Field of the Invention

The present invention relates to a vehicle safety light of the kind used on vehicles to temporarily warn others in the vicinity of a potential hazard and relates particularly, although not exclusively, to such a vehicle safety light for use on mine sites.

Background to the Invention

In many industrial situations vehicles are required by law to carry flashing lights that can be temporarily activated to warn other vehicles and persons in the vicinity of a potential hazard. These are commonly seen at mine sites, roadworks, airports and many other industries. Many mine sites require vehicles to have different coloured flashing lights depending on site specific rules and purpose of the vehicles, e.g. it is common practice on a mine site that a vehicle that carries explosives is required to have a blue flashing light when carrying explosives and an orange flashing light when not carrying explosives. This requires the installation of two different coloured flashing lights on the same vehicle.

Furthermore, in most industries that require vehicles to have flashing lights, reversing alarms are also required. Reversing alarms are currently only sold as a separate component, requiring two separate installations.

One of the main weaknesses of current flashing light technology is that flashing lights are often required to be left on once a vehicle engine is switched off, resulting in one of two potentially hazardous situations: 1. The flashing light runs the vehicle battery flat making the vehicle inoperable; or PU 1/AU2U13/UUU9 5

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2. The vehicle operator switches the flashing light off, (so as not to run the vehicle battery flat) leaving the vehicle exposed in a situation where a flashing light is a-safety requirement.

The present invention was developed with a view to providing an improved vehicle safety light which is less susceptible to at least some of the above- noted disadvantages of the prior art.

References to prior art in this specification are provided for illustrative purposes only and are not to be taken as an admission that such prior art is part of the common general knowledge in Australia or elsewhere.

Summary of the Invention

According to one aspect of the present invention there is provided a vehicle safety light comprising: a light housing including a lens and a base adapted for mounting on the roof of a vehicle; a light source mounted in the housing and adapted to generate a flashing light signal visible through the lens; a rechargeable battery mounted in the housing for supplying electrical power to the light source; a control circuit provided in the housing and operatively connected to the light source and the rechargeable battery for controlling operation of the light source.

Advantageously the vehicle safety light is also adapted to be connected to a vehicle battery and the control circuit is designed to switch the power supplied to the light source from the vehicle battery while the vehicle engine is running, and to switch the power supplied to the light source from the rechargeable battery when the vehicle engine is not running. Preferably the control circuit also controls recharging of the rechargeable battery from the vehicle battery while the vehicle engine is running.

Preferably the light source is adapted to generate the flashing light signal in a plurality of different colours selectable by the user. Typically the light source is adapted to generate the flashing light signal in three different colours. Preferably the control circuit also controls a plurality of different flashing sequences for the flashing light signal selectable by the user. Typically the plurality of flashing sequences includes three different flashing speeds (frequencies) and the option of blinking or rotating. Preferably the light source comprises a plurality of light emitting diodes (LEDs) mounted in an array. Preferably the array of LEDs is mounted on a LED mounting panel. Advantageously the LED mounting panel is one of a plurality of substantially identical LED mounting panels arranged within the light housing so as to face in different directions. Preferably plurality of LED mounting panels is arranged within the light housing in a polygonal arrangement when viewed in plan. In a preferred embodiment five LED mounting panels are arranged in pentagonal arrangement. Typically the plurality of LED mounting panels is fixed to a support panel. Advantageously the support panel is a printed circuit board (PCB) fixed to the base of the light housing.

Typically each LED mounting panel has the plurality of LEDs mounted in a uniform array, the plurality of LEDs on each panel including a plurality of groups of LEDs of respective different colours. In one embodiment the plurality of LEDs is mounted in a rectangular array comprising a respective plurality of columns and rows of LEDs, each column of LEDs corresponding to one of the groups of LEDs of a respective different colour.

Advantageously the vehicle safety light further comprises a built-in reversing beacon operatively connected to the control circuit for signalling an audible alarm when the vehicle is reversing. Preferably the reversing beacon also includes a built-in microphone to monitor the ambient background noise, and _T _

PL; 1 /AUZUl j$/DUL>y.35

4 the control circuit adjusts the volume of the alarm accordingly to a level that best suits the environment it is operating in.

Preferably the base comprises a base housing having a control panel moulded into a side wall thereof. Typically the control panel has a plurality of control buttons co-moulded into the base housing. Preferably the base housing also includes a series of light pipes which channel light to the control panel to provide a visual indication of the operation of vehicle safety light.

Advantageously the vehicle safety light further comprises a battery level indicator which provides a visual indication when the rechargeable battery is low in charge.

Throughout the specification, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers. Likewise the word "preferably" or variations such as "preferred", will be understood to imply that a stated integer or group of integers is desirable but not essential to the working of the invention.

