The present invention relates to LED beacons, and particularly to LED beacons having illumination provided by LEDs mounted upon radially disposed vanes within the beacon. The present invention is useful in that the vanes can be provided by two intersecting circuit boards having the electronics for the beacon, where heat from operation of the LEDs on such vanes can readily dissipate into the ambient air within the LED beacon, thereby avoiding the need for additional heat transfer material along the circuit boards to promote conduction of heat away from the LEDs of prior art LED beacons. The LEDs may emit light of the same color to provide an LED beacon having mono-color operation, or light of different colors to provide an LED beacon having multiple selectable colors of operation.
Light beacons have been provided with Fresnel collimating lenses which provide cylindrical beams from one or more light sources located centrally in the collimating lens on a raised structure, such as described for example in U.S. Pat. No. 3,221,162, issued Nov. 30, 1965 to Heenan et al, U.S. Pat. No. 6,425,678, issued Jul. 30, 2002, to Verdes et al., and U.S. Pat. No. 5,237,490, issued Aug. 17, 1993, to Ferng. It is important that the light from the one or more light sources fills the collimating lens of the beacon so that light from the collimating lens will exit the beacon having the desired output performance while satisfying any regulatory output requirements.
Improved optical systems have been developed to assist in directing illumination to the collimating lens using multiple LEDs mounted on different sides of a post. Such mounted LEDs direct illumination along different angles towards a cylindrical Fresnel lens via focus shifting optics, such as described in U.S. Pat. No. 8,662,702 of Mar. 4, 2014, and U.S. Pat. No. 8,840,268 of Sep. 23, 2014, both to Datz et al. However, mounting on such post is complex in that it requires four vertically disposed circuit boards with LEDs at a desired height in the beacon. Mounting further requires multiple pads of heat conductive material to carry heat away from the LEDs down to the beacon's base in order to ensure reliable LED operation. Thus, it would be desirable to provide an LED beacon with a raised structure that improves management of LED generated heat so as to avoid the need for heat transfer material along circuit boards, while assuring proper filling of the beacon's lens with LED light.
Accordingly, a principal object of the present invention is to provide LED beacons having LEDs mounted upon radially disposed vanes to convey light outwards to a lens providing the dome of the beacon.
It is a further object of the present invention to provide LED beacons having LEDs mounted upon radially disposed vanes each having opposing surfaces with LEDs providing light of one color or different colors.
A still further object of the present invention is to provide LED beacons having LEDs mounted upon four radially disposed vanes each having opposing surfaces with LEDs having one or more modes of operation of solid on, flashing patterns, and/or simulation of rotating motion of light along the 360 degree extent of the beacon's lens for projection from the beacon.
Briefly described, the present invention embodies an LED beacon having a base, a lens providing a dome over the base, and four vanes upon the base extending radially outwards from a central axis, which lies perpendicular to an upper surface of the base. Each of the vanes has two opposing surfaces, and upon each opposing surface is mounted at least one of a plurality of LEDs in proximity to the central axis to convey light outward from the beacon via the lens. The LEDs are disposed along the vanes so that the combination of light from the LEDs can be activated to convey light in 360 degrees to substantially cover the lens, or sequentially activated along the 360 extent of the lens to simulate rotating light. The lens projects the light received from the LEDs outwards from the beacon as warning signals.
The LEDs may be mounted upon each of two opposing surfaces of the vanes at a common height from the base, which is preferably approximately midway along a height of the lens from the base. Further, the lens of the beacon preferably collimates the light from the LEDs, and thus is referred to herein as a collimating lens. When the lens is a collimating lens, the common height at which LEDs may be mounted is in accordance with the focal point of the collimating lens which lies along the central axis. Other lenses than those providing collimation may optionally be used.
The vanes are formed by two circuit boards upon the base that intersect each other at a right angle at the central axis, in which each of the circuit boards provides two of the vanes extending outwards in opposite directions from the central axis. Wires extend via the base for connection to one of the vanes associated with a first circuit board to enable operation of electronics along the first circuit board and the LEDs disposed thereupon, and a second circuit board has electronics electrically connected to the electronics on the first circuit board to enable operation of the electronics on the second circuit board and the LEDs disposed thereupon. The electronics include a controller, such as a microcontroller or microprocessor, on one of the circuit boards which selectively enables the LEDs of the beacon to output light in different modes of at least solid on and flashing patterns along the 360 degree extent of the lens for projection from the beacon. Preferably, the controller can further operate the LEDs in a rotating mode, such as by continuously sequentially activating four different sets of LEDs, where each of the sets face a different direction at 0, 90, 180, and 270 degrees, respectively, about the beacon's central axis to simulate a rotating pattern of light from the beacon. Each of such sets of LEDs comprises LEDs along two different vanes that extend in opposite directions from the central axis, and face a common direction at either 0, 90, 180, or 270 degrees.
