U.S. patent number 3,818,439 [Application Number 05/243,029] was granted by the patent office on 1974-06-18 for warning light assembly with modularized inserts.
This patent grant is currently assigned to Work Area Protection Corp.. Invention is credited to Robert W. Maine.
United States Patent |
3,818,439 |
Maine |
June 18, 1974 |
WARNING LIGHT ASSEMBLY WITH MODULARIZED INSERTS
Abstract
An improved warning light assembly of the type providing an
intermittent flashing warning light which includes a top case
member and a bottom case member which are snap-fittingly
engageable, a unitary lens ring member having lock means formed
integrally therewith, the lens ring being so constructed as to
snap-fittingly lock into position in the case member, the top case
member also being provided with a series of three metallic pins
extending through the case interiorly of the light housing, a
circuit platform including an electrical candle mounted in
breakaway relationship with respect to the platform, and the
platform being provided with at least two electrically conductive
metallic strips to provide an electrical circuit between the
electrical candle and the power source, the circuit platform
further including apertures in lineal alignment with the metallic
strips whereby the metallic pins extending through the case may
contact and establish electrical communication with the metallic
strips, the metallic pins thereby providing external test points
for both the electrical candle and the power source.
Inventors: |
Maine; Robert W. (Cerritos,
CA) |
Assignee: |
Work Area Protection Corp.
(Addison, IL)
|
Family
ID: |
22917080 |
Appl.
No.: |
05/243,029 |
Filed: |
April 11, 1972 |
Current U.S.
Class: |
340/331; 362/455;
340/908.1 |
Current CPC
Class: |
F21L
2/00 (20130101) |
Current International
Class: |
B60Q
1/50 (20060101); B60Q 1/52 (20060101); B60q
001/52 () |
Field of
Search: |
;240/151,152
;340/81R,84,114B,118 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
1,134,907 |
|
Nov 1968 |
|
GB |
|
2,001,708 |
|
Oct 1970 |
|
DT |
|
Primary Examiner: Caldwell; John W.
Assistant Examiner: Nowicki; Joseph E.
Attorney, Agent or Firm: Dominik, Knechtel, Godula &
Demeur
Claims
What is claimed is:
1. An improved warning light assembly comprising in
combination:
a bottom case member for accommodating a power source,
a top case member including a top wall,
said top and bottom case members together forming the light
assembly housing,
said top case member having an aperture disposed in the top wall
thereof,
a unitary lens ring member having lock means formed integrally
therewith,
said lock means coacting with said aperture, thereby to lock said
lens ring into engagement with said top case member,
at least one optical lens plate carried by said lens ring,
a circuit platform assembly removably positionable within said
housing, said circuit platform assembly including,
a base plate,
a candle mounted on said base plate in snap-fitting breakaway
relation,
a light carried on said candle,
electrical contact means mounted on said base plate to provide
electrical communication between said power source and said
light,
and electrical circuitry for transmitting electrical power from the
power source to the light.
2. The improved warning light assembly as set forth in claim 1
above, wherein said lock means of said unitary lens ring member
comprises a plurality of finger members, each of said finger
members having an outwardly extending flange, each of said flanges
coacting with said aperture disposed in the top wall of said top
case member, thereby to lock said unitary lens ring member into
position on said top case member of said light assembly
housing.
3. The warning light assembly as set forth in claim 1 above,
wherein said electrical contact means comprises a plurality of
electrically conductive metallic strips mounted on said base plate
and in electrical communication with said power source and with
said light carried on said candle, whereby said light may be
effectively energized by said power source via said electrically
conductive metallic strips.
4. The warning light assembly as set forth in claim 1 above, which
further includes circuitry in electrical communication with said
power source and said electric light thereby to cause said light to
be intermittently energized an deenergized when the electrical
circuit is in the closed position.
5. The warning light assembly as set forth in claim 1 above, which
further includes switch means electrically interposed between said
power source and said light, thereby to permit opening and closing
of the circuit formed between said power source, said light and
said electrically conductive contact means.
6. The warning light assembly as set forth in claim 1 above,
wherein said lens ring member comprises a ring base, a ring member
upstandingly mounted on said ring base, and lock means mounted on
said ring base extending downwardly therefrom, said ring base, ring
member and lock means formed integrally as a unitary member.
7. An improved warning light assembly comprising in
combination,
a bottom case member for accommodating a power source,
a top case member including a top wall,
said top and bottom case members together forming the light
assembly housing,
said top case member having an aperture disposed in the top wall
thereof and a plurality of electrically conductive pins disposed
therethrough in predetermined locations,
a unitary lens ring member having lock means formed integrally
therewith,
said lock means coacting with said aperture thereby to lock said
lens ring into engagement with said top case member,
at least one optical lens plate carried by said lens ring,
a circuit platform assembly removably positioned within said
housing, said circuit platform assembly including,
a base plate,
a candle mounted on said base plate in snap-fitting breakaway
relation,
a light carried on said candle,
electrical contact means mounted on said base plate to provide
elecbrical communication between said power source and said
light,
electrical circuitry mounted on said base plate for transmitting
electrical power from the power source to the light,
said base plate further including means for establishing electrical
communication between said electrical contact means and said
electrically conductive pins disposed in said top case member
whereby the electrical capability of the power source and the
electrical candle may be determined externally of said warning
light assembly.
8. The warning light assembly as set forth in claim 7, wherein said
bottom case member is compartmentalized into two compartments and
said power source comprises two batteries, each of which is
positioned in a respective compartment in said bottom case
member.
