Patent Publication Number: US-7905622-B2

Title: Traffic safety cone incorporating a flashing light module

Description:
FIELD OF THE INVENTION 
     This invention relates, generally, to traffic control systems and, more particularly, to a flashing light module which can be installed on the top of a conventional traffic-control cone. 
     BACKGROUND OF THE INVENTION 
     Marker cones have long been used as a substitute for paint-marked lanes in the temporary direction of traffic. Traffic cones are typically low-cost, brightly-colored, hollow, light-weight, stackable markers made of an elastomeric material so as to minimize damage to vehicles and the markers, themselves, when vehicles inadvertently collide with them. In order to enhance nighttime visibility of marker cones, numerous attempts have been made to equip the cones with various illumination devices. 
     For example, U.S. Pat. No. Des. 315,874, U.S. Pat. No. Des. 277,739 and U.S. Pat. No. Des. 411,810 all disclose traffic cones incorporating a flashing light. 
     U.S. Pat. No. 5,269,251 to Donald H. Freeman, discloses devices and methods for utilizing standard traffic cones to support standard information signs, standard flags and staffs, standard barricade rope and standard barricade tape, standard chemical light sticks, and battery operated warning lamps. A polyvinylchloride adapter has a first end that fits over the top of a standard traffic cone, and a second end that is adapted to serve as a connector for signs, flags, chemical light sticks, a battery-operated warning lamp, and barricade rope or tape. 
     U.S. Pat. No. 5,755,174, also issued to Donald H. Freeman, improves on the apparatus of his earlier patent by providing a system for securing warning lights, signs, and warning flags to the tops of standard traffic cones either with or without the use of adapters. A cable having a first end is secured to the warning light, sign or warning flag. A second end of the cable is looped and passes through a central aperture in a removable security disc, which has a diameter such that it can be inserted only part way into the cone from the bottom thereof. A padlock is used to secure the looped second end of the cable within the central aperture. 
     U.S. Pat. No. 6,499,858 to David Alan Hart discloses an illuminated base which can be placed beneath a translucent cone. The illuminated base may be powered by a variety of sources, including a solar panel. 
     While the above described devices and methods denote important and useful traffic control systems, they do not provide solutions to the problems associated with traffic safety control security systems addressed by the instant invention. 
     SUMMARY OF THE INVENTION 
     The present invention provides a battery-powered flashing light module for installation on a conventional traffic cone. Given that traffic cones are intended to be placed in positions where they are likely to be struck by vehicles from time to time, it is an object of the present invention to provide a flashing light module that is designed to minimize damage to the lighting components if the cone is struck, so that it can be repaired with minimal cost. An additional object of the present invention to minimize the likelihood that the unit will fragment if struck. It is a further object of the invention to position the battery packs within the cone so as to lower the center of gravity of the cone and light assembly so that it is less easily tipped over. It is yet another object of the present invention to provide an efficient solar recharging system for the flashing light module. It is still another object of the present invention to provide a design for which will enable light emitting diodes to be incorporated into the flashing light module in such a manner that at least several of the LEDs can be clearly seen from any direction within a 360-degree arc about the light module. 
     The present invention fulfills the objects heretofore set forth. A traffic safety cone incorporating a flashing light module includes electrically coupled first and second modules. A planar solar cell array is positioned on the top surface of a circular disk that is surrounded by a resilient annular bumper that cushions the impact when the cone is struck or knocked over. The solar cell array and resilient annular bumper are secured to the top of a high-intensity LED flasher unit. The top of a traffic cone is truncated so as to have a top aperture diameter to precisely fit the flasher unit. The first module, which sits atop the truncated traffic cone, includes the solar cell array, the donut-shaped bumper, and the high-intensity LED flasher unit. Power cells or batteries, which power the flasher unit, battery recharging circuitry, and an ON/OFF switch are positioned in a cone-shaped housing and, together, form a second module, that is installed within the traffic cone from the bottom thereof. A module retainer plate, which also serves as a battery cover, is placed beneath the second module, and the module retainer plate and the second module are both secured to a pair of downwardly projecting threaded studs on the flasher unit using a pair of attachment rods, each of which has a tightening knob at one end (that can be manipulated with the fingers) and a female-threaded opposite end. The first and second modules are electrically coupled with a cable that preferably extends from the first module and plugs into a socket in the second module. The first and second modules can be tightened together with the attachment rods so that both modules and the traffic cone are securely united as a single unit. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an elevational view of a standard traffic safety cone and an exploded first module; 
         FIG. 2  is an elevational assembled view of the first module; 
         FIG. 3  is an elevational view of the second module; 
         FIG. 4  is an elevational cut-away view of the traffic safety cone, having first and second modules secured thereto with the attachment rods; 
         FIG. 5  is a cross-sectional view of a second embodiment stop washer having a cupped configuration, taken through the washer&#39;s central axis; 
         FIG. 6  is a cross-sectional view of the resilient annular bumper; and 
         FIG. 7  is a block diagram of the electrical circuitry of the traffic safety cone incorporating a high-intensity flasher unit. 