In one embodiment, a different one of the LEDs is mounted upon the four vanes along each of their two opposing surfaces in proximity to the central axis, so that a total of eight LEDs are mounted on the vanes. Each of the LEDs in such case may emit the same color of light to provide an LED beacon having mono-color operation. In another embodiment to provide an LED beacon having multicolor operation, the LEDs provide different colors of lights, and at least one of the LEDs of each different color are mounted upon the four vanes along each of their two opposing surfaces in proximity to the central axis. For example, two LEDs providing different colors of light when activated may be provided on each of the two opposing surfaces of each of the vanes of the beacon. This provides eight LEDs of each color in the beacon and thus a total of sixteen LEDs mounted on the vanes. The controller responsive to selection of one or both colors, operates LEDs of such color accordingly, such as in solid on, flashing, or rotating modes, thereby enabling selective activation of LEDs associated with each of the different colors.
While a single group of LEDs are mounted on the vanes at a common height from the base, alternatively, multiple groups of LEDs may be provided along the vanes, where each group is mounted to the circuit boards providing the vanes at a different height from the base in order to provide additional or different illumination to the lens for projection from the beacon. Such groups when numbering more than two may be equally or unequally staggered up and down along the vanes as desired.
The profile of the outer side edge of the vanes can be selected to provide a desired passage of light from LEDs to the lens for the particular application of the beacon. For example, to minimize dark or dimmed areas along lens that could be caused by vanes blockage of LED light, the vanes can each have an outer side edge with an angled opening disposed at a tilt with respect to the central axis to promote passage of light from the LEDs when activated. In another example, no such openings are present along the vanes, and the profile of the outer side edges of each vane extends along a dimension generally parallel to the central axis along at least a portion of the vane starting at a height lower than the height of the LEDs from the base to a top of the vane.
The present invention further embodies a method for providing an LED beacon having the steps of: mounting four vanes upon a base extending radially outward from a central axis which lies perpendicular to an upper surface of the base; providing on each of two opposing surfaces of the vane one or more LEDs emitting one or more different colors of light in proximity to the central axis; and selectively activating the LEDs to output light in each of the one or more colors via a lens. Such vanes preferably number four, and such mounting further has the step of forming the vanes using two circuit boards upon the base that intersect each other at a right angle, in which each of the circuit boards provides two of the vanes extending outwards in opposite directions from the central axis.
The foregoing and other objects and advantages of the invention will become more apparent from a reading of the following description in connection with the accompanying drawings in which:
Referring to
Referring to
As shown in
Referring to
Support bracket 21 may be of molded plastic material, and represents part of base 14 providing circular wall 19 and upper surface 18 upon which vanes 16 are situated. Upper surface 18 represents the upper surface of a wall 21a of bracket 21, where circular wall 19 extends upwards from wall 21a, and wall 21a extends radially outward from the base of circular wall 19 to provide an outer flange 21b. Extending downwardly from outer flange 21b are pegs 34 that are received into two holes 36 of bosses 37 extending upwards along the interior of bottom 25 of base 14. Two self-tapping screws 38 extend via holes 39 in the outer flange 21b of support bracket 21 into holes 40 of bosses 41 that extend upward along the interior of bottom 25 of base 14, so that pegs 34 and screws 38 retain support bracket 21 to base 14. Holes 39 may extend though bosses 21c (
Vanes 16 are formed by a first circuit board 42 and a second circuit board 43 which intersect at the central axis 15 at a right angle, such that each of the circuit boards 42 and 43 provides two of the four vanes 16 extending outwards in opposite radial directions from central axis 15. Circuit boards 42 and 43 are thin, such as 0.060 inches in width, and have two opposing surfaces 17a and 17b which are preferably white in color. As circuit boards 42 and 43 form vanes 16, these same reference numerals 17a and 17b characterize the opposing surfaces 17a and 17b of each of the vanes 16 as described earlier. The electronics on the circuit boards 42 and 43 for controlling and operating LEDs 20 mounted on surfaces 17a and 17b will be described later in connection with
Circuit board 42 has a slot 44 extending from its top edge 42a into which is received slot 45 of circuit board 43 extending from bottom edge 43b so that the circuit boards engage each other at a right angle with their top edges 42a and 43a, and bottom edges 42b and 43b in alignment as shown in
