Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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ELONGATED LIGHT EMITTING DIODE LIGHTING SYSTEM
Field of the Invention
The present invention relates to an elongated lighting system,
preferably of discrete length, i.e., in the form of modular units. The
elongated
lighting system is sufficiently robust to survive being placed in a road or
airport
taxiway. It may have a convex, curved top surface that sheds rainwater and,
in conjunction with wheeled vehicles, is self-cleaning. The elongated lighting
system has light emitting diodes (LEDs), or other alternate light sources or
electronics, on an elongated support which may act as a heat sink, connected
to a pair of electrical conductors of length equal to or less than the
elongated
lighting system. The LEDs and electrical conductors are all embedded into an
opaque, semi-transparent, or a mixed transparent and opaque plastic housing
preferably by moulding. An electrical source may be connected externally to
the plastic housing, but in another embodiment may be provided internally.
Background of the Invention
Painted lines and other markings on the pavements are important
safety devices for guiding pedestrians, aircraft, road vehicles and other
modes
of transportation. At night, or during heavy rainstorms, fog, snow, ice etc.,
there can be major problems in trying to view these markings that often
apparently completely disappear. This leaves pilots and motorists confused,
with difficulty in maintaining their position in relation to obstacles or
other
vehicles.
Elongated lighting systems are generally known. With regard to some
examples, the elongated lighting system is typically in the form of a linear
extrusion with encapsulated light emitting diodes (LEDs). Such lighting
systems are installed in roads, airport runways and the like as a pavement
inset, forming a lit guiding system for vehicles and people which reduces
confusion and increases safety by making critical markings on the pavement
visible in most weather conditions.
Elongated lighting systems usually require a channel support system
that is embedded in or on the mounting surface and which accommodates the
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elongated lighting system. If used, the channel support system must protect
the integrity of the elongated lighting system, permit easy installation of
the
elongated lighting system and, if necessary, permit repairs to be carried out.
Elongated lighting systems with LEDs are known. Examples of such
systems are described in Canadian patent application 2 182 548, published
March 01, 1997, and Canadian patent application 2 264 886, published March
12, 1998. Such systems are integrally formed with LEDs connected to a pair
of electrical conductors by bus elements, all embedded in an extruded plastic
material that completely encapsulates the LEDs and bus elements. The
lighting systems are manufactured by feeding bus elements and circuitry with
the LEDs to an extruder and co-extruding the elements and circuitry with a
thermoplastic material to encapsulate and embed the bus elements and LED
circuitry.
Alternative elongated lighting systems are required, especially to
provide for flexibility in lighting, both as to direction and provision of
semi-
continuous lighting, and to permit the lighting to be embedded at or above the
mounting surface as may be required.
Summary of the Invention
A modular elongated lighting system with flexibility in the lighting is
provided. Accordingly, one embodiment of the present invention provides a
module for an elongated lighting system, the module being of discrete length
and having a plurality of LEDs on an elongated support. The module has
LEDs connected to a pair of electrical conductors, the electrical conductors
having a length equal to or less than the discrete length of the module. The
module is moulded with the LEDs with elongated support and electrical
conductors embedded in transparent, opaque, semi-transparent or mixed
transparent and opaque plastic.
Another embodiment of the invention provides a module for an
elongated lighting system, the module being of discrete length and having a
plurality of light emitting materials or devices, detection devices or power
generating and/or storage devices on an elongated support. The module has
the materials or devices connected to a pair of electrical conductors, the
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electrical conductors having a length equal to or less than the discrete
length
of the module. The module is moulded with the materials or devices,
elongated support and electrical conductors embedded in transparent,
opaque, semi-transparent or mixed transparent and opaque plastic.
A further embodiment of the present invention provides an elongated
lighting system comprising a plurality of modules of discrete length arranged
end-to-end. The modules are connected to a source of electricity provided by
electrical cables disposed beneath the modules. Each of the modules have a
plurality of LEDs on an elongated support, the LEDs being connected to a pair
of electrical conductors having a length equal to or less than the discrete
length of the module. The modules are moulded with the LEDs, elongated
support and electrical conductors embedded in transparent, opaque, semi-
transparent or mixed transparent and opaque plastic.
A still further embodiment of the present invention provides an
elongated lighting system comprising a plurality of modules of discrete length
arranged end-to-end. The modules generate electricity and light, using
embedded piezoelectric devices or solar panels. Preferably the modules use
embedded or external electrical storage capacity using batteries, capacitors,
or other electrical storage devices. The modules have a plurality of LEDs on
an elongated support. The LEDs are connected to a pair of electrical
conductors having a length equal to or less than the discrete length of the
module. The modules are moulded with the LEDs, elongated support and
electrical conductors embedded in transparent, opaque, semi-transparent or
mixed transparent and opaque plastic.
Another embodiment of the present invention provides an elongated
lighting system comprising a plurality of modules of discrete length arranged
end-to-end. The modules are energized by an induced voltage using an
embedded magnetic core and coiled wire. The modules have a plurality of
LEDs on an elongated support, the LEDs being connected to a pair of
electrical conductors having a length equal to or less than the discrete
length
of the module. The modules are moulded with the LEDs, elongated support
and electrical conductors embedded in transparent, opaque, semi-transparent
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or mixed transparent and opaque plastic.
Brief Description of the Drawings
The present invention is illustrated by the embodiments shown in the
drawings, in which:
Fig. 1 is a schematic representation of a plan view of a module of the
elongated lighting system;
Fig. 2 is a schematic representation of a side view of the module of
Fig. 1;
Fig. 3 is a schematic representation of LEDs on a support;
Fig. 4 is a cross-section of the module of Fig. 1, through line A-A;
Fig. 5 is a plan view of a module of the present invention;
Fig. 6 is a plan view of a second module of the present invention;
Fig. 7 is a schematic representation of a cross-section of a module of
the invention in a channel system;
Fig. 8 is a schematic representation of a cross-section of a module of
the invention in an alternate channel system;
Fig. 8A is a schematic representation of a cross-section of a module of
the invention in a channel system with an alternate duel locking, key shaped
base;
Fig. 8B is a schematic representation of an alternate channel system
of a cross-section of a module of the invention with an alternate single
locking,
key shaped base in an alternate channel system;
Fig. 9 is a schematic representation of a cross-section of a module of
the invention in a further alternate channel system;
Fig. 10 is a schematic representation of the embodiment of Fig. 7
anchored in ground;
Fig. 11 is a schematic representation of the embodiment of Fig. 9
anchored to the ground;
Fig. 12 is a schematic representation of a cross-section of an alternate
filler pad;
Fig. 13 is a schematic representation of an alternate channel system
for the modules of the invention;
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Fig. 14 is a schematic representation of wiring on a ribbon;
Fig. 15 is a schematic representation of a locking module for use with
the modules of the invention; and
Fig. 16 is a schematic representation, in exploded view, of an alternate
5 module of the invention.
