Two-member fastening element

Abstract

A two-member fastening element for joining a planar object and an optical device to a carrier, comprising: a first portion having one or more first resilient pins, where the one or more first resilient pins comprise one or more protruding edges; the second part is provided with a second elastic pin; the third part is provided with a third elastic pin; a connecting portion between the first portion, the second portion and the third portion wherein the second portion extends substantially perpendicular to the connecting portion and the third portion extends at an angle perpendicular to the connecting portion, wherein the first resilient pin / edge and the second resilient pin are configured to generate a biasing force to engage the planar object and the carrier together, and wherein the first resilient pin / edge is insertable through a slot through the carrier to retain the planar object between the carrier and the second resilient pin, the third elastic pins engage the optical device or enable the optical device to be snapped in and between the two third elastic pins of the two dual-member fastening elements, and the optical device is held in place above the second portions of the two dual-member fastening elements.

Description

Technical Field

[0001] The present disclosure generally relates to a two-component fastening element. More particularly, but not exclusively, embodiments disclosed herein relate to fastening a planar object such as an LED board and an optical device such as a lens over the LED board to a carrier such as a lamp housing.

[0002] Light emitting diodes (LEDs) have the following advantages: they provide bright light, are reasonably inexpensive, have a long operating life, and consume very little power. As a result, LEDs are increasingly used in a variety of lighting applications as a replacement for other forms of lighting, such as incandescent lamps, halogen lamps, etc.

[0003] As part of the lamp manufacturing or assembly process, it is often necessary to fasten the LED board to the lamp housing and the optics or lens assembly to the LED board. Since there are numerous configurations and sizes of LED boards and optics across the lighting spectrum, the fastening process can be time-consuming and sometimes requires additional parts and / or other materials. Existing fastening methods include the use of screws, steel / aluminum rivets, and other specialized plastic fasteners. For certain lamp designs, this existing fastening method may have to be combined with a sheered lance and shape in the lamp housing.

[0004] When various fastening methods are employed across a product line, multiple fasteners in various forms and positions may be required, depending on the configuration and size of the LED board and optics. This leads to inconsistencies in manufacturing and assembly, which in turn increases costs. Therefore, a universal and inexpensive fastening device is needed to secure the LED board and optics to the luminaire housing. Furthermore, the fastening device should be reliable and consistent, regardless of the configuration and size of the LED board and optics.

[0005] The present disclosure relates to an apparatus and method for securing an at least partially planar object (such as an LED board) and an optical device (such as a lens above the LED board) to a carrier (such as a lamp housing). More specifically, in various embodiments, a dual-component fastening element constructed in accordance with selected aspects of the present disclosure can be used to secure at least partially planar objects (such as LED boards) and optical device configurations of various sizes to a carrier. The dual-component fastening element can clamp or snap onto the edge of the at least partially planar object with a "spring" or snap-on edge pressure that securely holds the at least partially planar object in place.

[0006] In some embodiments, the dual-member fastening element can be constructed of an insulator material, such as various types of plastic, thereby reducing or eliminating the possibility of grounding or sparking issues if the dual-member fastening element physically contacts electrical traces. In some embodiments, the dual-member fastening element can be used in any light fixture made of sheet metal with an LED board as the light source.

[0007] In some embodiments, a dual-component fastening element for joining a planar object and an optical device to a carrier may include: a first portion having one or more first resilient prongs, each of which may further include one or more protruding edges for engaging or snapping into the carrier; a second portion having a second resilient prong; a third portion having at least one third resilient prong extending at an angle perpendicular to the connecting portion; a connecting portion between the first, second, and third portions; and a tab extending vertically from the connecting portion. The third resilient prongs engage the optical device or enable the optical device to snap into and between the two third resilient prongs, and retain or rest the optical device on the second portions of the two dual-component fastening elements. The first resilient prong / protruding edge and the second resilient prong may be configured to generate a first biasing force and a second biasing force, respectively, to join the planar object and the carrier together. The second resilient prong can be pressed against the exposed surface of the planar object, and the two-component fastening element can be inserted through the slot through the carrier to retain the carrier (and held by the protruding edge of the first resilient prong) between the first and second resilient prongs.