Preferably prior to engagement of circuit boards 42 and 43 with each other using slots 44 and 45, the two bottom ends 42d of circuit board 42 are first received in two of slots 46, and two of tabs 47 are positioned alongside circuit board 42 so that their projections 47a snap into two of the slots 48 along circuit board 42 to lock circuit board 42 in place upon base 14. Next, slot 45 of circuit board 43 is positioned into slot 44 of circuit board 42 as described earlier, such that circuit boards 42 and 43 crisscross each other in an X shape (see
A connector 50 is provided at the end of wires 29 after passing from sealing member 30 upwards via one of slots 57 along the outer flange 21b of support bracket 21, as shown in
The profile of the side edges 42c and 43c of the circuit boards 42 and 43, respectively, forming the vanes 16 can be selected to provide a desired passage of light from LEDs 20 to the collimating lens 12 for the particular application of the beacon. For example, side edges 42c and 43c of the circuit boards 42 and 43, respectively, may be contoured to provide an opening 54, which preferably forms a right or 90 degree angle disposed at or approximately 45 degree angle tilt, denoted as 55, with respect to central axis 15 as shown in
In another example of the profile of the side edges 42c and 43c of the circuit boards 42 and 43, respectively, forming the vanes 16, no such openings 54 are present along the vanes 16, as shown along the vanes 16 of
The pair of vanes 16 formed by circuit board 43 symmetrically mirror each about central axis 15, while the pair of vanes 16 formed by circuit board 42 also symmetrically mirror each other above and below tab(s) 51 for engaging connector 50. Thus, the profile of each of the vanes above and below tab(s) 51 are preferably identical to each other about central axis 15.
The LEDs 20 mounted to circuit boards 42 and 43 may be light sources, such as for example, CREE XT-E or XQE LEDs, or a Lumileds LUXEON® Rebel or LUXEON® Z LEDs, and may emit white or any other color light as desired. Heat generated during the operation of the LEDs 20 when powered to generate light is readily dissipated to the ambient air within the beacon 10 by the orientation of the LEDs on opposite surfaces 17a and 17b of circuit boards 42 and 43. Such heat dissipated is further facilitated by the use of copper land areas on circuit boards 42 and 43 around each of the LEDs 20. Thus, secondary or additional heat conductive material, as used in LED beacons having a raised post with sides formed by circuit boards that mount LEDs along the post in order to facilitate transfer to heat as described in U.S. Pat. Nos. 8,662,702, and 8,840,268, are not needed in the beacon 10 of the present invention.
Referring to
As shown in
The controller 58 operates in accordance with a program stored in its memory (ROM or RAM) to enable operation of beacon 10. For example, controller 58 may be a PIC microcontroller as shown in
The pattern of operating LEDs 20 by controller 58 can be selected by a pattern select input or line 70. By placing on input 70 signals representative of one of different values, addresses, codes, or instructions, detectable by the controller 58, one of multiple different patterns of illumination by LEDs 20 and hence output light from beacon 10 may be selected, such as solid on, or flashing at different rates or patterns by controlling enable line 59. If no signal is provided along pattern select input 70, than a default pattern is used by controller 58 as set forth in memory of the controller. The present invention is not limited to any particular means for pattern input selection to controller 58. The flashing rate is in accordance with preset on and off intervals stored in memory of the controller 58. A clock in the controller 58 is used to measure each of the flash intervals.
A synchronization line 72 is provided to controller 58. When synchronization line 72 is switched from high to low, controller 58 resets the cycle of its internal clock. Such is useful when two different LED beacons 10 need to be synchronized to each other so that they flash at the same time, or alternate with each other.
Adjustable voltage source 74 represents a voltage converter to supply power to operate LEDs 20 (in accordance with the particular manufacturer specifications of the LEDs) when enabled at a high or lower power states. A low power select line 73 is provided to controller 58. When low power select line 73 is switched to high, the controller 58 sends a signal to voltage source 74 which changes the voltage to the drive circuit 61 so that illumination from the LED beacon 10 is in a lower power state, e.g., at or approximately 50% illumination is outputted by the LEDs 20. When low power select line 73 is low, the controller 58 disables the signal to adjustable voltage source 74 so that power output to the LEDs 20 returns to the high power state. Voltage source 74 may externally receive 12/24 VDC depending on the voltage source externally available to the LED beacon 10. Thus, the five wires 29 entering connector 50 provide ground, 12/24 VDC, pattern select line 70, synchronization line 72, and low power select line 73 to the electronics on the circuit boards.
