Abstract: A lens for directing light from an LED light source. The lens is formed by a plurality of layers and has a light-receiving inner-surface defining a pair of cavities. A portion of the inner-surface which defines one of the cavities is at least partially formed by an innermost layer of the plurality of layers. At least a portion of another of the plurality of layers extends inwardly between the pair of cavities. Another aspect of this invention is an optic member including a plurality of the lenses for directing light received from a plurality of spaced apart LED light sources.

Abstract: A method for manufacturing of a lens for distribution of light from a light emitter. The method provides an injection-molding cavity defined by a shape-forming configuration with a texturing in at least one area of the cavity. A thermoplastic elastomer is injected into the cavity shaping a lens-region thickness of the elastomer. Such lens-region thickness is cooled and set prior to sinking of the elastomer such that the lens-region thickness retains the texturing of the shape-forming configuration forming a textured surface portion of the lens.

Abstract: A lens for directing light from an LED light source. The lens is formed by a plurality of layers and has a light-receiving inner-surface defining a pair of cavities. A portion of the inner-surface which defines one of the cavities is at least partially formed by an innermost layer of the plurality of layers. At least a portion of another of the plurality of layers extends inwardly between the pair of cavities. Another aspect of this invention is an optic member including a plurality of the lenses for directing light received from a plurality of spaced apart LED light sources.

Abstract: An LED lens assembly that includes a secondary lens and a gasket molded to the secondary lens. At least one of the secondary lens and the gasket is made of a material that is curable using low temperature electromagnetic radiation.

Abstract: 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.

Abstract: A unitary optic member for directing light from a plurality of LED light sources on a board beneath the optic member which has a plurality of lens portions surrounded by and interconnected by a non-lens portion. The optic member being formed by a plurality of layers with layer-to-layer interface bonding between adjacent layers and comprising an asymmetric light-receiving inner-surface defining a pair of cavities, a portion of the inner surface which defines one of the cavities is at least partially formed by an innermost layer of the plurality of layers, at least a portion of another of the plurality of layers extending inwardly between the pair of cavities and being bonded to the innermost layer.

Abstract: An injection-molding apparatus for article formation. The injection-molding apparatus includes a single mold base supporting at least one grouping of a plurality of shape-forming configuration sets. Each set is shaped for forming one layer of a multilayered article comprising an asymmetric surface. Each set may include at least one cavity which retains each article region formed by the preceding injection-molding shot(s). The single mold base includes an internal movable part which moves within the single mold base with respect to a stationary part such that relative positions of the shape-forming configurations are advanced for each set to form a subsequent article region in the cavities. Each subsequent shot may be prior to full cooling of the article region formed in the previous shot.

Abstract: A lens for distribution of light from a light emitter having an emitter axis. The lens including an outer surface receiving light from the inner surface which defines an inner cavity and includes an axial inner-surface portion of a conical shape formed by a substantially cross-sectionally linear inner region extending outwardly from positions at the emitter axis toward an open end of the inner cavity. An LED light fixture comprising a mounting structure supporting a plurality of spaced LED light sources with a plurality of the lenses each in alignment with a corresponding one of the light sources.

Abstract: A method for manufacturing of a lens for distribution of light from a light emitter. The method provides an injection-molding cavity defined by a shape-forming configuration with a texturing in at least one area of the cavity. A thermoplastic elastomer is injected into the cavity shaping a lens-region thickness of the elastomer. Such lens-region thickness is cooled and set prior to sinking of the elastomer such that the lens-region thickness retains the texturing of the shape-forming configuration forming a textured surface portion of the lens.

Abstract: An LED lensing arrangement for lighting fixtures includes (1) a rigid light-transmissive outer structure having an outwardly-facing light-exit surface and an outer-structure light-input surface, (2) an optically-clear molded polymeric inner structure having a light-entrance surface and a light-output surface which is adhered to the outer-structure light-input surface, the inner structure being of a material which is pourable upon molding, one example being a liquid silicone rubber (LSR) material, and (3) at least one LED light source secured with respect to and optically coupled to the inner-structure light-entrance surface.

Abstract: A lens for distribution of light from a light emitter. The lens has thick and thin wall portions between inner and outer lens surfaces. The thick wall portion(s) are at least twice as thick as the thin wall portion(s). At least one of the inner and outer surfaces has a texturing for diffusion of emitter light passing therethrough. The lens may include at least one interface between two materials with different indices of refraction. At least one surface of the interface may have a texturing for diffusion of emitter light passing therethrough. And, a method for manufacturing of the lens by forming a lens region with a textured surface portion by injecting the thermoplastic elastomer into an injection-molding cavity defined by a shape-forming configuration with a texturing in at least one area of the cavity. The shape-forming configuration is configured to shape a thermoplastic elastomer into such thickness that the set elastomer retains the texturing.

