Light bar and method for making

A vehicle light bar having a housing extending substantially across a roof of the vehicle, the vehicle light bar made by the process of:

• fastening two or more emergency lights on a planar surface of a circuit board by matching a pattern of keys on each of the emergency lights to a complementary pattern of keys in the planar surface of the circuit board so as to position the two or more emergency lights at predetermined locations on the planar surface of the circuit board that (1) enable completion of electrical connections between the emergency lights and the circuit board and (2) position the emergency lights to beam light substantially along the planar surface of the circuit board;
• electrically connecting the two or more emergency lights to a cable connector on the circuit board by completing the electrical connections between the two or more emergency lights and the circuit board enabled by the fastening of the two or more emergency lights to the circuit board;
• and
• fastening the circuit board in the housing of the light bar for securing to a surface of the vehicle such that the planar surface of the circuit board extends longitudinally across the housing and the fastening is accomplished by longitudinally aligning complementing patterns of keys in the circuit board and the housing, resulting in the emergency lights being optically aligned with one or more lenses in the housing.

A vehicle light bar comprising:

• a housing, where the housing extends substantially across the emergency vehicle and having lenses in at least one of a front and a rear of the housing;
• one or more circuit boards mounted to the interior of the housing and oriented to have their planar surfaces extending longitudinally between the front and rear of the housing;
• each circuit board including conductive traces providing electrical connections between a connector on the circuit board and two or more sites on the circuit board for mounting emergency lights;
• and
• at least two of the sites on each of the circuit boards having keys for mating with complementary keys on the emergency lights in order to fasten the emergency lights at predetermined positions on the circuit board that align the emergency lights with the lenses of the housing and enable electrical connection between the circuit board and the emergency lights.