Silicone optics

Patent metadata

Field	Value
Publication number	US-11020917-B2
Application number	US-201816142338-A
Country	US
Kind code	B2
Filing date	Sep 26, 2018
Priority date	May 10, 2013
Publication date	Jun 1, 2021
Grant date	Jun 1, 2021

Abstract

Silicone-containing light fixture optics. A method for manufacturing an optical component may include mixing two precursors of silicone, opening a first gate of an optic forming device, moving the silicone mixture from the extrusion machine into the optic forming device, cooling the silicone mixture as it enters the optic forming device, filling a mold within the optic forming device with the silicone mixture, closing the first gate, and heating the silicone mixture in the mold to at least partially cure the silicone. Alternatively, a method for manufacturing an optical component may include depositing a layer of heat cured silicone optical material to an optical structure, arranging one or more at least partially cured silicone optics on the layer of heat cured silicone optical material, and heating the heat cured silicone optical material to permanently adhere the one or more at least partially cured silicone optics to the optical structure.

First claim

What is claimed is:

1. A method for manufacturing an optical component, the method comprising:
mixing two precursors of silicone to form a liquid silicone mixture;
moving the liquid silicone mixture from an extrusion machine into an optic forming device while cooling the liquid silicone mixture to maintain the liquid silicone mixture in a liquid form;
extruding the liquid silicone mixture through a die in the optic forming device, while heating the liquid silicone mixture, to form a continuous length of cured silicone; and
cutting the continuous length of the cured silicone at a desired length to form the optical component.

2. The method of claim 1 , further comprising:
co-extruding one or more additional elements with the liquid silicone mixture such that the one or more additional elements are at least partially encapsulated by the cured silicone.

3. The method of claim 2 , wherein
the one or more additional elements comprise one or more brackets, a first lens, and a second lens.

4. The method of claim 3 , wherein
an interface between the cured silicone and the first lens comprises an interface that contains no free air between the cured silicone and the first lens.

5. The method of claim 2 , wherein
at least one of the one or more additional elements comprises one or more structures to interlock the at least one of the one or more additional elements to the cured silicone.

6. A method of manufacturing an, comprising:
mixing two precursors of silicone to form a silicone mixture;
opening a first gate at an upstream end of an optic forming device;
moving the silicone mixture from an extrusion machine into the optic forming device while cooling the silicone mixture;
filling a mold within the optic forming device with the silicone mixture;
closing the first gate; and
heating the silicone mixture in the mold to form an at least partially cured optical component portion.

7. The method of claim 6 , further comprising:
separating a first half of the mold from a second half of the mold to access the at least partially cured optical component portion.

8. The method of claim 6 , further comprising:
opening a second gate at a downstream end of the mold;
forcing a portion of the at least partially cured optical component portion through the second gate leaving a vacant portion of the mold;
charging the vacant portion of the mold with additional silicone mixture; and
heating the additional silicone mixture in the mold to at least partially cure an additional optical component portion.

9. The method of claim 8 , wherein
the portion of the at least partially cured optical component portion is forced through the second gate by fluid pressure.

10. The method of claim 6 , further comprising:
arranging one or more additional elements in the mold such that the one or more additional elements are at least partially encapsulated by the silicone mixture.

11. The method of claim 10 , wherein
the one or more additional elements comprise a reflector.

12. The method of claim 10 , wherein:
the one or more additional elements comprise a lens; and
an interface between the silicone mixture and the lens comprises an interface that contains no free air between the silicone mixture and the lens.

13. The method of claim 10 , wherein
at least one of the one or more additional elements comprises one or more structures to interlock the at least one of the one or more additional elements to the at least partially cured optical component portion.

14. The method of claim 13 , wherein
the one or more structures comprise apertures or grooves.

15. The method of claim 6 , wherein
the at least partially cured optical component portion comprises one or more recessed areas.

16. The method of claim 6 , further comprising:
attaching the at least partially cured optical component portion to a structure.

17. The method of claim 16 , wherein
the structure comprises a printed circuit board to which one or more light sources are attached.

Assignees

• Abl Ip Holding Llc

Inventors

• Marquardt Craig Eugene
• Mccanless Forrest Starnes
• Chen Jie
• Harvey John Bryan
• Wu Yinan
• Weiss Daniel Aaron

Classifications

• G02B27/0966

  Cylindrical lenses (cylindrical lenses per se G02B3/06) · CPC title

• G02B19/0066

  in the form of an LED array · CPC title

• G02B19/0028

  refractive and reflective surfaces, e.g. non-imaging catadioptric systems · CPC title

• G02B3/06

  with cylindrical or toric faces · CPC title

• F21S4/28

  rigid, e.g. LED bars · CPC title