# Patent

## Title
Snap bracket locking device

## Abstract

A light bar snap bracket assembly includes an elongated rail member, multiple light modules, multiple snap brackets, and multiple locking devices. The light modules are disposed within the rail member channel in a line of light modules extending longitudinally from a first light module disposed at the first end of the rail member to a last light module disposed at the second end of the rail member, the line of light modules defining pairs of adjacent light modules. One of the snap brackets is disposed intermediate each light module in each pair of light modules, one of the snap brackets is disposed intermediate the first light module and the first end of the rail member, and one of the snap brackets is disposed intermediate the last light module and the second end of the rail member. Arm segments of each snap bracket extend longitudinally over tabs extending from the light module sides, of the adjacent light module half portion, with the tabs being received within the notches of the arm segments. Catches on the snap brackets engage shoulders of the rail member whereby the snap brackets lock the light modules to the rail member. Biasing segments of the locking device urge the snap bracket resilient members radially outward, locking the snap bracket catches in engagement with the rail shoulder.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 11/879,840 filed Jul. 19, 2007 now U.S. Pat. No. 7,404,658.


BACKGROUND
This disclosure relates generally to warning light systems for installation on land and marine vehicles. More particularly, the present disclosure relates to a light bar warning light system for installation on land and marine vehicles.
Warning light assemblies in the form of light bars mounted on emergency vehicles are well known in the art. Some of these light bars include a housing enclosing a rail member to which warning light modules are mounted. Other light bars do not include a housing, with the rail member and warning light modules mounted thereon being exposed to the weather. Generally, the warning light modules are manually positioned on the rail member and manually mounted to the rail member. In one conventional light bar, portions of the warning light modules are received in longitudinally extending slots in the rail member, and an operator must slide each warning light module into position on the rail member.
Thus it is desirable that a light bar be designed whereby the warning light modules may be positioned and mounted to the rail member by machine.
SUMMARY
There is provided a light bar snap bracket assembly comprising an elongated rail member, multiple light modules, multiple snap brackets, and multiple locking devices. The rail member includes first and second sidewalls forming a channel extending from a first end of the rail member to a second end of the rail member. First and second, oppositely disposed shelves extend laterally from the sidewalls into the channel. Each of the shelves have an upper surface and a lower shoulder. Each light module includes oppositely disposed, longitudinally extending first and second sides. At least one tab extends laterally from each side, with each of the tabs having upper and lower surfaces. Each snap bracket includes a web segment having oppositely disposed first and second ends, first and second resilient members disposed adjacent the first and second ends, respectively, and a catch extending laterally outward from each resilient member. First and second arm segments extend substantially orthogonally from the first and second ends of the web segment, respectively. Each of the arm segments have a lower edge defining at least one notch. Each locking device includes a body segment having oppositely disposed first and second ends and first and second biasing segments extending from the first and second ends, respectively. The light modules are disposed within the rail member channel in a line of light modules extending longitudinally from a first light module disposed at the first end of the rail member to a last light module disposed at the second end of the rail member, the line of light modules defining pairs of adjacent light modules. The lower surfaces of the tabs contact the upper surfaces of the shelves. One of the snap brackets is disposed intermediate each light module in each pair of light modules, one of the snap brackets is disposed intermediate the first light module and the first end of the rail member, and one of the snap brackets is disposed intermediate the last light module and the second end of the rail member. The first and second arm segments of each snap bracket extend longitudinally over the tab of the first and second sides, respectively, of the light module half portion adjacent the snap bracket web segment, with the tabs of the first and second light module sides being received within the notches of the first and second arm segments, respectively. The catches of the web segment resilient members engage the lower shoulders of the rail member shelves whereby the snap brackets mount the light modules to the rail member. One of the locking devices is disposed adjacent each snap bracket. The locking device biasing segments urge the snap bracket resilient members radially outward, whereby the locking devices lock the snap bracket catches in engagement with the rail shoulder.
Each locking device is a unitary C-shaped structure, with the body segment and biasing segments forming a receptacle for receiving a lower portion of the snap bracket web segment.
The snap bracket further includes first and second indexing members extending downwardly from the lower surface of the web segment, and the snap bracket web segment has an opening extending from the upper surface to the lower surface. The body segment of each locking device has first, second and third bores extending from the inner edge. The first and second snap bracket indexing members are received within the second and third bores, respectively. The body segment first bore is disposed intermediate the second and third bores and has a threaded surface.
The light bar snap bracket assembly further comprises a fastener having a threaded shaft. The threaded shaft is inserted through the snap bracket web segment opening to engage the threaded first bore of the locking device.
Each of the snap bracket resilient members includes an inner portion that extends upwardly from a center part of the web segment, and an outer portion that extends downwardly from the inner portion through an opening of the web segment. The catch extends laterally outward from an outer side of the outer portion. Each of the locking device biasing segments has a cam surface that engages an inner side of the resilient member outer portion, and biases the resilient member outer portion radially outward.
There is also provided a method of manufacturing a light bar assembly, the light bar assembly having one or more light modules mounted to an elongated rail member by multiple of snap brackets. Each light module includes oppositely disposed, longitudinally extending first and second sides, with at least one tab extending laterally from each side. The rail member includes first and second sidewalls defining a channel extending from a first end of the rail member to a second end of the rail member. First and second, oppositely disposed shelves extend laterally from the sidewalls into the channel. Each of the shelves has an upper surface and a lower shoulder. Each of the snap brackets includes a web segment having oppositely disposed first and second ends, first and second resilient members disposed adjacent the first and second web segment ends, respectively, and first and second arm segments extending substantially orthogonally from the first and second ends of the web segment, respectively. Each of the arm segments has a lower edge defining at least one notch. Each locking device includes a body segment having oppositely disposed first and second ends and first and second biasing segments extending from the first and second ends, respectively. The method comprises: A) positioning a first of the light modules in the rail member channel adjacent the rail member first end, with the lower surfaces of the light module tabs engaging the upper surface of the rail shelves; B) positioning a locking device between the rail member first end and the light module; C) positioning a snap bracket between the rail member first end and the light module; D) pushing the snap bracket toward the rail member and locking device until the light module tabs are received by the snap bracket first and second arm segment notches and a catch extending laterally outward from each resilient member is disposed below the rail shoulder thereby installing the light module; E) engaging the snap bracket with the locking device to lock the light module to the rail member; and F) determining whether a subsequent light module must be mounted to the rail member. If a subsequent light module must be mounted to the rail member, the subsequent light module is positioned in the rail member channel adjacent the installed light module; one of the locking devices is positioned between the installed light module and the subsequent light module; one of the snap brackets is positioned between the installed light module and the subsequent light module; the snap bracket is pushed toward the rail member and locking device until the light module tabs of the installed light module and the subsequent light module are received by the snap bracket first and second arm segment notches and the catch of each resilient member is disposed below the rail shoulder thereby installing the subsequent light module; the snap bracket is engaged with the locking device to lock the light module to the rail member; then step F is performed again. If a subsequent light module must not be mounted to the rail member, one of the locking devices is positioned between the installed light module and the subsequent light module, one of the snap brackets is positioned between the rail member second end and the installed light module, the snap bracket is pushed toward the rail member and locking device until the light module tabs are received by the snap bracket first and second arm segment notches and the of each resilient member is disposed below the rail shoulder, and the snap bracket is engaged with the locking device to lock the light module to the rail member thereby completing manufacturing of the light bar assembly.



BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawings in which:
FIG. 1 is a perspective view of a first embodiment of a partially assembled light bar snap bracket assembly in accordance with the disclosure;
FIG. 2 is an enlarged cross-sectional view of the rail of FIG. 1;
FIG. 3 is an enlarged side view of the intermediate snap bracket of FIG. 1;
FIG. 4 is a cross-sectional view of the intermediate snap bracket taken along lines 4-4 of FIG. 3;
FIG. 5 is an enlarged side view of the end snap bracket of FIG. 1;
FIG. 6 is an end view of the end snap bracket of FIG. 5;
FIG. 7 is an enlarged end view of the light module of FIG. 1;
FIG. 8 is a rear perspective view of the light module of FIG. 7;
FIG. 9 is a cross-sectional view taken along line 9-9 of FIG. 1;
FIG. 10 is a flow diagram of a first method of making a light bar snap bracket assembly;
FIG. 11 is a flow diagram of a second method of making a light bar snap bracket assembly;
FIG. 12 is a perspective view of a second embodiment of a partially assembled light bar snap bracket assembly in accordance with the disclosure;
FIG. 13 is an enlarged side view of the intermediate snap bracket of FIG. 12;
FIG. 14 is a cross-sectional view of the intermediate snap bracket taken along lines XIV-XIV of FIG. 13;
FIG. 15 is an enlarged side view of the end snap bracket of FIG. 12;
FIG. 16 is an end view of the end snap bracket of FIG. 15;
FIG. 17 is an enlarged perspective view of the locking device of FIG. 12;
FIG. 18 is an enlarged side view of the locking device of FIG. 12;
FIG. 19 is an enlarged front view of the locking device of FIG. 12; and
FIG. 20 is a flow diagram of the step of locking a snap bracket to the rail.



