Patent Publication Number: US-2010110708-A1

Title: Rack mounted warning light

Description:
BACKGROUND 
     This application relates generally to warning lights which are mounted to vehicles. This application also relates to racks which are mounted to vehicles such as pick-up trucks, vans and utility trucks for supporting items generally above the vehicle cab and/or bed for transport. 
     Racks of numerous configurations and usages have been employed on vehicles. For example, racks which extend above a truck bed or a van may employ crossbars for securing and supporting ladders above the roof of the vehicle. In some embodiments, the crossbars are elongated tubular members which are tapered for aerodynamic purposes and include an upwardly opening channel which functions as a track. Various hook and securement elements may be attached in the track for securing the cargo to be transported. Typically, the anchoring hardware is slidably adjustable along the track to accommodate numerous cargo configurations. 
     For some vehicular rack usages transport safety is a significant concern. It may be desirable to employ warning lights to address safety issues presented by the rack or the operation of the vehicle in general. 
     SUMMARY 
     Briefly stated, the warning light is adapted for mounting to an overhead rack of a vehicle. The warning light has a housing which through one end forms a throat configured to receive an end of a tubular rack member. The top has a recess to provide access to an upper track of the tubular rack member. A first light unit is mounted to the housing and positioned to emit light from an end opposite the end which receives the tubular rack member. The first light unit defines a central illumination axis generally coaxial with the rack member. A second light unit defines a second central illumination axis and is mounted to the housing and positioned to emit light from an acute angle to the illumination axis and oriented generally transversely to the first light assembly. A third light unit defines a third illumination axis and is mounted to the housing and positioned to emit light from the opposite acute angle to illumination axis. Preferably the first, second and third light units are substantially identical units which employ LEDs. 
     The housing comprises a pair of shell members which cooperate to define the rack member opening and windows for the first, second and third light units. The shell members have integral mounting brackets configured to fixably capture the light units for proper positioning. 
     A tubular rack member of a vehicle has opposed longitudinally spaced ends and defines a longitudinal track at an upward portion thereof. A warning light module is mounted to the tubular rack member at one end. The module comprises a housing which receives a portion of the rack member and has a recess at a top portion to provide access to a portion of the track. A pair of transversely spaced side light assemblies is mounted to the housing and positioned to emit light in generally opposing angled directions. The third end light assembly is mounted to the housing and positioned to emit light in a generally longitudinally outward direction from the member. The housing forms a receiving throat at one end portion. The throat has a geometry which is generally complementary to the geometry of the profile of the tubular member. In one embodiment, a module is mounted at each end of the overhead rack member. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top plan view of a warning light mounted to a vehicle rack (partially illustrated) with load retaining hardware; 
         FIG. 2  is an end elevational view of the warning light and hardware of  FIG. 1 ; 
         FIG. 3  is a sectional view of the warning light and rack portion taken along the lines  3 - 3  of  FIG. 2 ; 
         FIG. 4  is a side elevational view of the warning light, rack portion and hardware of  FIG. 1 ; 
         FIG. 5  is an end view of the warning light and rack portion of  FIG. 1  with the rack portion being viewed through the end thereof; 
         FIG. 6  is a bottom plan view of the warning light and rack portion of  FIG. 1 ; 
         FIG. 7  is an exploded perspective view of the warning light, rack portion and hardware of  FIG. 1 ; 
         FIG. 8  is a perspective view of the warning light and rack portion of  FIG. 1  with a top cover portion being removed; 
         FIG. 9  is a perspective view of the warning light of  FIG. 8  with the rack portion being additionally removed; 
         FIG. 10  is a perspective view of the warning light of  FIG. 9  with a light unit being additionally removed; 
         FIG. 11  is a perspective view of the removed top cover portion for the warning light of  FIG. 8 ; and 
         FIG. 12  is a perspective view, partly broken away and partly in schematic, of a rack with the mounted warning lights. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     With reference to the drawings, wherein like numerals represent like parts throughout the Figures, a warning light designated generally by the numeral  10  is mounted to the end of a cross-support of an overhead vehicle rack designated generally by the numeral  12  and only a portion of which is illustrated. The rack may be a ladder rack for mounting to a pick-up truck, a utility van or other vehicle to facilitate the transport of ladders and other elongated materials. Variably positonable anchoring/retaining hardware  14  of conventional form and function is typically mounted to the rack. The warning light  10  is adapted to mount to the tubular cross-support of the rack assembly at each of opposing end locations to provide a safety warning light and/or to alert others to the nature of the transported materials. 
     The cross-support  12  is typically an elongated extruded metal tubular member  20  with a longitudinally extending channel  22  which, at an upper portion, has a pair of opposed flanges  24  that cooperatively form a track. Various anchoring and retaining hardware  14  may be retained in the track at selected longitudinal spacings along the track for securing the cargo to be transported. With reference to  FIGS. 5 and 6 , the tubular member  20  may also be longitudinally traversed by a track along a channel  26  and flanges  28  along its bottom surface to provide a track at the bottom of the member for securing same to the vehicle via brackets or a support frame of the rack assembly. The front surface  21  of the rack member  20  is typically tapered to present an aerodynamic surface for the cross-support of the rack. 