Detailed Description of the Invention
The present invention may be used with LEDs or other lighting or
electrical or electronic elements. Examples of the latter include laser
diodes,
incandescent bulbs, electroluminescent strips, road condition sensors,
weather condition sensors, piezoelectric devices, smart detectors of
stationary
vehicles or vehicle speed, axle load measuring devices, visibility detectors,
and the like. In addition, light-emitting plastic compositions, polymers or
organic substances may be used. Any of the above mentioned light-emitting
devices can be optically controlled. In addition, the light-emitting devices
may
have a lens system associated therewith such as a symmetric or asymmetric,
fresnel or other single or combination of lenses, or tensing devices, or
tensing,
holographic, micro-grooved film, or other devices for directing or partially
directing the emitted light in a particular direction or pattern. Such tensing
systems may be embedded, formed as part of the light emitting devices,
incorporated with the other electronics or formed as part of a pattern imposed
on or in the transparent, opaque, semi-transparent or mixed transparent and
opaque plastic portion. The tensing system may be located adjacent to the
transparent, opaque, or semi-transparent or mixed transparent and opaque
plastic. The tensing system may form a portion of a cover portion.
Permanent or electrical magnets, radar reflective or absorbing
materials, lights or electronics may similarly be embedded to provide
guidance for machine vision, computer controlled, automated vehicles,
adapted to guide themselves along highways with or without passengers.
However, the present invention will be particularly described herein with
respect to use of LEDs, which is the preferred embodiment.
Fig. 1 shows a module generally indicated by 1. Module 1 has three
LEDs, shown as 2A, 2B and 2C. Each of the LEDs 2A, 2B and 2C are
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located on a support 3. Support 3 may be made of any convenient material,
but is most preferably a metallic material, and especially a metallic material
that will act as a heat sink. Preferably, the metallic material may be bent or
moulded to allow for material expansion or shrinkage or to reduce the
temperature of a particular shape, and will retain that shape. The heat sink
may be desirable during manufacture to protect the LEDs against the heat
during the moulding process by reducing the temperature applied to the
LEDs, as discussed herein and for the longevity of the LEDs thereafter. The
heat sink is also important as it may also be used to anchor the LEDs in a
particular orientation during manufacture.
LEDs 2A, 2B and 2C have first electrical connectors 4A, 4B, 4C and
4D. Electrical connector 4A is connected to LED 2A through LED connector
9. LED 2A is further connected to electrical connector 4B. Electrical
connector 4B is then connected to LED 2B, which in turn is connected to
electrical connector 4C. Electrical connector 4C is connected through LED
2C to electrical connector 4D.
First electrical conductor 5 and second electrical conductor 6 are
laterally outside or distal to electrical connectors 4A-4D. First electrical
conductor 5 is connected to electrical connector 4A through resistor 8A, and
similarly electrical 4D is connected to second electrical conductor 6 though
resistor 8B. Electrical resistors 8A and 8B may be used to control the current
passing through the LEDs. Alternatively, one of resistors 8A and 8B may be
a resistor and the other may be replaced with simple electrical connection.
Alternatively, other components (e.g., a diode to block reverse voltage) may
be substituted for the resistor, for different functionality.
As is illustrated in Fig. 1, module 1 is an elongated module. LEDs 2A,
2B and 2C are disposed down the central section of the module with electrical
connectors 4A-4D located parallel to and laterally outside the LEDs. First
electrical conductor 5 and second electrical conductor 6 are distal to
electrical
connectors 4A-4D. It will be noted that the LEDs, electrical connectors 4A-
4D, first electrical conductor 5 and second electrical conductor 6 are aligned
in parallel, which is the preferred arrangement, but may also be moved
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vertically, in that first electrical conductor 5 and second electrical
conductor 6,
may be located above or below the other components. All of the electrical
components are embedded in transparent, opaque, semi-transparent or
mixed transparent and opaque plastic 11. Furthermore, the electrical
components terminate prior to end 12 of the transparent, opaque, semi-
transparent or mixed transparent and opaque plastic 11, and there is no
connection through end 12 to an adjacent module (not shown), unless an
external end connector system is used which connects first electrical
conductor 5 and second electrical conductor 6 to the next section.
It will be further noted that the LEDs 2A-2C, and electrical connectors
4A-4D, form a single unit of LEDs, and are separated from a subsequent unit
of LEDs, of which only electrical conductors 7A and 7B are shown in Fig. 1.
LEDs 2A, 2B and 2C are electrically disposed in series, yet electrically in
parallel in respect to other LED units or circuits. It is understood that LED
circuits will be made up of a number of LEDs and although Fig.1
demonstrates a three LED circuit, other circuits with differing numbers of
LEDs and other components are also contemplated. The region between the
units of LEDs is shown as having attachment orifice 10 through transparent,
opaque, semi-transparent or mixed transparent and opaque plastic 11.
Attachment orifice 10 is optional, and would most commonly be present to
permit anchoring to the mounting surface; especially in embodiments in which
the elongated lighting system would be used at least partially above a
mounting surface, to permit anchoring to the mounting surface.
Fig. 2 shows a side view of the module of Fig. 1. In the embodiment of
Fig. 2, the LEDs 2A-2C are shown at a higher location than that of the
corresponding electrical connectors 4A and 4C and the electrical conductor 5.
This is for convenience and clarity of illustration, and in practise the LEDs,
electrical connectors and electrical conductors would most commonly be
aligned in a co-planar arrangement, although, as previously noted, this is not
essential. First electrical source conductor 13 is shown as being disposed
beneath transparent, opaque, semi-transparent or mixed transparent and
opaque plastic 11, and is not part of module 1.
