Search

US-12624808-B2 - Apparatus, method, and system for hanging lights along a suspension wire of a bridge

US12624808B2US 12624808 B2US12624808 B2US 12624808B2US-12624808-B2

Abstract

An LED module includes a lens, a split housing, and a cradle. The cradle defines a central opening, and includes a plurality of upwardly extending flanges, a plurality of downwardly extending flanges, and a pair of mounting cars.

Inventors

  • Matthew F. Smith
  • Brady L. Dieleman
  • Alex K. Bryan
  • Joel D. DeBoef
  • Chris P. Lickiss
  • Thomas M. Halloran
  • LUKE C. McKEE

Assignees

  • MUSCO CORPORATION

Dates

Publication Date
20260512
Application Date
20250624

Claims (20)

  1. 1 . An LED module comprising: a PCB provided with one or more LEDs; a lens; a split housing; and a cradle; wherein the cradle defines a central opening, and includes a plurality of upwardly extending flanges retaining the lens, a plurality of downwardly extending flanges retaining the PCB, and a pair of mounting ears orienting the cradle inside the split housing.
  2. 2 . The LED module of claim 1 , wherein each of the pair of mounting ears of the cradle are adjacent to the central opening and define a cradle locating feature.
  3. 3 . The LED module of claim 2 , wherein the cradle locating feature is a hole and the split housing includes a top housing member that includes a boss that is configured to pass through the hole.
  4. 4 . The LED module of claim 1 , wherein the plurality of upwardly extending flanges includes a first top flange extending upwardly from adjacent to the central opening and the second top flange extending upwardly from adjacent to the central opening.
  5. 5 . The LED module of claim 4 , wherein the cradle further defines a top lens support surface.
  6. 6 . The LED module of claim 1 , wherein the plurality of downwardly extending flanges includes a first side flange that defines a first side opening and a first PCB retaining finger and a second side flange that defines a second side opening and a second PCB retaining finger.
  7. 7 . The LED module of claim 6 , wherein the cradle further defines a bottom PCB stop surface disposed above the first PCB retaining finger and the second PCB retaining finger.
  8. 8 . The LED module of claim 1 , wherein the plurality of downwardly extending flanges includes a first flange portion extending from one of the pair of mounting ears and a second flange portion extending from the other of the pair of mounting ears.
  9. 9 . The LED module of claim 1 , wherein the lens includes a flat mounting portion and a light emitting portion.
  10. 10 . The LED module of claim 9 , wherein the light emitting portion has an at least partially hemispherical configuration or an at least partially cylindrical configuration.
  11. 11 . The LED module of claim 1 , further comprising a pair of cord grips attached to the split housing of the LED module.
  12. 12 . The LED module of claim 9 , wherein the light emitting portion defines a LED light receiving cavity.
  13. 13 . The LED module of claim 1 , wherein the split housing includes a top housing member that defines a stepped cavity including a pair of shallow portions and a deep portion disposed between the pair of shallow portions.
  14. 14 . The LED module of claim 13 , wherein the shallow portions are configured to receive the pair of mounting ears of the cradle and the deeper portion is configured to receive the lens and the upwardly extending flanges of the cradle.
  15. 15 . The LED module of claim 13 , wherein the top housing member includes a pair of cable receiving tube portions that are in communication with the shallow portions of the top housing member.
  16. 16 . The LED module of claim 13 , wherein the top housing further comprises a plurality of fastener receiving apertures, and a top seal interface.
  17. 17 . The LED module of claim 16 , wherein the plurality of fastener receiving apertures is defined by a plurality of fastener defining bosses, and the top seal interface is a seal receiving groove.
  18. 18 . The LED module of claim 13 , wherein the top housing member defines a lens receiving thru aperture and a seal ring forming groove.
  19. 19 . The LED module of claim 1 , wherein the split housing includes a bottom housing member defines a plurality of bottom fastener receiving apertures, a bottom seal interface, and a plurality of ribs forming a series of core out cavities.
