Patent ID: 8657465

Claim:
An improved LED lamp assembly of the type having a metallic heat sink ( 102 ) defining a circuit board receiving region ( 143 ), said heat sink ( 102 ) further defining on an upper outwardly facing surface ( 122 ) thereof a substantially continuous channel ( 142 ) surrounding said circuit board receiving region ( 143 ), said channel ( 142 ) defined between an inner rib ( 144 ) and a radially outermost peripheral portion ( 140 ) of said heat sink ( 102 ); a circuit board ( 108 ) positioned in said circuit board receiving region ( 143 ) and having a plurality of light emitting diodes (LEDs) ( 110 ) operatively fixed thereto; and a housing cover ( 112 ) formed of a plastics material, said housing cover ( 112 ) comprising a longitudinally extending median region ( 158 ) having a lower surface ( 160 ) facing said circuit board ( 108 ) and an upper surface ( 162 ) facing away from said circuit board ( 108 ), and defining a depending peripheral rib ( 164 ) formed on said lower surface ( 160 ), said housing ( 112 ) cover further comprising an integrally molded optic ( 114 ) comprising a plurality of reflectors ( 176 ) disposed on said housing cover ( 114 ), an optical axis (A) of said optic ( 114 ) being transverse said median region ( 158 ), wherein said peripheral rib ( 164 ) is formed at an outermost peripheral region of said housing cover ( 112 ) and sized and shaped to register with said channel ( 142 ) formed in said heat sink ( 102 ), wherein said optic ( 114 ) has a lower optic portion ( 168 ) extending downwardly from said lower surface ( 160 ) toward said circuit board ( 108 ) and an upper optic portion ( 166 ) extending upwardly above said median region ( 158 ), and said housing cover ( 112 ) further comprising on said lower surface ( 160 ), adjacent said lower optic portion ( 168 ), a plurality of registration pads ( 180 ) extending toward said circuit board ( 108 ) to thereby limit in an assembled condition a spaced relationship between said optic ( 114 ) and said plurality of LEDs ( 110 ), wherein the improvement comprises: the upper outermost peripheral portion ( 140 ) of the heat sink ( 102 a ) that bounds said channel ( 142 ) is deformed continuously around an entire perimeter of the heat sink ( 102 a ) radially inward towards the peripheral rib ( 164 ) of the housing cover ( 112 a ) whereby said peripheral rib ( 164 ) is compressed towards said inner rib ( 144 ) thereby locking said housing cover ( 112 a ) to said heat sink ( 102 a ).