Patent ID: 8636395

Claim:
A process for making an emergency light whose external housing is divided into separable sections and contains light assemblies comprising beam shaping devices that each produce a separate light beam, the process including: populating a circuit board with two or more of the light assemblies by registering each of the light assemblies with respect to one or more references on the circuit board, which registration properly positions the light assembly for generating a light beam; fastening each of the light assemblies to the circuit board at the proper position, where the proper position orients the light beam produced by the beam shaping device of the light assembly to be substantially in a direction perpendicular to a normal of a flat surface of the circuit board; piloting the circuit board to mate with an interior surface of at least one of the sections of the housing by aligning one or more references fixed to the circuit board and one or more references fixed to the housing, which alignment registers each of the light assemblies fastened to the circuit board with a lens in the housing such that each individual light assembly corresponds to an individual lens in the housing; fastening the circuit board to the interior surface of the housing section; and mating the sections of the housing so that the circuit boards and the light assemblies are contained within a closed space defined by the interior of the housing.