Patent Document

FIELD OF THE INVENTION 
     The present invention relates generally to a self-actuating, self-powered light for directionally illuminating a pole-mounted flag, banner, pennant or the like. In particular, the present invention relates to such a light that has a luminous source located in a laterally extended cover mounted on top of the pole, and is capable of continuously directing a fully encompassing beam of light toward the flag, banner, pennant or the like as wind causes the flag to be changed in radial direction about the pole. 
     BACKGROUND OF THE INVENTION 
     Pole-mounted flags deserving of presentation are typically those representing a nation, company, university, or other prestigious organization and intended to, by the elevation, care and clear visualization of such flags, instill a sense of respect and awe for the organization whose memory is recalled. There is no better time for effective visualization of such a flag than at night. All prior art for presentation of flags at night is directed at the same basic requisite function—to illuminate the flag while minimizing lighting equipment and utility costs. The advantage and disadvantage of a ground mounted, high-powered spotlight has been obvious since the 1800&#39;s. Regardless of its ground level distance from the flag pole, a single beam of light directed at a flag from ground level generally loses the dramatic of such lighting through about three fourths of a flag&#39;s potential radial extension from the pole as wind direction causes the flag to be blown in several different directions. It is well known to place a ground level directional light in the direction of the prevailing wind so that a flag will be illuminated much of the time. An obvious solution is to increase the number of ground level directional lights to ring the flagpole, with subsequent increase in equipment and utility costs. Ground level equipment is a barrier to traffic about the flag pole but it convenient for maintenance. 
     Not so for sources of illumination raised to the top of a flagpole. Maintenance must essentially be eliminated for a source of light raised to a top of a flagpole to illuminate a flag flying just below and adjacent to that source of light. That requirement alone eliminates from consideration of practical use many proposed devices in the prior art which are intended to illuminate a direction-changing, wind blown flag. A structure at the top of a flagpole experiences the most severe of local weather conditions in terms of extremes of temperature and precipitation, as well as receiving the occasional well-fed avian visitor and its excremental deposits. The requirements of a flag-top illumination device must be minimal to avoid taking the entire pole down or to bring to the flag pole a personnel lift of extreme lifting height to conduct repairs or replacement of equipment. At the minimum, any illumination source for a pole-top light must have an exceptionally long life and operate substantially to accomplish its illumination job in at least partial failure mode so maintenance can be delayed until regularly planned events. 
     A further challenge in providing illumination of a wind blown flag is to provide directionally efficient lighting. A simple pole-top light wired to a ground level source of electricity and having a transparent or translucent globe draws attention more to the light than to the illuminated flag. Its axial location provides a point source illumination more to the sky than to the desired flag lighting. However, such a simple device provides illumination for the radial extension of the flag in its potentially 360 degree travel path. 
     A rather simple-minded but ineffective improvement to the light bulb on top of the flag pole is found in U.S. Pat. No. 7,275,495. The &#39;495 patent discloses what is essentially a replacement of the light bulb which illuminates spherically with a flashlight aimed at an angle of about 45 degrees downward and outward (but mounted within) from a decorative sphere at the top of the flagpole. It is rotatable via its integration with the pulley wheels for flag-elevating and supporting rope or cable so that a rotation of the flag about the pole pulls at the supporting rope, which in turn pulls at the pulley, which in turn pulls at the flashlight to kind of direct it toward the new direction of the flag. The requisite broad downward angle of the light cause it to, like the simple pole top light, illuminate unnecessary space and often not the space in which the flag is to be found. A ground level viewer will be somewhat blinded by the light in favor of viewing the flag. 
     The &#39;425 patent identifies a problem which its intended device does not solve. While such a device allows for the use of less light than a floodlight, it still does not solve the problem of illuminating more of the surrounding sky than the flag itself. 
     Therefore, a need exists for an improved pole top light which minimizes requirement for any maintenance, operates in substantial failure mode to effect illuminating a flag, and is exceptionally responsive directionally for nighttime illumination of the flag in whatever direction it is moved by the wind. 