To power controller 58, a voltage regulator (not shown) is also provided in the electronics on circuit board 42 to supply +5 VDC to the input VDD of controller 58. Such voltage regulator is powered by the same input line which provides 12/24 VDC to adjustable voltage source 74. The electronics on circuit board 42 and programming of controller 58 may be the same or similar as in mono-color Star Halo® LED Beacons, but with additional drive circuit 61 connections to LEDs 20 between the two circuit boards 42 and 43 as described above. The controller 58 starts operating LEDs 20 in accordance with a selected pattern, and synchronization (if any) upon applied power to the controller 58, i.e., when external 12/24 VDC is provided via one of wires 29.
While a single group of eight LEDs 20 are mounted on the vanes 16 provided by circuit boards 42 and 43, alternatively multiple groups of eight LEDs may be provided along the circuit boards, where each group is at a different height from the base 14 in order to provide additional or different illumination to collimating lens 12. Thus, a different pattern of illumination from the beacon is provided when the LEDs of one, or more than one, of the groups are in operation. Each additional group of LEDs may be separately driven by a different enable line by controller 58 in the same manner as described above for a single group of LEDs 20 along circuit boards 42 and 43. Such groups may be staggered equally or unequally up and down along the vanes 16 as desired.
Referring to
Controller 58 outputs signals along an enable line 75a or 75b which when high (on) switches on a current source 77a or 77b, respectively, to drive current to LEDs 20 of drive circuit 76a or 76b, respectively, on circuit board 42, and when the enable line 75a or 75b, respectively, is low (off), the current source 77a and 77b, respectively, disables drive current in drive circuit 76a or 76b, respectively. Drive circuits 76c and 76d extend between circuit boards 42 and 43 using three connector pins or pads 78a provided on circuit board 42, which connect to three connector pins or pads 78b provided on circuit board 43, as shown in
By placing on pattern select input 70 signals representative of one of different values, addresses, codes, or instructions, detectable by the controller 58, one of multiple different patterns of illumination by LEDs 20 and hence output light from beacon 10 may be selected, such as solid on, or flashing at different rates or patterns by controlling enable lines 75a, 75b, 75c, and 75d. For example, if the signal on pattern select input 70 is detected by controller 58 for operating LED beacon 10 in a solid on mode, then all LEDs are activated using their enable lines 75a, 75b, 75c, and 75d until the signal on input 70 changes. However, if the signal on pattern select input 70 is detected by controller 58 for operating LED beacon 10 in a flash mode, then all LEDs 20 are periodically activated via output along their enable lines 75a, 75b, 75c, and 75d at a desired flash rate. The flashing rate is in accordance with preset on and off intervals stored in memory of the controller 58, such as every 0.5 seconds. A clock in the controller 58 is used to measure each of the flash intervals.
If the signal on pattern select input or line 70 is detected by controller 58 for operative LED beacon 10 in a rotating mode, the drive circuits 76a, 76c, 76b, and 76d are continuously sequentially activated by controller 58 so that the light from beacon 10 appears to be traveling or moving in a rotating pattern. For example, the following states 1-4 are repeated by controller 58: (1) enable line 75a is high to enabled drive circuit 76a with LEDs 20 on surface 17a of circuit board 42 and enable lines 75b, 75c, and 75d are low; (2) enable line 75c is high to enabled drive circuit 76c with LEDs 20 on surface 17a of circuit board 43 and enable lines 75a, 75b, and 75d are low; (3) enable line 75b is high to enable drive circuit 76b with LEDs 20 on surface 17b of circuit board 42 and enables lines 75a, 75c, and 75d are low; and (4) enable line 75d is high to enable drive circuit 76d with LEDs 20 on surface 17b of circuit board 43 and enable lines 75a, 75b, and 75c are low. The time intervals between successive states may be 0.5 seconds, but other time intervals may be used as stored in memory of controller 58 for selection by pattern select line 70. Thus, the perception of rotation is enabled by continuous sequential activation of each of four different sets of two LEDs 20 operated using enable lines 75a,c,b,d, where each set faces the same direction at one of four angles of 0, 90, 180, and 270 degrees about the 360 degrees circumference of lens 12. Each of the four sets of two LEDs 20 comprises LEDs 20 along two different vanes 16 that extend in opposite directions from central axis 15, but face the same common direction at either 0, 90, 180, or 270 degrees.