9. The warning light assembly as set forth in claim 7, wherein said
top case member and bottom case member disengagably lock in
snap-fitting relationship.
10. The warning light assembly as set forth in claim 7 above,
wherein said aperture in said top wall of said top case member
includes an undercut shoulder to facilitate coaction with said lock
means of said unitary lens ring member, thereby to effect positive
locking of said unitary lens ring member on said top case
member.
11. The warning light assembly as set forth in claim 7 above,
wherein said lens ring member comprises a ring base, a ring member
upstandingly mounted on said ring base, and lock means mounted on
said ring base and extending downwardly therefrom, said ring base,
ring member and lock means formed integrally as a unitary
member.
12. The warning light assembly as set forth in claim 10 wherein
said lock means comprises a plurality of finger members, each of
said finger members having an outwardly extending flange, each of
said flanges coacting with said undercut shoulder to provide
positive locking of said lens ring in said aperture.
13. The warning light assembly as set forth in claim 11, above
wherein said unitary lens ring member is provided with a plurality
of screw mounts to accommodate the mounting of optical lens plates
thereon by screws inserted through said lens plates and into said
screw mounts, said screw mounts formed integrally with said unitary
lens ring member.
14. The warning light assembly as set forth in claim 7 above,
wherein said electrical candle is mounted on said base plate in
impact-breakaway relation.
15. The warning light assembly as set forth in claim 7 above, which
further includes switch means electrically interposed between said
power source and said electrical contact means, said switch means
thereby permitting manual energizing and de-energizing of said
light.
16. The warning light assembly as set forth in claim 7 above,
wherein said electrical contact means comprises a plurality of
electrically conductive metallic strips, mounted on said base plate
and in electrical communication with said metallic pins extending
through said case top member and with said power source whereby the
electrical capability of said power source as well as said light
may be tested externally of the light housing assembly by
establishing an electrical circuit through the portions of said
electrically conductive pins which are exposed externally of the
warning light assembly.
17. The warning light assembly as set forth in claim 16 above
wherein said base plate is provided with separate electrically
conductive metallic strips in order to accommodate independent
testing of said power source and said light.
18. In a warning light assembly of the type including a housing
formed of a top case member and a bottom case member, the top and
bottom case members being interconnected in disengageable relation
and containing therein a power source, an electrical candle and
circuitry interconnecting the electrical candle with the power
source, the top case member being provided with an aperture in the
top wall thereof for accommodating the positioning of the
electrical candle therethrough to provide an external warning
light, the improvement comprising,
a unitary lens ring for carrying at least one optical lens plate
therein,
said unitary lens ring including lock means formed integrally
therewith,
said lock means coacting with the aperture in the top case member
thereby to effect locking engagement of said lens ring with said
top case member,
said lock means being so formed and coacting with the aperture in
such manner as to permit said lens ring to be freely rotatable
throughout an arc of 360.degree. when locked into position on the
top case member,
whereby the lens ring carrying the optical lens plate may be locked
into position on the top case member thereby to form a warning
light assembly while permitting complete rotation of the lens ring
and optical lens plate assembly with respect to the housing.
19. The warning light assembly as set forth in claim 18 above,
wherein said unitary lens ring comprises a ring base, a ring member
upstandingly mounted on said ring base and lock means mounted on
said ring base and extending downwardly therefrom, said ring base,
ring member and lock means formed as a unitary integral member.
20. The warning light assembly as set forth in claim 18 above,
wherein said lock means comprises a plurality of finger members,
each of said finger members having an out-turned peripheral flange
formed thereon, and said aperture in said top case member includes
an undercut shoulder, said peripheral flanges and said undercut
shoulder coacting thereby to form positive lock means for locking
said lens ring assembly on said top case member.
21. The warning light assembly as set forth in claim 20 above,
wherein a total of four finger members are provided, each of said
finger members being curvilinear in configuration and together
defining a diameter slightly less than the diameter of the aperture
in said top case member.
22. The warning light assembly as set forth in claim 18 above,
which further includes a gasket disposed between said unitary lens
ring and said top case member, thereby to facilitate the rotational
movement of said unitary lens ring when locked into position on
said top case member.
23. The warning light assembly as set forth in claim 18 above,
wherein said unitary lens ring further includes a plurality of
screw mounts mounted thereon thereby to provide mounting sites for
mounting the optical lens plates thereon, said screw mounts being
formed integrally with said unitary lens ring.
24. A method for interconnecting a lens assembly to a casing in
rotatable relationship thereby to form a warning light assembly of
the type including a self-contained power source, an electrical
candle and circuitry interconnecting the electrical candle with the
power source, comprising the steps of
providing a housing having at least a top case member including an
aperture disposed in the top wall thereof,
forming a unitary lens ring for carrying at least one optical lens
plate and provided with lock means formed integrally therewith,
engaging said lock means in said aperture in the top case member
thereby to lockingly engage said unitary lens ring in position on
said top case member,
whereby said lens ring assembly may be locked into position on the
top case member without the need for extraneous lock members while
permitting the lens ring assembly to be completely rotatable
throughout an arc 360.degree. when so locked into position.
25. The method as set forth in claim 24 above, wherein said lens
ring is jam-fitted into said aperture in said top case member,
thereby to engage said lock means and secure said lens ring to case
in rotating relationship.
