structure for the fasteners  226 , as the pillar  5  does not have the holes  30  to receive the fasteners  226 . The clip nuts  250  are provided adjacent the fittings  40  of the trim cover  10 . As best seen in  FIG.  29   , the clip nuts  250  have a bracket or clip integral with the nut head. The clip nuts  250  are mounted in the openings  35  of the base piece  15 , with the bracket of the clip nut  250  holding the metal sheet material of the base piece  15 . In this way, the clip nuts  250  can be used to secure the mounting assembly  200  with respect to the vehicle pieces  10 ,  15  and therefore with respect to the pillar  5 . The head and shank of the fastener  226  as well as the inclusion of a washer thereon, which is common with these types of fastener arrangements, are also clearly visible in  FIG.  29   . Of course, clip nuts  250  may be also used in other embodiments of the mounting assembly  200 , for example those with the bracket  210  and adapter  230  provided as separate components and/or including multiple brackets  210 ,  212 , as in the previous example of  FIGS.  8 - 13   , depending on the pillar mounting configuration. 
     Referring also now to  FIGS.  30 - 34   , the pan/tilt mechanisms of the searchlight assembly  300  are described. A controller  332  is provided within the searchlight head  330  which controls operation of the electronic components, such as the light source and motors, based on user input (e.g. wired or wireless). The internal components are covered, in part, by at least one housing shell  370 . The depicted embodiment comprises left and right housing shells  370 . 
     During horizontal pan movement, the pivot post  320  and the head  330  are both rotated relative to the support arm  310 . For the pan mechanism, a first reversible motor  334  drives belt  336 , which drives sprocket  338 . Sprocket  338  includes another gear face which drives vertical gear  340 . Pan gear  340  is in a locked connection with the shaft of miter gear  342 , such that rotation of vertical gear  340  causes rotation of miter gear  342 . Rotating miter gear  342  acts against fixed miter gear  344 . Miter gear  344  is positionally fixed on the support arm  310 , thereby causing rotation of the pivot post  320  and head  330  relative to the support arm  310 . 
     In the depicted embodiment, the bottom end of miter gear  344  comprises threading which mates with the opposite end of the internal conduit  316  of the support arm  310  when the miter gear  344  is installed on the support arm  310 , although other configurations may also be used. The miter gear  344  has an internal conduit  346  for running wiring through the internal conduit  316  of the support arm  310  up into the pivot post  320 . Bearings  348  are provided between the miter gear  344  and the pivot post  320  for rotating the pivot post  320 , and therefore also the head  330 , relative to the support arm  310 . The support arm  310  may further comprise a stop  318 , which sits within a stop channel  322  formed on the bottom of the pivot post  320 , to limit the degree of horizontal rotation. In the depicted embodiment, the available pan rotation arc is approximately 270°. The available pan rotation arc is preferably configured to prevent the optical device of the searchlight head  330  from being accidentally pointed into the passenger cabin of the automobile, whereby the approximately 90° arc through which the head  330  is unable to rotate corresponds to the facing direction of the optical device with respect to the passenger cabin area. The length and positional arrangement of the stop channel  322  on the pivot post  320  may be selected for a given application, for example, where the searchlight system  100  is to be mounted to the right A-pillar rather than the left A-pillar of the automobile. 
     During vertical tilt movement, the head  330  is rotated relative to both the pivot post  320  and the support arm  310 . For the tilt mechanism, a second reversible motor  350  drives belt  352 , which drives sprocket  354 . Sprocket  354  includes another gear face which acts against fixed gear  356 . Gear  356  is fixed with respect to one of the support plates  358 . The support plates  358  are fixed with respect to the pivot post  320  via fasteners  360  in the depicted embodiment. The tilt mechanism may also include a torsion spring  362 , which is biased to assist in tilting the head  330  upwards against gravity. A tilt stop  368  is built into one or both support plates  358 . The stops  368  limit travel of the cradle  362  during tilt movement, which can be used to prevent over-rotation. The fixed gear  356  and its respective support plate  358  have an internal conduit for running wiring from the pivot post  320  into the interior of the head  330  (e.g. to the controller  332  and/or other electronic components). 