DETAILED DESCRIPTION
With reference to the drawings wherein like numerals represent like parts throughout the several figures, a light bar snap bracket assembly 10 is a component of a warning light system that may be installed on land or marine vehicles. The warning light system may include a housing that surrounds the light bar snap bracket assembly 10 and a base member for mounting the warning light system to the vehicle. Alternatively, the warning light system may not include a housing, with the light bar snap bracket assembly 10 being exposed to the weather. With reference to FIGS. 1 and 12, the light bar snap bracket assembly 10 includes an elongated rail 12, light modules 14, snap brackets 16, 18, 216, 218 that mount the light modules 14 to the rail 12, and a wiring harness 20 connecting the light modules 14 to a power supply (not shown).
With reference to FIG. 2, the rail 12 is preferably an aluminum extrusion, although other suitable materials and methods of manufacture may be used. The rail 12 has a U-shape, with a base 22 connecting first and second sidewalls 24, 26. The U-shape of the rail 12 forms a channel 28 having an outer portion 30, for receiving the light modules 14 and snap brackets 16, 18, 216, 218, and an inner portion 32 for receiving the wiring harness 20. The rail 12 may include one or more longitudinally extending T-slots 34 for mounting the rail 12 to the base member or another structural member of the warning light system, as is known in the art. First and second, oppositely disposed shelves 36, 38 extend laterally from the inner surface 40 of the rail sidewalls 24, 26, into the outer portion 30 of channel 28, and longitudinally the length of the rail 12. The first and second shelves 36, 38 are configured to support the light modules 14. The shelves 36, 38 are positioned at a predetermined distance 42 from the base 22 whereby the rear surface 44 of the light modules 14 supported on the shelves 36, 38 are located at a sufficient distance 46 (FIG. 9) from the base 22 to allow channel inner portion 32 to receive the wiring harness 20. A number of other protrusions 48 may extend laterally from the inner surface 40 of the rail sidewalls 24, 26 and longitudinally the length of the rail 12 to provide additional mechanical strength to the rail 12.
As shown in FIG. 1, each light bar snap bracket assembly 10 generally includes multiple light modules 14 that are arranged in a line of adjacent light modules 14. With additional reference to FIGS. 7 and 8, each light module 14 includes an upper portion 50, a lower portion 52, and multiple tabs 54 extending laterally from the sides 56 the light module 14 intermediate the upper and lower portions 50, 52. The width 58 of the light module lower portion 52 is less than the distance 60 between the edges 62 of the rail shelves 36, 38, such that the light module lower portion 52 is easily inserted between the rail shelves 36, 38. The distance 64 between the laterally outer edges 66 of tabs 54 on one side of the light module 14 and the laterally outer edges 66′ of the tabs 54 of the other side of the light module 14 is greater than the distance 60 between the edges 62 of the rail shelves 36, 38. Accordingly, the lower surface 68 of the tabs 54 engage the upper surface 70 of the rail shelves 36, 38 whereby a light module 14 mounted to the rail 12 is supported on the rail shelves 36, 38. A pair of wires 72 may extend from the light module lower portion 52 for connection to the wiring harness 20.
A combination of two types of snap brackets are used to mount the light modules 14 to the rail 12, with an intermediate snap bracket 16, 216 being positioned between each pair of adjacent light modules 14 and an end snap bracket 18, 218 being positioned at the free end of each end light module 14.
With reference to FIGS. 1, 3 and 4, each H-shaped intermediate snap bracket 16 has a web segment 74 connecting first and second arm segments 76, 78. The first arm segment 76 is positioned at a distance 80 from the second arm segment 78 such that the upper portion 50 of a light module 14 may be received therebetween. The web segment 74 includes a pair of downwardly extending resilient members 82, with one of the resilient members 82 being disposed adjacent each of the arm segments 76, 78. A catch 84 extends laterally outward from each resilient member 82. A cam surface 86 extends obliquely downward from the catch 84. As shown in FIG. 9, an upper contact surface 88 of the catch 84 engages a shoulder 90 of the rail shelf 36, 38 when the snap bracket 16 is installed. In the embodiment shown in the Figures, each resilient member 82 includes an inner portion 92, that extends upwardly from a center part of the web segment 74, and an outer portion 96 that extends downwardly from the inner portion 92 and through an opening 98 intermediate the web center part 94 and the arm segment 76, 78. This structure provide sufficient flexibility to the resilient member 82 to facilitate installation while providing sufficient resiliency to ensure that the catch 84 is biased to a position under the rail shelf 36, 38 whereby the catch contact surface 88 engages the rail shoulder 90.
As shown in FIG. 1, the web segment 74 and arm segments 76, 78 form first and second receptacles 100, 102 for receiving and engaging half portions of two adjacent light modules 14. The lower edge 104 of each arm segment 76, 78 includes notches 106, 108 for receiving the light module tabs 110, 112 that are located in the light module half portions received in the receptacles 100, 102. In the example shown in the Figures, the light module 14 has three tabs on each side and the intermediate snap bracket has four notches 106, 108 each arm segment. The end notches 106 have a length 114 that is substantially one-half the length 116 of middle tab 110 and the intermediate notches 108 (i.e. the notches disposed intermediate the arm segment end portions and the web segment 74) have a length 118 that is substantially equal to the length 120 of the end tabs 112. Whereby, substantially half of each middle tab 110 of the adjacent light modules 14 are received in the end notches 106 and the end tabs 112 of the half portions are received in the intermediate notches 108 of the respective receptacle 100, 102.
With reference to FIGS. 12, 13 and 14, intermediate snap brackets 216 have a construction that is similar to intermediate snap brackets 16. Each H-shaped intermediate snap bracket 216 has a web segment 220 connecting first and second arm segments 222, 224. The first arm segment 222 is positioned at a distance 226 from the second arm segment 224 such that the upper portion 50 of a light module 14 may be received therebetween. The web segment 220 includes a pair of downwardly extending resilient members 228, with one of the resilient members 228 being disposed adjacent each of the arm segments 222, 224. A catch 230 extends laterally outward from each resilient member 228. A cam surface 232 extends obliquely downward from the catch 230. An upper contact surface 234 of the catch engages a shoulder 90 of the rail shelf 36, 38 when the snap bracket 216 is installed. In the embodiment shown in the Figures, each resilient member 228 includes an inner portion 236, that extends upwardly from a center part of the web segment 220, and an outer portion 238 that extends downwardly from the inner portion 236 and through an opening 240 intermediate the web center part 242 and the arm segment 222, 224. This structure provide sufficient flexibility to the resilient member 228 to facilitate installation while providing sufficient resiliency to ensure that the catch 230 is biased to a position under the rail shelf 36, 38 whereby the catch contact surface 234 engages the rail shoulder 90.