26. The method as set forth in claim 25 above, wherein said lock
means formed on said unitary lens ring comprises a plurality of
finger members, each of said finger members having an out-turned
peripheral flange, and said aperture formed in said top case
includes an undercut shoulder, said out-turned peripheral flanges
caocting with said undercut shoulder thereby to provide positive
locking of said lens ring in sait top case member.
Description
BACKGROUND OF INVENTION
Warning lights of the type which flash intermittently and are
adapted for mounting on wooden barricades, road warning sign
stands, and the like, are well-known in the art. The standard
construction of such warning light assemblies generally includes a
top case member and a bottom case member, the two case members
being so designed as to snap-fittingly engage one with the other,
and the bottom case being so designed as to carry one or more
batteries as the power source. The top case member generally houses
the electric candle as well as the circuitry which interconnects
the light with the batteries. Finally, the optical lens plates are
usually held in position on top of the case by means of a lens ring
which in the usual construction is bolted to the top case.
While lights of this general construction are presently in use, and
do function for the intended purpose, nevertheless, various
difficulties have been noted with respect to many of these prior
art devices. For example, where the lens ring which carries the
optical lens plates is bolted to the case housing, it is often very
difficult to rotate the lens plate assemblies once the light has
been attached to the barricade. In many such constructions, it is
necessary to completely remove the top case member from the bottom
case member in order to obtain access to the bolt holding the lens
ring in position, in order to loosen same and permit rotation of
the complete lens plate assembly. Hence, rather than completely
disassemble the light assembly, very often in order to change the
direction in which the flashing light is visible, one must
completely move the barricade or other structure upon which the
light is mounted.
Another difficulty which has been noted with respect to prior art
constructions is that in many cases, the circuitry inside of the
housing is exposed. Hence, it is not unusual to find constructions
wherein the wiring runs through appropriate holes in the bolt
holding the lens ring in position and connects the electric candle
to the switch assembly, and to the power source, is completely
exposed inside of the casing. Clearly, when an attempt is made in
the field to disassemble the light assembly, such as for example,
to change the batteries or the light bulb, the danger of
accidentally severing an electrical connection of the wires is
present. In addition, if the barricade or other structure upon
which such a light is located is struck by a vehicle and the light
is impacted against the roadway, often such warning lights cannot
be repaired and must be entirely replaced in order to maintain the
safety standards in connection with the particular project
involved. Hence, another undesirable feature of such lithts is
apparent, since many of these warning light assemblies do not have
replaceable modules which may be merely inserted into the light to
repair same.
An example of one of the prior art type warning light devices is
shown in U.S. Pat. No. 3,221,300. In the construction as shown in
this patent, it will be noted that the wiring for interconnecting
the electric light with the power source hangs loosely within the
case. Hence, when one attempts to change the batteries by
disassembling the case housing there is a great danger present of
accidentally severing one of the wires leading from the candle to
the power source or batteries. Furthermore, it will be noted that
the candle holder is based within the casing and extends upwardly
through an aperture provided in the top case. In the event that the
barricade or structure holding the light is sruck and the light
strikes the pavement with great force, the danger that the candle
will snap and break is imminently present. Finally, it will be
noted that the lens assembly is merely pressed down over the candle
holder or sleeve, which, while permitting the lens plates to be
freely rotated, nevertheless increases the danger that such lens
assemblies will be stolen by vandals, or at least may be easily
removed by anyone. Usually, such lens assemblies are expensive to
replace and hence, if a lens assembly is easily removable,
replacement costs for stolen or damaged lens assemblies are high
and this feature represents a significant cost drawback.
Another prior art warning light assembly is shown in U.S. Pat. No.
3,015,804. The structure as disclosed in this patent is actually
designed as part of a barricade and due to its construction, can
only be used in conjunction with barricades which are specially
designed to carry these particular lights. This feature is
definitely a drawback to such a prior art device since
interchangeability with other types of barricades cannot be
achieved. Clearly, interchangeability is a commercially desirable
feature to have, since one cannot rely upon the fact that all
contractors or other parties that use such lights would have the
necessary specially designed barricade.
A more improved warning light assembly is shown in U.S. Pat. No.
3,266,015, wherein there is shown a case housing consisting of a
top case member and a bottom case member which interconnects via a
snapping action. A circuit platform is provided, having contact
strips disposed thereon for contact with a power source, such as a
battery or a pair of batteries, and a lens assembly which is
mounted to the top case member. However, the structure of the
warning light assembly as shown therein has several drawbacks. For
example, it will be noted that the lens assembly is bolted to the
top case. Such structure proves to be very costly in manufacture,
since the labor to assemble such a construction is significant. In
addition, should the screws that hold the lens assembly in position
be tightened too tightly, then in that event, great difficulty
would be encountered in attempting to rotate the lens assembly to
direct the warning light in a different direction. In order to
loosen the screws holding the light assembly in position, it is
necessary to completely disassemble the case in order to obtain
access to the two screws holding the lens assembly in position.
Another drawback feature of the light assembly as shown in U.S.
Pat. No. 3,266,015 is the fact that the electric light bulb holder,
or candle member, is formed integrally with the circuit platform.
Hence, should the light be struck or impacted against the pavement,
the danger that the candle would break is increased. Any such
breakage would then necessitate that one replace the complete
circuit platform and candle, since these are both formed as a
unitary piece.