  20. 20 . The LED module of claim 19 , further comprising a pair of alignment projections, and wherein the bottom seal interface is a seal engaging bead.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation-in-part application claiming priority to and the benefit of the National Stage application with application Ser. No. 18/839,606 filed on Aug. 19, 2024, which in turn claims priority to and the benefit of International Patent Application No. PCT/US2023/080636, filed Nov. 21, 2023, which claims priority to, and the benefit of U.S. Provisional Patent Application No. 63/384,680, filed Nov. 22, 2022, each of which are hereby incorporated by reference in their entirety. TECHNICAL FIELD The disclosure generally relates to a system for hanging LED lights from a suspension wire or rope of a bridge. More specifically, the disclosure enables such a system that may be less prone to light outages, requires fewer strings of wires, or that includes a bracket for attaching the string of wires and LEDs to the suspension rope or wire. BACKGROUND It has become more common to light bridges or the like using LEDs or other types of lights for decorative purposes. In particular, such lights may be attached to the vertical and/or parabolic suspension wires or ropes of the bridge. If LEDs are employed, wires leading from the LEDS from the top to the bottom of the bridge may provide power and communication to the PCB boards that control the LEDs, allowing light shows and special effects, different colors etc. to be displayed. Bridges are often located over the ocean near cities where a combination of smog and saltwater can deteriorate the LEDs, lens, wires, etc. leading to light outages (see 50 in FIG. 1) or discoloration, etc. Also, the extensive vertical height or length (e.g., 50 feet or more) of such strings of lights can strain the tensile strength of the wiring that supplies the power and communication to the individual LED modules from one end to another end (e.g., from the bottom to the top of a vertical suspension wire). Consequently, multiple strings of wires need to be strung up or routed in parallel so that the entire length of the suspension wire is covered with LEDs. This may require multiple trips along the suspension wire during installation to provide enough LEDs, which can be time consuming. In some applications, it is desirable to have two sets of LEDs facing in different directions so that viewers on one side of the bridge can see one set of LEDs and viewers on the other side of the bridge can see the other set of LEDs. However, this too can increase installation time as two different sets of strings of lights may need to be routed. In some cases, the light emitted by the LEDS may cause glare or distraction to the motorists on the bridge, which is undesirable. The art lacks a system for hanging lights that is efficiently installed, which emits light in multiple directions, which is durable enough to withstand corrosive environments, and that allows glare control as motorists pass over the bridge. SUMMARY An LED module according to an embodiment of the present disclosure may include a lens, a split housing, and a cradle. The cradle may define a central opening, and may include a plurality of upwardly extending flanges, a plurality downwardly extending flanges, and a pair of mounting ears. A method of assembling an LED module according to an embodiment of the present disclosure may comprise attaching a lens to a cradle, attaching a PCB to the cradle, and inserting the cradle, the PCB and the lens into a housing member. The details of one or more examples of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims. BRIEF DESCRIPTION OF DRAWINGS The following drawings are illustrative of particular examples of the present disclosure and therefore do not limit the scope of the disclosure. The drawings are not necessarily to scale, though examples can include the scale illustrated, and are intended for use in conjunction with the explanations in the following detailed description wherein like reference characters denote like elements. Examples of the present disclosure will hereinafter be described in conjunction with the appended drawings. FIG. 1 illustrates a prior art system for hanging LED lights along a vertical suspension wire of a bridge. Light outages are depicted. FIG. 2 shows a system for hanging LED lights along a suspension wire of a bridge that is configured according to various embodiments of the disclosure that may reduce the likelihood of light outages, discoloration as well as ease assembly and/or routing the string of lights. FIG. 3 is a detailed view taken from FIG. 2 zooming up on a portion of a vertical suspension wire with lights attached to it. A couple of LED modules with brackets holding the string of lights on the suspension wire can be seen. FIG. 4 is a perspective view of a single instance of a LED module in a bracket taken from FIG. 3 removed from the suspension