As shown in FIG. 12, the web segment 220 and arm segments 222, 224 form first and second receptacles 244, 246 for receiving and engaging half portions of two adjacent light modules 14. The lower edge 248 of each arm segment 222, 224 includes notches 250, 252 for receiving the light module tabs 110, 112 that are located in the light module half portions received in the receptacles 244, 246. In the example shown in the Figures, the light module 14 has three tabs on each side and the intermediate snap bracket has four notches 250, 252 in each arm segment 222, 224. The end notches 250 have a length 254 that is substantially one-half the length 116 of middle tab 110 and the intermediate notches 252 (i.e. the notches disposed intermediate the arm segment end portions and the web segment) have a length 256 that is substantially equal to the length 120 of the end tabs 112. Whereby, substantially half of each middle tab 110 of the adjacent light modules 14 are received in the end notches 250 and the end tabs 112 of the half portions are received in the intermediate notches 252 of the respective receptacle 244, 246.
An opening 258 extends from the upper surface 260 of the web segment 220 to the lower surface 262 of the web segment 220. Generally, opening 258 will be positioned in the center of web segment 220. First and second indexing members 264, 266 extend downwardly from the lower surface 262 of the web segment 220, on either side of opening 258.
With reference to FIGS. 1, 5 and 6, the end snap brackets 18 have a construction that is similar to the intermediate snap brackets 16. Each end snap bracket 18 includes a web segment 122 connecting first and second arm segments 124, 126, with the arm segments 124, 126 being positioned such that the upper portion 50 of a light module 14 may be received therebetween. The web segment 122 includes a pair of downwardly extending resilient members 128, with a catch 130 extending laterally outward from each resilient member 128. An upper contact surface 132 of the catch 130 engages the rail shelf shoulder 90 when the end snap bracket 18 is installed. Each resilient member 128 may include an inner portion 134 extending upwardly from a center part 136 of the web segment 122, and an outer portion 138 extending downwardly from the inner portion 134 and through an opening 140 intermediate the web center part 136 and the arm segment 124, 126.
The web segment 122 and arm segments 124, 126 form a single receptacle 142 for receiving and engaging a half portion of the end light modules 14′. In the example shown in the Figures, the end snap bracket 18 has two notches 144, 146 each arm segment 124, 126, with the end notches 144 having a length 148 that is substantially one-half the length 116 of middle tab 110 and the intermediate notches 146 having a length 150 that is substantially equal to the length 120 of the end tabs 112. Substantially half of each middle tab 110 of the end light module 14′ is received in the end notches 144 and the end tabs 112 of the half portion are received in the intermediate notches 146.
With reference to FIGS. 12, 15 and 16, end snap brackets 218 have a construction that is similar to the end snap brackets 18. Each end snap bracket 218 includes a web segment 268 connecting first and second arm segments 270, 272, with the arm segments being 270, 272 positioned such that the upper portion 50 of a light module 14 may be received therebetween. The web segment 268 includes a pair of downwardly extending resilient members 274, with a catch 276 extending laterally outward from each resilient member 274. An upper contact surface 278 of the catch 276 engages the rail shelf shoulder 90 when the end snap bracket 218 is installed. Each resilient member 274 may include an inner portion 280 extending upwardly from a center part 282 of the web segment 268, and an outer portion 284 extending downwardly from the inner portion 280 and through an opening 286 intermediate the web center part 282 and the arm segment 270, 272.
The web segment 268 and arm segments 270, 272 form a single receptacle 288 for receiving and engaging a half portion of the end light modules 14′. In the example shown in the Figures, the end snap bracket 218 has two notches 290, 292 in each arm segment 270, 272, with the end notches 290 having a length 294 that is substantially one-half the length 116 of middle tab 110 and the intermediate notches 292 having a length 296 that is substantially equal to the length 120 of the end tabs 112. Substantially half of each middle tab 110 of the end light module 14′ is received in the end notches 290 and the end tabs 112 of the half portion are received in the intermediate notches 292.
An opening 298 extends from the upper surface 300 of the web segment 268 to the lower surface 302 of the web segment 268. Generally, opening 298 will be positioned in the center of web segment 268. First and second indexing members 304, 306 extend downwardly from the lower surface 302 of the web segment 268, on either side of opening 298.
With reference to FIGS. 1, 9 and 10, the light bar snap bracket assembly 10 may be assembled by connecting 152 the wires 72 of a first light module 14 to the wiring harness 20. The light module 14 is positioned 154 by inserting the light module lower portion 52 through the rail channel outer portion 30, into the rail channel inner portion 32, until the lower surfaces 68 of the light module tabs 110, 112 engage the upper surface 70 of the rail shelves 36, 38. An end snap bracket 18 is positioned 156 such that the half portion of the light module proximate to the rail end is disposed intermediate the two arm segments 124, 126, with the end notches 144 located above the light module middle tabs 110 and the intermediate notches 146 located above the light module end tabs 112. Pushing the end snap bracket 18 toward the rail 12 engages the cam surfaces 160 of the resilient members 128 with the inner edge 62 of the rail shelves 36, 38, biasing the resilient member outer portions 138 towards the rail centerline 158. The end snap bracket 18 is mounted 162 by pushing the snap bracket 18 toward the rail 12, until the light module tabs 110, 112 are inserted into the respective end snap bracket notches 144, 146 and the catch contact surfaces 132 are disposed below the rail shoulder 90, whereby outer portions 138 of the resilient members 128 are biased away from the rail centerline 158 by the resilient member inner portions 134 and the catch contact surfaces 132 are disposed below the rail shoulders 90, locking the end light module end half portion to the rail 12.