In view of the difficulties noted above, among others, with various
of the prior art warning light assemblies, it is considered to be
desirable to provide an improved warning light assembly. Hence, the
provision of such a warning light assembly which is both easy to
manufacture while at the same time reducing the total cost thereof
is intended. Furthermore, a modularized construction is provided
whereby the repair or replacement of damaged or lost parts is
facilitated in the field, where the light is actually used. In
addition, it is obviously advantageous to provide a warning light
assembly which permits free rotation of the lens assembly
throughout an arc of 360.degree. in order to direct the warning
light in any desired direction, while at the same time insuring
that the lens assembly cannot easily be removed unless the lens
assembly is completely destroyed. Finally, it is desirable to
provide a warning light assembly which includes a modularized
circuit platform carrying the necessary electric candle, circuitry,
switch means and electrical contact means, all as a sub-assembly,
which is completely interchangeable with existing warning light
housing assemblies.
BRIEF SUMMARY OF THE INVENTION
The novel warning light assembly of the present invention is
provided with a housing consisting of a top case member and a
bottom case member which snap-fittingly engage one with the other.
A modularized circuit platform assembly is provided which includes
a candle for holding the electric light, in breakaway relation with
respect to the platform. The circuit platform also includes a
series of either two or three electrical contact strips for
establishing electrical communication between the power source and
the candle, as well as serving to coact with a series of three
metallic pins which are disposed in the top case member and
establish electrical contact with the metallic strips, thereby to
provide external test points for both the power source and the
electric light. The lens assembly is formed as a unitary lens ring,
having mounting fingers thereon, whereby the lens ring may be
snapped into position on the case, thereby effecting a locked
relationship as between the lens ring and the case, while
nevertheless permitting the lens ring and the optical lens plates
carried thereby to be freely rotated throughout a 360.degree. arc,
without necessitating any adjustment of screws, bolts, or the
like.
OBJECTS AND ADVANTAGES
It is therefore the principal object of the present invention to
provide an improved warning light assembly which includes in
combination a bottom case member for accommodating a power source,
a top case member including a top wall, the top and bottom case
members together forming the light assembly housing, the top case
member having an aperture disposed in the top wall, and a plurality
of metallic pins disposed therethrough in predetermined locations,
a unitary lens ring member having lock means formed integrally
therewith, the lock means coating with the aperture in the top wall
thereby to lock the lens ring into engagement with the top case
member, a circuit platform assembly removeably positionable within
the housing, the circuit platform including a base plate, an
electrical candle mounted on the base plate, electrical contact
means mounted on the base plate to provide electrical communication
between the power source and the elctrical candle, and the base
plate further including means for establishing electrical
communication between the electrical contact means and the metallic
pins disposed in the top case member, whereby the presence and
absence of electric current in the power source and in the
electrical candle may be determined externally of the light housing
assembly.
A further object of the present invention is to provide a warning
light assembly of the type set forth, wherein the lens ring member
comprises a ring base, a ring member upstandingly mounted on the
ring base, and lock means mounted on the ring base and extending
downwardly therefrom, the ring base, ring member and lock means
formed integrally as a unitary member.
Still another object of the present invention is to provide a
warning light assembly of the type set forth, wherein the aperture
in the top case member includes an undercut shoulder and the lock
means of the lens ring member includes a plurality of finger
members having outstanding peripheral flanges extending therefrom,
the flanges and undercut shoulder coacting to form lock means for
locking the lens ring member into position on the top case
member.
Yet another object of the present invention is to provide a warning
light assembly of the type set forth wherein the electrical candle
is mounted on the circuit platform in breakaway relationship
whereby upon impact, the electrical candle is permitted to break
away from the circuit platform and may be easily replaced by merely
snap-fitting the pieces back together.
In connection with the foregoing object, it is still a further
object of this invention to provide a warning light assembly of the
type described wherein the electrical candle is so constructed such
that the light bulb removably positioned therein will always
re-register with the center of the two lenses within tolerances of
between 0.002 and 0.003 of its original position when re-installed
whether due to breakage of replacement.
Another object of the present invention is to provide a warning
light assembly of the type set forth wherein the electrical contact
means mounted on the base plate comprises a plurality of
electrically conductive metallic strips in electrical communication
with the metallic pins extending through the top case member and
with the power source whereby the electrical ability of the power
source as well as the electrical candle may be tested externally of
the light housing assembly by establishing an electrical circuit
through the portion of the metallic pins which are exposed
externally of the light housing assembly.
Still another object of the present invention is to provide a
method for interconnecting a lens assembly to a case housing in
rotatable relationship to form a warning light assembly of the type
including a self-contained power source, an electrical candle and
circuitry interconnecting the electrical candle with the power
source, comprising the steps of providing a housing having at least
a top case member including an aperture disposed in the top wall
thereof, forming a unitary lens ring for carrying at least one
optical lens plate and provided with lock means formed integrally
therewith, engaging the lock means in the aperture in the top case
member, thereby to lockingly engage the unitary lens ring in
position on the top case member, whereby the lens ring assembly may
be locked into position on the top case member without the need for
extraneous lock members while permitting the lens ring assembly to
be completely rotatable throughout an arc of 360.degree. when so
locked into position.
Further features of the invention pertain to the particular
arrangement of the elements and parts whereby the above-outlined
and additional operating features thereof are attained.
The invention both as to its organization and method of operation,
together with further objects and advantages thereof will best be
understood by reference to the following specification taken in
connection with the accompanying drawings, in which:
FIG. 1, is a perspective view of a completely assembled warning
light assembly of the present invention.
FIG. 2 is a side elevational cross-section view showing the various
components of the warning light assembly, as assembled.