[0008] In some embodiments, a lighting device may include: a light emitting diode (LED) board including at least one LED chip; a lamp housing for receiving the LED board; one or more slots extending through the lamp housing; and one or more two-component fastening elements that grasp at least one of the two components of the LED board and are inserted through the one or more slots to attach the LED board and optical device to the lamp housing. Each of the one or more two-component fastening elements may include: a second portion having one or more second resilient prongs extending toward an exposed surface of the LED board; a first portion having a first resilient prong extending toward a surface of the lamp housing; a third portion having a third resilient prong extending at a perpendicular angle to the connecting portion; a connecting portion located between the first, second, and third portions; and a tab extending vertically from the connecting portion. The first and second resilient prongs may be configured to exert opposing biasing forces on the LED board and the lamp housing. The third resilient prongs of the two two-component fastening elements may be configured to exert opposing biasing forces to enable the optical device to snap therebetween.

[0009] In some embodiments, a method of joining one or more planar objects to a carrier using one or more dual-member fastening elements may include: placing the one or more planar objects on the carrier in a manner that aligns at least one dual member in the one or more planar objects with one or more slots through the carrier; and inserting the one or more dual-member fastening elements through the one or more slots to join the one or more planar objects to the carrier by opposing biasing forces exerted by the one or more dual-member fastening elements on the one or more planar objects and the carrier. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Features of the present disclosure are illustrated by way of example and not limitation in the following figures, in which like reference numerals indicate like elements.

[0011] Figure 1A 、 Figure 1B and Figure 1C is a perspective view of a two-component fastening element according to an embodiment of the present disclosure.

[0012] Figure 2 is a side view of the dual-component fastening element of FIG. 1 attaching a planar object such as an LED board and an optical element such as a lens to a carrier such as a lamp housing according to an embodiment of the present disclosure.

[0013] Figure 3is a perspective view of the two-component fastening element of FIG. 1 attaching a planar object (such as an LED board) and an optical device (such as a lens) to a carrier (such as a luminaire housing) according to an embodiment of the present disclosure.

[0014] Figure 4 is a flow chart of a processor for joining a planar object and an optical device to a carrier using the dual-member fastening element of FIG. 1 according to an embodiment of the present disclosure.

[0015] Figure 5 is a side view of two or three dual-member fastening elements of FIG. 1 attaching two planar objects (such as an LED board) and an optical device (such as a lens) to a carrier (such as a lamp housing) according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0016] For simplicity and illustrative purposes, the present disclosure is described primarily with reference to its examples. In the following description, many specific details are set forth in order to provide a thorough understanding of the present disclosure. However, the present disclosure may be practiced without limitation to these specific details. In other examples, some methods and structures are not described in detail in order to avoid unnecessarily obscuring the present disclosure.

[0017] The elements depicted in the accompanying drawings may include additional components, and some components depicted in the accompanying drawings may be removed and / or modified without departing from the scope of the elements disclosed herein. The elements depicted in the accompanying drawings may not be drawn to scale, and therefore, the elements may have sizes and / or configurations different from those shown in the drawings.

[0018] The examples discussed below will focus on the implementation of the devices and techniques described below within the context of LED applications. However, it will be appreciated that the devices and techniques can also be used in conjunction with other applications in different technical fields.

[0019] Figure 1A 、 Figure 1B and Figure 1C is a perspective view of a dual-component fastening element 10 according to an embodiment of the present disclosure. The dual-component fastening element 10 may include a first portion 12, a second portion 20, a third portion 15, and a connecting portion 16. The first portion 12 may include a first elastic prong and a second elastic prong 14. In some embodiments, one or more first elastic prongs 14 may also include one or more protruding edges 13 to engage or snap onto the carrier 3 (see FIG. 1 ). Figure 2 and Figure 5 ), the carrier is, for example, a lamp housing. The second portion 20 includes at least one elastic plug 22, which extends substantially perpendicular to the connecting portion 16 to engage with an at least partially planar object 2 (such as an LED board). Figure 1A and 1BThe third portion 15 includes at least one third elastic pin 17, which extends at an angle (α) perpendicular to the axis 26 and the connecting portion 16, as shown in FIG. Figure 1A and Figure 1B As shown in Figure 2 and 5 As shown, third spring prongs 17 engage or enable optical device 24 to snap into and between the third spring prongs 17 of the two dual-member fastening elements 10, holding / supporting optical device 24 in place above second portion 20. Furthermore, this provides for a flush assembly between optical device 24 and dual-member fastening element 10. Connecting portion 16 may connect first portion 12, second portion 20, and third portion 15. In some embodiments, at least one tab 18 may extend vertically (e.g., parallel) from connecting portion 16.