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Fig. 3 shows LEDs 20A-20D located on LED support 21. In this
embodiment, LED support 21 is in a non-linear shape. LED 20B is shown as
being located in the trough of LED support 21, whereas LED 20C is shown as
being on a peak of LED support 21. Such an alternate arrangement may be
provided so that LEDs 20B and 20C provide light in different perspectives
(e.g., the differences in vertically positioning of the LEDs will provide some
change in the visibility of the light). LED 20A is shown on a rising section
of
LED support 21, oriented towards the left as viewed, and LED 20D is shown
as being on a falling section of LED support 21, and thus oriented towards the
right as viewed. Such LEDs would tend to shine along the length of the
module i.e. axially, rather than shine directly upwards. Whilst a particular
shape is shown in Fig. 3, it will be understood that many other shapes exist,
both with sharp corners and/or with simple curves, which may be essential for
a particular end use, or to achieve a particular light orientation. Similarly,
a
wedge shape or some other physical object may be used to orient the LEDs
to give directionality to the light. In another embodiment a tensing system or
device may be used to provide directionality or pattern to the light.
A twist may be imposed on LED support 21 so that LEDs 20A-20D
illuminate away from the axis of LED support 21. Thus the LEDs may be
disposed to shine directly upwards, in a longitudinal (axial) direction along
the
axis of LED support 21 or transverse to that axis. Such different
arrangements would be used in different end uses of the elongated lighting
system (e.g., roadways versus crosswalks) where the preferred directions of
the lighting are different.
Fig. 4 shows a cross section of module 1 of Fig. 1 though line A-A. In
this illustration, the LEDs, electrical connectors and electrical conductors
are
shown in substantially a co-planar arrangement. In other embodiments the
arrangement is not coplanar. In other words, the electrical conductors are
offset in a vertical and/or horizontal plane. Second electrical conductor 6 is
shown having connector 22 to second electrical source conductor 14. It
should be understood that first electrical source conductor 13 would also have
a connector to first electrical conductor 5, which is not shown in the cross-
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section of Fig. 4.
Figs. 5 and 6 show two different arrangements of LEDs within module
1. In Fig. 5, LEDs 23A-23D are in a spaced apart relationship, compared with
LEDs 25A-25D of Fig. 6. In both instances, the LEDs may be separated from
further LEDs in the same module by an orifice 10, which is optional. In Fig.
5,
LEDs 23A-23D are separated from LEDs 24A-24D (not shown) of the same
module. In Fig. 6, LEDs 25A-25D are separated from LEDs 26A and 26B of
the same module. As an illustration of the different LED spacing, the spacing
gap between LED 23A and 23B may be about 60 mm, whereas the spacing
between LED 25A and 25B may be about 30 mm. It will be understood that
any convenient spacing may be used, but differences in spacing may be used
to provide different intensities of light from the elongated lighting system.
The transparent, opaque, semi-transparent or mixed transparent and
opaque plastic should have a low vapour transmission rate for moisture, be
stable with respect to ultraviolet light, be tough, be impact resistant,
especially
at low temperatures (e.g., as low as -60°C or lower) to which the
module may
be subjected during use. It is understood that the plastic may contain
suitable
stabilizers, colours, modifiers and other chemicals to improve resistance to
loading, abrasion, cuts, UV weathering, chemical attack, and/or changes to
the transparency of the plastic. Examples of transparent, opaque, and semi-
transparent plastics include Surlyn~ ionomer resin from G.E., other ionomers,
high-density polyethylene and polychlorotrifluoroethylene, and nylon. It
should be understood that dyes, holographic, or grooved or etched material
may be added to achieve any level of transparency.
Fig. 7 shows a module 1 of the present invention located in a channel
in ground 50. Module 1 is shown in cross-section, but some parts of the
module have been omitted for clarity of the drawing. Module 1 is located
between arms 31 and 32 of channel 30, and supported by central support 34
and lateral or distal supports 33 and 35. Channel 30 has two grooves therein,
30 36 and 37, in which are located electrical source conductors 38 and 39.
Electrical source conductor 38 is separated from module 1 by a filler pad 40.
Similarly electrical source conductor 39 is separated from module 1 by filler
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pad 42. These filler pads provide support to module 1 across the gap left by
the grooves. Power is transferred from the electrical conductors 38, and 39 at
chosen positions using a knife-edge connector block instead of the filler
pads.
An alternate connector system may be an embedded cylinder within the
5 transparent, opaque, semi-transparent or mixed transparent and opaque
plastic 11, pre-attached to the electronic circuit 5 and 6 of the elongated
lighting system. As such, the underneath connector system would have a
conductive screw type connector to bring power to the system from electrical
conductors 39 and 38.
10 Fig. 8 shows a module 1 located in a channel that is similar to the
channel shown in Fig. 7, but in which the filler pads 40 and 42 have been
omitted. Fig. 8 also shows the module in a channel in a typical end-use
position, located and embedded in mounting surface 50 to a depth that
corresponds with the top of the module. Such positioning of a module in a
channel in the mounting surface is described herein as the preferred
embodiment, useful for roads, runways and other areas. It is located in a
manner that is unobtrusive to traffic using the surface, slightly below the
surface such that it permits the surface to be cleared of snow, ice or the
like
by snowplows or brushes, which pass over it without damage.
Fig. 8A shows a module 1 located in a channel that is similar to the
channel shown in Fig. 7, but in which the filler pads 40 and 42 have been
omitted and module 1 has been shaped with dual legs 152 and 151 to fit into
the channel. Fig. 8A also shows the module in a channel in a typical end-use
position, located and embedded in mounting surface 50 to a depth that
corresponds with the top of the module. Such positioning of a module in a
channel in the mounting surface is described herein as the preferred
embodiment, useful for roads, runways and other areas. It is located in a
manner that is unobtrusive to traffic using the surface, slightly below the
surface such that it permits the surface to be cleared of snow, ice or the
like
by snowplows or brushes, which pass over it without damage.
