Silicone optics

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.

What is claimed is: 
     
         1 . A method for manufacturing a light fixture that includes (a) an artificial light source, and (b) an optical component configured to direct light emitted from the artificial light source, the method comprising:
 manufacturing the optical component by:
 providing a glass sheet, 
 providing a pre-molded silicone optic in an only partially cured state, 
 providing an uncured layer of a silicone optical material between the pre-molded silicone optic in the only partially cured state, and the glass sheet, such that the uncured layer of the silicone optical material is interposed between and directly contacts both of (a) the pre-molded silicone optic in the only partially cured state, and (b) the glass sheet, and 
 curing the layer of the silicone optical material to adhere the pre-molded silicone optic to the glass sheet, thereby forming the optical component; and 
   positioning the optical component within the light fixture such that the pre-molded silicone optic is located between the glass sheet and the artificial light source, such that when light is emitted from the artificial light source, the light will be directed into and pass through the pre-molded silicone optic prior to passing through the glass sheet.   
     
     
         2 . The method of  claim 1 , further comprising attaching the artificial light source to a heat sink, and wherein a distance between the glass sheet and the heat sink is approximately one inch. 
     
     
         3 . The method of  claim 1 , further comprising arranging a reflector adjacent to the artificial light source such that the reflector extends toward, but is detached from, the pre-molded silicone optic. 
     
     
         4 . The method of  claim 1 , wherein the layer of the silicone optical material comprises a room temperature vulcanizing silicone or a liquid silicone rubber. 
     
     
         5 . The method of  claim 1 , wherein curing the layer of the silicone optical material comprises thermal curing in at least one of (i) a curing oven and (ii) a continuous kiln with a conveyor belt. 
     
     
         6 . A light fixture, comprising:
 an artificial light source; and   an optical component configured to direct light emitted from the artificial light source, wherein the optical component includes:
 a pre-molded silicone optic initially provided in an only partially cured state, 
 a pre-formed component, formed of a first material and having a first region configured to pass light therethrough, and 
 a silicone optical material that is first interposed between, and directly contacts, both of (a) the pre-molded silicone optic in the only partially cured state, and (b) the pre-formed component, and is subsequently cured to adhere the pre-molded silicone optic to the pre-formed component; and 
   support structure that positions the optical component with the pre-molded silicone optic between the pre-formed component and the artificial light source, such that when light is emitted from the artificial light source, the light will be directed into and pass through the pre-molded silicone optic prior to passing through the first region.   
     
     
         7 . The light fixture of  claim 6 , wherein the support structure comprises a heat sink to which the artificial light source is attached. 
     
     
         8 . The light fixture of  claim 7 , wherein a distance between the first region and the heat sink is approximately one inch. 
     
     
         9 . The light fixture of  claim 6 , further comprising a reflector adjacent to the artificial light source, such that the reflector extends toward, but is detached from, the pre-molded silicone optic. 
     
     
         10 . The light fixture of  claim 6 , wherein the pre-molded silicone optic comprises a cross-sectional shape comprising a plurality of wedge-shaped protrusions, and wherein the plurality of wedge-shaped protrusions extend away from the pre-formed component. 
     
     
         11 . The light fixture of  claim 10 , wherein the plurality of wedge-shaped protrusions have varying heights that decrease when moving toward a center of a width of the pre-molded silicone optic, wherein each low point between adjacent wedge-shaped protrusions is approximately equidistant from the pre-formed component. 
     
     
         12 . The light fixture of  claim 10 , wherein:
 the cross-sectional shape further comprises a portion having a circular protrusion;   the plurality of wedge-shaped protrusions are arranged symmetrically about the circular protrusion; and   the circular protrusion has a constant radius, and extends a greater distance from the pre-formed component, compared to a majority of the plurality of wedge-shaped protrusions.   
     
     
         13 . An optical component configured to direct light emitted from an artificial light source, the optical component comprising:
 a pre-formed component, formed of a first material and having a first region configured to pass light therethrough, wherein:
 the first material is not silicone, and 
 the first region is of a constant thickness and comprises an upper surface and a lower surface; and 
   a customized optic, formed of silicone and provided on the lower surface of the first region, such that a portion of the customized optic at least partially covers the lower surface, wherein:
 the customized optic comprises a varying thickness; and 
 the customized optic is disposed between the pre-formed component and the artificial light source. 
   
     
     
         14 . The optical component of  claim 13 , wherein at least a portion of the customized optic is in intimate contact with the lower surface of the first region of the pre-formed component. 
     
     
         15 . The optical component of  claim 13 , wherein the first material comprises glass, and further comprising a layer of silicone optical material disposed between, and for attaching, the customized optic and the pre-formed component. 
     
     
         16 . The optical component of  claim 13 , wherein the customized optic comprises a cross-sectional shape comprising a portion having a circular protrusion with a constant radius. 
     
     
         17 . The optical component of  claim 13 , wherein the customized optic comprises a cross-sectional shape comprising a plurality of wedge-shaped protrusions, and wherein the plurality of wedge-shaped protrusions extend away from the pre-formed component. 
     
     
         18 . The optical component of  claim 17 , wherein the plurality of wedge-shaped protrusions have varying heights that decrease when moving toward a center of a width of the customized optic, wherein each low point between adjacent wedge-shaped protrusions is approximately equidistant from the pre-formed component. 
     
     
         19 . The optical component of  claim 17 , wherein:
 the cross-sectional shape further comprises a portion having a circular protrusion;   the plurality of wedge-shaped protrusions are arranged symmetrically about the circular protrusion; and   the circular protrusion has a constant radius, and extends a greater distance from the pre-formed component, compared to a majority of the plurality of wedge-shaped protrusions.