     SUMMARY OF THE INVENTION 
     The present invention continuously directs an umbrella shaped beam of light substantially downward from a thin, aerodynamic, lateral-extension housing toward a flag, banner, pennant or the like as the wind blows the same in diverse radial directions about an axis of a supporting flagpole. The flag fixed to a top of a flagpole of the present invention is adapted to rotate freely into any radial direction from the flagpole axis in a manner well known in the art, whereby a top cap is provided with a bearing or axle about which the cap is free to rotate relative to the flagpole. The flag is fixed at the top of one vertical edge to this rotatable cap and at the lower end of said edge to an unfixed loop about the flagpole lower down. The rotatable cap is often provided with a sphere or statue of some type to enhance the aesthetics of the flagpole. 
     The prior art devices for rotatable cap flagpoles as just described are provided with a standard or typical clearance of about 1.5 to 2.5 inches between said decorative sphere and a topmost surface of said rotatable cap. Between the sphere and the rotatable cap is a supporting rod fixed at one end in the sphere and threaded at another end to be removably fixed in a threaded opening at the top of the rotatable cap. The present invention, in one form, is adapted to be mounted as a retrofit in a prior art rotatable cap flagpole within the 1.5 to 2.5 inches of the supporting rod exposed between the decorative sphere or other piece and a topmost end of the rotatable cap. Alternately, any vertical pole can be adapted to receive the invention light and associated flag or pennant. 
     The invention light is comprises a housing that is very thin vertically, narrow in its lateral extension from a flagpole axis and aerodynamically formed so that it presents very small resistance to wind, rain, sleet and snow, a critical feature of a light elevated to a top of a flagpole. The invention light has been tested for continuous flagpole lighting in the severe fall and winter conditions of Chicago and Minnesota with no failure or wear detected after such testing. In a preferred vertical thickness from a top surface of a housing to an underside of a transparent light cover, the invention light is from about 1.00 to 2.00 inches thick, and more preferably from 1.25 to 1.75 inches thick. The invention light is provided with a substantial solar panel integrated into the top surface of its housing, providing power for the LED&#39;s of the preferred lighting source. 
     The invention light further comprises weather proof protection for its rotation bearing. Said bearing is fixed at an inner race between a top rotation fitting and a lower rotation fitting so that the invention light may rotate upon contact of the housing with an outer race of the bearing or by rotation upon the inner race of the bearing, where the top rotation fitting, in combination with close coupling with said decorative sphere, provides a water tight seal from exposure of the underlying bearing and electrical components to water, sleet, or snow. Such protection has been found to extend the operational life of the rotation bearing and the electrical components of the invention light. 
     An object of the invention flagpole light is to provide a laterally extended pole top light which is highly directional in providing an umbrella shaped, downward illumination of a flag located just beneath said illumination by way of rotational connection with said flag of a rotatable cap flagpole. 
     A further object of the invention is provide a laterally extended pole top light having a minimized wind resistance profile. 
     Yet another object of the invention is to provide for a laterally extended pole top light having multiple power sources for recharging batteries with which to power lights via a solar panel and/or a small wind driven generator. 
     Another object of the invention is to provide a retrofit for a rotatable cap flagpole using an existing decorative sphere separated from a topmost part of the rotatable cap by a standard or typical vertical distance of about 1.5 to 2.5 inches. 
     Other objects, features, and advantages of the present invention will become apparent upon inspection of the following detailed description of the preferred embodiment of the invention, taken in conjunction with the drawings and appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is side view of one form of the invention pole top light for flagpoles. 
         FIG. 2  is a side and exploded view of the pole top light for flagpoles shown in  FIG. 1 . 
         FIG. 3  is a cross section of items of  FIG. 2  relating to the invention pole top light for flagpoles. 
         FIG. 4  is a bottom perspective view of the pole top light for flagpoles shown in  FIG. 1  with a transparent bottom cover removed and showing portion of an interior of a cavity of a top housing with a part of reflective shield lifted up. 
