Bridge Seal for Modular Warning Light Assembly

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Solution Overview

Problem

Existing modular warning light assemblies for vehicles face challenges in maintaining a sealed elongated cavity due to exposure to elements and high wind speeds, which leads to leakage issues and difficulty in servicing, especially when using modular components with single-piece domes that are limited in color combinations and lengths.

Innovation Solution

A modular warning light assembly design featuring an extruded strength member with housing modules, including end and center modules, and a bridge seal component that integrates flexible gutter seals to create a weather-resistant enclosure for control and power distribution conductors, allowing for various configurations while ensuring a sealed environment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If modular housing components are used to create different product configurations, then adaptability is improved, but sealing reliability deteriorates due to multiple interface points between modules

Engineering Contradiction:

Improveproduct configurationsVSAvoidsealing

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The lightbar is divided into multiple housing modules that can be assembled in different configurations. Each module contains light sources and can be independently manufactured, then joined together using bridge seals to form complete lightbar assemblies of various lengths and styles.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Bridge seals serve as intermediary components between adjacent housing modules. These seals include gutter seals that extend into the bridge seal cavity to prevent water ingress at the module interfaces, resolving the sealing challenge created by modular construction.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If single-piece dome design is used, then manufacturing simplicity is improved, but product versatility deteriorates due to limitations in color combinations and lengths

Engineering Contradiction:

Improvesealing simplicityVSAvoidcolor combinations and lengths

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The dome is segmented into multiple sections corresponding to different housing modules. Each dome section can be manufactured separately and joined to matching base sections, enabling various color combinations and lengths while maintaining sealed construction principles.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Standardized base sections with universal mounting interfaces allow different dome sections to be combined with the same base types. This enables a single base design to support multiple dome configurations, achieving versatility without sacrificing manufacturing simplicity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If modular components are joined by sealed dividers, then product versatility is improved, but serviceability deteriorates due to difficulty in servicing sealed assemblies

Engineering Contradiction:

Improveproduct configurationsVSAvoidserviceability

Core Design Contradiction:

Adaptability or versatilityVSEase of repair

Solution Approach 1:

The bridge seals and gutter seals are designed as removable components that can be detached from the housing modules. This dynamic sealing approach allows service personnel to remove seals to access internal components for servicing, then reinstall the seals to restore the sealed environment.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The sealed assembly is segmented into serviceable sections where bridge seals can be independently removed. This segmentation allows technicians to access specific modules without disassembling the entire lightbar, improving serviceability while maintaining modular versatility.

Inventive Principle:

Principle #1Segmentation

4Ease of manufacture

If housing modules are exposed to elements at interface points, then modular assembly is simplified, but durability deteriorates due to water ingress and damage to internal components

Engineering Contradiction:

Improvemodular assemblyVSAvoiddurability

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

Gutter seals act as intermediary water-blocking structures that extend into the bridge seal cavity. These seals create a waterproof barrier at the module interfaces, preventing water ingress while maintaining the modular assembly structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The bridge seals and gutter seals are pre-installed on housing modules before final assembly. This preliminary sealing action prevents water from reaching internal components during the assembly process and throughout the product lifecycle, protecting against environmental damage.

Inventive Principle:

Principle #9Preliminary anti-action

Data Source

PatentUS7854531B1Bridge seal for a warning light assembly

Publication Date: 2010.12.21 WHELEN ENGINEERING COMPANY

AI summary

The disclosed bridge seal includes a substantially rigid bridge component and flexible gutter seal arranged to span the openings between adjacent housing modules of a modular warning light assembly such as a lightbar. The bridge seal physically connects the adjacent ends of base and dome components to each other and defines a fluid flow channel to guide water away from the area between housing modules. The disclosed bridge seal integrates discrete housing modules into a connected weather resistant enclosure having a longitudinal path for control and power distribution conductors extending the length of the lightbar.