If additional light modules 14 must be installed 164, the wires of the subsequent light module 14′′ are connected 152 to the wiring harness 20. The light module lower portion 52 is inserted 154 through the rail channel outer portion 30, into the rail channel inner portion 32, until the lower surfaces 68 of the light module tabs 110, 112 engage the upper surface 70 of the rail shelves 36, 38. An intermediate snap bracket 16 is positioned 156 such that the inner half portion 166 of the end light module 14 is disposed below the first receptacle 100 and the adjacent half portion 168 of the subsequent light module 14′′ is disposed below the second receptacle 102, with the end notches 106 located above the light module middle tabs 110 and the intermediate notches 108 located above the light module end tab 112. Pushing the intermediate snap bracket 16 toward the rail 12 engages the cam surfaces 86 of the resilient members 82 with the inner edge 62 of the rail shelves 36, 38, biasing the resilient member outer portions 96 towards the rail centerline 158. The intermediate snap bracket 16 is mounted 162 by pushing the snap bracket 16 toward the rail 12, until the light module tabs 110, 112 are inserted into the respective end snap bracket notches 106, 108 and the catch contact surfaces 88 are disposed below the rail shoulder 90, whereby outer portions 96 of the resilient members 82 are biased away from the rail centerline 158 by the resilient member inner portions 92 and the catch contact surfaces 88 are disposed below the rail shoulders 90, locking the end light module inner half portion 166 and the subsequent light module adjacent half portion 168 to the rail 12.
The wires 72 of each subsequent light module 14′′′, 14′ are connected 152 to the wiring harness, the adjacent half portions of each subsequent light module 14′′′, 14′ are mounted 154, 156, 162 to the rail 12 with intermediate snap brackets 16 as described above, and the end half portion 170 of the last light module 14′ is mounted 172 to the rail 12 with a second end snap bracket 18 as described above.
With reference to FIGS. 1, 9 and 11, the light bar snap bracket assembly 10 may also be assembled by connecting 174 the wires 72 of each light module 14 of the assembly 10 to the wiring harness 20. The light modules 14 are all positioned 176 by inserting the light module lower portion 52 through the rail channel outer portion 30, into the rail channel inner portion 32, until the lower surfaces 68 of the light module tabs 110, 112 engage the upper surface 70 of the rail shelves 36, 38. An end snap bracket 18 is positioned 178 such that the half portion of the light module proximate to the rail end is disposed intermediate the two arm segments 124, 126, with the end notches 144 located above the light module middle tabs 110 and the intermediate notches 146 located above the light module end tabs 112. The end snap bracket 18 is mounted 180 by pushing the snap bracket 18 toward the rail 12, until the light module tabs 110, 112 are inserted into the respective end snap bracket notches 144, 146 and the catch contact surfaces 132 are disposed below the rail shoulder 90.
Intermediate snap brackets 16 are consecutively positioned 178 such that the inner half portion 166 of the prior light module 14 is disposed below the first receptacle 100 and the adjacent half portion 168 of the subsequent light module 14′′ is disposed below the second receptacle 102, with the end notches 106 located above the light module middle tabs 110 and the intermediate notches 108 located above the light module end tab 112. Each intermediate snap bracket 16 is mounted 180 by pushing the snap bracket 16 toward the rail 12, until the light module tabs 110, 112 are inserted into the respective end snap bracket notches 106, 108 and the catch contact surfaces 88 are disposed below the rail shoulder 90, locking the remaining half portion of the prior light module inner half portion 166 and the subsequent light module adjacent half portion to the rail 12. After the last intermediate snap bracket is mounted 182, the end half portion 170 of the last light module 14′ is mounted 184 to the rail 12 with a second end snap bracket 18.
In a variation of the second method, the wires 72 of all of the light modules 14 are connected 174 to the wiring harness 20 and the light modules 14 are positioned 176 in the rail 12, as described above, and then all of the snap brackets 16, 18, 216, 218 are mounted 180 to the rail 12 at the same time.
Warning light systems that are subjected to greater vibration-induced mechanical stress, such as those mounted on vehicles that can be driven off-road, may be constructed utilizing intermediate snap brackets 216, end snap brackets 218, locking device 308 and fastener 310 (FIGS. 12-19). As explained in greater detail below, the locking devices 308 bias the resilient members 228, 274 of the snap brackets 216, 218 outward, preventing disengagement of the snap brackets 216, 218 from the rail 12 without removal of the locking device 308.
With additional reference to FIGS. 17, 18 and 19, each locking device 308 is a unitary C-shaped structure having first and second biasing segments 312, 314 extending obliquely from either end of a central, body segment 316. The inner edge 318 of the biasing segments 312, 314 and the body segment 316 forming a receptacle 320 for receiving the lower portions 322, 324 of the snap bracket web segments 220, 268. The body segment 316 has first, second and third bores 326, 328, 330 extending from the inner edge 318, with the inner surface 332 of the first bore 326 being threaded. The diameter 334 of the second and third bores 328, 330 are sufficiently larger than the outside diameter 336 of the snap bracket indexing members 264, 266, 304, 306 to facilitate inserting the indexing members 264, 266, 304, 306 into the bores 328, 330.
The light bar snap bracket assembly 10 is assembled in the manner described above, with the addition of positioning 350, 352 one of the locking devices 308 between each of the light modules 14 and positioning 350, 352 one of the locking devices 308 adjacent to each rail end before the intermediate snap brackets 216 and the end snap brackets 218 are positioned. The snap brackets 216, 218 are positioned such that the snap bracket indexing members 264, 266, 304, 306 are aligned with the second and third bores 328, 330 of the locking devices 308 and the snap bracket openings 258, 298 are aligned with the first bore 326 of the locking device 308. As the snap brackets 216, 218 are pushed toward the rail 12, the lower portions 322, 324 of the snap bracket web segments 220, 268 are received within the locking device receptacles 320 and the snap bracket indexing members 264, 266, 304, 306 are received within the second and third bores 328, 330.
After the snap bracket catches 230, 276 engage the rail shoulders 90, the snap brackets 216, 218 are locked 354 to the rail 12. With reference to FIG. 20, the threaded shaft 338 of a fastener 310 is inserted 356 through the opening 258, 298 of each snap bracket 216, 218. The fastener head 340 is initially rotated to engage 358 the fastener threaded shaft 338 with the threaded inner surface 332 of the first bore 326 of the associated locking device 308, and further rotation, or torquing 360, of the fastener head 340 causes the locking device 308 to be drawn 362 toward the snap bracket 216, 218. As the locking device 308 advances toward the snap bracket 216, 218, portions of the outer edges of the biasing segments 312, 314 act as cam surfaces 342, 344, engaging the inner sides 346, 348 of the resilient member outer portions 238, 284 and forcing 364 the resilient member outer portions 238, 284 radially outward such that the catches 230, 276 cannot be moved away from the rail shoulder 90 by forces imparted by movement of the vehicle. As the locking device 308 advances toward the snap bracket 216, 218, the snap bracket indexing members 264, 266, 34, 306 are inserted deeper into the second and third bores 328, 330, while preventing rotation of the locking device 308 that would result in misalignment between can surfaces 342, 344 and inner sides 346, 348.
It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

