Abstract:
A lamp comprises an optical lens. The lamp further comprises a self-locking trim ring including a plurality of teeth. The self-locking trim ring is disposed over the optical lens. The lamp further comprises a heat sink. The heat sink has an inner chamber wherein the optical lens is disposed in the inner chamber. The heat sink also has an outer chamber disposed radially outwardly from the inner chamber. The outer chamber has a recess that engages the plurality of teeth. The self-locking trim ring secures the optical lens to the heat sink.

Description:
FIELD OF DISCLOSURE 
       [0001]    The present disclosure relates to the field of lamps. More particularly, the present disclosure relates to a method and apparatus for securing an optical lens to a lamp housing or heat sink. 
       BACKGROUND 
       [0002]    A lamp has, among other components, an optical lens for refracting, reflecting, or otherwise transmitting light. Assembling the lamp requires securing the optical lens to a lamp housing or a heat sink. Existing dry assembly techniques may secure the optical lens to the heat sink using a number of screws. Existing wet assembly may techniques apply an adhesive in a ridge in the heat sink before inserting the screws. The screws provide pressure while the adhesive between the heat sink and the optical lens cures. A decorative finish ring may be added to conceal the adhesive and screws. 
         [0003]    Existing assembly techniques, however, may require multiple component parts. Using multiple component parts may result in an increase in cost of manufacturing the lamp as well as an increase in labor time necessary for assembly. Using multiple component parts may also result in increased occurrences of assembly error since additional assembly steps may be required. Furthermore, existing heat sink and lamp assemblies are not easily adaptable for both wet and dry assembly techniques. 
       SUMMARY OF THE DISCLOSURE 
       [0004]    A lamp comprises an optical lens. The lamp further comprises a self-locking trim ring including a plurality of teeth. The self-locking trim ring is disposed over the optical lens. The lamp further comprises a heat sink. The heat sink has an inner chamber wherein the optical lens is disposed in the inner chamber. The heat sink also has an outer chamber disposed radially outwardly from the inner chamber. The outer chamber has a recess that engages the plurality of teeth. The self-locking trim ring secures the optical lens to the heat sink. 
         [0005]    A lamp has a self-locking trim ring with a plurality of ridges having flanks. The lamp further has a lens housing. The lens housing has an inner channel configured to support an optical lens. The lens housing also has an outer channel with a recess configured to engage the flanks of the plurality of ridges. The self-locking trim ring is configured to secure the optical lens to the lens housing. 
         [0006]    Further, according to another aspect of the present disclosure, a method for securing an optic lens to a heat sink includes the step of inserting an optic lens into an inner chamber of a heat sink. The method further includes the step of aligning a plurality of teeth of a self-locking trim ring with a plurality of cutouts of a recess in an outer chamber of the heat sink. The method further includes the step of inserting the teeth into a groove in the outer chamber, via the cutouts. The method further includes the step of rotating the self-locking trim ring to engage the recess with the plurality of teeth. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    In the accompanying drawings, structures are illustrated that, together with the detailed description provided below, describe exemplary aspects of the present teachings. Like elements are identified with the same reference numerals. It should be understood that elements shown as a single component may be replaced with multiple components, and elements shown as multiple components may be replaced with a single component. The drawings are not to scale and the proportion of certain elements may be exaggerated for the purpose of illustration. 
           [0008]      FIG. 1  illustrates a perspective view of an example lamp according to one exemplary aspect of the present teaching. 
           [0009]      FIG. 2  is a top view of an example heat sink of  FIG. 1 . 
           [0010]      FIG. 3  is a bottom view of an example self-locking trim ring of  FIG. 1 . 
           [0011]      FIG. 4  illustrates an example method for securing an optical lens to a heat sink. 
           [0012]      FIG. 5  is a cross-sectional side view of the example lamp of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0013]      FIG. 1  illustrates a perspective view of an example lamp  100  according to one exemplary aspect of the present teaching. Lamp  100  comprises a heat sink  102 , an optical lens  104 , and a self-locking trim ring  106 . Self-locking trim ring  106  is configured to secure optical lens  104  to heat sink  102 . It should be understood that, although the example aspects of the present disclosure describes optical lens  104  as being secured to heat sink  102  specifically, self-locking trim ring  106  may be used to secure optical lens  104  to a lamp housing or other similar fixture as well. 
         [0014]    As shown herein, the illustrated self-locking trim ring  106  is a single part and is configured to secure optical lens  104  to heat sink  102  without the need for additional part. As a result, the assembly time and cost of lamp  100  may be reduced. Similarly, the rate of occurrence of assembly errors may be reduced as well since the number of steps required to assemble lamp  100  may be less than otherwise required. Moreover, self-locking trim ring  106  and heat sink  102  are configured for both dry and wet location applications. This combined functionality may result in cost savings as well since such combined functionality may eliminate the need to manufacture separate lamp components for both dry and wet location applications. 