FIG. 3 is a side elevational view of the warning light of the
present invention showing the external electrical testing points
disposed on the top case member.
FIG. 4 is an exploded view, patly in cross section, of the various
component parts forming the warning light assembly of the present
invention.
FIG. 5 is a top plan view of the circuit platform comprising one of
the component parts of the warning light of the present
invention.
FIG. 6 is a view of the undersurface of the top case member taken
in the direction of the arrows along the line 6--6.
FIG. 7 is a side elevational exploded view showing the component
parts forming the circuit platform assembly.
Referring now to FIGS. 1 through 3 of the drawings, the warning
light assembly, generally referred to by the number 10, is shown in
its assembled state. It will be noted that the assembly 10 consists
of a bottom case member 12, a top case member 14, and a lens
assembly 16. The top case member 14 is shown to be in overlapping
relationship with respect to the bottom case member 12, the two
case members 12 and 14 being provided with means to achieve a
snap-fitting engagement whereby the case members 12 and 14 are
disengageably held in position. The warning light assembly 10 is
completed by means of a bolt (not shown) which is inserted through
a bolt aperture 18 carried on a bolt support platform 20, the bolt
then threadedly secured into a bolt plate 22, carried on the
reverse side wall of the top case member 14. In the usual
application, and where desired, the warning light assembly 10 is
mounted to a barricade or other such structure and the mounting is
accomplished by first threading the bolt through an aperture
provided on the barricade or other structure, and thence into the
bolt aperture 18 and threadedly secured in the bolt plate 22.
Usually the bolts which are employed in such application have
safety features associated therewith in order to prevent vandals or
other unauthorized persons from removing such assemblies from the
barricades or otherwise damaging same. For example, such bolts are
usually provided with special heads which can only be inserted into
the assembly or removed therefrom by means of special tools which
are carried by the crews or other authorized personnel who deal
with the lights in order to mount or demount same from the desired
position.
The detailed construction of the warning light assembly of the
present invention is more clearly shown in FIGS. 2 and 4 of the
drawings. The bottom case member 12 includes a bottom wall 24 and a
series of peripheral side walls 26. The central portion of the
bottom wall 24 is raised upwardly to form a U-shaped dividing wall
28 thereby to compartmentalize the bottom case member 12 into two
compartments 29 and 30 respectively. The opposed side walls 26 are
each provided with an outwardly turned flange 32 which forms part
of the closing mechanism for engaging the top case member 14 with
the bottom case member 12.
The upper interior portion of the U-shaped dividing wall 28 is
provided with a lip 33, which extends laterally outwardly for a
short distance. The lip 33 snap-fittingly engages the bolt aperture
18 of the top case member 14, thereby to provide a three-point
locking of the top case of 14 with the bottom case 12 when the two
are lockingly engaged. Furthermore, the lip 33, serves as a bearing
point when the bolt is inserted and tightened, thereby preventing
excessive deformation of the top case 14. Such a three point
locking system permits the locking of not only the opposed ends of
the corresponding cases, but also one of the side walls of each of
the top case 14 and bottom case 12.
The top case member 14 includes a top wall 34 and a series of
pheripheral side walls 36. The lower end of each of the two opposed
short side walls 36 is provided with a reverse flange 38, the
reverse flange 38 coacting with the outwardly turned flange 32 of
the bottom case member 12, to effect a snap-acting lock mechanism
for locking the top case member 14 with the bottom case member 12
in disengageable relationship. The central portion of the top wall
35 is provided with a central aperture 40 which is surrounded by a
thickened section 42 of the top wall 34. The thickened section 42
is also provided with an undercut shoulder 44, adjacent the lower
end thereof and interiorly disposed, the thickened section 42 and
undercut shoulder 44 being provided for a purpose to be more fully
described hereinafter.
The construction of the undersurface 46 of the top wall 34 is more
particularly shown in FIGS. 4 and 6 of the drawings. With
particular reference to FIG. 6 of the drawings, it will be noted
that the thickened section 42 surrounding the aperture 40 is
provided with a plurality of radial structural ribs 48, extending
outwardly therefrom, the thickened section 42 and radial ribs 48
providing structural support for the top case member 14, at the
point where the lens assembly 16 is mounted. One of the elongated
side walls 36 is shown to include a side aperture 50 for receiving
the bolt (not shown) therethrough in the manner described
hereinabove. The opposed elongated side wall 36 is provided with a
bolt plate 52 which is riveted to the wall 36 by means of a pair of
rivets 53. Alternatively, the bolt plate 52 may be provided with
expandable bosses which would be forced through corresponding
apertures in the top case 14 to achieve fastening of the bolt plate
52 thereto. A threaded sleeve 54 extends interiorly of the top case
member 14, the threaded sleeve 54 providing a receptacle into which
the bolt may be threadedly secured when completing the final
assembly of the light assembly 10. The side aperture 50 and
threaded sleeve 54 are so positioned as to horizontally align with
the uppermost portion of the U-shaped dividing wall 28 of the
bottom case member 12, thereby to enable the top case member 14 and
bottom case member 12, to be snap-fitted together via the outwardly
turned flange 32 and reverse flange 38 to achieve the engagement of
the top and bottom case members 12 and 14 respectively.
The undersurface of the top case member 14 also includes a series
of four spacer lugs 56 which function for a purpose to be more
fully described hereinafter. In addition, the undersurface 46
includes a pair of friction posts 58 which, again, function for a
purpose to be more fully described hereinafter. Finally, the
undersurface 46 includes a series of three pin sleeves 60, which
are molded as an integral part of the top case 14 and hence, firmly
anchored in a supporting wall 62, extending downwardly into the
interior of the top case member 14.