     
    
    
     PREFERRED EMBODIMENT OF THE INVENTION 
     The invention will now be described with reference to the attached drawing  FIGS. 1 through 5 . It should be understood that the drawing figures are not necessarily drawn to scale and are meant to be merely illustrative of the invention. 
     Referring now to  FIG. 1 , a traffic control cone incorporating a flashing light module includes a standard traffic control cone  101 , a stop washer  102 , a high-intensity LED flasher unit  103 , a resilient annular bumper  104 , a solar panel mounting platform  105 , and a solar cell array  106 . The high-intensity LED flasher unit  103  puts out sufficient candlepower in bright daylight that it cannot be ignored. A flasher unit of this type can be purchased from Ingram Products, Inc. Of Jacksonville, Fla. 32257. The specifications of the product can be found on Ingram Products&#39; Internet website: www.ingramproducts.com. A preferred flasher is identified as SunBurst Model SB1224AD. This particular model operates on either 12 or 24 volts DC and draws 395 mA of current when in a steay-on state. Current draw is less than half that amount when operating in the flashing mode of 60 flashes per minute. The flashing circuitry is built into the two-inch diameter cylindrical base  107 . The polycarbonate plastic lens  108  is available in red, amber, green or clear. An array of high-intensity LEDs is visible through the lens  108  about a full-circle arc of 360 degrees. For the present invention, the cautionary amber color lens is considered the preferred option. It will be noted that two threaded studs  109 A and  109 B protrude from the cylindrical base  107  of the flasher unit  103 . As will be subsequently shown, these threaded studs will be used to secure the flasher unit to the cone  101 . It will be noted that a pair of conductors  110 A and  110 B are coupled to the solar cell array  106 . It will further be noted that the solar panel mounting platform  105  has a circumferential rim  111 . 
     Referring now to  FIG. 2 , the stop washer  102 , the a high-intensity LED flasher unit  103 , the resilient annular bumper  104 , the solar panel mounting platform  105 , and a solar cell array  106  have been assembled into a single first module  201 . The solar panel mounting platform  105  has been adhesively bonded to the top of the lens  108  of the flasher unit  103 . It will be noted that three conductors exit the bottom of the cylindrical base  107 . A brown conductor  202  and a center black common conductor  203  are connected to a 12-volt DC potential for flashing operation; a blue conductor  204  and the center black common conductor  203  are connected to a 12-volt DC potential for steady-on operation. The conductors  110 A and  110 B of the solar cell array  106  are rounted through a hole (not shown) drilled in the top of the lens  108  and are routed through the flasher unit  103  and through the bottom of the base  107 , along with the flasher conductors  202 ,  203  and  204 . The solar panel mounting platform  105  has a funnel shaped base  205  that elevates the platform above the lens so that it will minimize blockage of the lens from a driver&#39;s view. The horizontal mounting position provided by the solar mounting platform  105  is considered the optimum location for a solar cell array, as it ensures the most constant and most uniformly intense reception of light from the sun. It will be noted that the diameter of the circular aperture of the stop washer  102  is sized to ride against an annular ridge  206  of the base  107  when installed thereon. 