         [0015]    In one aspect of the present disclosure, self-locking trim ring  106  is a synthetic material. For example, self-locking trim ring  106  may be made of plastic. In an example embodiment, self-locking trim ring  106  may be made of a flexible material to allow for bending of the self-locking trim ring  106  during assembly. 
         [0016]    In one aspect of the present disclosure, heath sink  102  is a single block of material such as aluminum, ceramic, plastic, or other material with suitable thermal properties. In another aspect of the present disclosure, heat sink  102  comprises a plurality of components combined to form a single component part. 
         [0017]      FIG. 2  is a top view of an example heat sink  102  of  FIG. 1 . Heat sink  102  comprises an inner chamber  202 , or channel, configured to receive optical lens  104  and support optical lens  104  from underneath. 
         [0018]    In one aspect of the present disclosure, inner chamber  202  comprises an inner groove  216 . Inner groove  216  may be configured to receive a sealant. The sealant may be an adhesive such as glue. Alternatively, the sealant may be silicone. Alternatively, the sealant may be a pre-formed gasket or ring. The sealant helps create a bond between optical lens  104  and heat sink  102  to prevent liquids from penetrating. Thus, with the additional inner groove  216  configured to receive a sealant, lamp  100  may be assembled for either a wet application or dry application without modifying lamp  100 . 
         [0019]    In one aspect of the present disclosure, optical lens  104 , illustrated in  FIG. 1 , has a flange (not shown) protruding from the underside. Inner groove  216  may be configured to receive the flange. Such a flange may provide for a more secure fitting of optical lens  104  with heat sink  102 . The flange and inner groove  216  may also provide a guide for an assembler to easily position optical lens  104  in inner chamber  202  when assembling lamp  100 . 
         [0020]    Heat sink  102  further comprises an outer chamber  204 , or channel. Inner chamber  202  and outer chamber  204  are separated by barrier  206 . In one aspect of the present disclosure, barrier  206  is configured to surround the perimeter of optic lens  104  to hold optic lens  104  in place to prevent optic lens  104  from shifting within inner chamber  202 . 
         [0021]    Outer chamber  204  comprises a recess  208 . Recess  208  protrudes in from an outer wall  210  of outer chamber  204  and perpendicular to outer wall  210 , and partially overlays or covers outer chamber  204 . In one aspect of the present disclosure, recess  208  supports self-locking trim ring from underneath. 
         [0022]    In one aspect of the present disclosure, recess  208  comprises a plurality of cutouts  214   a - h  or openings (hereinafter referred to as cutouts  214 ). It should be understood that although  FIG. 2  illustrates eight cutouts  214 , recess  208  may comprise any number of cutouts  214 . In one aspect of the present disclosure, outer chamber  204  further comprises an outer groove  212 . 
         [0023]      FIG. 3  is a bottom view of an example self-locking trim ring  106  of  FIG. 1 . Self-locking trim ring  106  has a plurality of teeth  302   a - d  (hereinafter referred to as teeth  302 ), or ridges having flanks. The teeth  302  extend out from underneath self-locking trim ring  106 . Recess  208 , illustrated in  FIG. 2 , is configured to engage the teeth  302 , or the flanks of the ridges, of self-locking trim ring  106 . In other words, teeth  302  are configured to couple with recess  208  which is configured to hold teeth  302  in place. In one aspect of the present disclosure, outer groove  212 , illustrated in  FIG. 2 , is configured to receive teeth  302  via cutouts  214 . It should be understood that although  FIG. 3  illustrates self-locking trim ring  106  comprising four teeth  302 , self-locking trim ring  106  may comprise any suitable number of teeth. 
         [0024]    In one aspect of the present disclosure, self-locking trim ring  106  has a plurality of bosses  304   a - d  (hereinafter referred to as bosses  304 ), or protruding guides, configured to align with cutouts  214 . Bosses  304  sink into cutouts  214  and prevent self-locking trim ring  106  from rotating after assembly is complete. Thus, in one aspect of the present disclosure, the combination of recess  208  engaging teeth  302  of self-locking trim ring  106  and cutouts  214  of recess  208  aligning with bosses  304  of self-locking trim ring  106  result in a permanent lock. In other words, once engaged, self-locking trim ring  106  cannot be removed from heat sink  102  without altering the shape or form of self-locking trim ring  102  by breaking, bending, or cutting self-locking trim ring  106 . 
         [0025]    It should be understood that, although the figure illustrates four bosses  304 , self-locking trim ring  102  may comprise any number of bosses  304 . 
         [0026]    Referring back to  FIG. 1 , in one aspect of the present disclosure, self-locking trim ring  106  further includes at least one trim-ring guide mark  108  on the top side, corresponding to one of the teeth  302  illustrated in  FIG. 3 . Additionally, heat sink  102  further includes at least one heat sink guide mark  110 . Trim-ring guide mark  108  and heat sink guide mark  110  provide an assembler with a guide for aligning teeth  302  illustrated in  FIG. 3  with cutouts  214  illustrated in  FIG. 2 , which are not visible to the assembler during an assembly process. 