     The warning light  10  is adapted to efficiently mount or clamp to the end of the rack member  20  to provide a warning light which is visible from both the front and rear and the side of the vehicle. The warning light  10  has a low profile, sleek and compact construction which, upon mounting to the rack and placed in use, is aerodynamically stable. The warning light  10  is structured so that it does not significantly interfere with the function of the rack, including the tracks, and is efficiently and aesthetically integrated with the rack assembly. 
     The warning light  10  comprises a base (bottom) shell  30  and a cover (upper) shell  32  which mount and house LED light units  34 ,  36  and  38 . The shells  30  and  32  are preferably molded components. The shells  30  and  32  cooperate to form a smooth sculpted, aerodynamic appearance and to provide the required mounting structures for attachment to the end of the rack cross-support. In this regard, the warning light  10  is clamped onto the end of the rack cross-support  12  via an intermediate locating thread, and is secured in place from the bottom. 
     The side LED light units  34  and  36  are preferably angled at 10° relative to the central axis through the cross member  20  and the warning light. The end LED unit  38  is oriented to extend transversely to the axis. The LEDs preferably emit an amber light. In one preferred embodiment, the LED light units  34 ,  36  and  38  are LIN 3 LED warning lights which are manufactured and distributed by Whelen Engineering Company of Chester, Conn. The LED light units are sealed components which include exterior lenses  35 ,  37  and  39  and have a rigid housing. The light units preferably include built-in flashers and are synchronizeable and are structured as substantially described in U.S. Pat. No. 6,641,284, the disclosure of which is incorporated herein by reference. 
     With reference to FIGS.  3  and  6 - 8 , the bottom shell  30  comprises a bottom panel  40  integrally connecting a pair of centrally located bosses  42  which project upwardly. The bosses  42  threadably receive fasteners  44  which connect through openings in the underside track of the rack member  20  for securing the warning light in position. The bottom shell  30  may be described as a beveled quasi-trapezoid box-like shape with four bosses  46  projecting from the panel  40  upwardly into the interior. The bosses receive fasteners  48  and threadably engage with the upper shell  32  for securing same to the lower shell. 
     A circumferential side skirt extends upwardly along four sides from the bottom panel and forms a mounting recess opening  50  and three windows  52 ,  54  and  56  for receiving portions of the light units ( FIG. 7 ). Support brackets  58  integrally project from the panel for locating, positioning and supporting the light units. Tabs  60  at opposed inward locations from the windows and spaced outwardly from the brackets  58  provide a side retaining bracket for each of the light units. 
     With additional reference to  FIG. 11 , the upper shell  32  forms a recess opening  35  which cooperates with recess opening  50  to provide a socket opening complementary to the profile of the cross-section of the tubular member  20 . The upper shell also includes integral downwardly projecting bosses  47  which mate with bosses  46  for threadably receiving fasteners  48  to secure the upper shell in position to the lower shell. Upper windows  74 ,  76  and  78  also mate with the respective windows of the bottom panel to provide an aperture for each of the light units. In addition, locating and end retaining brackets  80  and  82  extend downwardly from the cover at its interior to engage against the top of the light units  34 ,  36  and  38  for properly locating and fixably capturing the light units. The upper shell  32  forms a recess  90  which longitudinally extends to provide an access to end locations of the upper track. 
     With reference to  FIGS. 8-10 , it should be appreciated that the spacing and structure of the retaining components including the brackets  58 ,  60 ,  80  and  82 , are selected to complement the exterior housings of the light assembly so that the light units  34 ,  36  and  38  may be dropped into position and self-positioned with the bottom shell. The upper shell  32  functions as a top cover and is then mounted over the shell  30 . Fasteners  48  are driven through the bottom base shell  30  into the shell  32  to secure the cover shell  32  in position. 
     It should be appreciated that the recess  90  provides access to the track of the rack cross-support  12 . A stop  92  projects downwardly from the housing and engages into the upper track. Likewise, a stop  94  projects upwardly from the lower shell and is received in the lower track of the cross-support. Although the warning light  10  upon mounting may substantially seal with the support member  20 , such a sealing engagement is not required because of the sealed nature of the light units  34 ,  36  and  38 . 
     With reference to  FIG. 12 , the wires from each of the three light units (not illustrated) are connected as appropriate and the wire harness  98  extends through the hollow tubular rack  20  member through the rack supports  25  for connection with a power supply  102  and a controller  104  located within the vehicle cab for activating and deactivating the light units. The warning light emissions can be synchronized and function as flashers so that upon activation, warning lights will be projected from the front, rear and sides of the end of the rack. Warning lights  10  as described may be mounted to opposed ends of a rack cross-support  20  or both cross-supports (not illustrated). 
     While preferred embodiments of the foregoing have been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit and the scope of the present invention.