     A cradle  362  provides a mounting structure for the controller  332 , motors  334 ,  350 , and sprockets  338 ,  354 . The cradle  362  is fixed with respect to the housing shell  370 , both directly and indirectly through the motor caps  364  via fasteners  366  in the depicted embodiment. Sealed bearings (not shown) are provided between each of the support plates  358  and the cradle  362  for rotating the cradle  362 , and therefore the rest of the head  330 , relative to the support plates  358 , and therefore also the pivot post  320  and support arm  310 . On the pan mechanism side, bearings (not shown) are also provided between the respective support plate  358  and both the vertical gear  340  and miter gear  342 —which gears  340 ,  342  rotate together relative to the support plate  358  in acting on the fixed miter gear  344  inside the pivot post  320 . 
     Referring also now to  FIGS.  35 - 37   , the head  300  further comprises a heat sink  372 . The heat sink  372  is made of a material with good heat-dissipation properties. For example, aluminum or other metals may be used. Those of skill in the art will understand that any material having similar heat-exchange properties could also be used. The heat sink  372  comprises cooling fins  374 , which help dissipate heat, and a heat sink ring structure  376 . The heat sink ring  376  forms a part of the exterior surface of the head  300  and is therefore exposed to the ambient environment, which promotes substantial heat dissipation between the head  330  and its outside surroundings. In the depicted embodiment, the heat sink ring  376  is integral with the remainder of the heat sink  372 ; the heat sink  372  with its fins  374  and ring  376  being formed from a single cast. In other embodiments, the heat sink ring  376  may be provided as a separate component which contacts the heat sink  372  to establish thermal communication therebetween, whereby heat from the heat sink  372  is transferred to the heat sink ring  376  and then dissipated to the exterior environment. A ring gasket  378  is provided between the heat sink ring  376  and the housing shells  370 , which helps seal against the ingress of water and/or dirt into the interior of the head  300 . On its other side, the heat sink ring  376  abuts a bezel  380 . The bezel  380  holds the lens cover  382  (see also  FIG.  38   ) in place which in turn supports the optical or sensor device system against the heat sink  372 . For illustrative clarity, the lens cover  382  is depicted being opaque; it being understood that the lens cover  382  is transparent or at least partially translucent for purposes of light emission. For attachment, fasteners  384  are inserted through the bezel  380  (which provides the fastener head contact surface), through the heat sink  372  and anchored into bosses  386  of the housing shells  370 . 
     Referring also now to  FIGS.  38 - 41   , one possible optical device configuration is described. Although the optical device of the depicted embodiment is an LED lamp, other optical or sensor systems (e.g. halogen or HID lamps, cameras, infrared sensors, heat sensors, etc.) may also be used according to the present disclosure. Indeed, one aspect of the searchlight system  100  is the modular exchange of different searchlight assemblies  300  with respect to an already-installed mounting assembly  200 , including for the purpose of switching out different optical or sensor device systems as desired under the circumstances. Further, although the depicted optical device has a reflective design which utilizes a reflective surface to redirect and concentrate light emitted by one or more LEDs into an output beam, other embodiments comprise a refractive design which utilizes at least one projection lens to redirect and concentrate emitted light into an output beam. Some embodiments incorporate both reflective and refractive designs. A searchlight system according to the present disclosure and the various aspects thereof may be used with any suitable optical device system; no limitation is intended nor should be inferred. 
     In the depicted embodiment, a reflector  388  is provided under the lens cover  382 . The surface of the reflector  388  is configured to redirect and concentrate light emitted through LED openings  390  in the reflector  388 . The reflector  388  is positioned adjacent a front surface  392  of the heat sink  372  (opposite the fins  374 ). The geometry of the front surface  392  may correspond to the geometry of the reflector  388 , as in the depicted embodiment, which helps to correctly align the reflector  388  between the heat sink  372  and the lens cover  382 . The front surface  392  includes apertures  394  for running wiring to the controller  332  within the head  330 . The front surface  392  also has a cavity  396  which receives a LED mounting bracket  400 . Bores  398  (see also  FIG.  35   ) are provided in the upper portion of the cavity  396  to receive fasteners (not shown) for coupling the heat sink  472  to the mounting bracket  400 . 