[0020] like Figure 2 and 3 , the resilient prongs 22 may extend toward the exposed surface 5 of the at least partially planar object 2, while the first and second resilient prongs 14 may extend toward the surface 6 of the carrier 3. The at least planar object 2 will be referred to herein simply as the "planar object 2," but it will be understood that a planar object is not required to be completely or even exactly planar. For example, a fastening element 10 constructed in accordance with selected aspects of the present disclosure may be used to secure an object that includes a portion that is at least generally planar, but not exactly planar, to another object that may or may not also include a generally planar portion. In some embodiments, the surfaces 5 and 6 may occupy parallel planes and may face in opposite directions, such as Figure 2 and 5 , with the exposed surface 5 facing upward and the surface 6 facing downward. In some embodiments, when the dual-component fastening element 10 is deployed, the connection 16 between the first portion 12 and the second portion 20 can be perpendicular to the other surface 7 of the carrier 3 and / or perpendicular to the exposed surface 5 of the planar object 2.

[0021] The optical device 24 is engaged or snapped between the two dual-component fastening elements 10. In particular, the optical device 24 is pushed or snapped between the respective offsets 17 to at least partially rest between the respective offsets 17 and the respective second portions 20 of the two dual-component fastening elements 10. A portion of the optical device 24 may extend beyond the dual-component fastening elements 10.

[0022] Tab 18 can extend vertically, and in some cases, parallel to axis 26, and from connecting portion 16, and in some embodiments, when fastening element 10 is deployed, tab can be approximately parallel to surface 7 of carrier 3. In some embodiments, offset portion 17. In some embodiments, tab 18 can extend from an outer section of connecting portion 16 to provide gap 21 between tab 18 and second portion 12, and provide a spacer between first portion 12 and partially planar object 2, although this is not required.

[0023] In the embodiment shown in FIG1 , the dual-component fastening element 10 has a symmetrical configuration about axis 26, with the first portion 12, second portion 20, and third portion 17 being identical or mirror images. Thus, each dual-component fastening element 10 has two mirror images of its sides 27. In other embodiments, the first portion 12, second portion 20, and third portion 17 may have different configurations. For example, the second elastic insert 22 may have different lengths. The offset portion 17 may extend perpendicular to the connecting portion 16 at different angles. The first and second elastic prongs 14 may have different lengths to accommodate uneven carriers 3.

[0024] The dual-component fastening element 10 can be constructed from a relatively flexible material that allows the first and second spring prongs 14, as well as the at least one third spring prong 17 of the third portion 15, to exert opposing biasing forces on the carrier 3 and the optical device 24, respectively. In some embodiments, the dual-component fastening element 10 can be made from a relatively flexible insulator material, such as various types of plastics, including but not limited to acrylic, polycarbonate, nylon, or any other plastic-type material that is suitably strong enough to achieve the desired results and meet certain standards and / or regulations (e.g., UL / ETL requirements). Being constructed from an insulator material, the dual-component fastening element 10 is less likely to interfere with (e.g., short) electrical traces, which increases the versatility of the dual-component fastening element.