In FIGS. 2, 4, 5 and 7 of the drawings, the structure of the
circuit platform assembly 65 is illustrated. The circuit platform
assembly 65 includes a base plate 66 which is provided with a
candle holding aperture 68 centrally disposed therein, the candle
holding aperture 68 being surrounded by an annular support wall 70.
A pair of friction post receptacles 72 is disposed in the base
plate 66, the friction post receptacles 72 being disposed in
opposed relation along an angular line so as to be in substantially
vertical alignment with the friction posts 58 when the circuit
platform assembly 65 is positioned interiorly of the top case
member 14. The friction posts 58 coact with the friction post
receptacles 72 to provide a friction locking mechanism for holding
the circuit platform assembly 65 in the top case member 14.
The circuitry is housed in a circuit housing 74, which is
snap-fittingly held to the base plate 66 by means of locking lugs
75 which coact with lug receptacles 76, whereby the circuit housing
74 is held in suspended relationship from the bottom of the base
plate 66, and immediately below the candle holding aperture 68. The
circuit housing 74 provides a convenient location for disposing the
switch mechanism 78 as well as the circuitry 80 which, in turn,
controls the intermittent or sequential flashing of the warning
light. The complete circuitry 80 is actually contained within a
casing 81 (shown in phantom in FIG. 7) which is then completely
filled with a potting compound of the type generally employed in
the electronics industry. The necessary wires 82 extend out from
the casing 81 and are provided with terminal lead ends for the
purpose of establishing electrical connection to the appropriate
terminals. The underside of the base plate 66 is provided with a
series of three electrically conductive strips 84 which are
conveniently formed of an electrically conductive metal and are
held in place by means of a plurality of strip cradles 86 which are
formed as a part of the base plate 66. The wiring 82 leading from
the circuitry 80 contained within the circuit housing 74 is
electrically connected such as by soldering or the like, to the
electrically conductive strips 84, and due to the elongated
configuration of the electrically conductive strips 84, the
undersurface of each of the electrically conductive strips is
caused to come into contact with the power source, such as
batteries having spring wound battery terminals, of the type
generally known in the art, thereby to complete the circuit and
establish electrical communication as between the power source, the
electric switch, and the warning light.
The light assembly 88, comprises a tubular candle 90 which
terminates in a base 91, base 91 having a short tubular extension
92 extending downwardly therefrom and terminating in a peripheral
bead 94 angularly disposed thereabout. The length of the short
tubular extension 92 is substantially the same as the combined
thickness of the base plate 66 and support wall 70 whereby the
tubular candle 90 may be snap-fitted into engagement through the
candle holding aperture 68 in the base plate 66. The upper portion
of the candle 90 is provided with a light bulb holding collar 94,
which is slotted in the customary manner for the purpose of holding
a warning light bulb 95 thereon. Electrical communication as
between the light bulb 95 and the circuitry 80 is accomplished by
means of wiring 96 thereby completing the circuit as described
hereinabove.
In the preferred embodiment of the circuit platform assembly 65,
the base plate 66 is shown to include a pair of opposed end-to-end
attachment apertures 97, and another pair of angularly opposed
rectangular apertures 98. Both of these pairs of apertures are
provided for the purpose of permitting the circuit platform
assembly 65 to be inserted into other presently existing top case
members wherein the friction posts 58 are located in positions
vertically aligned with the apertures as set forth above. Hence, it
will be apparent that the circuit platform assembly 65 of the
present invention may be fitted into and positioned within any top
case member which is presently available.
Finally, the circuit platform assembly 65 is completed by a series
of three contact apertures 99 which are positioned in vertical
alignment immediately above a corresponding electrically conductive
strip 84. In addition, the contact apertures 99 are also in
vertical alignment with a corresponding pin sleeve 60 whereby a
metallic pin 100, which is disposed through the pin sleeve 60 will
be permitted to have one head 101 exposed externally of the top
case member 14 while having the opposed head 102 extending through
a corresponding contact aperture 99 and in contact with a
corresponding electrically conductive strip 84. Due to the
circuitry involved, and the means by which each of the electrically
conductive strips 84 is wired to the power source, switch and light
bulb, the electrical ability of the power source as well as the
light bulb 95 may be individually tested by making electrical
contact with the appropriate exposed pin heads 101 by means of an
electrical tester externally of the top case member 14. If desired,
and in order to avoid the danger of accidentally short circuiting
the power source and/or the light bulb 95, the top case member may
be provided with a series of four upstanding walls 103 thereby to
separate the three pin heads 101, one from the other.
The details of construction of the lens assembly 16 is shown in
FIGS. 2 and 4 of the drawings. The lens assembly 16 is shown to be
formed by a unitary lens ring structure 110, which is formed by a
ring base 112, which is centrally apertured as shown in 114, and
having a ring member 116 extending upwardly therefrom. The ring
member 116 includes a series of four screw mounts 118 which are
provided for the purpose of carrying at least one optical lens
plate 120, in the manner shown in FIG. 1 of the drawings. The
optical lens plate 120 is held into position on the ring member 116
by means of screws 122 inserted through apertures provided in the
optical lens plate 120 and through the screw mounts 118 carried by
the ring member 116. The screws 122 are held in position by means
of nuts (not shown) which engage the threaded end of the screws on
the opposed surface of the ring member 116 in a manner commonly
known in the art.