         FIGS. 5 and 6  are bottom perspective views of broken away sections of the pole top light for flagpoles shown in  FIG. 1  showing a rotation connection between a flag rotatably fixed to the flagpole and the pole top light for flagpoles shown in  FIG. 1 . 
         FIG. 7  is a bottom view of a housing of the pole top light for flagpoles shown in  FIG. 1  with said transparent cover and reflective shield removed. 
         FIG. 8  is a top view of the pole top light for flagpoles shown in  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention is now discussed with reference to the figures. 
     The pole top light  10  for flagpoles shown in  FIG. 1  comprises an aerodynamic housing  11  facing downward with an umbrella like illumination  15   a  projecting through a transparent cover  15  upon a flag illumination zone  15   b  shown in broken lines. Zone  15   b  is representative of a flag or pennant fixed at a top corner of a vertical edge at or near flange  22  by way of a closeable clip or carribeaner clip passing through opening  23  and a grommet at said corner and then also releasably and rotatably fixed at a lower corner of the same flag edge to the flagpole  24 . Flange  22  laterally extends from rotatable band  21 , which is supported from cylindrical band  24   a  and rotatably engages the top of flagpole  24 . Metal loop  16   a  provides rotating inducing connection between flange  22  and rotation connector  16  extending downward from cover  15 . When a flag in zone  15   b  is made to rotate to another of diverse radial angles from a flagpole axis than that shown in  FIG. 1 , housing  11  is drawn by its connection to flange  22  in path  25  so that it maintains its illumination  15   a  over a flag in zone  15   b  at all times. 
     Housing  11  comprises an axial end  14  arranged to be supported from an exposed portion of a support bolt extending downward from decorative sphere  17  through axial end  14 , threaded through nut  19 , and finally secured by threaded connection to pole top adapter  20 , which is insertable into an open end flagpole  24 , which supports rotatable band  21 . Housing  11  also comprises a lateral extension end  12 , an upper surface  13  of which bears a substantial solar panel which will absorb the sun&#39;s radiation and convert it to electrical power stored in batteries within housing  11 . In the side view of  FIG. 1 , a vertical thickness of housing  11  and cover  15  is between 1.00 to 2.50 inches, and more preferably between 1.25 and 1.75 inches. Peripherally, housing  11  is substantially arcuately sloped from a lowest outer edge upward to upper surface  13  to achieve substantially unobstructed air flow from above or from any side of housing  11 , forcing such air flow over an upper side of the solar panel and cleaning and scouring its surface of radiation blocking dirt or deposits. Locating said solar panel at an elevation typical of a flagpole and having such an arcuately sloped peripheral edge takes advantage of the stronger winds and precipitation to keep the invention pole top light functioning longer to absorb solar radiation at relatively full strength with a self-cleaning solar panel. 
       FIG. 2  shows additional detail of each normally separable part of the invention pole top light  10 , where sphere  17  further comprises a bolt top  26  and a threaded bolt end  27  and a top rotation fitting  18  comprises an upper water tight seal  28  and first lower section  29  extending down from seal  28  with a cylindrical diameter greater than that of second lower section  30 . A bottom rotation fitting  31  comprises a larger diameter section  33  from which extends upward a cylindrical section  32  of the same diameter as that of section  30  of top rotation fitting  18 . A nut  19  is adapted to be threaded to the end of bolt end  27  after it passes sequentially through top rotation fitting  18 , axial end  14  of housing  11 , and bottom rotation fitting  31 , whereafter nut  19  is threaded sufficiently upward on bolt end  27  so that top rotation fitting  18  and bottom rotation fitting  31  compress respectively top and bottom edges of an inner race of a bearing secured within axial end  14  with sufficient threaded length extending from a bottom side of nut  19  to be threaded into adapter  20  to support the entire assembly above it. 