Fig. 8B shows a module 1 located in a channel that is similar to the
channel shown in Fig. 7, but in which the filler pads 40 and 42 have been
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omitted. Module 1 is located between arms 31 and 32 of channel 30, and the
module 1 and distal supports 33 and 35 of channel 30 have been elongated
so module 1 rests on these sections. Module 1 has also been shaped with a
single leg 153, to fit into the channel, which has electrical source
conductors
38 and 39 embedded in channel 30. Fig. 8B also shows the module in a
channel in a typical end-use position located and embedded in mounting
surface 50 to a depth that corresponds with the top of the module. Such
positioning of a module in a channel in the mounting surface is described
herein as the preferred embodiment, useful for roads, runways and other
areas. It is located in a manner that is unobtrusive to traffic using the
surface,
slightly below the surface such that it permits the surface to be cleared of
snow, ice or the like by snowplows or brushes, which pass over it without
damage.
Fig. 9 shows a module 1 in a channel system that is similar to that of
Fig. 7, except that the channel is intended to be located above the mounting
surface 50. In this embodiment of the channel, arms 43 taper towards the
mounting surface 50, and provide a smooth transition at 44 with the mounting
surface 50. In this manner, module 1 may be located above the mounting
surface level, particularly in a temporary manner with the channel providing
for ease of movement of vehicular traffic over module 1. A variety of degrees
of taper may be used, with varying ease for passage of traffic over the
module.
In the embodiment of Fig. 9, the channel is shown as being anchored
to the mounting surface through orifice 45 using pin 46. As an alternative, a
pin may be placed through orifice 47, which is a centrally located orifice
within
the channel. Orifice 47 would normally be located such that the pin may be
passed through orifice 10 of module 1, as shown in Fig. 1, through orifice 47
of the channel to anchor the system to the ground.
The embodiments shown in Figs. 7, 8, 8A and 8B illustrate the
invention in a channel system embedded in the ground. A groove is cut in the
ground surface at a width and depth sufficient for the channel support system
to be inserted in the ground. It is understood that arms 31 and 32 would
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typically be at a level with, or slightly below the ground, so that vehicles
may
readily pass over the elongated lighting system. In particular, snow-clearing
vehicles at airports and on roadways need to be able to pass over the
elongated lighting system without the blades from such vehicles snagging on
the channel support system.
In the embodiments shown in Figs. 7, 8, 8A and 8B, the channel
support system is placed within the groove in the ground surface, and held in
place. For example, this may be done mechanically by drilling a hole through
the complete system and inserting fasteners (e.g., flush mounted expansion
bolts) using hard setting epoxy, or other systems disclosed herein and/or by
having adhesive underneath to assist with retention of the channel support
system within the groove in the ground.
In the embodiment shown in Fig. 9, the channel support system may
be partially embedded within a groove in the ground or mounted above
ground level i.e. located on the surface of the ground. If the channel support
system is partially embedded, it may be held in place by methods described
above for the embedded system. Alternatively, and especially when located
completely above ground level, the channel support system may be anchored
in position using spikes or other means that pass through the channel system,
with a flush or recessed fitting with the channel system, to anchor the system
to the ground. The tapered sections (see, e.g., 44) would normally be
anchored, using fasteners (e.g., chemical and/or mechanical fasteners).
It is understood that the tapered sections 44 may be used with any
embodiment shown herein. Indeed in the embodiment shown in Fig. 9, the
elongated lighting system may be partially embedded within a groove in the
ground or mounted above ground level, i.e., located on the surface of the
ground. If the elongated lighting system is partially embedded, it may be held
in place by methods described above for the embedded system.
Alternatively, and especially when located completely above ground level, the
elongated lighting system may be anchored in position, with or without an
accompanying U channel, using spikes or other means that pass through the
system, with a flush or recessed fitting with the system, to anchor the system
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to the ground. The elongated lighting system may be made with tapered
sections (see, e.g., 44) that would normally be anchored, using fasteners
(e.g., chemical and/or mechanical fasteners).
Fig. 10 shows the embodiment of Fig. 7 with screw orifice 49 in the
channel system, screw orifice 51 in the lighting system and screw 53 inserted
therein. It will be noted that screw 53 is flush with the upper surface of the
lighting system, but it may be recessed. It will be noted that LEDs 2B and
electrical connectors 5 and 6 are absent, as screw orifice 51 is located
between units of LEDs.
Fig. 11 shows a similar system in the embodiment of Fig. 9 (i.e. with
the system above ground). In Fig. 11, screw 53A in screw orifice 51 extends
through the housing. In Fig. 10 discussed above, screw 53 does not. Screw
53A is in use in anchoring the channel system of Fig. 11. In Fig. 10, screw
53 is in use in attaching the elongated lighting system to the channel system.
One or both types of screw systems would be used, depending on the
particular end-use.
The present invention has been particularly described herein with
reference to use of a channel support system having a pair of spaced apart
grooves in which electrical conductors are located. However, one groove may
be provided, with both electrical conductors therein, or more than two grooves
may be provided so that additional wiring or cable may be installed.
The channel support system may be formed from a variety of materials.
For instance, the channel support system may be formed from rubber
materials including recycled rubber EPDM (Ethylene-Propylene-Terpolymers
Rubbers), EPM (Ethylene-Propylene-Copolymer Rubbers), neoprene,
stainless steel, titanium, nickel coated steel, or any other non-corroding
metal
or plastic. These need to be of sufficient hardness and corrosive resistance
to
withstand normal use in the particular location of use.
The channel support system may be made of a variety of techniques,
especially moulding and extrusion. For instance, if the channel support
system has a degree of flexibility, the channel support system may be
extruded in continuous lengths and stored on rolls prior to installation. In
this
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manner, a long length of channel support system may be installed, and
modular lengths of an elongated lighting system subsequently installed.
However, in other embodiments, the channel support system is moulded or
extruded in a modular length, and in particular in a modular length that
corresponds to the modular length of an elongated lighting system.
Fig. 12 shows an alternate embodiment of a filler pad, known as a
packer and generally indicated by 52. Packer 52 is shown located within a
channel system, shown in dotted lines. Packer 52 has upper plate 54, which
rests on distal support member 33 and 35 of a channel support system.
Upper plate 54 has two legs 56 and 58 that extend downwards into grooves
36 and 37, respectively. Legs 56 and 58 extend only partially into grooves 36
and 37, to permit electrical conductors (not shown) to be located in grooves
36 and 37 as described herein.
Packer 52 is shown with upper adhesive strip 60 and lower adhesive
strip 62. Upper adhesive strip 60 facilitates retention of an elongated
lighting
system on packer 52. Lower adhesive strip 62 facilitates retention of packer
52 in a channel system.