The unitary lens ring structure 110 also includes a series of four
finger member 124 extending downwardly from the ring base 112, each
of the finger members 124 having a length approximately equal to
the thickened portion 42 surrounding the central aperture 40 in the
top case member 14. Each finger member 124 terminates in a
peripheral flange 126 extending outwardly from the corresponding
finger member 124, each of the peripheral flanges 126 coacting with
the undercut shoulder 44 provided in the central aperture 40,
thereby to form lock means for locking the unitary lens structure
110 into position in the top case member 14. In the preferred
embodiment, prior to the assembly of the lens ring structure 110
into the top case member 14, a gasket 128 is provided between the
lower surface of the ring base 112, and the upper surface of the
top case member 14. Hence, once the unitary lens ring structure 110
is inserted into position in the top case member 14, the rotational
movement of the unitary lens ring structure 110 is facilitated by
the presence of gasket 128.
With regard to the manner in which the warning light assembly 10 is
assembled, it will be apparent from the above description that the
circuit platform assembly 65 may be preassembled and supplied as a
sub-assembly. The benefits to be gained from such a sub-assembly
will be clear when reference is had to the normal abuse to which
such warning lights are subjected. Hence it is clear that where any
portion of the circuit platform assembly 65 is damaged, whether due
to impact, vandalism or the like, the complete circuit platform
assembly 65 may be easily removed from the warning light assembly
10 and replaced with a completely new circuit platform
assembly.
In any event, the lens assembly 16 is connected to the top case
member 14 by inserting the finger members 124 through the gasket
128 and then into the central aperture 40 in the top case member.
The unitary lens ring structure 110 is press-fitted downwardly with
the finger members 124 each being inserted through the aperture 40
until the peripheral flanges 126 of each of the finger members 124
engages with the undercut shoulder 40 disposed adjacent the
innermost portion of the thickened portion 42 of the top case
member 14. Either one or a pair of optical lens plates 120 may then
be mounted to the ring member 116 by means of screws 122 inserted
through suitable apertures provided in the optical lens plate 120
and then through the screw mounts 118 disposed in the ring member
116 and held in position by threaded nuts. The circuit platform
assembly 65, as described above, is provided as a sub-assembly,
having the electrically conductive strips 84 inserted into position
in the strip cradles 86, and the circuit housing 74 duly locked
into position on the base plate 66 with the switch mechanism 78 and
circuitry 80 contained therein and duly wired so as to connect the
electric light bulb 95 with circuitry 80.
The circuit platform assembly 65 is then inserted into the top case
member 14 until the friction posts 58 are inserted through the
friction post receptacles 72 in the base plate 66, thereby to hold
the circuit platform assembly 65 into position in the top case
member 14. The spacer lugs 56 contact the top surface of the base
plate 66 not only to keep the circuit platform 65 in spaced
relation with respect to the top wall 34 of the top case member 14,
but also to tension the circuit platform 65 against the spring
terminals of the batteries and ensure electrical contact between
the metallic strips 85 and battery terminals. The power source
consists of a pair of dry cell batteries, each battery having a
pair of spring terminals of the type commonly known in the art, and
one of each of the batteries is inserted in the corresponding
compartment 29 and 30 respectively, formed in the bottom case
member 12. The top case member 14 having the lens assembly 16
locked into position and the circuit platform assembly 65 engaged
internally thereof is then brought down over the bottom case member
12 until the upwardly turned flanges 32 of the bottom case member
12 meet and coact with the reverse flanges 38 of the top case
member 14 thereby disengageably locking the top and bottom case
member 14 and 12 respectively, into position. When assembled in
this fashion, the tubular candle 90 will extend upwardly through
the central aperture 40, gasket 128, central aperture 114, and into
the area bounded by the optical lens plates 120. A switch aperture
130 is provided in one of the elongated side walls of the top case
member 14 in horizontal alignment with the positioning of the
switch mechanism 78 internally within the top case member 14. A rod
or other tool may then be inserted through the switch aperture 130
in order to engage and activate the switch mechanism 78 thereby to
close the circuit and establish electrical communication as between
the power source, the circuitry 80 and the light bulb 95, thereby
powering the light.
Where desired, and as an optional feature, the base plate 66 of the
circuit platform assembly 65 is provided with a mounting site
generally represented by the numeral 132 where a photocell may be
mounted. As is known in the art, photocells may be employed in such
warning light assemblies thereby to activate and deactivate the
light during the night-time hours and the daylight hours
respectively. In most of the present commercially available
structures, when photocells are provided with the warning light
assembly, the photocells are disposed in the candle portion of the
light in order to be exposed to the outside environment. Due to the
fact that the unitary lens ring structure 110 of the present
invention is formed of a high impact polycarbonate, the plastic is
relatively clear and hence, light is able to penetrate through the
ring base 112, central aperture 40, and will reflect onto the top
surface of the base plate 66. The mounting point 132 is so disposed
as to permit the photocell to be activated and/or deactivated by
the sunlight by reflection through the ring base 112 in the manner
as described above.