## Claims

1. A light bar snap bracket assembly comprises:
an elongated rail member including
first and second sidewalls defining a channel extending from a first end of the rail member to a second end of the rail member,
first and second, oppositely disposed shelves extending laterally from the sidewalls into the channel, each of the shelves having an upper surface and a lower shoulder;

a plurality of light modules, each light module including
oppositely disposed, longitudinally extending first and second sides, and
at least one tab extending laterally from each side, each of the tabs having upper and lower surfaces,
each light module defining first and second half portions, the second half portion extending longitudinally from the first half portion;

a plurality of snap brackets, each snap bracket including
a web segment having
oppositely disposed first and second ends,
first and second resilient members disposed adjacent the first and second ends, respectively, and
a catch extending laterally outward from each resilient member, and

first and second arm segments extending substantially orthogonally from the first and second ends of the web segment, respectively, each of the arm segments having a lower edge defining at least one notch; and

a plurality of locking devices, each locking device including a body segment having oppositely disposed first and second ends and first and second biasing segments extending from the first and second ends, respectively,
wherein
the light modules are disposed within the rail member channel in a line of light modules extending longitudinally from a first light module disposed at the first end of the rail member to a last light module disposed at the second end of the rail member, the line of light modules defining pairs of adjacent light modules, the lower surfaces of the tabs contacting the upper surfaces of the shelves,
one of the snap brackets is disposed intermediate each light module in each pair of light modules, one of the snap brackets is disposed intermediate the first light module and the first end of the rail member, and one of the snap brackets is disposed intermediate the last light module and the second end of the rail member, the first and second arm segments of each snap bracket extending longitudinally over the at least one tab of the first and second sides, respectively, of the light module half portion adjacent the snap bracket web segment, the tabs of the first and second light module sides being received within the notches of the first and second arm segments, respectively, the catches of the web segment resilient members engaging the lower shoulders of the rail member shelves whereby the snap brackets mount the light modules to the rail member, and
one of the locking devices is disposed adjacent each snap bracket, the locking device biasing segments biasing the snap bracket resilient members radially outward whereby the locking devices lock the snap bracket catches in engagement with the rail shoulder.