[0025] In some embodiments, the planar object 2 may be an LED board 2, and the carrier 3 may be a lamp housing 3. In some such embodiments, the LED board 2 and the lamp housing 3 (or components thereof) may be made of any suitable material to allow the LED board 2 and the lamp housing 3 to meet certain standards and / or regulations while also maintaining durability in view of one or more conditions to which the LED board 2 may be exposed. Examples of such materials may include, but are not limited to, aluminum, stainless steel, fiberglass, plastic, nylon, and rubber. Figure 2As shown, the LED board 2 may include one or more LED chips 1 located on an exposed surface 5. The LED board 2 may be mounted on a surface 7 of a carrier 3 and then secured to the carrier 3 by two or more dual-component securing elements 10. The optical device 24 is snapped between the two or more dual-component securing elements 10 and on top of the LED board 2. Figure 2 As shown, two LED boards 2 may include one or more LED chips 1 located on an exposed surface 5. The LED boards 2 may be mounted on a surface 7 of a carrier 3 and then secured to the carrier 3 by three dual-component fastening elements 10. An optical device 24 is snapped between the three dual-component fastening elements 10 and located on top of the LED boards 2.

[0026] The number of LED chips 1, LED board 2 and optical device 24 can vary, and the LED chips 1, LED board 2 and optical device 24 can be arranged in different arrays or configurations. The LED chips 1 described herein may include any type of LED technology, including but not limited to chip-on-board or discrete die. In addition to ordinary LED chips 1, in some embodiments, other different types of light sources, such as organic light-emitting LED (OLED) chips, may be provided on the LED board 2. The LED chips 1 can be electrically coupled to each other. For example, multiple LED chips 1 can be electrically connected in series in some manner, for example, electrically connected in series in rows. Control signals and / or power signals (e.g., voltage, current) can be transmitted to the LED board 2 by a power supply (e.g., LED driver) (not shown here) located inside, on and / or outside the LED board 2. Such power signals and / or control signals can be used to illuminate the LED chips 1 on the LED board 2.

[0027] As described above, one or more two-component fastening elements 10 may be used to fasten the planar object 2 to the carrier 3 and to fasten the optical device 24 to the two-component fastening element 10. For example, Figure 2 and 3 As shown in FIG, dual-component fastening elements 10 can be arranged in pairs on both sides of a planar object 2 and inserted through respective slots 4. The slots 4 can be provided through the carrier 3 according to the specific size of the planar object 2. In some embodiments, the symmetrical arrangement of slots 4 and corresponding dual-component fastening elements 10 positioned along the length of both sides of the planar object 2 can be replaced by other configurations, such as a random arrangement of slots 4 and corresponding dual-component fastening elements 10 along the length of one or both sides of the planar object 2. In LED applications, different numbers and / or configurations of slots 4 can be used to accommodate various LED board widths with different performance requirements.

[0028] The shape and / or size of the groove 4 can vary. In some embodiments, the groove 4 can be stamped into the carrier 3 as a rectangular shape. In some such embodiments, the fastening element 10 can have a cross-sectional shape or profile that resembles a circle (as viewed along the first portion 12). However, the groove 4 can be of any size and / or shape, and the fastening element 10 is generally.

[0029] In use, the plurality of dual-component fastening elements 10 can generate opposing biasing forces to respectively join the plurality of planar objects 2 and carriers 3 together, and generate opposing biasing forces to join the optical device 24 therebetween. Figure 2 and Figure 5 As shown, with the planar object 2 in place, when the dual-component fastening element 10 is inserted into the slot 4, the second resilient prongs 22 expose the surface 5 from the default position to the tensioned position. In addition, the first and second resilient prongs 14 grip the carrier 3 by a biasing force, and the one or more protruding edges 13 engage or snap into the surface 6 of the carrier 3 when inserted into the slot 4.

[0030] Similarly, when the optical device 24 is inserted or snapped between the two dual-component fastening elements 10, an opposing biasing force is generated to engage and retain the optical device 24 therebetween. In addition, the third resilient prongs 17 further engage the optical device 24 to prevent removal without applying additional vertical force.

