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 of manufacturing an optical component configured to direct light emitted from a light source, the method comprising:
 depositing silicone on an underside of an optic shell, the optic shell being formed of a first material and having a light-emitting region through which light passes through the optic shell, wherein the light-emitting region is of a constant thickness, and forms an underside that defines an approximately semi-spherical recess;   filling at least a portion of the approximately semi-spherical recess with silicone; and   curing the silicone to form a customized optic, such that the customized optic is provided on and in intimate contact with the underside of the light-emitting region.   
     
     
         2 . The method of  claim 1 , wherein depositing the silicone on the underside of the optic shell comprises adding liquid silicone to the optic shell. 
     
     
         3 . The method of  claim 1 , wherein the first material comprises at least one of glass or plastic. 
     
     
         4 . The method of  claim 1 , further comprising:
 at least partially filling at least one void in the optic shell with the silicone; and   curing the silicone in the at least one void to mechanically interlock the optic shell and the customized optic together.   
     
     
         5 . The method of  claim 1 , wherein filling comprises filling only a portion of the approximately semi-spherical recess with the silicone, and wherein curing the silicone to form the customized optic comprises forming a cavity on an underside of the customized optic. 
     
     
         6 . The method of  claim 5 , further comprising positioning the optical component adjacent the light source such that when the light source emits the light, at least a portion of the light passes through the cavity and the customized optic before passing through the optic shell. 
     
     
         7 . The method of  claim 5 , further comprising forming the cavity such that, for a cross section through a center of the optical component, the cavity includes a curved portion that meets an approximately linear portion at a maximum depth of the cavity. 
     
     
         8 . The method of  claim 7 , wherein the maximum depth of the cavity is offset from a centerline of the optical component, and wherein the second and third portions meet and form a nonzero angle at the maximum depth of the cavity. 
     
     
         9 . An optical component configured to direct light emitted from a light source, the optical component comprising:
 an optic shell formed of a first material and having a light-emitting region through which light passes, wherein the light-emitting region is of a constant thickness and comprises an underside that forms an approximately semi-spherical recess; and   a customized optic formed of a second material and provided on and in intimate contact with the underside of the light-emitting region such that a portion of the customized optic at least partially fills the approximately semi-spherical recess,   wherein the first material is different from the second material, and wherein the second material is silicone.   
     
     
         10 . The optical component of  claim 9 , wherein the first material comprises at least one of glass and plastic. 
     
     
         11 . The optical component of  claim 9 , wherein:
 the optic shell further comprises at least one flange extending from the light-emitting region;   at least one void is defined in an underside of at least one of the at least one flange; and   another portion of the customized optic at least partially fills the at least one void to mechanically interlock the optic shell and the customized optic together.   
     
     
         12 . The optical component of  claim 9 , wherein the at least a portion of the customized optic within the approximately semi-spherical recess of the optic shell comprises a non-constant thickness across the approximately semi-spherical recess. 
     
     
         13 . The optical component of  claim 12 , wherein the a ratio of a thickest value of the non-constant thickness of the customized optic, to a thinnest value of the non-constant thickness of the customized optic, is at least 4:1. 
     
     
         14 . The optical component of  claim 9 , wherein an underside of the customized optic, within the approximately semi-spherical recess of the optic shell, defines a cavity. 
     
     
         15 . The optical component of  claim 14 , wherein, when the optical component is positioned adjacent the light source, the cavity is interposed between the optical component and the light source such that light emitted from the light source passes through the customized optic before passing through the optic shell. 
     
     
         16 . The optical component of  claim 14 , wherein the cavity comprises a first part and a second part, wherein the first part comprises an approximately partially spherical shape and the second part comprises an approximately partially cylindrical shape. 
     
     
         17 . The optical component of  claim 14 , wherein the cavity is asymmetric about a centerline through the light-emitting region of the optic shell. 
     
     
         18 . The optical component of  claim 14 , wherein, at a cross section through a center of the optical component, the cavity comprises a curved portion that meets an approximately linear portion at a maximum depth of the cavity. 
     
     
         19 . The optical component of  claim 18 , wherein the maximum depth of the cavity is offset from a centerline of the optical component. 
     
     
         20 . The optical component of  claim 14 , wherein:
 the optic shell comprises a first flange, adjoining and extending radially outward from the underside of the light-emitting region, to a perimeter of the optic shell;   the light-emitting region extends substantially perpendicular to the first flange where the light-emitting region adjoins the first flange; and   the customized optic comprises a second flange that extends radially outward from the cavity so as to contact at least a portion of an underside of the first flange.