Patent Publication Number: US-2023151933-A1

Title: Modular lightbar system and method

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 17/724,542, filed Apr. 20, 2022, now pending, which is a continuation of U.S. patent application Ser. No. 17/161,872, filed Jan. 29, 2021, now U.S. Pat. No. 11,313,522, which is a continuation of U.S. patent application Ser. No. 16/893,848, filed Jun. 5, 2020, now U.S. Pat. No. 10,914,435, which is a division of U.S. patent application Ser. No. 15/945,843, filed Apr. 5, 2018, now U.S. Pat. No. 10,683,973, which claims priority to U.S. Provisional Patent Application No. 62/489,586 filed Apr. 25, 2017, the contents of which are incorporated by reference herein. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to improvements to modular lightbar systems. 
     BACKGROUND OF THE INVENTION 
     Lightbar systems continue to increase in popularity and utility as they become easier to use and install, and cheaper to manufacture and operate. Using solid state lights (SSL) as the light source provides increased reliability and usable life, as well as simplicity of installation and service. Lightbar systems with an SSL light source are virtually trouble-free, and last well beyond the expected life of incandescent or fluorescent light sources. 
     Lightbar systems typically comprise one or more lightbar assemblies connected in a desired layout, e.g., under-cabinet lighting in a kitchen, display cases, cove lighting, track lighting, and wall wash lighting applications. The lightbar assemblies are elongate rectangularly shaped, and connected, end-to-end, using a joiner that electrically connects one lightbar assembly to another. Once the lightbar assemblies are connected to form a lightbar system, a single lightbar assembly cannot be removed without removing the adjacent lightbar assemblies to which it is connected. This presents significant problems for removing a lightbar assembly that is not located at an end of the lightbar system. It may be the case that the entire lightbar system must be disassembled to service or replace a single lightbar assembly. 
     Thus, there exists a need for a solution to the above-identified shortcomings of the prior art. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a modular light system that overcomes the above-described shortcomings in the art. Specifically, in accordance with an embodiment of the present invention, and as an object of the present invention, a modular lightbar system is provided that is more flexibly configurable, enabling easy installation, configuration and service. 
     Such a design and configuration enables the lightbar assembly connector and lightbar assembly to be connected by moving the lightbar assembly connector in a direction generally transverse to the longitudinal axis of the lightbar assembly (or by moving the lightbar assembly in a direction generally transverse to the major surface of the lightbar assembly connector). It is thus possible, in accordance with embodiments of the present invention, to assemble a lightbar system comprised of a plurality of lightbar assemblies and lightbar assembly connectors, any of which are removable, replaceable, serviceable, etc., without having to disassemble the entire lightbar system. Any one component (e.g., lightbar assembly, lightbar assembly connector, etc.) may be removed and replaced simply, easily and safely. 
    
    
     
       DESCRIPTION OF THE DIAGRAMS 
       Embodiments of the present invention will now be described with reference to the following diagrams, wherein: 
         FIG.  1    depicts a lightbar system in accordance with an embodiment of the present invention; 
         FIG.  2    is a perspective view of a lightbar assembly in accordance with an embodiment of the present invention; 
         FIG.  3    is an exploded view of a lightbar assembly in accordance with an embodiment of the present invention; 
         FIG.  4    depicts a plug end of a lightbar assembly and a variety of lightbar assembly connectors in accordance with an embodiment of the present invention; 
         FIG.  5    depicts a receptacle end of a lightbar assembly and a variety of lightbar assembly connectors in accordance with an embodiment of the present invention; 
         FIG.  6    depicts a plug end and a receptacle end of two lightbar assemblies, and a straight lightbar assembly connector in accordance with an embodiment of the present invention; 
         FIG.  7    depicts a plurality of lightbar assemblies and lightbar assembly connectors in accordance with an embodiment of the present invention; 
         FIGS.  8 A and  8 B  are perspective views of two embodiments of an angle lightbar assembly connector in accordance with embodiments of the present invention; 
         FIGS.  8 C and  8 D  depict, respectively, a T-connector lightbar assembly connector, and a variable angle lightbar assembly connector in accordance with embodiments of the present invention; 
         FIG.  9    is a perspective view of a straight lightbar assembly connector in accordance with an embodiment of the present invention; 
         FIGS.  10 A and  10 B  are perspective views of two embodiments of a joiner assembly in accordance with embodiments of the present invention; 
         FIG.  11    is a perspective view of a distribution box in accordance with an embodiment of the present invention; 
         FIG.  12    is a perspective view of a power connection box in accordance with an embodiment of the present invention; and 
         FIGS.  13 A- 13 D  are views of three embodiments of a mounting bracket in accordance with embodiments of the present invention. 