Packer 52 would be made of a material that will support, cushion and
hold the module 1 in place.
Fig. 13 shows an alternate embodiment of a channel system. U-
shaped channel 70 has recess 72 that would accommodate an elongated
lighting system. Arms 74 and 76 of U-shaped channel 70 and base 78 form
recess 72. Base 78 has two electrical conductors 80 and 82 embedded
therein. Electrical access to electrical conductors 80 and 82 would be by
penetration of base 78. U-shaped channel 70 may be provided with distal
support members (not shown), to provide for a filler pad or packer of
appropriate shape to be inserted (e.g., to provide cushioning or other effects
for the elongated lighting system). U-shaped channel 70 may be provided
with a connector system at each end thereof.
The channel system may be a conduit for other wires or for fibre optic
cable utilized by the module, or may provide a right of way for said wires,
fibre
optics or cable. An additional groove may be required to accommodate such
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wires or cable.
The channel system may also be provided with a base suitable for
attachment to a particular mounting surface. For instance, if the surface was
steel (e.g., the deck of a ship) a steel base or channel may be provided or
the
5 material of the channel selected or treated to enhance adhesion to the
mounting surface.
In embodiments of the invention, the channel system has a roughened
or keyed surface for retention of modules. In particular, the modules and
channel system have co-operative keying elements to assist in retention of
10 the modules.
One advantage of the channel system is that it allows for relatively
easy access to the coated electrical conductors 25 and 24, so replacement of
modules of the elongated lighting system can be readily carried out.
The channel system, including an elongated lighting system of the
15 invention, provides a protective shell for the electrical power
distribution for
the lighting. This is especially useful in environments that impose high
physical or other demands on the system, including use on roads. The
system also provides quick and easy accessibility to the electrical power
conductors, without digging for recovery, permitting maintenance or up-grades
of the system that are less time consuming and less disruptive to users.
The channel system used in association with the lighting system of the
invention needs to be adapted to the particular end-use. In particular, the
channel should be sealed to the ground (e.g., road) whether concrete, asphalt
or other surface. The channel system also assists in excluding water from the
lighting system. A continuous groove also alleviates potential problems. In
embodiments of the invention, particularly where the end-use is outside (e.g.,
in a road or runway) the channel system is provided at intervals with a
groove,
slot, orifice or the like to permit relief from any water pressure that should
occur within the channel system or exterior thereto in the groove cut into the
ground surface.
In addition, the channel system should provide cushioning when loaded
(e.g., when a vehicle passes over the channel system and the elongated
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lighting system). The channel system should also allow the lighting to be
removed if road repairs are required, while providing secure anchoring for the
system.
Electrical power connection from below the light system permits
multiple power connections for redundancy and repair. It also increases the
electrical connection. For example, during use, the weight of a vehicle would
tend to urge the light system downwardly potentially improving the electrical
connection. Different sizes of filler or packing permit use of wire of
different
diameters.
The modules disclosed herein are manufactured in a moulding
process, as this permits flexibility in manufacture. While a multi-stage
moulding process may be used, a single stage process is preferred. The
electronic circuitry is placed into the cavity of a mould of an injection
moulding
apparatus, and held in position in the mould. Molten thermoplastic polymer is
injected into the cavity to fully encapsulate the electronic circuitry.
The LEDs are temperature sensitive, and exposure to high
temperatures can lead to degradation or degeneration of the LEDs, and
consequent loss of useful life or even failure. Thus, the thermoplastic
polymer
needs to have a relatively low melting point, consistent with the other
required
properties of the plastic (e.g., clarity, toughness etc.). The heat sink
described herein assists in reducing the temperature to which the LED is
subjected and/or decreases the time that the LED is at the maximum
temperature that the LED attains.
In another embodiment, the electronic circuitry includes contacts for
providing electricity from the electrical supply conductors. These contacts
would then act as supports while the circuitry is in the cavity.
Alternatively,
the contacts may be in the form of a pin that is gripped by the mould or
recessed into an orifice with the mould, from the moulded part.
Encapsulation of the electronics of the module in a single piece, solid,
transparent, opaque, semi-transparent or mixed transparent and opaque
plastic matrix provides an enclosure for the electronics that it is safe from
environmental effects. In a preferred embodiment as disclosed herein, the
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electronic circuit is mounted on a platform ribbon made of the same material
as the plastic used in the encapsulation. During an injection moulding
process, the ribbon melts and blends into the melt that is injected in the
injection moulding process, so that no layers are formed within the module,
although an interface line might exist. The molten plastic flows around all
components to give complete encapsulation.
As alternatives to injection moulding, extrusion or casting or other
forming techniques may be used, depending on the particular components of
the lighting system. For instance, a base having electrical conductors and
modules of components may be embedded within a linear plastic moulding,
and subsequently mated with modular lighting, intelligent or smart sensors or
communicating devices, to be customized to a particular end-use.
In other embodiments, the circuits are set down on hard circuit boards
made from traditional materials attached to the electrical conductors 5 and 6.
In alternate embodiments, the plastic under the LEDs may be opaque,
translucent or be reflective. For example, such plastic may contain flake
aluminium, glass beads, luminescent or coloured paint, lenses, holographic,
microgrooved film, or other devices or other material with light guiding or
reflective properties to enhance visibility.
In alternate embodiments, there may be a moulded section of plastic
without any electronics or LEDs embedded within it, which would act as a
passive "blank" or 'filler". This "filler" may be opaque, translucent or be
reflective. For example, such plastic may contain flake aluminium, glass
beads, luminescent or coloured paint, lenses, holographic materials or
devices, microgrooved film, or other devices and material with light guiding
or
reflective properties. Such a "blank" system would be used as a "filler" for
areas that do not require active electronics or LEDs, as on roads, airfields
or
helicopter pads, where continuous lit markings are not desired, and where a
dashed, broken, or skip line marking is required. A continuous channel would
be installed, with intermittent active and passive elements.
With the active systems, the LEDs may be further mounted on a
support, which should be a metallic support that will act as a heat sink. In
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addition, the support may be fabricated so that it may be twisted, bent or
otherwise shaped to provide for differences in the directionality of the LEDs.