Brief Description of the Drawings

The nature of the invention will be better understood from the following detailed description of several specific embodiments of a vehicle safety light, given by way of example only, with reference to the accompanying drawings, in which: Figure 1 is top perspective view of a first embodiment of a housing for a vehicle safety light according to the present invention;

Figure 2 is an exploded view of the vehicle safety light housing of Figure 1 ; PU l/AUZU13 UUUy 5

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Figures 3(a) and 3(b) are top perspective views of first and second embodiments of a base cover for the vehicle safety light housing of Figure 1 ;

Figures 4(a) and 4(b) are a side elevation and bottom plan view respectively of the vehicle safety light housing of Figure 1 ;

Figure 5 is a functional block diagram for a preferred embodiment of the vehicle safety light according to the present invention;

Figure 6 is a top perspective view of a preferred embodiment of a light source for the vehicle safety light according to the present invention; and,

Figure 7 is bottom perspective view of a base panel for the light source of Figure 6.

Detailed Description of Preferred Embodiments A preferred embodiment of vehicle safety light 10 in accordance with the invention, as illustrated in Figures 1 to 7, comprises a light housing 12 including a lens 14 and a base 16 adapted for mounting on the roof of a vehicle (not shown). A light source 18 (see Figure 6) is mounted in the housing 12 and is adapted to generate a flashing light signal visible through the lens 14. A rechargeable battery 20 is also mounted in the housing 12 for supplying electrical power to the light source 18. A control circuit 22 is provided in the housing 12 and is operatively connected to the light source 18 and the rechargeable battery 20 for controlling operation of the light source (see Figure 5). Advantageously the vehicle safety light 10 is adapted to be connected to a vehicle battery (not shown) and the control circuit 22 is designed to switch the power supplied to the light source 18 from the vehicle battery while the vehicle engine is running, and to switch the power supplied to the light source 18 from the rechargeable battery when the vehicle engine is not running. The

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6 built-in rechargeable battery 20 eliminates the problem of the two potentially hazardous situations described above by supplying power to the vehicle safety light 10 from the rechargeable battery 20 when the vehicle engine is not running, and supplying power to the vehicle safety light 10 from the vehicle battery when the vehicle engine is running.

Preferably the control circuit 22 also controls recharging of the rechargeable battery 20 from the vehicle battery while the vehicle engine is running.

Preferably the light source 18 is adapted to generate the flashing light signal under the control of control circuit 22 in a plurality of different colours selectable by the user. Typically the light source 18 is adapted to generate the flashing light signal in three different colours. In the described embodiment the light source 18 is adapted to generate the flashing light signal in the colours orange, blue and red; however it will be understood that this may easily be modified to include other colours. Preferably the control circuit 22 also controls a plurality of different flashing sequences for the flashing light signal selectable by the user. In the illustrate embodiment, the plurality of flashing sequences includes three different flashing speeds (frequencies) and the option of blinking or rotating. Advantageously the control circuit 22 automatically selects a different flashing speed depending on whether the power supplied to the light source 18 is from the built-in rechargeable battery 20 or from the vehicle battery, in order to conserve power.

As can be seen most clearly Figure 2, the housing 12 of the vehicle safety light 10 comprises generally cylindrical lens 4 made of translucent material for dispersing light generated by the light source 18 into the immediate vicinity of a vehicle on which vehicle safety light 10 is mounted. Both the lens 14 and base 16 are typically made from suitably strong plastics materials formed by injection moulding. The lens 14 is fixed to the base 16 either by ultrasonic welding, gluing or spin welding to create a watertight bond between them. _p

7

The base 16 comprises a base housing 24 having a base cover 26 and an internal divider 28. The base housing 24 also has a control panel 30 moulded into a side wall thereof, as can be seen most clearly in Figure 4(a). In this embodiment the control panel 30 has three control buttons 32 co-moulded into the base housing 24. One button 32a is an ON/OFF switch for the vehicle safety light 10, a second button 32b is used to select a mode or flashing light sequence, and a third button 32c is used to select a colour.

The base housing 24 also includes a series of light pipes 34 which channel light to the control panel 30 to provide a visual indication of the operation of vehicle safety light. The light pipes 34 are also ultrasonically welded or glued into the base housing 24 to create a watertight seal. Advantageously the vehicle safety light 10 is also provided with a battery level indicator, which provides a visual indication when the rechargeable battery 20 is low in charge. Two versions of the base cover 26 are illustrated in Figures 3(a) and 3(b) respectively. The first version 26a, shown in Figure 3(a) (and in Figure 4(b)) is a base cover for a siren version of the vehicle safety light 10. It has a centre opening 36, three 3 nutserts 38 and a cable opening 40 to accommodate a siren or audible alarm (not shown) in the base housing 24. The second version of the base cover 26b, shown in Figure 3(b), is for an "In- Cab" version of the vehicle safety light 10. It has no centre opening or cable entry.