2. The light bar snap bracket assembly of claim 1 wherein each locking device is a unitary C-shaped structure, the body segment and biasing segments defining a receptacle for receiving a lower portion of the snap bracket web segment.

3. The light bar snap bracket assembly of claim 2 wherein the snap bracket web segment defines an opening extending from an upper surface of the web segment to a lower surface of the web segment, and the snap bracket further includes first and second indexing members extending downwardly from the lower surface of the web segment.

4. The light bar snap bracket assembly of claim 3 wherein the body segment of each locking device defines first, second and third bores extending from an inner edge of the body segment, the first and second snap bracket indexing members being received within the second and third bores, respectively.

5. The light bar snap bracket assembly of claim 4 wherein the first bore is disposed intermediate the second and third bores and has a threaded surface.

6. The light bar snap bracket assembly of claim 5 further comprising a fastener having a threaded shaft extending from a head, the threaded shaft being inserted through the snap bracket web segment opening to engage the threaded first bore of the locking device.

7. The light bar snap bracket assembly of claim 2 wherein
each of the snap bracket resilient members includes
an inner portion that extends upwardly from a center part of the web segment, and
an outer portion that extends downwardly from the inner portion through an opening of the web segment, the catch extending laterally outward from an outer side of the outer portion; and

each of the locking device biasing segments has a cam surface engaging an inner side of the resilient member outer portion and biasing the resilient member outer portion radially outward.

8. A method of manufacturing a light bar assembly, the light bar assembly having one or more light modules mounted to an elongated rail member by a plurality of snap brackets and locked to the rail member by a plurality of locking devices, each light module including oppositely disposed, longitudinally extending first and second sides, and at least one tab extending laterally from each side, each of the tabs having upper and lower surfaces, the rail member including first and second sidewalls defining a channel extending from a first end of the rail member to a second end of the rail member and first and second, oppositely disposed shelves extending laterally from the sidewalls into the channel, each of the shelves having an upper surface and a lower shoulder, each snap bracket including a web segment having oppositely disposed first and second ends, first and second resilient members disposed adjacent the first and second web segment ends, respectively, and first and second arm segments extending substantially orthogonally from the first and second ends of the web segment, respectively, each of the arm segments having a lower edge defining at least one notch, each locking device including a body segment having oppositely disposed first and second ends and first and second biasing segments extending from the first and second ends, respectively, the method comprising:
A) positioning a first of the light modules in the rail member channel adjacent the rail member first end, the lower surfaces of the light module tabs engaging the upper surface of the rail shelves;
B) positioning a locking device between the rail member first end and the light module;
C) positioning a snap bracket between the rail member first end and the light module;
D) pushing the snap bracket toward the rail member and locking device until the light module tabs are received by the snap bracket first and second arm segment notches and a catch extending laterally outward from each resilient member is disposed below the rail shoulder thereby installing the light module;
E) engaging the snap bracket with the locking device to lock the light module to the rail member;
F) determining whether a subsequent light module must be mounted to the rail member; and
G) if a subsequent light module must be mounted to the rail member
1) positioning the subsequent light module in the rail member channel adjacent the installed light module, the lower surfaces of the light module tabs engaging the upper surface of the rail shelves,
2) positioning one of the locking devices between the installed light module and the subsequent light module,
3) positioning one of the snap brackets between the installed light module and the subsequent light module,
4) pushing the snap bracket toward the rail member and locking device until the light module tabs of the installed light module and the subsequent light module are received by the snap bracket first and second arm segment notches and the catch of each resilient member is disposed below the rail shoulder thereby installing the subsequent light module,
5) engaging the snap bracket with the locking device to lock the light module to the rail member, and
4) performing step D; or

H) if a subsequent light module must not be mounted to the rail member
1) positioning one of the locking devices between the rail member second end and the installed light module,
2) positioning one of the snap brackets between the rail member second end and the installed light module,
3) pushing the snap bracket toward the rail member and locking device until the light module tabs are received by the snap bracket first and second arm segment notches and the of each resilient member is disposed below the rail shoulder, and
4) engaging the snap bracket with the locking device to lock the light module to the rail member, thereby completing manufacturing of the light bar assembly.

9. The method of claim 8 wherein the snap bracket further includes first and second indexing members extending downwardly from the lower surface of the web segment and the locking device body segment defines first, second and third bores extending from an inner edge of the body segment, and wherein positioning the snap bracket includes aligning the snap bracket first and second indexing members with the second and third bores of the locking device body segment.

10. The method of claim 9 wherein pushing the snap bracket includes inserting the snap bracket first and second indexing members into the second and third bores of the locking device body segment.

