Thin lamp assembly method
First Claim
1. A thin lamp assembly comprising:
- a. a lamp housing and a lens heat staked together;
b. a light source positioned in between the lens and the lamp housing;
c. a plurality of plastic stakes located on the lens'"'"' back side and sporadically around the lens'"'"' periphery;
d. a plurality of receiving holes located sporadically around the lamp housing'"'"'s outer periphery wherein each of the plurality of receiving holes contains one of the plurality of plastic stakes; and
e. a plurality of mushroom caps that each cover one of the plurality of plastic stakes and one of the plurality of receiving holes.
8 Assignments
0 Petitions
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.
-
Citations
23 Claims
-
1. A thin lamp assembly comprising:
-
a. a lamp housing and a lens heat staked together;
b. a light source positioned in between the lens and the lamp housing;
c. a plurality of plastic stakes located on the lens'"'"' back side and sporadically around the lens'"'"' periphery;
d. a plurality of receiving holes located sporadically around the lamp housing'"'"'s outer periphery wherein each of the plurality of receiving holes contains one of the plurality of plastic stakes; and
e. a plurality of mushroom caps that each cover one of the plurality of plastic stakes and one of the plurality of receiving holes. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
-
-
14. A method of assembling a thin lamp assembly comprising the steps of:
-
a. providing a lamp housing having at least one light source and a plurality of receiving holes located sporadically around the lens'"'"' periphery;
b. providing a lens having a plurality of plastic stakes located sporadically around the lamp housing'"'"'s outer periphery;
c. providing a seal channel;
d. placing a sealant into the seal channel;
e. placing the lens on top of the lamp housing so that the light source is enclosed by the lens and the lamp housing and the plurality of plastic stakes are inserted into the plurality of receiving holes; and
f. heat staking each of the plurality of plastic stakes in order to heat stake the lens and the lamp housing together. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22)
-
-
23. A thin lamp assembly comprising:
-
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.
-
Specification