Thin lamp assembly method
First Claim
1. A thin lamp assembly comprising:
- a. a lamp housing and a lens heat staked together; and
b. a light source positioned in between the lens and the lamp housing.
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Accused Products
Abstract
The subject invention comprises a thin lamp assembly having a lens and a lamp housing heat staked and sealed together. The subject invention further comprises the method of assembling the thin lamp assembly. In one embodiment, the lens has a plurality of plastic stakes and a lens rib located around the lens'"'"' periphery. Further, the lamp housing has a plurality of receiving holes around its outer periphery and a lamp housing rib around its inner periphery. In this embodiment, a sealant is placed on the lamp housing and the plastic stakes are inserted into the receiving holes so that the lens rib and lamp housing rib form a seal channel to contain the sealant and the lens is flush with the lamp housing. A heat source is then used to heat treat the plastic stakes to form a plurality of mushroom caps that act to attach the lens to the lamp housing.
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Citations
36 Claims
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1. A thin lamp assembly comprising:
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a. a lamp housing and a lens heat staked together; and
b. a light source positioned in between the lens and the lamp housing. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
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23. A method of assembling a thin lamp assembly comprising the steps of:
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a. providing a lamp housing;
b. providing a lens;
c. providing a light source;
d. providing a seal channel;
e. placing a sealant into the seal channel;
f. placing the lens on top of the lamp housing so that the light source is enclosed by the lens and the lamp housing; and
g. heat staking the lens and the lamp housing together. - View Dependent Claims (24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34)
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35. A thin lamp assembly comprising:
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a. a lamp housing having (i) a plurality of receiving holes located sporadically around the lamp housing'"'"'s outer periphery; and
(ii) a lamp housing rib located around the lamp housing'"'"'s inner periphery;
b. a light source secured to the lamp housing;
c. a lens heat staked to the lamp housing, the lens having (i) a plurality of plastic stakes located on the lens'"'"' backside and sporadically around the lens'"'"' periphery; and
(ii) a lens rib located on the lens'"'"' backside and around the lens'"'"' periphery;
d. a seal channel located in between the lens rib and lamp housing rib;
e. a sealant located in the seal channel; and
f. a plurality of mushroom caps that each cover each of the plurality of plastic stakes and each of the plurality of receiving holes.
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36. A thin lamp assembly comprising:
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a. a means for attaching a lens to a lamp housing utilizing a plurality of plastic stakes; and
b. a means for sealing the lens and the lamp housing together.
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Specification