         [0027]      FIG. 4  illustrates an example method for securing optical lens  104  to heat sink  102 . At step  402 , an assembler, inserts optical lens  104  into inner chamber  202  of heat sink  102 . In one aspect of the present disclosure, the assembler inserts optical lens  104  by inserting a flange of optical lens  104  into inner groove  216  of inner chamber  202  of heat sink  102 . In one aspect of the present disclosure, the assembler adds a glue, or a sealant, to inner chamber  202  before inserting optical lens  104 . 
         [0028]    At step  404 , the operator aligns teeth  302  of self-locking trim ring  106  with cutouts  214  of recess  208  in outer chamber  204  of heat sink  102 . In one aspect of the present disclosure, the operator aligns teeth  302  with cutouts  214  by aligning trim ring guide mark  108  with heat sink guide mark  110 . 
         [0029]    At step  406 , the assembler inserts teeth  302  into outer groove  212  of outer chamber  204  via cutouts  214 . At step  408 , the assembler rotates self-locking trim ring  106  to engage recess  208  with teeth  302 . In one aspect of the present disclosure, the assembler rotates self-locking trim ring  106  until bosses  304  of the self-locking trim ring  106  align with cutouts  214  of recess  208  and sink into cutouts  214 . This locks in self-locking trim ring  106  and prevents self-locking trim ring  106  from rotating further. In one aspect of the present disclosure, such rotating permanently locks, or couples, self-locking trim ring  106  with heat sink  102 , or permanently engages recess  208  with teeth  302 . 
         [0030]    In another aspect of the present disclosure, an assembler aligns self-locking trim ring  106  such that one or more teeth  302  align with corresponding cutouts  214  in outer chamber  204 . Assembler applies pressure to top of self-locking trim ring  106  at one or more points corresponding to the top side of one or more teeth  302 , flexing self-locking trim ring  106  about bosses  304 , which do not align with any cutout  214 , in order to insert teeth  302  into cutouts to a depth sufficient to parallel the corresponding outer groove  212 . While initially maintaining pressure, assembler rotates self-locking trim ring  106 , engaging one or more teeth  302  and outer groove  212 . Rotation is continued until bosses  304  align with and sink into one or more cutouts  214 , releasing the deflection of self-locking trim ring  106 , halting rotation of the self-locking trim ring  106 , and locking self-locking trim ring  106  into place. Accordingly, in one aspect of the present disclosure, self-locking trim ring  106  is made of a flexible material. 
         [0031]    In one aspect of the present disclosure, an assembler flexes or bends self-locking trim ring  106  while simultaneously applying pressure to the top of self-locking trim ring  106 , at one or more points corresponding to the top side of one or more teeth  302 , in order to insert teeth  302  into outer groove  212 . In one aspect of the present disclosure, the installer maintains self-locking trim ring  106  in a flexed position and also maintains pressure on the top of self-locking trim ring while rotating self-locking trim ring  106  until bosses  304  align with and sink into cutouts  214 . Once bosses  304  align with and sink into cutouts  214 , assembler releases the pressure being applied to self-locking trim ring  106  which allows self-locking trim ring  106  to straighten from its flexed position and lock into place. Accordingly, in one aspect of the present disclosure, self-locking trim ring  106  is made of a flexible material. 
         [0032]      FIG. 5  is a cross-sectional side view of lamp  100  of  FIG. 1  after self-locking trim ring  106  has been inserted to secure optical lens  104  to heat sink  102 , according to the method described in  FIG. 4 . Heat sink  102  has inner chamber  202  with inner groove  216  for receiving flange  502  of optical lens  104 . Heat sink  102  also has outer chamber  204  with outer groove  212  for receiving teeth  302  of self-locking trim ring  106 . Outer chamber  204  also has recess  208  for engaging teeth  302 . 
         [0033]    To the extent that the term “includes” or “including” is used in the specification or the claims, it is intended to be inclusive in a manner similar to the term “comprising” as that term is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term “or” is employed (e.g., A or B) it is intended to mean “A or B or both.” When the applicants intend to indicate “only A or B but not both” then the term “only A or B but not both” will be employed. Thus, use of the term “or” herein is the inclusive, and not the exclusive use. See, Bryan A. Garner, A Dictionary of Modern Legal Usage 624 (2d. Ed. 1995). Also, to the extent that the terms “in” or “into” are used in the specification or the claims, it is intended to additionally mean “on” or “onto.” Furthermore, to the extent the term “connect” is used in the specification or claims, it is intended to mean not only “directly connected to,” but also “indirectly connected to” such as connected through another component or components. 
         [0034]    While the present application has been illustrated by the description of example aspects of the present disclosure thereof, and while the example aspects have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the application, in its broader aspects, is not limited to the specific details, the representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant&#39;s general inventive concept.