     
    
    
     DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     The present invention will now be described in detail and with reference to the drawing figures. Referring first to  FIGS.  1 - 7   , a lightbar system  100  in accordance with an embodiment of the present invention comprises a lightbar assembly  200  and at least a lightbar assembly connector  110 ,  130 ,  150 ,  170  or  190 . The lightbar assembly connector may be a straight connector  130 , and angle connector  110 , a joiner assembly  150 , a distribution box  170  or a power connector box  190 . Each of these will be described in more detail below. The embodiment of  FIG.  1    depicts a plurality of lightbar assemblies  200  connected by a plurality of lightbar assembly connectors  110 ,  130  to form a “S”, “Z”, “C”, or “U” shaped configuration. This depiction is exemplary only, and the present invention is flexibly and selectively configurable in countless configurations. Each lightbar assembly  200  has a receptacle end  210  and a plug end  220  that are located at longitudinally separated ends of the lightbar assembly  200 . The receptacle end  210  has a receptacle end cap  216  that is configured as a receptacle connector  218  having two receptacles  212 , each with a conductive external terminal  214 . The external terminals  214  are not accessible beyond the confines of the space defined by the receptacle  212 , thus providing a safe connector that prevents unintended or accidental contact with these terminals  214 . The plug end  220  has a plug end cap  226  that is configured as a plug connector  228  having two plugs  222 , each with a conductive internal terminal  224 . Each of the external terminals  214  and internal terminals  224  extend in a direction transverse to a longitudinal axis of the lightbar assembly  200 . 
     As depicted in  FIG.  3   , a lightbar assembly  200  in accordance with embodiments of the present invention comprises a housing  240  that may be constructed of extruded aluminum, for example, and that is generally elongate with a square, rectangular, oval, elliptical, or other geometric cross section. A SSL strip  250  light source has a plurality of LEDs  252  electrically connected. Conductive pins  256  connect one end of the SSL strip  250  to the external terminals  214  of the receptacle end cap  216 , and the other end of the SSL strip  250  to the internal terminals  224  of the plug end cap  226 . Ground terminals  310  are mechanically secured to receptacle end cap  216  and plug end cap  226  and to support  254  to provide a ground connection for the SSL strip  250  and for the lightbar assembly  200 . The SSL strip  250  is supported by at least one support  254 , preferably two supports  254 , that maintain the SSL strip  250  in a desired position within the housing  240 . The supports  254  may be positioned in thermal contact with the SSL strip  250 , acting as a heat sink. If at least one support  254  is in contact with the housing  240 , the housing  240  will also function as a heat sink to the SSL strip  250 . A lens  260  connects with the housing  240  to enclose the SSL strip  250  within the lightbar assembly  200 . The lens  260  may provide diffusion for the light emitted by the LEDs  252 . Driver circuitry (not shown) for the SSL strip  250  may be at least partially contained in a driver enclosure  270 . Other components may also be provided in the lightbar assembly  200 , including, by way of non-limiting example, motion sensors to control aspects of the lightbar assembly such as on/off, brightness, etc., Bluetooth® connectivity, brightness controls, color control, and other components suitable for controlling one or more LEDs. 
     The modular lightbar system  100  of the present invention also comprises at least one of a straight connector  130 , and angle connector  110 , a joiner assembly  150 , a distribution box  170  or a connection box  190 , as depicted in  FIGS.  4  and  5   . Any one of the lightbar assembly connectors depicted may be connected with the lightbar assembly  200 , as described in more detail herein. Referring first to  FIG.  4   , the plug end  220  of a lightbar assembly  200  is depicted with two angle connectors  110 , a straight connector  130  and a joiner assembly  150 —only one of which may be releasably connected to a plug end  220  of the lightbar assembly  200  at one time. The plug connector  228  has two plugs  222 , each having a conductive internal terminal  224 . The plugs  222  and terminals  224  are sized and shaped to respectively engage with and contact a receptacle and terminal of any of an angle connector  110 , a straight connector  130  and a joiner assembly  150 . 
