FIELD
The present disclosure generally relates to a solar road stud. In particular, the present disclosure relates to a simple, efficient, durable, and less expensive mechanism to adjoin reflectors to the solar road stud.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Generally, roadway solar pavement markers are frequently utilized for light reflective indications of lane and roadway arrangement. Solar pavement markers are widely used on Highways, GT Roads, institutions, or any area where consciousness is required to alert the passengers, drivers, and people. The alerts may be in the form of turns on the road, speed breakers, schools, hospitals, pedestrian crossings, etc. In the past, such a function was typically accomplished by painting portions of a roadway surface. Modern solar pavement markers offer significant advantages over paint such as dramatically increased visibility and/or reflectance and improved durability. The solar pavement markers are generally highly visible because of a reflector that is provided on the side layer of the solar pavement markers. The reflector serves as an indicator when installed upon the roadway surface. So, in solar pavement markers, the reflectors play an important role.
Further, in the conventional method, these reflectors are pasted on the Aluminum die casted housing using an adhesive. However, the disadvantage of the conventional method is that the pasting of the reflector adds up the process of curing before putting the solar pavement markers in use, and in winter the curing time may also add up. Furthermore, over a period of time, these reflectors come out from the pasted surface of the solar pavement markers.
Therefore to avoid the drawbacks of the existing mechanisms, there is a need felt to design and develop a solar road stud that is simple, efficient, durable, and less expensive.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the present disclosure is to provide a solar road stud.
Another object of the present disclosure is to provide a solar road stud that is economical, save time and energy, and has better mechanical strength automatization.
Yet another object of the present disclosure is to provide the solar road stud that enhanced the life of the reflector.
Yet another object of the present disclosure is to provide a solar road stud that is simple, efficient, durable, and less expensive.
Other objects and advantages of the present disclosure will be more apparent from the following description when read in conjunction with the accompanying figures, which are not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a solar road stud. The solar road stud comprising a metallic die casted housing includes a quadrilateral base surface, sidewalls extending in a slanting manner from corresponding edges of the base surface, so as to define a central cavity accessible from the top side of the housing, a first set of through-holes is formed on a first pair of oppositely formed operative sidewalls, so as to receive light emitting devices from the central cavity, and a second set of through holes is extending from the base surface to the operative sidewalls. The solar road stud further comprises a pair of plastic reflectors, each of which is locked with a corresponding operative sidewall by ultrasonic welding of plastic pins to the plastic reflector through the second set of through holes formed in the metallic die casted housing.
In an aspect, the second set of through holes is formed in a direction perpendicular to the first set of through holes.
In an aspect, the second set of through holes extends from the base surface to the outer end of the first set of through holes.
In an aspect, the sidewalls are formed at a predefined inclined angle from the base, and the predefined angle ranges from 30 degrees to 60 degrees.
In an aspect, one through hole is formed on each of the second pair of oppositely formed non-operative sidewalls for abutting the housing against the road surface.
In an aspect, the central cavity includes a solar cell forming a top surface of the housing for receiving the sunlight and converting it into electrical energy; a battery connected to the solar cell for receiving and storing the electrical energy; and a printed circuit board connected to the battery to operate its processing unit for controlling the activation of the light emitting devices.
In an aspect, the processing unit is configured to receive an input from a photodetector mounted beneath the solar cell, and activate the light emitting devices when the input indicates the absence of illumination in the vicinity of the photodetector.
In an aspect, the solar cell is a photovoltaic cell, and the light emitting devices are light emitting diodes (LEDs).
In an aspect, the plastic reflector is a polycarbonate reflector, and the plastic pins are pressure die casted polymer pins.
A method for manufacturing a solar road stud, the method comprising:
placing a metallic die casted housing on a welding platform of an ultrasonic welding machine, the metallic die casted housing includes:
• a quadrilateral base surface,
• a plurality of sidewalls extending in a slanting manner from corresponding edges of the base surface, so as to define a central cavity accessible from top side of the housing,
• a first set of through-holes formed on a first pair of oppositely formed operative sidewalls, so as to receive light emitting devices from the central cavity, and
• a second set of through holes is extending from base surface to the operative sidewalls
positioning of plastic reflectors on the operative sidewalls of the metallic die casted housing;
inserting plastic pins in the second set of through holes extending from the base surface to the operative sidewalls of the metallic die casted housing; and
performing ultrasonic welding of the plastic pins to the plastic reflectors through the second set of through holes formed in the metallic die casted housing.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
Solar road stud of the present disclosure will now be described with the help of the accompanying drawings, in which:
Figure 1 illustrates a solar road stud, in accordance with an embodiment of the present disclosure;
Figures 2a, 2b, and 2c illustrate various components of the solar road stud, in accordance with an embodiment of the present disclosure; and
Figure 3 illustrates a method for assembling solar road stud, in accordance with an embodiment of the present disclosure.