11. The method of claim 10 wherein the snap bracket web segment defines an opening extending from an upper surface to a lower surface and the locking device body segment defines a threaded bore, and wherein engaging the snap bracket with the locking device includes:
inserting a threaded shaft of a fastener through the snap bracket web segment opening; and
engaging the fastener threaded shaft with the threaded first bore of the locking device.

12. The method of claim 11 wherein engaging the snap bracket with the locking device also includes torquing a head of the fastener whereby the locking device is drawn toward the snap bracket;
the locking device biasing segments engage the snap bracket resilient members; and
the locking device biasing segments bias the snap bracket resilient members radially outward, whereby the snap bracket catches are locked in engagement with the rail shoulder.

13. A light bar snap bracket assembly comprises:
an elongated rail member including
first and second sidewalls defining a channel extending from a first end of the rail member to a second end of the rail member,
first and second, oppositely disposed shelves extending laterally from the sidewalls into the channel, each of the shelves having an upper surface and a lower shoulder;

a plurality of light modules, each light module including
oppositely disposed, longitudinally extending first and second sides,
first and second end tabs extending laterally from each side, and
a middle tab extending laterally from each side intermediate the end tabs,
each light module defining first and second half portions, the second half portion extending longitudinally from the first half portion;

a plurality of intermediate snap brackets, each intermediate snap bracket including
a web segment having
oppositely disposed first and second ends,
first and second resilient members disposed adjacent the first and second ends, respectively, and
a catch extending laterally outward from each resilient member, and

first and second arm segments extending substantially orthogonally from the first and second ends of the web segment, respectively, each of the arm segments having
a lower edge defining at least one notch, and
oppositely disposed first and second ends the web segment first and second ends being disposed at a position intermediate the first and second ends of the first and second arm segments, respectively;


a plurality of end snap brackets, each end snap bracket including
a web segment having
oppositely disposed first and second ends,
first and second resilient members disposed adjacent the first and second ends, respectively, and
a catch extending laterally outward from each resilient member, and

first and second arm segments extending substantially orthogonally from the first and second ends of the web segment, respectively, each of the arm segments
having a lower edge defining at least one notch, and
oppositely disposed first and second ends the web segment first and second ends being disposed adjacent the first end of each arm segment; and


a plurality of locking devices, each locking device including a body segment having oppositely disposed first and second ends and first and second biasing segments extending obliquely from the first and second ends, respectively;
wherein
the light modules are disposed within the rail member channel in a line of light modules extending longitudinally from a first light module disposed at the first end of the rail member to a last light module disposed at the second end of the rail member, the line of light modules defining pairs of adjacent light modules, the lower surfaces of the tabs contacting the upper surfaces of the shelves,
one of the intermediate snap brackets is disposed intermediate each light module in each pair of light modules, one of the end snap brackets is disposed intermediate the first light module and the first end of the rail member, and another one of the end snap brackets is disposed intermediate the last light module and the second end of the rail member, the first and second arm segments of each snap bracket extending longitudinally over the at least one tab of the first and second sides, respectively, of the light module half portion adjacent the snap bracket web segment, the tabs of the first and second light module sides being received within the notches of the first and second arm segments, respectively, the catches of the web segment resilient members engaging the lower shoulders of the rail member shelves whereby the snap brackets mount the light modules to the rail member, and
one of the locking devices is disposed adjacent each snap bracket, the locking device biasing segments biasing the snap bracket resilient members radially outward whereby the locking devices lock the snap bracket catches in engagement with the rail shoulder.

14. The light bar snap bracket assembly of claim 13 wherein each locking device is a unitary C-shaped structure, the body segment and biasing segments defining a receptacle for receiving a lower portion of the adjacent snap bracket web segment.

15. The light bar snap bracket assembly of claim 14 wherein each snap bracket web segment defines an opening extending from an upper surface of the web segment to a lower surface of the web segment, and each snap bracket further includes first and second indexing members extending downwardly from the lower surface of the web segment.

16. The light bar snap bracket assembly of claim 15 wherein the body segment of each locking device defines first, second and third bores extending from an inner edge of the body segment, the first and second snap bracket indexing members being received within the second and third bores, respectively.

17. The light bar snap bracket assembly of claim 16 wherein the locking device first bore is disposed intermediate the second and third bores and has a threaded surface.

18. The light bar snap bracket assembly of claim 16 wherein the locking device first bore has a threaded surface and the assembly further comprises a plurality of fasteners, each fastener having a threaded shaft extending from a head, the threaded shaft of one of the fasteners being inserted through the opening of each snap bracket web segment to engage the threaded first bore of the adjacent locking device.

19. The light bar snap bracket assembly of claim 14 wherein
each of the snap bracket resilient members includes
an inner portion that extends upwardly from a center part of the web segment, and
an outer portion that extends downwardly from the inner portion through an opening of the web segment, the catch extending laterally outward from an outer side of the outer portion; and

each of the locking device biasing segments has a cam surface engaging an inner side of the resilient member outer portion and biasing the resilient member outer portion radially outward.