     Referring next to  FIG.  5   , the receptacle end  210  of a lightbar assembly  200  is depicted with two angle connectors  110 , a straight connector  130 , a joiner assembly  150 , a distribution box  170 , and a power connector box  190 —only one of which may be releasably connected to a receptacle connector  218  of the lightbar assembly  200  at one time. The receptacle connector  218  has two receptacles  212 , each having a conductive external terminal  214 . The receptacles  212  and terminals  214  are sized and shaped to respectively engage with and contact a plug and terminal of any of an angle connector  110 , a straight connector  130 , a joiner assembly  150 , a distribution box  170  and a power connector box  190 . 
     Referring next to  FIGS.  8 A and  8 B , an angle connector  110  in accordance with embodiments of the present invention will now be descried in more detail. An angle connector  110  enables connection of two lightbar assemblies  200  at a predefined angle with respect to each other. Preferably, the predefined angle is 90 degrees, but other fixed or selectable angles are contemplated by and within the scope and spirit of the present invention. The embodiments of  FIGS.  8 A and  8 B  differ mainly in the orientation of the angle with respect to a longitudinal center line of each lightbar assembly  200 . The orientation of the angle of these embodiments differs by 180 degrees when the predetermined angle of the angle connector  110  is 90 degrees. In use, a first lightbar assembly  200  will be installed so that is longitudinal center line is in a desired orientation. A second lightbar assembly  200  may be connected to the first lightbar assembly  200  using an angle connector  110  so that the longitudinal center line of the second lightbar assembly  200  will be at a 90-degree orientation with respect to the longitudinal center line of the first lightbar assembly  200 . Whether the second lightbar assembly  200  extends to the right or left of the first lightbar assembly  200  depends upon which angle connector  110  is used. 
     The angle connector  110  has a receptacle connector  128  and a plug connector  126 . The receptacle connector  128  has two receptacles  112 , each having a conductive external terminal  114  therein. The receptacles  112  and external terminals  114  are sized and shaped to respectively receive and contactingly engage a plug  222  and conductive internal terminal  224  of a lightbar assembly  200 . The plug connector  126  has two plugs  122 , each having a conductive internal terminal  124 . The plugs  122  and internal terminals  124  are sized and shaped to respectively insert into and contactingly engage a receptacle  212  and conductive external terminal  214  of a lightbar assembly  200 . The internal terminals  124  and external terminals  114  each extend in a direction transverse to a major surface  118  (see, e.g.,  FIG.  1   ) of the angle connector  110 . A post  116  is provided near each of the two receptacles  112  and the two plugs  122  to releasably engage a complementarily sized and shaped part of a lightbar assembly  200 . The post  116  has a ground terminal  300  that conductively connects with a ground terminal  310  (see, e.g.,  FIG.  3   ) on the complementarily sized and shaped part of the lightbar assembly  200  to which the angle connector  110  is connected. This ensures that the lightbar assembly  200  is fully grounded. The post  116  and part of the lightbar assembly  200  releasably secure the angle connector  110  and lightbar assembly  200  together. An exemplary and illustrative non-limiting connection of an angle connector  110  with a lightbar assembly  200  is depicted in  FIGS.  1  and  7   . 
     Referring next to  FIGS.  8 C and  8 D , alternative embodiments of connectors in accordance with the present invention are depicted and will now be discussed.  FIG.  8 C  depicts a T-connector  230  having two plug connectors  126  aligned with each other, and a receptacle connector  128  arranged perpendicular to the plug connectors  126 . Alternative configurations are contemplated by, and within the scope and spirit of the present invention.  FIG.  8 D  depicts a variable angle connector  280  having a plug connector  126  and a receptacle connector  128  that are arrangeable with respect to each other at any angle from 90° to 0°. Hinging may be by a living hinge, or other known or hereafter developed hinge of any type or construction. Electrical connection between the conductive components of the variable angle connector  280  is maintained throughout movement of the plug connector  126  and receptacle connector  128  with respect to each other by circuitry, circuit boards, conductive paths, cables, wires, or any known or hereafter developed conductive part, material or means. 