     Referring now to  FIG. 3 , a second module  301  designed for installation within the traffic control cone  101 . The second module  301  includes a truncated cone-shaped, or frustrum-shaped housing  302 , a pair of rechargeable 6-volt batteries  303 A and  303 B, each of which is installed within a recess  304 A and  304 B, respectively, in the housing  302 . It will be noted that the frustrum-shaped housing  302  has a lower base with a diameter less than that of said larger lower opening at the base of the truncated safety cone  101 , and an upper base with a diameter greater than that of the upper opening of the truncated safety cone  101 . The ceiling of each recess  305 A and  305 B, respectively, incorporates a pair of battery terminal contact plates  306 A,  306 B,  306 C and  306 D. It will be noted that contact plates  306 B and  306 C are tied together to couple the two batteries  303 A and  303 B in series in order to provide a nominal output of 12-volt DC. A tray at the top of the housing  302 , provides a mounting location for battery recharging and regulation circuitry. It will be noted that there a pair of cylindrical apertures  307 A and  307 B are formed in the housing  302 , only one of which ( 307 A) is visible in this hidden view. If the housing were axially rotated 90 degrees, both would then be visible in a hidden view format. It will be noted that a module retainer plate  308 , which also functions as a battery cover, is installed beneath the housing  302 . It is equipped with apertures  309 A and  309 B (only  309 A is visible as a hidden item in this view), which align with cylindrical apertures  307 A and  307 B, respectively. It should be clear that the 6-volt batteries  303 A and  303 B could be replaced with eight individual rechargeable electro-chemical cells, or power units, each of which has a nominal voltage of 1.5 volts. 
     Referring now to  FIG. 4 , the traffic safety cone unit  400 , which incorporates a flashing light module  103  is shown in a fully-assembled, cut-away view. It will be noted that the second module  301  is secured to the threaded studs  109 A and  109 B of the first module  201  with a pair of attachment rods  401 A and  401 B (only  401 A is visible as a hidden item in this view). Each attachment rod is equipped with a tightening knob  402  at one end (that can be manipulated with the fingers) and a female-threaded opposite end  403 . It will be noted that the first module  201  is electrically coupled to the second module  301  via a multi-conductor connector cable  404 , which plugs into a socket  405  in the circuit board  406  containing the battery recharging and regulation circuitry. 
     Referring now to  FIG. 5 , a second embodiment of the stop washer  102  is shown. This second embodiment washer  501  is cup shaped to prevent the entry of water into the cone when used in inclement conditions. The seal can be improved by hermetically sealing the joint where the washer  501  makes contact with the annular ridge  206 . The aperture  502  of the second embodiment stop washer  501  can be seen in this cross-sectional view. 
     Referring now to  FIG. 6 , in this cross-sectional view of the resilient annular bumper  104 , it can be clearly seen how the inner groove  601  can fit over the circumferential rim  111  of the solar panel mounting platform  105 . 
     Referring now to the electrical block diagram of  FIG. 7 , the high-intensity flasher unit  103  is coupled to the series-connected rechargeable 6-volt batteries  303 A and  303 B through three-position switch  701 . The three positions of the switch are flashing on, steady on and off. The solar cell array panel  106  is coupled to the batteries  303 A and  303 B through regulator circuitry  702 . A recharge jack  703  provides a means to charge the batteries  303 A and  303 B using an external low-voltage DC source. The three-position switch  701  and the recharge jack  703  may be positioned in a variety of convenient locations on the unit  400 . 
     It should be clear that there are several significant advantages to having interconnected first and second modules  201  and  301 . The first significant advantage is a much lower center of gravity that would be possible if the batteries, in particular, were installed in a single unit on top of the traffic control cone  101 . Thus, the batteries  303 A and  303 B act as ballast having a low center of gravity for the truncated traffic safety cone. A second advantage is that by securing the second module  301  to the first module  201 , both modules are secured to the traffic control cone  101 . This feature lessens the likelihood that components of the unit  400  will be scatted on the roadway if the cone  400  is inadvertently or intentionally struck by a moving vehicle. A further advantage is that by placing components that need not be visible within the cone, itself, those hidden components are afforded greater protection from damage in the event the unit  400  is struck by a vehicle. In addition, by placing the batteries  303 A and  303 B within the cone, much higher capacity batteries can be used than would be possible if the batteries were placed in a single module mounted atop the cone  101 . 
     Although only a single embodiment of the traffic safety cone incorporating a flashing light module is shown and described herein, it will be obvious to those having ordinary skill in the art that changes and modifications may be made thereto without departing from the scope and the spirit of the invention as hereinafter claimed.