REFERENCE NUMERALS
100 – Solar Road Stud
102 – Metallic Die Casted Housing
104 –Base Surface
106 – Sidewalls
106-O – Operative Sidewalls
108 – First Set of Through-Holes
110 – Light Emitting Devices
112 – Second Set of Through Holes
114 – Pair of Plastic Reflectors
116 – Solar Cell

DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
Generally, roadway solar pavement markers are frequently utilized for light reflective indications of lane and roadway arrangement. Solar pavement markers are widely used on Highways, GT Roads, institutions, or any area where consciousness is required to alert the passengers, drivers, and people. The alerts may be in the form of turns on the Road, Speed breakers, Schools, Hospitals, Pedestrian crossings, etc. In the past, such a function was typically accomplished by painting portions of a roadway surface. Modern solar pavement markers offer significant advantages over paint such as dramatically increased visibility and/or reflectance and improved durability. The solar pavement markers are generally highly visible because of a reflector that is provided on the side layer of the solar pavement markers. The reflector serves as an indicator when installed upon the roadway surface. So, in solar pavement markers, the reflectors play an important role.
Further, in the conventional method, these reflectors are pasted on the Aluminum die casted housing. The pasting of the reflector on the Aluminum die casted housing can be performed by using an adhesive. However, the disadvantage of the conventional method is that the pasting of the reflector adds up the process of curing before putting the solar pavement markers in use, and in winter the curing time may also add up. Furthermore, with a period of time, these reflectors come out from the pasted surface of the solar pavement markers.
To overcome the above-mentioned drawbacks, the present disclosure envisages a power distribution unit (PDU) casing 100 for a vehicle.
Figure 1 illustrates a solar road stud 100, in accordance with an embodiment of the present disclosure. In an aspect, solar road stud 100 comprising a metallic die casted housing 102 includes a quadrilateral base surface 104, sidewalls 106 extending in a slanting manner from corresponding edges of the base surface 104, so as to define a central cavity accessible from the top side of the housing 102, the sidewalls 106 are formed at a predefined inclined angle from the base, the predefined angle ranges from 30 degrees to 60 degrees, a first set of through-holes 108 formed on a first pair of oppositely formed operative sidewalls 106-O, so as to receive light emitting devices 110 from the central cavity, and a second set of through holes 112 extending from the base surface 104 to the operative sidewalls 106-O. A solar road stud 100 further comprises a pair of plastic reflectors 114, each of which is locked with a corresponding operative sidewall by ultrasonic welding of plastic pins to the plastic reflector 114 through the second set of through holes 112 formed in the metallic die casted housing 102.
Figure 2a, Figure 2b, and Figure 2c illustrate various components of the solar road stud 100, in accordance with an embodiment of the present disclosure. In an aspect, the second set of through holes 112 is formed in a direction perpendicular to the first set of through-holes 108. The second set of through holes 112 extends from the base surface 104 to the outer end of the first set of through-holes 108. One through hole 112 is formed on each of the second pair of oppositely formed non-operative sidewalls for abutting the housing against the road surface. the central cavity includes a solar cell 116, a battery, and a printed circuit board. A solar cell 116 is forming a top surface of the housing. The solar cell 116 is configured to receive sunlight and convert it into electrical energy. The battery is connected to the solar cell 116 for receiving and storing electrical energy. The printed circuit board is connected to the battery to operate its processing unit for controlling the activation of the light emitting devices 110. The processing unit is configured to receive an input from a photodetector mounted beneath the solar cell 116, and activate the light emitting devices 110 when the input indicates the absence of illumination in the vicinity of the photodetector. In an aspect, the solar cell 116 is a photovoltaic cell, and the light emitting devices 110 are light emitting diodes (LEDs). The plastic reflector is a polycarbonate reflector, and the plastic pins are pressure die casted polymer pins.
Figure 3 illustrates a method 300 for manufacturing a solar road stud 100 as shown in accordance with an embodiment of the present disclosure. The order in which the method 300 is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any appropriate order to carry out the method 300 or an alternative method. Additionally, individual blocks may be deleted from the method 300 without departing from the scope of the subject matter described herein. The method for assembling solar road stud 100, includes steps of:
At step 301: the method 300 includes placing a metallic die casted housing 102 on a welding platform of an ultrasonic welding machine, wherein the metallic die casted housing 102 includes:
• a quadrilateral base surface 104.
