THERMOPLASTIC STAKE MOUNTING SYSTEM AND METHOD

1 . A method of securing an optical component to a support surface having a plurality of light emitting diodes (LEDs) mounted thereon, the method comprising:

providing a support surface with first and second opposite sides having a plurality of holes disposed therethrough and a plurality of LEDs mounted on the first side thereof;

positioning at least one optical component over one or more of the plurality of LEDs on the first side of the support surface, the at least one optical component having a plurality of thermoplastic stakes extending from a back surface thereof;

for each thermoplastic stake of the plurality of thermoplastic stakes, inserting an end thereof through a hole of the plurality of holes in the support surface such that the end projects outwardly from the second side of the support surface;

disposing elastomeric compensators around the plurality of thermoplastic stakes projecting outwardly from the second side of the support surface;

interposing the support surface and the at least one optical component between first and second plates; and

utilizing the first and second plates to apply heat and pressure to the ends of the thermoplastic stakes to form the ends thereof into rivet-like heads and compress the elastomeric compensator between the rivet-like head and the second side of the support surface.

2 . The method of claim 1 , wherein the optical component is a lens.

3 . The method of claim 1 , wherein at least one hole of the plurality of holes is countersunk from the second side of the support surface.

4 . The method of claim 3 , wherein at least one thermoplastic stake of the plurality of thermoplastic stakes extends through the at least one countersunk hole and the rivet-like head formed therefrom at least partially conforms to the countersunk hole.

5 . The method of claim 1 and further comprising:

calculating a volume of thermoplastic material needed to form a rivet-like head having a predetermined diameter and thickness; and

providing the at least one optical component having thermoplastic stakes with physical dimensions based upon on the volume calculated.

6 . The method of claim 1 and further comprising:

determining variability in heights of the plurality of optical components;

providing the elastomeric compensators having a thickness greater than the determined variability.

7 . The method of claim 1 and further comprising:

calculating physical dimensions of the rivet-like heads needed to withstand a threshold force applied to the at least one optical component; and

providing the at least one optical component having thermoplastic stakes with lengths and widths based upon the physical dimensions calculated.

8 . The method of claim 1 , wherein the plurality of thermoplastic stakes are tubularly shaped with at least a portion thereof being hollow.

9 . The method of claim 8 , wherein the tubularly shaped thermoplastic stakes a have walls of a predetermined thickness based upon a volume of thermoplastic material needed to form a rivet-like head having a predetermined size.

10 . A method of securing an optical component to a board having a plurality of light emitting diodes (LEDs) mounted thereon, the method comprising:

providing a board having a plurality of holes disposed therethrough and a plurality of LEDs mounted on a first side thereof;

providing a plurality of optical components to be mounted to the board, each optical component having a plurality of thermoplastic stakes protruding therefrom;

inserting the plurality of thermoplastic stakes into the holes from the first side, through the board, and extending outwardly from a second side of the board opposite the first side;

positioning an elastomeric compensator around each thermoplastic stake on the second side of the board;

positioning the board, the optical components, and the elastomeric compensators between a first surface and a second, generally flat surface for applying pressure thereto; and

moving the first and second surfaces toward each other while applying heat to the plurality of thermoplastic stakes to form a rivet-like head on each thermoplastic stake and to compress the elastomeric compensator between the rivet-like head and the second side of the board.

11 . The method of claim 10 , wherein at least one hole of the plurality of holes having a thermoplastic stake passing therethrough is countersunk from the second side of the board and the rivet-like head formed on the thermoplastic stake at least partially conforms to a shape of the countersunk hole.

12 . The method of claim 10 and further comprising:

determining a variability of a physical dimension of the plurality of optical components; and

providing the elastomeric compensator having a thickness greater than the variability of the physical dimension.

of the based on manufacturing variability of the plurality of optical components.

13 . The method of claim 10 and further comprising:

calculating a minimum surface area of the rivet-like head needed to withstand a threshold force applied to an optical component of the plurality of optical components; and

providing thermoplastic stakes having lengths and widths based upon the minimum surface area calculated.

14 . The method of claim 10 , wherein all of the rivet-like heads are formed at the same time.

15 . A lighting system having a plurality of light emitting diodes (LEDs) mounted on a circuit board and encapsulated by one or more optical components, the lighting system comprising:

a board having a generally flat mounting surface, a backside surface oppositely disposed from the mounting surface, and a plurality of holes extending from the mounting surface to the backside surface;

a plurality of LEDs mounted to the mounting surface;

at least one optical component disposed over one or more of the plurality of LEDs and abutting the mounting surface of the board;

a plurality of thermoplastic stakes extending from the at least one optical component, passing through holes of the plurality of holes, and projecting outwardly from the backside surface of the board;

a plurality of rivet-like heads disposed along the backside surface of the board and formed from the plurality of thermoplastic stakes; and

a plurality of elastomeric compensators disposed on the backside surface of the board, each elastomeric compensator being disposed around a thermoplastic stake of the plurality of thermoplastic stakes and compressed between a rivet-like head of the plurality of rivet-like heads and the backside surface of the board.

16 . The lighting system of claim 15 , wherein the elastomeric compensators bias the rivet-like heads away from the backside surface of the board.

17 . The lighting system of claim 15 , wherein the elastomeric compensators have a thickness greater than a variability in heights of the plurality of optical components.

18 . The lighting system of claim 15 , wherein at least one of the rivet-like heads have a recess disposed therein on a backside thereof.