While the support may be continued for the full length of the module, it may
be
more convenient to utilize short lengths corresponding to the units of the
LEDs. In this way, sections of the module may be attached to a mounting
surface between various units of LEDs, modules may be cut through at such
point, or different orientations of LEDs may be provided in the same module.
It will be appreciated that the length of the modules may be varied, including
by being severed between units of LEDs, as the electrical source conductors
are located underneath the plastic material of the module. Thus, there is no
need for any type of connector between modules.
The support provides a heat sink for the LEDs during fabrication, as
well as during operation. In both instances, this protects the LED from
excessive heat and premature degeneration of the life of the LED.
The plastic should preferably be a plastic that will bond to the metal of
the electrical conductors and the support, to assist in ensuring waterproof
integrity of the module so that water does not migrate along the interface
between the metal and the plastic.
Each unit of LED lamps is wired in parallel and is independent of the
next unit of LEDs within the module. Thus, any failure of any electrical
connection or LED within a unit of LEDs does not affect the operation of other
units of LEDs within the same module, or within any other module that is
being used.
The circuit component used in the manufacture of the modules of the
present invention must be capable of being subjected to the fabrication
process, and still be capable of functioning in an acceptable manner,
especially exhibiting a long life with minimal maintenance. The physical and
other demands placed on the circuit component during the manufacturing
process will vary depending on the particular type of process that is used.
In one embodiment, a linked wire construction may be used for the
circuit component. In this construction, the wire is in the form of copper
traces
laid down on a ribbon of a plastic composition. Preferably, the plastic
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composition of the ribbon is the same composition that is used for the
remainder of the moulding, so that a good bond between the ribbon and the
remainder of the plastic composition may be achieved during the moulding
process (e.g., the two parts are bonded in a substantially leak-free manner).
The required electrical circuit may be made by cutting the trace as required,
to
form an electrical break in the circuit and thereby creating a base circuit
board. A punch, water cutter, laser cutter, vibration cutter, or other
mechanical means may be used to obtain such cuts. Individual sections of the
circuit would then be linked by components or other connections. A heat sink
may be attached to the base plastic ribbon, ready to be formed into the
desired shape after the components have been attached, as discussed
herein.
As an alternative, multiple strands of wire may be used on a base, with
the circuit being formed by connection to the strands in an appropriate
manner. The strands may be on a ribbon or other base, preferably formed
from the same polymeric composition as is to be used in the moulding
process, to ensure effective encapsulation, or may be inside a jacket material
with the multiple wire runs pre-joined together into a "flex." An example of
the
multiple strands of wire, shown with a heat sink, is shown in Fig. 14. Fig. 14
shows heat sink 90 with ribbon 92 attached thereto. Wires 94A, 94B, 94C
and 94D are located on ribbon 92.
As a further alternate, a miniature circuit board capable of withstanding
the moulding process may be fabricated for the mounting of the components.
The circuit board would need to be small, in order to not adversely impede the
flexibility of the system disclosed herein. The board may be made from
traditional materials fixed to the traces by the use of solder or by
mechanical
means (e.g., crimping or pinning).
In another alternative, a two-part locking module may be used to make
the connections in the circuit and to form a soldering base for the components
of the circuit. An example of half of such a locking module is given in Fig.
15.
Locking module 100 is shown in cross section and in part, the other part being
for example a mirror image (female and/or male) of the part illustrated.
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Locking module 100 has base 102 from which legs 104 and 106 extend
downwards. Legs 104 and 106 have locking teeth 108 and 110 thereon,
which are intended to lock into corresponding recesses in the opposite
(female) half. Intermediate, between legs 104 and 106, are notches 112 and
5 114, cooperatively located with solder pads 116 and 118 located on the upper
surface of base 102. Pins 120 and 122 extend between solder pads 116 and
118 and notches 112 and 114, respectively, for electrical connection to an
electrical conductor (not shown). A heat sink cavity 124 is located adjacent
leg 106.
10 A variety of means of connecting the electrical connectors to the
electrical source conductors may then be used, some of which are discussed
above. In a preferred embodiment, a connection may be built into the lower
surface of the module, from the electrical conductor, during the moulding of
the conductor. Subsequently, during use, electrical connection is made using
15 suitable conductive padding, pins, spikes or other arrangements through the
coating of the electrical conductors to provide the appropriate isolated,
weather proof, electrical connections. In this manner, multiple connections
may be made in this manner from each module to the electrical source
conductors, to provide for a redundancy of connections in the event of failure
20 of one such connection.
Fig. 16 shows one alternate method of providing electrical connection
between a module and an electrical conductor. Module 130 has LED 132 and
associated electrical connectors 134 and 136. Each of electrical connectors
134 and 136 has a cavity associated therewith. Cavity 138 extends from
electrical connector 134 down module leg 140 and terminates prior to recess
142 therein. Similarly, cavity 144 extends from electrical connector 136 down
module leg 146 and terminates prior to recess 148. Recesses 142 and 148
are intended to retain an O-ring (not shown) to provide a seal with a
connector
pin, of which only connector pin 150 is shown. Connector pin 150 is intended
to penetrate module leg 140 at recess 142 and connect with electrical wire
152 extending downwards from electrical connector 134 into cavity 138.
Connector pin 150 is also intended to make electrical contact with electrical
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conductor 154. Connector 150 is shown as a screw, and would be screwed
into module leg 140.
Another method of providing electrical connection is through use of
induction coils. Embedded magnetic core and coiled wire are able to attract
an induced voltage from a similar magnetic core and energised coiled wire in
the connector block below. Each connector block is electrically connected to
others via electrical cables disposed beneath said modules.
In use, the modules of the invention may be inserted in a continuous
end-to-end manner so that a continuous light is obtained. Alternatively, some
modules may be replaced with sensors, two way communication, (receiving
and radiating, transmitting), intelligent or smart responsive, active, self-
initiating, power generating or power storage devices. Some modules may
not incorporate LEDs or may incorporate LEDs emitting a different coloured
light than other modules. This may be provided by using tinted plastic
material to provide the different colours, using lenses to provide different
patterns or light direction, or by using LEDs of a different colour. Filler
modules or sections may be used that do not provide light. Such filler
sections may be, for example, reflective, luminescent, coloured white or
opaque. In this manner, such markings as between lanes may be similar to
that which is already typically found on highways with airports, with
intermittent white or yellow lines. During dark or inclement weather, light
may
be emitted from the active LED modules. The active component would then
emit the light providing increased safety and visibility.