     A straight connector  130  depicted in  FIG.  9    enables connection of two lightbar assemblies  200  at a predefined angle with respect to a longitudinal center line of the lightbar assemblies  200 . The preferred predefined angle is 0 degrees, but other angles are contemplated by and within the scope and spirit of the present invention. The straight connector  130  has a plug connector  146  and a receptacle connector  148 . The receptacle connector  148  has two receptacles  132 , each having a conductive external terminal  134  therein. The receptacles  132  and external terminals  134  are sized and shaped to respectively receive and contactingly engage a plug  222  and conductive internal terminal  224  of a lightbar assembly  200 . The plug connector  146  has two plugs  142 , each having a conductive internal terminal  144 . The plugs  142  and internal terminals  144  are sized and shaped to respectively insert into and contactingly engage a receptacle  212  and conductive external terminal  214  of a lightbar assembly  200 . The internal terminals  144  and external terminals  134  each extend in a direction transverse to a major surface  138  (see, e.g.,  FIG.  1   ) of the straight connector  130 . A post  136  is provided near each of the two receptacles  132  and the two plugs  142  to releasably engage a part of a lightbar assembly  200 . The post  136  has a ground terminal  300  that conductively connects with a ground terminal  310  (see, e.g.,  FIG.  3   ) on the complementarily sized and shaped part of the lightbar assembly  200  to which the straight connector  130  is connected. This ensures that the lightbar assembly  200  is fully grounded. The post  136  and part of the lightbar assembly  200  releasably secure the straight connector  130  and lightbar assembly  200  together. An exemplary and illustrative non-limiting connection of a straight connector  130  with a lightbar assembly  200  is depicted in  FIGS.  1 ,  6  and  7   . 
     An exemplary connection between and among two lightbar assemblies  200  and a straight connector  130  is depicted in  FIG.  6   . The plug end  220  of a first lightbar assembly  200  is positioned proximate the receptacle end  210  of a second lightbar assembly  200 . A straight connector  130  is positioned so its receptacles  132  are aligned with the plugs  222  of the plug connector  228  of the first lightbar assembly  200 , and so its plugs  142  are aligned with the receptacles  212  of the receptacle connector  218  of the second lightbar assembly  200 . The straight connector  130  is moved in a direction generally transverse to the longitudinal axes of the lightbar assemblies  200  so the plugs  222  of the first lightbar assembly  200  are received in the receptacles  132  of the straight connector  130 , and the internal terminals  224  of the plugs  222  contact the external terminals  134  of the receptacles  132  to establish an electrical connection therebetween. Similarly, the plugs  142  of the straight connector  130  are received in the receptacles  212  of the second lightbar assembly  200 , the external terminals  214  of the second lightbar assembly contacting the internal terminals  144  of the straight connector  130  to establish an electrical connection therebetween. The posts  136  and ground terminals  300  on the straight connector  130  releasably engage a complementarily sized and shaped part defined in each of the plug end cap  226  and receptacle end cap  216 , and the ground terminals  310  is each of the plug end cap  226  and receptacle end cap  216 . In similar fashion, the plurality of lightbar assembly connectors depicted in  FIG.  7    are releasably connectable with the plurality of lightbar assemblies  200 . The various lightbar assembly connectors depicted in  FIG.  7    would be rotated as indicated when connecting them to the lightbar assemblies  200 . The present invention thus provides a simple, convenient, safe and reliable lightbar system  100  where components may be connected and disconnected to add, replace, service or reconfigure the lightbar system  100  without having to unnecessarily remove components. This is accomplished by orienting the various conductive terminals generally transverse to a longitudinal axis of a lightbar assembly and to a major surface of the lightbar assembly connectors, resulting in the ability to connect and disconnect various components simply and easily. 