• a plurality of sidewalls 106 extending in a slanting manner from corresponding edges of the base surface 104, so as to define a central cavity accessible from top side of the housing.
• a first set of through-holes 108 formed on a first pair of oppositely formed operative sidewalls 106-O, so as to receive light emitting devices 110 from the central cavity.
• a second set of through holes 112 extending from base surface 104 to the operative sidewalls 106-O.
At step 302: the method 300 includes positioning of plastic reflectors 114 on the operative sidewalls 106-O of the metallic die casted housing 102.
At step 303: the method 300 includes inserting plastic pins in the second set of through holes 112 extending from the base surface 104 to the operative sidewalls 106-O of the metallic die casted housing 102.
At step 304: the method 300 includes performing ultrasonic welding of the plastic pins to the plastic reflectors 114 though the second set of through holes 112 formed in the metallic die casted housing 102.
The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a solar road stud is:
• that it is economical, save time and energy, and has better mechanical strength automatization;
• that it has enhanced the life of the reflector; and
• that is simple, efficient, durable, and less expensive.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

WE CLAIM:

1. A solar road stud (100) comprising:
a metallic die casted housing (102) includes:
• a quadrilateral base surface (104),
• a plurality of sidewalls (106) extending in a slanting manner from corresponding edges of said base surface (104), so as to define a central cavity accessible from a top side of the housing (102),
• a first set of through-holes (108) formed on a first pair of oppositely formed operative sidewalls (106-O), so as to receive light emitting devices (110) from the central cavity, and
• a second set of through holes (112) extending from said base surface (104) to the operative sidewalls (106-O); and
a pair of plastic reflectors (114), each of which is locked with a corresponding operative sidewall by ultrasonic welding of plastic pins to the plastic reflector (114) through the second set of through holes (112) formed in the metallic die casted housing (102).
2. The solar road stud (100) as claimed in claim 1, wherein the second set of through holes (112) is formed in a direction perpendicular to the first set of through holes (108).
3. The solar road stud (100) as claimed in claim 1, wherein the second set of through holes (112) extends from the base surface (104) to outer end of the first set of through holes (108).
4. The solar road stud (100) as claimed in claim 1, wherein said plurality of sidewalls (106) are formed at a predefined inclined angle from said base, and wherein the predefined angle ranges from 30 degrees to 60 degrees.
5. The solar road stud (100) as claimed in claim, 1 wherein one through hole is formed on each of the second pair of oppositely formed non-operative sidewalls for abutting the housing against the road surface.
6. The solar road stud (100) as claimed in claim 1, wherein the central cavity includes:
a solar cell (116) forming a top surface of the housing, wherein the solar cell (116) is configured to receive the sunlight and convert it into electrical energy;
a battery connected to the solar cell (116) for receiving and storing the electrical energy; and
a printed circuit board connected to the battery to operate its processing unit for controlling the activation of the light emitting devices (110).
7. The solar road stud (100) as claimed in claim 6, wherein the processing unit is configured to:
receive an input from a photodetector mounted beneath the solar cell (116); and
activate the light emitting devices (110) when the input indicates the absence of illumination in the vicinity of the photodetector.
8. The solar road stud (100) as claimed in claim 6, wherein the solar cell (116) is a photovoltaic cell, and the light emitting devices (110) are light emitting diodes (LEDs).
9. The solar road stud (100) as claimed in claim 1, wherein said plastic reflector is a polycarbonate reflector, and wherein said plastic pins are pressure die casted polymer pins.
10. A method (300) for manufacturing a solar road stud (100), said method comprising:
placing a metallic die casted housing (102) on a welding platform of an ultrasonic welding machine, wherein said metallic die casted housing (102) includes:
• a quadrilateral base surface (104),
• a plurality of sidewalls (106) extending in a slanting manner from corresponding edges of said base surface (104), so as to define a central cavity accessible from top side of the housing,
• a first set of through-holes (108) formed on a first pair of oppositely formed operative sidewalls (106-O), so as to receive light emitting devices (110) from the central cavity, and
• a second set of through holes (112) extending from the base surface (104) to the operative sidewalls (106-O).
positioning of plastic reflectors (114) on the operative sidewalls (106-O) of the metallic die casted housing (102);
inserting plastic pins in the second set of through holes (112) extending from the base surface (104) to the operative sidewalls (106-O) of the metallic die casted housing (102); and
performing ultrasonic welding of the plastic pins to the plastic reflectors (114) through the second set of through holes (112) formed in the metallic die casted housing (102).