Patent ID: 7025485

Claim:
A method of manufacturing an automotive lamp comprising a lens, a printed circuit board having at least one of LED, and a lamp housing, the method comprising the steps of: a. fixing the lens to the printed circuit board to form a PCB subassembly, the fixed relationship between the lens and the printed circuit board thereby securing a proper alignment between the lens and the at least one LED on the printed circuit board; and b. fixing the PCB subassembly to the lamp housing; c. wherein the lens is fixed to the printed circuit board by first contacting the lens and the printed circuit board such that a plurality of stakes, mounted on the lens, extend through a plurality of associated holes in the circuit board, and then melting the plurality of stakes extending through the plurality of holes; and d. wherein the PCB subassembly is fixed to the lamp housing by first contacting the PCB subassembly and the lamp housing such that a plurality of stakes, mounted on the housing, extend through a plurality of associated holes in the circuit board, and then melting the plurality of stakes extending through the plurality of holes.