[0031] Figure 4 is a flow chart of an exemplary method 40 for securing a planar object 2 and an optical device 24 to a carrier 3 using a dual-component securing element 10. Referring generally to FIGs. 1 to 4 Figure 4 The method 40 may begin at block 41, where one or more planar objects 2 may be placed over a carrier 3 by aligning at least one dual member of the planar object 2 with one or more slots 4 on the carrier 3. In block 42, one or more dual member fastening elements 10 may be snapped into or inserted through the one or more slots 4 on the carrier 3 to join the planar object 2 to the carrier 3 via the first portion 12 and the second portion 20 by opposing biasing forces on the planar object 2 and the carrier 3. In block 43, one or more optical devices 24 may be placed over the one or more dual member fastening elements 10 by aligning at least one edge of the one or more optical devices 24 with one or more protruding edges 13 on the one or more dual member fastening elements 10, and then pushing / snapping the optical devices 24 into and between the two or more dual member fastening elements 10.

[0032] Using the dual-member fastening element 10 described herein allows for flexibility when installing LED boards and optical configurations. The dual-member fastening element 10 can accommodate any (at least partially) planar object 2 of any width and / or any thickness (e.g., up to 2 mm). The dual-member fastening element 10 can be easily removed for repair and / or replacement. The installation process of the dual-member fastening element 10 is also faster and less expensive than using an equivalent number of other fasteners (such as screws) because the dual-member fastening element 10 snaps into place without requiring additional tools (such as a rotary driver) for installation. The dual-member fastening element 10 eliminates the need for a sheer-formed lance member, so the planar object 2 is not restricted to a specific location on the carrier 3. As a result, the surface 7 of the carrier 3 remains clean and flat.

[0033] Although several inventive embodiments have been described and illustrated herein, those skilled in the art will readily devise various other means and / or structures for performing the functions and / or achieving the results and / or one or more advantages described herein, and each of such variations and / or modifications is considered within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are intended to be exemplary and that actual parameters, dimensions, materials, and / or configurations will depend on the specific application or applications in which the inventive teachings are used. Those skilled in the art will recognize or be able to ascertain, using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. Therefore, it should be understood that the foregoing embodiments are presented by way of example only, and that, within the scope of the appended claims and their equivalents, the inventive embodiments may be practiced otherwise than as specifically described and claimed. The inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and / or method described herein. Furthermore, any combination of two or more such features, systems, articles, materials, kits, and / or methods (provided such features, systems, articles, materials, kits, and / or methods are not mutually inconsistent) is included within the inventive scope of the present disclosure.

[0034] All definitions, as defined and used herein, should be understood to be governed by dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0035] Unless explicitly stated to the contrary, the indefinite articles "a" and "an" as used herein in the specification and claims should be understood to mean "at least one."

[0036] As used herein in the specification and claims, the phrase "and / or" should be understood to refer to "either or both" of the elements so combined, i.e., elements that are present in combination in some cases and separately in other cases. Multiple elements listed with "and / or" should be interpreted in the same manner, i.e., "one or more" of the elements so combined. Other elements may optionally be present in addition to the elements specifically identified by the "and / or" clause, whether related or unrelated to those specifically identified elements. Thus, as a non-limiting example, when used in conjunction with open language such as "comprising," a reference to "A and / or B" may, in one embodiment, refer to only A (optionally including elements in addition to B); in another embodiment, to only B (optionally including elements in addition to A); in yet another embodiment, to both A and B (optionally including other elements); and so on.

[0037] As used herein in the specification and claims, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating items in a list, "or" or "and / or" should be interpreted as inclusive, i.e., including at least one of a plurality of elements or a list of elements, but also including more than one, and optionally additional unlisted items. Only terms that clearly indicate the contrary, such as "only one" or "exactly one," or when used in a claim, "consisting of..." will mean including exactly one element of a plurality of elements or a list of elements. Generally, when preceded by an exclusive term, such as "any one," "one of," "only one," or "exactly one," the term "or" as used herein should only be interpreted to indicate exclusive alternatives (i.e., "one or the other but not both"). When used in a claim, "consisting essentially of..." has its ordinary meaning as used in the art of patent law.