     Adapter  20  comprises a top end  34  defining a threaded bolt hole, a flange skirt  35  extending out from top end  34  to support the entire assembly above it from rotatable band  21 , and a cylindrical insert  36  extending down from skirt  35 , which firmly engages inside cylindrical walls of a top end of flagpole  24 . A rotatable cap in the present specific example comprising a simple cylindrical band  24   a  fixed at just below a top of flagpole  24  which supports the rotatable band  21  from which laterally extends flange  22 . Rotatable band  21  rotates about flagpole  24  when wind causes a flag attached to flange  22  to be drawn in a different radial direction. Such firm engagement supports the entire superior assembly for long term use for the objects of the invention. 
       FIG. 3  shows side cross sections of top rotation fitting  18  (with smooth bore  37 ), housing  11 , bottom rotation fitting  31  (with smooth bore for receiving bolt end  27 ), nut  19  (with a threaded bore), and adapter  20  (with threaded bore  53  for receiving bolt end  27  support the entire structure above adapter  20 ). Referring now to the cross section of housing  11 , top surface  13  is seen to define an impression in which solar panel  38  is secured, preferably by gluing or other long lasting adhesive means. Housing  11  is preferably formed from aluminum or other corrosion and erosion resistant materials and forms a substantial downward facing cavity  11   a , which is sealingly covered with a transparent cover  15  and comprises connector  16  with bore  16   a.    
     Cover  15  further comprises openings for passage of screws  48  through aligned holes in a reflective shield  45 , which is about the same size as cover  15 , and allows screws  48  to be threaded into screw extensions  44 , thereby securing cover  15  to shield  45 , and both secured to the underside of housing  11 . Cover  15  is curved downward from a flat reflective shield  45  (preferably comprising a thin metal sheet) to accommodate extension through shield  45  of  10  light emitting diodes  47  from circuit board  46   b  to a bottom side of shield  45  so that a mirrored and/or reflective underside of shield  45  causes lighted LED&#39;s  47  to provide the umbrella of light according to the objects of the invention. 
     An object of the invention is to provide for a rotatable poletop light having instantly replacable parts. The device of  FIG. 3  provides for a microprocessor circuit board  46  to be glued or releasably attached to an inside ceiling of housing  11 . Microprocessor  46  comprises a microprocessor and circuitry required for operation of the invention device, such that batteries  50  (preferably 3 metal hydride type batteries secured in battery pack  50 , which is attached by screws to housing  11 ), LED&#39;s  47 , and solar panel  38  all comprise removable plug connections  46   a  to circuit board  46 , allowing for quick and inexpensive replacement of any of those components, including circuit boards  46  and  46   b . The electrical components have been designed for separable replacement according to an optimization of cost and replacement times. 
     Referring now to axial end  14  of housing  11  of  FIG. 3 , a downwardly open cylindrical bearing holder  43  maintains therein a cylindrical bearing  41  by way of nut  19  threading to bolt end  27  to compress a lower edge of section  29  of top rotation fitting  18  onto a top edge of an inner race  42  while an upward facing edge of section  33  of bottom rotation fitting compresses upon a bottom edge of inner race  42 , with sections  30  and  32  providing intervening support for bearing  41  from bolt end  27  as it passes through to engage nut  19  and adapter  20 . A weather and water tight seal is formed when a lower surface of the decorative sphere  17  is impressed upon a top portion of section  28  of top rotation fitting  18  and a skirt underside of section  28  is impressed into a receiving cylindrical impression defined by rim  39  at the top surface of axial end  14 . Opening  40  defined in the axial end  14  provides for passage of section  29  into said axial end  14 . 
     Referring again to  FIG. 3 , it will be appreciated that assembly of the components results in the device shown in  FIG. 1 , whereby, as shown in  FIGS. 5 and 6 , ring  16   a  connects connector  16  extending from cover  15  to flange  22  of rotatable band  21 . Thus, the assembly of the decorative sphere and housing  11  and its integral components (including cover  15 ) are effectively made rotatable upon any rotation of rotatable band  21  via flag  56  (a top vertical corner being shown and being attached via carribeaner clip  55  to flange  22 ) being rotated about a vertical axis of flagpole  24 , resulting in flag  56  being illuminated by lighting provided according to the objects of the invention. 
