Snap bracket locking device

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.

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.