Currently available portable vehicle flashing light units require the unit to be plugged into the vehicle cigarette lighter and a cable to be run from the vehicle cigarette lighter in the cab to the flashing light, typically mounted on the roof of the vehicle. This generally results in a cumbersome cable running past the driver, potentially partially obscuring or distracting his view and creating an inconvenient obstacle when getting into and out of the vehicle. An "In-Cab" portable version of the vehicle safety light (VSL) was developed in parallel to the standard VSL 10. The "In-Cab" VSL is charged in the cab via P(J l/AU2U1 /UUUy^ 5

8 a separate cable and then can be used wirelessly on the roof of the vehicle using power supplied from the built-in rechargeable battery 20.

Preferably the light source 18 comprises a plurality of light emitting diodes (LEDs) 44 mounted in an array on a rectangular LED mounting panel 46 (see Figure 6). In the illustrated embodiment the rectangular LED mounting panel 46 is one of a plurality of substantially identical LED mounting panels 46 arranged within the light housing 12 so as to face in different directions. The plurality of LED mounting panels is preferably arranged within the light housing 12 in a polygonal arrangement when viewed in plan. In the illustrated embodiment five LED mounting panels 46a, 46b, 46c, 46d and 46e are arranged in pentagonal arrangement. Typically the plurality of LED mounting panels 46 is fixed to a support panel 48. The hollow space formed within the pentagonal arrangement of the LED mounting panels 46 can be used to house the rechargeable battery 20. Advantageously the support panel 48 is a printed circuit board (PCB) which is mounted in the base housing 24. As can be seen most clearly in Figure 7, the PCB 48 is of generally circular configuration to fit inside the follow confines of the base housing 24. Four holes 50 are provided in the PCB 48 for attaching the PCB to the internal divider 28 (see Figure 2). The various electronic components of the control circuit 22 are mounted on the underside of the PCB 48, including three switches 52a, 52b and 52c which align with the three control buttons 32a, 32b and 32c respectively on the control panel 30 on the side wall of the base housing 24.

Typically each LED mounting panel 46 has the plurality of LEDs 44 mounted in a uniform array, the plurality of LEDs 44 on each panel including a plurality of groups of LEDs 44 of respective different colours. In the illustrated embodiment the plurality of LEDs 44 is mounted in a rectangular array comprising a respective plurality of columns and rows of LEDs. Each column of LEDs 44 corresponds to one of the groups of LEDs of a respective different colour, i.e. in this case there are three columns of LEDs 44, corresponding to the colours orange, blue and red. Hence, if it is desired to

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9 have a blue flashing light then only the column of blue LEDs 44 on all five LED mounting panels 46 will be illuminated by the control circuit 22. On the other hand, it an orange flashing light is required, then only the column of orange LEDs 44 on all five LED mounting panels 46 will be illuminated by the control circuit 22.

If the flashing sequence (mode) selected is rotating light, then the corresponding column of LEDs 44 on each LED mounting panel 48 is separately illuminated in a rotating sequence. On the other hand, if the flashing sequence (mode) selected is blinking light then the corresponding column of LEDs 44 on all five LED mounting panels 46 are illuminated simultaneously in a flashing sequence at the appropriate speed. Because the LEDs 44 draw much less power than a conventional light globe, and there are no moving parts in the VSL 10, it can function for an extended period on the power supplied from the rechargeable battery 20. Advantageously the vehicle safety light further comprises a built-in reversing beacon 60 operatively connected to the control circuit for signalling when the vehicle is reversing. Preferably the reversing beacon 60 includes an audible reversing alarm 62. Advantageously the reversing beacon 60 has a built-in microphone 64 to monitor the ambient background noise, and the control circuit 22 adjusts the volume of the alarm 62 accordingly to a level that best suits the environment it is operating in. This will be beneficial in situations such as a mine site where large heavy equipment is operating and a loud reversing beacon is necessary. But if the same vehicle is operating in an urban environment, a quieter alarm is more suitable. Typically the control circuit 22 will also automatically select an appropriate flashing sequence for the light source 18 when the reversing beacon 60 is activated.

Now that preferred embodiments of the vehicle safety light have been described in detail, it will be apparent that the described embodiments provide a number of advantages over the prior art, including the following: υΐ/Αυζυΐ /ϋϋϋ935

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(i) The built-in rechargeable battery avoids the problems associated with accidental run-down of the vehicle battery when the vehicle is not running.

(ii) The light flashes at different speeds dependent on whether the VSL is using the built-in rechargeable battery or using the vehicle battery. This allows an observer to tell whether a vehicle is switched on or off at a glance or from a distance.

(iii) The built-in reversing beacon combines two devices in one reducing costs and the inconvenience of separate installations.

(iv) The LEDs employed as the light source provide a low-power flashing light with various colours and sequences easily provided in the one unit.

(v) The absence of moving parts makes the VSL a more robust unit requiring less maintenance and/or repairs.

It will be readily apparent to persons skilled in the relevant arts that various modifications and improvements may be made to the foregoing embodiments, in addition to those already described, without departing from the basic inventive concepts of the present invention. For example, other types of low-power light emitting devices may be employed for the light source. LEDs are particularly advantageous as they already come in different colours. Therefore, it will be appreciated that the scope of the invention is not limited to the specific embodiments described.