It is apparent from the foregoing description that one of the
improved features of the present invention is the fact that the
method for attaching the lens assembly to the top case member 14
has been so improved as to eliminate any need for bolts, pins, or
other extraneous locking means, while at the same time improving
the ability to rotate the lens assembly 16 even after the warning
light assembly 10 has been bolted into position on a barricade or
other appropriate structure. Ideally, and in the preferred
embodiment, the unitary lens ring structure is completely molded as
a one-piece unit from a high impact polycarbonate plastic, and as
described hereinabove, the unitary lens ring structure includes as
part of the unitary structure, the ring base 112, the ring member
116, the screw mounts 118, the finger members 124 and the
peripheral flanges 126. Hence, in order to complete the mounting of
the lens assembly 16 to the top case member 14, the only
manufacturing step necessary is to position the gasket 128 about
the lower surface of the ring base 112 and then force the unitary
lens ring structure 110 into the central aperture 40 of the top
case member 14 until the peripheral flanges 126 coact with and
engage the undercut shoulder 44. The presence of the gasket 128
serves the purpose of facilitating the ability to manually rotate
the lens assembly 16 after the warning light assembly 10 has been
placed into position on a barricade, or other appropriate
structure. In addition, the gasket 128 serves the additional
purpose of a seal for preventing moisture from entering into the
internal portions of the light assembly, as well as to absorb
manufacturing tolerances so that constant tension is always
maintained by locking finger members 124 on the top case 14. Hence,
adequate friction is thereby developed so that the lens ring
structure 110 may be held in any pre-fixed or pre-set position
while still permitting easy rotation to a new position where
desired. Furthermore, it is clear that it is now totally
unnecessary to disengage the top case member 14 from the bottom
case member 12 in order to obtain access to the lens assembly 16 to
permit a worker to rotate the lens assembly 16 since no bolts or
lock pins are utilized in the connection of the unitary lens ring
structure 110 to the top case member 14.
Both the top case member 14 and bottom case member 12 are formed of
resilient polyethylene and are molded via an injection molding
process.
The circuit platform assembly 65 is also formed of a resilient
polyethylene plastic material and may also be molded via an
injection molding process. As mentioned hereinabove, the tubular
candle 90 is snap-fitted onto the base plate 66 by means of the
coaction as between the candle base 91, short extension 92 and
peripheral bead 93, with the candle holding aperture 68 provided in
the base plate 66. This construction permits the tubular candle 90
to break away from the base plate 66 in the event of impact, should
the barricade or other structure holding the light be struck by a
vehicle. Hence, manufacturing costs are minimized as well as the
cost of repairs and/or replacement parts while at the same time
providing a more improved circuit platform assembly. In addition,
it will be noted that in the assembled state, the circuit platform
assembly 65 as a sub-assembly, eliminates loose wires from the
interior portion of the light assembly by providing a circuit
housing 74 within which the circuitry 80 as well as the wiring 82
is contained. As further mentioned above, another advantage derived
from the construction of the circuit platform assembly 65 of the
present invention resides in the fact that the complete assembly
may be easily removed from a light assembly which has been struck
and damaged, and replaced by merely disengaging the top case member
14 from the bottom case member 12, removing the damaged circuit
platform assembly 65, and inserting therein a replacement circuit
platform assembly. Finally, additional commercial desirability is
achieved due to the fact that the base plate 66 is provided with
apertures which will mate with the top case members of other
presently existing warning light assemblies whereby the circuit
platform assembly 65 as a unit of production in and of itself has
interchangeability with other presently available warning
lights.
Another one of the improved features of the present invention
resides in the fact that the top case member is provided with
external test points via pins 100 having exposed pin heads 101,
positioned thereatop. As described above, the pins 100 extend down
through the pin sleeves 60 and are in electrical contact with the
electrically conductive strips 84. The pins 100 are long enough
such that when the same contact the conductive strips 84, the
strips 84 are slightly deformed when in the assembled
configuration, such deformation not only assures adequate contact
pressure but also a scrubbing action is achieved thereby to always
ensure a fresh, clean contact surface for minimum resistance
contact. It will therefore be apparent that a tester may determine
the electrical capability of both the light bulb 95 as well as the
batteries within the warning light assembly 10 by merely employing
an electrical tester and making electrical contact with the
appropriate pin heads 101. Quite clearly, a great safety factor is
thereby achieved since one may test a great many of these lights in
a very short period of time in order to determine what, if
anything, is wong with a particular light and proceed to change
either the batteries or the light bulb without having to completely
disassemble every light assembly to be tested.
From the above description, it will be apparent that an improved
warning light assembly has been provided in that the number of
parts necessary to manufacture such an assembly has been reduced,
the ease of manufacture has been improved, and a more serviceable
assembly has been provided. Furthermore, due to the unitary
construction of the lens ring structure, the method of
interconnecting the lens assembly with the top case member has been
improved in that no locking pins or bolts are necessary in order to
effect disengageable locking of the lens assembly to the case
housing, while at the same time improving the ability to rotate the
complete lens assembly throughout an arc of 360.degree.. In
addition, the warning light assembly of the present invention
provides a modularized circuit platform assembly which may be
manufactured as a sub-assembly and which may be easily inserted and
removed from an existing light without the need of splicing wires
and having to rewire in order to change such a structure.
Furthermore, the candle holding the electric light on the base
plate is mounted in breakaway relation with the base plate, thereby
to permit the assembly to withstand great impact without resulting
in damage to the various component parts; the candle, once broken
away from the base plate, may be easily reinserted therein by the
snap-fitting action provided as a result of the construction as
described herein.
In summary, a warning light assembly accomplishing all of the
foregoing objects and advantages has been developed and described
herein. While there has been described what is at present
considered to be the preferred embodiment of the invention, it will
be understood that various modifications may be made therein, and
it is intended to cover in the appended claims all such
modifications as may fall within the true spirit and scope of the
invention.
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