As mentioned previously, other modules may be placed in the
elongated lighting system for reasons other than providing lighting. All such
other modules may be made in a similar fashion as the LED-containing
modules. The modules providing lighting and other modules are both
sufficiently robust to survive being placed in a road or airport taxiway and
preferably have a convex curved cap or shape on a top portion to shed
rainwater and, in conjunction with wheeled vehicles, would be self cleaning.
Other modules may be placed in the elongated lighting system for other
reasons. For instance, modules may be placed to detect localized weather
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conditions, traffic patterns, vehicle counts or to provide other functions.
Such a system of lighting and other modules may be interactive.
Relevant information detected by the system may be broadcast and
transmitted to interested parties and users. Similarly, instructional
information
broadcast to, and received by, the system would precipitate action (i.e., a
sensor module might detect a traffic jam, or freezing bridge). These
circumstances may then be communicated to all interested users and
authorities as a warning message. The intelligent or smart sensor module or
modules may be pre-programmed to autonomously change the colour of the
LEDs on a freezing bridge section. However, on receiving instructions via a
broadcast signal from a local transportation authority they would start the
lighting system flashing, to warn drivers of possible hazards, or close or
clear
lanes for emergency vehicles. A variety of sophisticated modules having
different functionality may be incorporated into any system in a modular
fashion, to customize the system to an end user's requirements.
The system may be as simple as providing guidance lighting only, or
be fully computerised and interactive. The system may include
communication devices, for instance infrared, microwave, radio or other
wavelengths suitable for communication, LED or other light sources. Such
communication devices, which may transmit analog or digital data, would
allow motorists and regulatory authorities (e.g., police) to receive data on
road
conditions and preferably do so in real time. The transmissions may be
unidirectional or multidirectional. The electrical conductors used for the
modules described herein may provide the power for such alternate modules.
The communication to and from such modules may be incorporated as
transmitters and receivers within the modules themselves, or in particular,
wiring, fibre optics or other communication devices, for such alternate
modules may pass through the channel system, as disclosed herein for use
with the elongated lighting system of the invention, or alternatively may not
be
involved with the system, but just use the channel system for a right of way.
Thus, the modular aspect of the invention provides a high degree of
flexibility
in use of the elongated lighting system for a variety of reasons.
Alternatively,
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or in conjunction with regular powered modules, there may be replaceable
modules designed to generate and store the needed electricity. The
generation of electricity may be accomplished via induction methods, whereby
embedded coils, manufactured by injection moulding, extrusion or casting
process, at right angles to an electric current would have electricity induced
within them. Other panels may be similarly embedded, in the plastic of an
elongated lighting system, the channel portion of the module or mounted at
within a specialized channel in the road. Other panels mounted at the side of
the road or taxiway may generate needed electricity. The power storage
devices may be similarly manufactured, encased and mounted. If the side of
road or taxiway was used, then other forms of electrical generation such as
solar, wind, water, or fuel or a combination thereof may be used to generate
the needed electricity.
Back-up power and electrical storage capacity may be provided by
batteries or other electrical storage devises either similarly encapsulated or
separately mounted at the side of the road, taxiway etc. These types of
generator/storage modules would be modular and designed to provide
specific LED concentrations with power. They may act as back up power
supplies in emergencies, or to power LED and other smart modules in remote
locations, where no main power was available. They may be placed between
the active LED modules such that the markings on a road between lanes may
be similar to that which is typical on highways or airports with intermittent
white or yellow lines.
It is contemplated that an elongated lighting system may include a
plurality of modules of specified length arranged end-to-end, the modules
being energised and having a plurality of LEDs on an elongated support. The
LEDs may be connected to a pair of electrical conductors having a length
equal to or less than the discrete length of the module. The modules may be
moulded with the LEDs, elongated support and electrical conductors
embedded in transparent, opaque, semi-transparent or mixed transparent and
opaque plastic. In addition, the modules may include permanent or electrical
induced magnets. The modules may include radar reflective or absorbing
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materials, with lights or electronics similarly embedded to provide the
guidance for machine vision, or computer controlled or automated vehicles.
Such an elongated lighting system may have embedded internally or
externally a portion of an induction current generating system to produce an
electric current via induction in a vehicle, via a magnetic electric, or
electronic
collection assembly, within or external to a vehicle passing close to or over
an
induction current system for powering said vehicle as well as providing via
signal or other means guidance for said vehicle and/or levitation of said
vehicles.
The elongated line of light, as provided in the present invention, is
more visible from greater distances in a greater variety of weather conditions
than a traditional point source of light (e.g., from an overhead lighting
system
or passive reflectors, "cats eyes") on the road. In addition, it is more
visible
than traditional white or yellow-painted lines on a pavement, particularly at
times of inclement weather. The system also provides flexibility in
installation,
for a variety of uses. Intelligent or smart module systems, as customized by
end users could detect and notify users of potential hazards. These types of
systems may also receive instructions and take pre-programmed actions to
increase viewer safety. The system also provides flexibility in installation.
For
instance, the typical installation will be accomplished by forming a groove in
a
pavement surface, into which the elongated lighting system is placed. A
channel system is placed in the groove and modules placed into the channel
system in a desired pattern. However, as disclosed herein, the elongated
lighting system may be placed on the surface of the pavement, and anchored
by convenient means (e.g., by providing spikes through orifices or an
alternate channel system). In this manner, temporary lighting may be
installed on roadways, construction sites or other areas to assist in guidance
and safety of traffic. This is of particular importance at night in
construction
areas, on roadways where temporary lane systems are used, often involving a
variety of directional changes for a driver, in short distances.
Most end-use environments impose rigid specifications on the ability of
an elongated lighting system to be used. For instance, roadways and airport
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runways in snow-belt locations have to be cleared of snow, subjected to
sanding, and/or sprayed with salt or other compositions to keep the pavement
in a safe, useable (navigable) condition. The use of a flush or low profile
lighting system as disclosed herein reduces the likelihood of damage by
5 equipment involved in clearing of the pavement surface of snow or ice.