     Further describing adapter  20 , a threaded bolt hole  53  is defined in flange skirt  35 , which extends out from an upper periphery of cylindrical insert  36 , which, upon insertion into an open top end of flagpole  24 , engages its inside cylindrical walls  24   c . A rotatable cap in the present specific example comprising the simple cylindrical band  24   a  fixed at just below a top of flagpole  24  which supports the rotatable band  21  (which may also include a plastic cylindrical sleeve  21   a  to reduce friction between an outside surface of flagpole  24  and an inside surface of rotatable band  21 ) from which laterally extends flange  22 . 
     A broken away section shows an exemplary lower flag rotatable band  21   b  with sleeve  21   c  and lateral flange  22   a , which is supported on flagpole  24  by way of attachment to a lower corner of an attached flag, providing rotational attachment for that lower corner in cooperating with rotatable band  21 . 
     Referring again to  FIG. 3 , circuit board  46  comprises a microprocessor operating by way of a control program to provide for solar panel charging of batteries and turning LED&#39;s on and off. An input to the microprocessor is compared with a pre-set limit of ambient illumination LED&#39;s  47  turn on when ambient illumination is below a pre-set level, such as at nighttime, and turning LED&#39;s  47  off at times of high ambient illumination. Said input may comprise either of falling of solar panel charging below a pre-set level (indicating reduction in ambient light) or from input from an light sensor (not shown). Said microprocessor also provides means for charging batteries  51  via input from solar panel  13  and for powering LED&#39;s  47  from said batteries  51 . Circuit board  46  is releasably attached to housing  11  for easy removal and replacement. Batteries  51  are also easily replaced, as is cover  15 , shield  45 , bearing  41 , and solar panel  38 . Failure of any component of the invention light requires only quick replacement of a low cost component, not the rest of housing  11  and its integral components and parts. The invention light is provided with means for inexpensive and quick replacement for any failed component. 
       FIG. 4  shows housing  11  and cover  15  separated with screws  48  with drawn from their securing positions. LED&#39;s  47  are shown in a U-shaped pattern extending through reflective shield  45 , which is raised to battery pack  50 , bottom rotation fitting  31  and bearing  41  in axial end  14 . A peripheral edge  55  seals to an inside surface of housing  11  when assembled, whereby opening  54  provides for passage of bottom rotation fitting therethrough for assembly as well. Screws  48   a  are provided to attach shield  45  to housing  11 . 
       FIG. 7  shows housing  11  with its cover and shield removed, with a slight inward extension  53  to accommodate definition of a recess for solar panel  38  (as shown in  FIG. 8 ). Battery pack  50  is adapted to provide an on-off switch  52  for turning electrical battery power on and off for the circuitry. Bearing holder  43  is shown as having an inner cylindrical diameter just larger than an outside diameter of bearing  41 , allowing housing  11  and its other integral components to rotate about a flagpole axis either entirely upon a compressed inner race of bearing  41  or in combination with contact of housing  11  through holder  43  with the outer race of bearing  41 . Such distribution of rotational forces extends the life of bearing  41 , which is critical in a difficult to reach installation location as the top of a flagpole. 
     A further object of the invention is to provide a laterally extending and rotatable poletop light for flagpoles where a center of gravity of the light assembly is within about 4 inches of an axial rotation connection with the flagpole. Forming the housing of aluminum and locating the battery pack adjacent to a rotation bearing results in an unloading of force on said bearing, whereby the center of gravity of the entire assembly is close to the battery pack. 
     Preferred dimensions for the invention housing and integral cover attached are a lateral extending length of from 8 to 15 inches, and more preferably from 10 to 12 inches, a widest width at the lateral extension end  12  of from 3 to 6 inches, and more preferably from 4 to 5 inches, and a depth as described above. 
     The above design options will sometimes present the skilled designer with considerable and wide ranges from which to choose appropriate apparatus and method modifications for the above examples. However, the objects of the present invention will still be obtained by that skilled designer applying such design options in an appropriate manner.

Technology Category: 2