     A joiner assembly  150 , depicted in  FIGS.  10 A and  10 B , may be connected to a lightbar assembly  200  to route power around an object. For example, it may be desirable to power two lightbar assemblies  200  from the same power source  50 , but it is not possible to directly connect the two lightbar assemblies  200  due to an obstruction located between them. A first joiner assembly  150  may be connected to a first lightbar assembly  200 , and a second joiner assembly  150  may be connected to a second lightbar assembly  200 . A cable  160  may be connected between the two joiner assemblies  150  and routed around the obstruction to provide a path for power between the lightbar assemblies  200  despite the presence of an obstacle. The embodiment of  FIG.  10 A  has a modular connector  158  with two plugs  162 , each having a conductive internal terminal  164 , and the embodiment of  FIG.  10 B  has a modular connector  158  with two receptacles  152 , each having a conductive external terminal  154 . Both embodiments also have a post  156  to releasably engage a complementarily sized and shaped part of a lightbar assembly  200 . The post  156  has a ground terminal  300  that conductively connects with a ground terminal  310  on the complementarily sized and shaped part of the lightbar assembly  200  to which the joiner assembly  150  is connected. 
     A distribution box  170 , depicted in  FIG.  11   , may be connected to at least one lightbar assembly  200 . The embodiment depicted in  FIG.  11    has two plug connectors  176  and one receptacle connector  188 . Alternatively, the distribution box  170  may have two receptacle connectors  188  and one plug connector  176 . Each of the plug connectors  176  has two plugs  172 , each having a conductive internal terminal  174 . The receptacle connector  188  has two receptacles  182 , each having a conductive external terminal  184 . A switch  178  controls power to the transversely aligned connector, and to the components connected thereto. For the embodiment of  FIG.  11   , the switch  172  controls power to the receptacle connector  188 . 
     A power connector box  190 , depicted in  FIG.  12   , provides connection between the power source  50  and a lightbar assembly  200 . Connection to the power source  50  is made using a power cable (not shown) routed to an interior of the power connector box  190  through an opening  198  to terminals (not shown) in the interior of the power connection box  190 . The interior terminals are conductively connected to conductive internal terminals  196  provided in plugs  192  of a plug connector  194 . Connection of the plug connector  194  to a receptacle connector  218  of a lightbar assembly  200  provides a path to the lightbar assembly  200  from the power source. Alternatively, the power connector box may have a receptacle connector that is connectable to a plug connector  228  of a lightbar assembly  200 . 
     Individual lightbar assemblies  200  and the lightbar system  100  of the present invention are mountable to a surface using one or more mounting brackets, such as depicted in  FIGS.  13 A- 13 C . The mounting bracket  10  of  FIG.  13 A  comprises two clips  12  that are sized and shaped to self-guide a lightbar assembly  200  into the bracket  10 , and that are self-biased to hold the lightbar assembly  200  in place. Two mounting holes  16  are provided for screws or other similar mounting means to secure the mounting bracket  10  to a surface such as, for example, the underside of a kitchen cabinet. The mounting holes  16  are located outside the footprint of a lightbar assembly  200  when it is held in place in the mounting bracket  10  by the clips  12 , as depicted in  FIG.  13 D . The mounting bracket  10  may alternatively have a base  14  that adheres to a surface without the need for additional fasteners or mounting means. The embodiment depicted in  FIG.  13 B  includes a magnet (not shown) in the base  14  to secure the mounting bracket  10  to a magnetic surface. Alternatively, double-sided tape, Velcro®, or other known or hereafter developed self-fastening or self-securing means may be provided to secure the base  14  of this embodiment to a surface. In another alternative embodiment depicted in  FIG.  13 C , the mounting bracket  10  comprises a pivotable mounting bracket  30  connected to the base  14  with a coupling  20  that may provide pivoting or rotating movement of the lightbar assembly  200  mounted to the surface using this mounting bracket  10 . This enables selective positioning of the lightbar assembly  200  to control the direction of light distribution. Mounting holes  16  for this embodiment are also provided outside the footprint of a lightbar assembly  200  when it is held in place in this mounting bracket  10 . 
     Modifications to embodiments of the present invention are possible without departing from the scope of the invention as defined by the accompanying claims. Expressions such as “including,” “comprising,” “incorporating,” “consisting of,” “have,” “is,” used to describe and claim the present invention are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described herein also to be present. Reference to the singular is to be construed to relate to the plural, where applicable.