Modular Vehicle Light Bar Assembly with Adjustable Mounting

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Solution Overview

Problem

Existing motor vehicle light bars are inflexible, requiring multiple prefabricated assemblies to accommodate different lighting needs, and are prone to damage from external objects, while lacking aesthetic appeal and efficient illumination.

Innovation Solution

A modular front light bar assembly with a main frame, vehicle mounting members, a light box, and an over rider bar, allowing for adjustable light placement and protection, with a decorative panel for aesthetic purposes, and featuring removable connections for easy configuration and maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If lights are permanently fixed to mounting brackets at the factory, then installation is easier, but it becomes difficult to vary the number, style and location of the lights

Engineering Contradiction:

Improveinstallation easeVSAvoidlight configuration flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The light bar assembly is divided into separate modular components: mounting brackets, light bars, and cover assemblies that can be independently selected and assembled. This allows customers to choose different configurations without requiring complete pre-assembly of multiple variants.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A universal mounting bracket design with multiple mounting hole patterns and adjustable features serves multiple light bar configurations. The same bracket can accommodate different light bar sizes, styles, and positions, eliminating the need for specialized brackets for each configuration.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If different prefabricated light bars are made to meet various user demands, then lighting needs are satisfied, but a large inventory of different light bars must be stocked

Engineering Contradiction:

Improvelighting configuration varietyVSAvoidinventory quantity

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The system segments the light bar into a common mounting structure and interchangeable light bar modules. This allows a single mounting bracket inventory to support multiple light bar configurations, reducing the need to stock complete prefabricated assemblies for each variant.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mounting system incorporates adjustable and reconfigurable elements that allow the same physical hardware to dynamically adapt to different lighting requirements. Customers can reconfigure the mounting brackets for different light bar positions and orientations without requiring specialized hardware for each configuration.

Inventive Principle:

Principle #15Dynamics

3Illumination intensity

If lights are placed on the exterior of a vehicle, then additional illumination is provided, but the lights are subject to impact damage from trees, shrubs, rocks, flying debris

Engineering Contradiction:

Improvelighting capabilityVSAvoidimpact damage risk

Core Design Contradiction:

Illumination intensityVSObject-affected harmful factors

Solution Approach 1:

The design incorporates protective cover assemblies that can be installed before operation to shield the lights from impact damage. These covers act as a first line of defense against rocks, debris, and vegetation contact.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The protective cover assembly uses durable, impact-resistant materials that form a protective shell around the light bar while allowing the light to function. The cover design balances protection with light transmission and aesthetic considerations.

Inventive Principle:

Principle #30Flexible shells and thin films

4Ease of manufacture

If the light box has a standard height, then manufacturing is simplified, but the front panel may not fit between the main frame and the front bumper

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidinstallation fitment

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The light box assembly incorporates adjustable height parameters through variable thickness spacers or adjustable mounting mechanisms. This allows the same basic light box design to be adapted to different vehicle configurations and spacing requirements without requiring multiple specialized designs.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10427587B2Front light bar assembly for vehicle

Publication Date: 2019.10.01 NAADE INC

AI summary

A front light bar assembly is provided to fasten to the vehicle so the assembly is in front of the grill and above the front bumper. The assembly has a main frame with a front tubular member and a mounting plate permanently fastened to and above that front member. The mounting plate has a plurality of fastener holes. Two vehicle mounting members connect the main frame and extend rearwardly to connect to the motor vehicle and position the main frame above the front bumper and in front of the front grill. A light box is releasably fastened below the main frame. A front panel of the light box has an elongated opening with a mounting bracket on each opposing end of the opening to hold a light bar. A decorative panel may cover the opening. A top cover plate may cover the fastener openings. Lights may be optionally connected to the mounting plate, below an over rider bar also optionally connected to the main frame.