Other or different patterns can be provided by separately or simultaneous enabling drive circuits 76a-d as desired by programming controller 58. Other than the additional patterns available by enabling drive circuits 76a-d as described above, the operation of controller 58 is the same as described earlier in connection with
Referring to
Electronics shown in
Controller 58 outputs signals along an enable line 88a, 88b, 89a, 89b, 90a, 90b, 91a, and 91b which when high (on) switches on a current source 92a, 92b, 93a, 93b, 94a, 94b, 95a, and 95b, respectively, to drive current to their respective LEDs 20a or 20b to emit light via drive circuit 84a, 84b, 85a, 85b, 86a, 86b, 87a, or 87b, respectively, and when the enable lines 88a, 88b, 89a, 89b, 90a, 90b, 91a, or 91b, respectively, is low (off), switches the current source 92a, 92b, 93a, 93b, 94a, 94b, 95a, and 95b, respectively, to disable drive current in drive circuit 84a, 84b, 85a, 85b, 86a, 86b, 87a, or 87b, respectively. Drive circuits 86a, 86b, 87a, and 87b extend between circuit boards 42 and 43 using five connector pins or pads 96a provided on circuit board 42, which connect to five connector pins or pads 96b provided on circuit board 43, as shown in
To enable each Color A and Color B, two inputs 104a and 104b are provided to controller 58 to select one of Color A of LEDs 20a or Color B LEDs 20b, respectively, according to the selected pattern via pattern select input 70 to controller 58. Illumination may be selected utilizing light of Color A or Color B, or both, responsive to inputs 104a and/or 104b being high (enabled) or low (disabled). Thus, one of multiple different patterns of illumination by LEDs 20a and/or 20b and hence output light from beacon 10 may be selected, such as solid on or flashing at different rates or patterns of all LEDs 20a of Color A and/or all LEDs 20b of Color B, by controller 58 controlling enable lines 88a, 89a, 90a, 91a and/or enable lines 88b, 89b, 90b, and 91b, respectively, to go high or low at the same time in accordance with the selected illumination. Further, if Color A is selected and the signal on pattern select input 70 is detected by controller 58 for operative LED beacon 10 in a rotating mode, the drive circuits 84a, 86a, 85a, and 87a are continuously sequentially activated by controller 58 in the same manner as drive circuits 76a, 76c, 76b, and 76d, respectively, are enabled and disabled to provide such rotating mode as described earlier. Similarly, if Color B is selected and the signal on pattern select input 70 is detected by controller 58 for operative LED beacon 10 in a rotating mode, the drive circuits 84b, 86b, 85b, and 87b are continuously sequentially activated by controller 58 in the same manner as drive circuits 76a, 76c, 76b, and 76d, respectively, are enabled and disabled to provide such rotating mode as described earlier.
As shown in
Other than the additional patterns and Colors A and B available by using drive circuits 84a, 84b, 85a, 85b, 86a, 86b, 87a, and 87b, the operation of controller 58 is the same as described earlier in connection with
Referring to
The electronics of the beacon 10 of
As the upper and lower groups 106a and 106c of LEDs 20 are slightly above and below, respectively, the ideal height for focusing onto lens 12 at which the middle group 106b of LEDs are mounted, light from the upper and lower groups 106a and 106c of LEDs 20 is less collimated than light from the middle group 106b, as depicted by light 22a in
While an integrated raised structure in beacon 10 is preferably provided by circuit boards 42 and 43 as shown in the figures, other raised structures providing multiple vanes 16 of three or more in number, such as 3 to 6, radially extending from central axis 15 may be used which are mountable onto base 14 and similarly support LEDs 20 (or LEDS 20a and 20b) on surfaces 17a and 17b of each of the vanes.
From the foregoing description, it will be apparent that there has been provided improved LED beacons. Variations and modifications in the herein described LED beacons within the scope of the invention will undoubtedly suggest themselves to those skilled in the art. Accordingly, the foregoing description should be taken as illustrative and not in a limiting sense.
This application claims priority to U.S. Provisional Patent Application No. 62/534,521, filed Jul. 19, 2017, which is incorporated herein by reference.
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Number | Date | Country | |
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62534521 | Jul 2017 | US |