     Referring also now to  FIGS.  42 - 44   , the LED mounting bracket  400  is arranged within the cavity  396  between the reflector  388  and the heat sink  372 . The top surface of the mounting bracket  400  has anchor holes for mating with fasteners (not shown) which extend through the heat sink bores  398  in coupling the bracket  400  to the heat sink  372 . LEDs  402  are provided on circuit board  404 , which is mounted to the mounting bracket  400 . The LEDs  402  are positioned to emit light through the reflector openings  390  onto the surface of the reflector  388 , which may be configured to redirect and concentrate the light into a beam as in the depicted embodiment. In other embodiments, one or more LEDs  402  are positioned along the front surface  392  of the heat sink  372 , and at least one projection lens (not shown) is arranged between the LEDs  402  and the lens cover  382 , the at least one projection lens configured to redirect and concentrate light into a beam, in which case the front surface  392  of the heat sink  372  may be flat or take on different shapes and the reflector  388  omitted entirely. 
     Reference is also now made to  FIGS.  45  and  46   . In the tilt mechanism described above, the head  330  (including housing shells  370 ) rotates relative to both the stationary pivot post  320  and fixed support plates  358 . Therefore, at least some clearance space is provided between a lower edge  406  of each housing shell  370  and the pivot post&#39;s neck  324  and body  326  (see  FIG.  34   ) and the support plates  358  to accommodate this motion. However, water, dust and the like could potentially enter through such clearance space into the interior of the head  330  and negatively affect mechanical or electronic components. To mitigate against this problem, a special insert piece  408  is provided for each housing shell  370 . Together with the housing shells  370  and cradles  362 , the insert pieces  408  seal the area of the head  330  occupied by the pivot post  320  and support plates  358  from the rest of the interior of the head  330  containing parts that might be negatively affected by moisture/particle ingress. The internal surface  410  of each housing shell  370  comprises fitting projections  412  for positioning the insert piece  408  thereon. Sealant or adhesive is provided along the contact points between each housing shell  370  and its respective insert piece  408 . In other embodiments (not shown), one or more rubber, elastomer or like seals may be provided along these contacts points. On the opposite interior-facing end of each insert piece  406 , one or more rubber, elastomer or like seals  414  is/are provided along the contact points with the other insert piece  408  and the cradle  362 . Since the geometry provided by the special insert pieces  408  is not integrated into the housing shells  370  themselves, the housing shells  370  may be readily produced by efficient processes such as injection molding. 
     While a number of aspects and embodiments have been discussed, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations are possible. It is intended that the following claims are interpreted to include all such modifications, permutations, additions and sub-combinations, as they are within the true spirit and scope of the present disclosure and the claims. Each embodiment described herein has numerous equivalents. 
     The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions to exclude any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Accordingly, it should be understood that although the invention has been specifically disclosed by selected embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims. Whenever a range is given in the specification, all intermediate ranges and subranges, as well as all individual values included in the ranges given are intended to be included in the disclosure. When a Markush group or other grouping is used herein, all individual members of the group and all combinations and sub-combinations possible of the group are intended to be individually included in the disclosure. 
     In general, the terms and phrases used herein have their art-recognized meaning, which can be found by reference to standard texts, journal references and contexts known to those skilled in the art. The above definitions are provided to clarify their specific use in the context of the invention. 
     