Similar requirements are encountered in dusty arid areas where brushes have
to be used. Furthermore, in normal use, a linear lighting system embedded
flush with the surface is not subjected to the full loading of a vehicle
passing
over the lighting system, as a substantial part of the load is still carried
by the
10 surrounding pavement.
The lighting system of the present invention provides linear light
guidance. Linear light guidance tends to be preferable to point light
guidance,
in that a line can provide substantially more information to persons viewing
the lighting system. For example, unlike point sources, which need to be
15 aligned and have to have a number of them visible at the same time, a
single
lit linear section of the lighting system, as disclosed herein, would provide
both positional and directional information and when of a known length would
provide range information. A driver viewing a number of linear lit sections
should normally receive help in depth perception at night. The information
20 provided to the viewer would not only act as a guidance indicator (e.g.,
the
linear lighting system shows the position of the lanes on a road), but may
also
aid in providing some or all of depth perception information, correct
direction
information, perspective, speed, range information and the like.
The lighting system is lit (i.e., it is powered and not just reflective as
25 with reflectors or "cats eye" road studs). Thus a viewer is able to see the
system as far as visibility permits. This would be beneficial in adverse
weather conditions, including snow, rain and fog. Since the system can be
seen as far as visibility permits, it would provide guidance at far greater
viewing distances than a series of reflectors. Consequently, a viewer should
have much earlier opportunities to appreciate and act upon the guidance (as
in curves and hazards) leading to increased viewer time to react thereby
contributing to safety. These advantages are provided with less light output
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than traditional street lights, providing energy savings and thereby reducing
night-time glare, and causing less light pollution. In addition, intelligent
or
smart module systems, as customised by end users, would detect and notify
users of potential hazards. These types of systems may also receive
instructions and take pre-programmed actions to increase viewer safety.
Linear guidance reduces the likelihood of confusion, and may be
combined with directional devices to reduce hesitation. It is believed that
night-time direction is interpreted more readily, as the viewer sees the whole
lit line system as a unit, rather than an individual or a few series of
reflected
points of light. If point lights are used close together, a viewer can get a
sense of direction, but for economical reasons these points are normally
spread out and consequently tend to be less readily understood. Point lights
can also be confused with other lights in the background, particularly if the
road is wet and reflects street, building or other lights.
The light output value of a line is believed to be cumulative, with many
lit sections being viewed at the same time. Thus, the system appears brighter
than might otherwise be interpreted for a single light source.
The directional control of the light in the system is important for the
economics of the system, as less LEDs should be required for a given
visibility. Moreover, the present invention is versatile, as it is capable of
being
manufactured so that most of the light is viewed in one or more directions,
depending on the angle of orientation of the LEDs, or the use of tensed, or
light directional systems. For example, a lateral twist and/or longitudinal
bending, imposed on the heat sink in manufacture, will direct most of the
light
in the direction of the lateral twist or bend. Similar effects may be achieved
with the use of tensed, or light directional systems. Critical situations, for
example pedestrian cross walks, require low visibility in a linear direction,
but
a high visibility in a lateral direction, so that the cross walk is very
visible to an
approaching automobile.
The system has flexibility in the choice of components. Changes in
LED shape, numbers, colour or the use of other types of light or electronic
systems may all be accommodated by the system. Modules of various
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lengths may be manufactured with a variety of characteristics and installed in
a variable sequence to provide a wide variety of guidance, information and the
like, including information to motorists and to authorities administering the
road (e.g., police, Departments of Transportation or other regulatory body
etc.). It is also contemplated to link to the system current traffic control
devices or the like.
The system may incorporate or be connected to sensors, smart
modules or the like to determine a wide variety of traffic conditions (e.g.,
stalled or slow traffic, accidents, weather, temperature, barometric pressure,
fog and ice). The system may include communication devices, for instance
infrared, microwave, radio or other wavelengths suitable for communication,
LED or other light sources. Such communication devices, which may transmit
analog or digital data, would allow motorists and regulatory authorities
(e.g.,
police) to receive data on road conditions and preferably do so in real time.
The transmissions may be unidirectional or multidirectional. The latter would
allow mobile or static police, fire, ambulance or military or other
authorities to
communicate via the modules, within a particular location, to motorists to
clear
lanes for emergency vehicles, or for other reasons. In addition, the
communication devices may communicate with any and all wireless receivers
for individual information and up-dates on road conditions for the immediate
location or for distant locations. It would thus be possible to obtain road
information for a proposed route, and enable alternative routes to be selected
well in advance of anticipated problems. The sensors or smart modules may
communicate with global positioning systems, for communication to motorists
of information on an individual customized route plan selected by a motorist.
The system may also incorporate magnetic or radar reflective sections, or
other reflective sections, for use in guidance of machine vision vehicles
(e.g.,
vehicles guided by means of such reflective devices). Magnetic or other
devices may be incorporated to power and/or lift vehicles.
Smart segments may also flash the LED lamps within a section, or
even the individual LEDs, in response to an authorized order from police etc.
to help clear a lane or slow traffic for some reason, or may be set to
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automatically function in a prearranged fashion once a hazardous situation,
fog, accident, icing of a bridge etc. was detected.
The system allows for sophisticated connectors, which are usually the
weakest link in the system, and permits continued operation even if one
module should fail. The LEDs have the ability to withstand extreme physical
and chemical conditions, including the weight of aircraft and other vehicles,
corrosive materials especially salt and sand, summer and winter
temperatures, impact at low temperatures and the like.
The system is versatile in the potential end-uses. For instance, it may
be useful in marine, mining, explosive, aggressive, difficult maintenance and
bad weather areas, where traditional lighting systems can be difficult to
install
and maintain, and also tend to be unreliable. The system is rugged, is mobile
for emergency or other use, as in helipads, and with solar, wind or other
forms
of power generation, may be installed in areas that have no grid power, or are
difficult to access such as signs on high rise buildings, or mining and other
elevator shafts (e.g., the elevator shafts used for the transportation of
goods
or bringing up explosives and munitions in the military).
The system has low power consumption, and in some instances may
be operated using solar power. The system has low maintenance, a long life,
is economic and environmentally acceptable. Use of solar power would make
the system useful for emergency guidance lighting in remote locations.
The system should provide for the increases in safety, especially at
night and in adverse weather conditions. This is important in view of current
population demographics with the ageing of society, as night vision becomes
much more difficult as a person ages.
