One-piece multi-lens optical member and method of manufacture

• Main Authors: Wilcox, Kurt S, Raleigh, Craig
• Format: Patent
• Language: English
• Published: 24.09.2019
• Subjects: AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING; BLASTING; FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMSTHEREOF; HEATING; INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULARARTICLES; INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21Sand F21V, RELATING TO THEFORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THELIGHT EMITTED; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATINGELEMENTS; LIGHTING; MECHANICAL ENGINEERING; NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; PERFORMING OPERATIONS; PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCESIN A PLASTIC STATE; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDEDFOR; SHAPING OR JOINING OF PLASTICS; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHERARTICLES, NOT OTHERWISE PROVIDED FOR; TRANSPORTING; WEAPONS; WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL

A one-piece optical member with a plurality of secondary lenses over corresponding LED light sources, the one-piece optical member comprises (a) each with an outward lens flange surrounding a light-transmitting portion which is formed by a plurality of layers and has an asymmetric inner surface defining a pair of cavities with at least one of the plurality of layers at least partially extending between the pair of cavities, a portion of the inner-surface which defines one of the cavities is at least partially formed by another of the plurality of layers which is bonded to the at least one layer extending between the pair of cavities. The polymeric materials may be different; e.g., the innermost lens layer may be of an LSR material. The invention is also a method of manufacturing the one-piece optical member and an LED light fixture with the one-piece member over a plurality of LED light sources spaced on a circuit board.