       
         
           
               
             
               
                   
               
               
                 LIST OF REFERENCE NUMERALS 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
            
               
                 5 
                 A-pillar 
               
               
                 10 
                 trim cover 
               
               
                 15 
                 base trim piece or tracking 
               
               
                 20 
                 cover openings 
               
               
                 25 
                 fasteners 
               
               
                 30 
                 A-pillar mating holes 
               
               
                 35 
                 base piece openings 
               
               
                 40 
                 trim cover fittings 
               
               
                 100 
                 mounted searchlight system 
               
               
                 200 
                 mounting assembly 
               
               
                 210 
                 upper bracket 
               
               
                 212 
                 lower bracket 
               
               
                 214 
                 interior bracket surface 
               
               
                 216 
                 exterior bracket surface 
               
               
                 218 
                 projection 
               
               
                 220 
                 bore 
               
               
                 222 
                 end wall 
               
               
                 224 
                 bore 
               
               
                 226 
                 fastener 
               
               
                 230 
                 adapter 
               
               
                 232 
                 adapter mounting collar 
               
               
                 234 
                 bracket opening 
               
               
                 236 
                 bracket interface surface 
               
               
                 238 
                 fasteners 
               
               
                 240 
                 first adapter projection 
               
               
                 242 
                 second adapter projection 
               
               
                 244 
                 fasteners 
               
               
                 246 
                 adapter internal conduit 
               
               
                 248 
                 adapter collar conduit 
               
               
                 250 
                 clip nuts 
               
               
                 300 
                 searchlight assembly 
               
               
                 310 
                 support arm 
               
               
                 312 
                 projections 
               
               
                 314 
                 fastener mating bores 
               
               
                 316 
                 arm internal conduit 
               
               
                 317 
                 arm external aperture 
               
               
                 318 
                 pan stop 
               
               
                 320 
                 pivot post 
               
               
                 322 
                 stop channel 
               
               
                 324 
                 pivot post neck 
               
               
                 326 
                 pivot post body 
               
               
                 330 
                 head 
               
               
                 332 
                 electronics controller 
               
               
                 334 
                 pan reversible motor 
               
               
                 336 
                 pan belt 
               
               
                 338 
                 pan sprocket 
               
               
                 340 
                 pan gear 
               
               
                 342 
                 pan rotating miter gear 
               
               
                 344 
                 pan fixed miter gear 
               
               
                 346 
                 miter gear conduit 
               
               
                 348 
                 post bearings 
               
               
                 350 
                 tilt reversible motor 
               
               
                 352 
                 tilt belt 
               
               
                 354 
                 tilt sprocket 
               
               
                 356 
                 tilt fixed gear 
               
               
                 358 
                 support plates 
               
               
                 360 
                 fasteners 
               
               
                 362 
                 cradle 
               
               
                 364 
                 motor caps 
               
               
                 366 
                 fasteners 
               
               
                 368 
                 tilt stop 
               
               
                 370 
                 housing shell 
               
               
                 372 
                 heat sink 
               
               
                 374 
                 cooling fins 
               
               
                 376 
                 heat sink ring 
               
               
                 378 
                 heat sink ring gasket 
               
               
                 380 
                 bezel 
               
               
                 382 
                 lens cover 
               
               
                 384 
                 fasteners 
               
               
                 386 
                 housing bosses 
               
               
                 388 
                 reflector 
               
               
                 390 
                 LED reflector openings 
               
               
                 392 
                 front surface of heat sink 
               
               
                 394 
                 heat sink apertures 
               
               
                 396 
                 heat sink cavity 
               
               
                 398 
                 heat sink bores 
               
               
                 400 
                 LED mounting bracket 
               
               
                 402 
                 LEDs 
               
               
                 404 
                 LED circuit board 
               
               
                 406 
                 housing edge 
               
               
                 408 
                 insert piece 
               
               
                 410 
                 internal housing surface 
               
               
                 412 
                 insert piece fittings 
               
               
                 414 
                 seals