[0038] As used herein in the specification and claims, the phrase "at least one" referring to a list of one or more elements should be understood to mean at least one element selected from any one or more of the elements in the list, but not necessarily including at least one of each element specifically listed within the list, and not excluding any combination of elements in the list. This definition also allows for the optional presence of elements other than the elements specifically identified within the list to which the phrase "at least one" refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, "at least one of A and B" (or equivalently, "at least one of A or B," or equivalently, "at least one of A and / or B") can, in one embodiment, mean at least one (optionally including more than one) A without B (and optionally including elements in addition to B); in another embodiment, mean at least one (optionally including more than one) B without A (and optionally including elements in addition to A); in yet another embodiment, mean at least one (optionally including more than one) A and at least one (optionally including more than one) B (and optionally including other elements); and so on.

[0039] It should also be understood that in any method claimed herein that includes more than one step or action, the order of the method steps or actions is not necessarily limited to the order in which the method steps or actions are described unless explicitly stated to the contrary.

[0040] In the claims, as well as in the foregoing description, all transitional phrases such as "comprises," "comprising," "carrying," "having," "containing," "involving," "maintaining," "including," and the like are to be construed as open-ended, meaning including, but not limited to, the following. Only the transitional phrases "consisting of" and "consisting essentially of" are to be considered closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedure, Section 2111.03. It is to be understood that the use of certain expressions and reference characters in the claims pursuant to Rule 6.2(b) of the Regulations under the Patent Cooperation Treaty ("PCT") do not limit the scope.

Claims

1. A two-component fastening element (10) for joining two planar objects (2) and an optical device (24) to a carrier (3), the two-component fastening element (10) having two symmetrical sides (27) along a central axis, the two-component fastening element comprising: a first portion (12), the first portion having two first elastic pins (14), wherein one or more of the first elastic pins (14) include one or more protruding edges (13); a symmetrical second portion (20), the second portion having a second elastic pin (22); A symmetrical third portion (15), the third portion having a symmetrical third elastic pin 17; a connecting portion (16), the connecting portion being between the first portion (12), the second portion (20) and the third portion (15); wherein the second portion (20) extends substantially perpendicular to the connecting portion, and the third portion extends at an angle perpendicular to the connecting portion (16); wherein each side of the first resilient pin (14) / edge (13) and the second resilient pin (22) of the dual-component fastening element (10) is configured to generate a biasing force to engage the corresponding planar object (2) with the carrier (3), wherein the first resilient pin (14) / edge (13) is insertable through a slot (4) passing through the carrier (3) to retain the corresponding planar object (2) between the carrier (2) and the second resilient pin (22); Each side of the third elastic pin (17) of the dual-component fastening element (10) engages a corresponding optical device (24) or enables the corresponding optical device (24) to be snapped into the two third elastic pins (17) of the two dual-component fastening elements (10) and located between the two third elastic pins (17), and the optical device (24) is held in place above the second parts (20) of the two dual-component fastening elements (10).

2. The two-component fastening element (10) according to claim 1, wherein: The third elastic pin (17) forms an acute angle (α) with respect to the connecting portion (16).

3. The two-component fastening element (10) according to claim 1, wherein: The planar object (2) is an LED board (2).

4. The two-component fastening element (10) according to claim 1, wherein The carrier (3) is a lamp housing (3).

5. The two-component fastening element (10) according to claim 1, wherein The two-component fastening element (10) is constructed from a non-conductive material.

6. The two-component fastening element (10) according to claim 5, wherein: The non-conductive material is at least one of acrylate, polycarbonate or nylon.

7. The dual-component fastening element (10) of claim 1, further comprising a tab (18) extending vertically downwardly from the connecting portion 16 and the third portion 15, d to provide a gap (21) between the tab 18 and the second portion 12, and to provide a spacer between the first portion 12 and the partially planar object 2.

8. The two-component fastening element (10) according to claim 1, wherein The one or more protruding edges (13) of the first elastic pin (14) are snapped into the slot (4) of the carrier (3).

9. A light-emitting device comprising: two light emitting diode (LED) boards (2); A lamp housing (3), the lamp housing being used to receive the LED board (2); three or more slots (4) passing through the lamp housing (3); and Three two-component fastening elements (10) as claimed in claim 1, which grasp the two LED boards (2) and are inserted through the three or more slots (4) to join the two LED boards (2) to the lamp housing (3).

Images