Abstract: An LED light fixture including a heat-conductive overstructure having upper and lower surfaces and a plurality of upwardly-protruding elongate fins which extend along the upper surface adjacent to at least one opening through the fixture permitting air flow from beneath the lower surface to above the upper surface. An LED light source is secured with respect to the lower surface. The fins have heights which gradually increase toward fin-ends proximal to the at least one opening.

Abstract: An LED light fixture includes a heat-sink, a circuit board thereon with a plurality of spaced LED light sources, and a one-piece optical member with a plurality of secondary lenses over corresponding LED light sources and having a lens flange surrounding the lenses and integral with each lens. The optical member includes a polymeric carrier portion surrounding the lenses, overlapping with and molded onto the lens flanges across such overlapping, and extending therefrom to a peripheral edge portion. The optical member has an outer surface infused with an ultraviolet inhibitor to increase long-term weathering performance. The infused outer surface includes an outer layer of each lens and extends to form an outer layer of the lens flanges and therebeyond to form an outer layer of the carrier portion. The invention also includes a method of manufacturing such infused optical member.

Abstract: A lens for distribution of light from a light emitter having an emitter axis. The lens including an outer surface receiving light from the inner surface which defines an inner cavity and includes an axial inner-surface portion of a conical shape formed by a substantially cross-sectionally linear inner region extending outwardly from positions at the emitter axis toward an open end of the inner cavity. An LED light fixture comprising a mounting structure supporting a plurality of spaced LED light sources with a plurality of the lenses each in alignment with a corresponding one of the light sources.

Abstract: LED lighting apparatus including (a) a circuit board which has a plurality of light sources spaced thereon, (b) a heat sink to which the circuit board is thermally coupled, and (c) a securement structure which includes a rigid peripheral structure applying force along a peripheral area of the circuit board toward the heat sink to increase the thermal coupling therebetween to facilitate heat transfer from the light sources during operation. The lighting apparatus may also include an optical member with a plurality of lens portions over corresponding light sources and a peripheral region, the securement structure engaging the peripheral region which sandwiches a gasket against the heat sink. The apparatus may use manipulation involving surface convexity, such as bowing, thereby allowing the securement structure to further facilitate surface-to-surface thermal coupling between the circuit board and the heat sink.

Abstract: A lens for distribution of light from a light emitter. The lens has thick and thin wall portions between inner and outer lens surfaces. The thick wall portion(s) are at least twice as thick as the thin wall portion(s). At least one of the inner and outer surfaces has a texturing for diffusion of emitter light passing therethrough. The lens may include at least one interface between two materials with different indices of refraction. At least one surface of the interface may have a texturing for diffusion of emitter light passing therethrough. And, a method for manufacturing of the lens by forming a lens region with a textured surface portion by injecting the thermoplastic elastomer into an injection-molding cavity defined by a shape-forming configuration with a texturing in at least one area of the cavity. The shape-forming configuration is configured to shape a thermoplastic elastomer into such thickness that the set elastomer retains the texturing.

Abstract: A lens for distribution of light from a light emitter having an emitter axis. The lens includes an inner surface defining an inner cavity and including a substantially cross-sectionally convex inner region along an open end of the inner cavity and a substantially cross-sectionally linear inner region joining the substantially cross-sectionally convex inner region and extending therefrom toward the emitter axis. The convex region is configured for refracting emitter light rays toward the emitter axis. The lens further includes an outer surface receiving the light from each of the inner regions. A lens flange surrounds the lens and has an outer flange surface extending radially outwardly from the lens outer surface at positions axially spaced from the light emitter. The convex inner region is configured to refract emitter light to the outer surface such that the outer flange surface is substantially free from receiving any emitter light.

Abstract: LED lighting apparatus including (1) a plurality of primary lenses each over a corresponding one of LED arrays spaced on a circuit board, and (2) a one-piece lensing member over the circuit board and having a plurality of secondary lenses each spaced over one of the primary lenses on the circuit board, the circuit board and lensing member having first and second mating features positioned and configured for inter-engagement for high-precision lens alignment. The circuit board and one-piece lensing member are each joined to a mounting surface of a heat-conductive member, and such assembly, while facilitating high-efficiency assembly, does not interfere with high-precision lens alignment.

Abstract: An injection-molding apparatus for article formation. The injection-molding apparatus includes a single mold base supporting at least one grouping of a plurality of shape-forming configuration sets. Each set includes at least one cavity and is shaped for forming one of first-formed, intermediate-formed and last-formed regions of the article in the cavities by a corresponding one of injection-molding shots. Each cavity retains each article region formed by the preceding injection-molding shot(s). The single mold base includes a movable part which moves internally within the single mold base with respect to a stationary part such that relative positions of the shape-forming configurations are advanced for each set to form a subsequent article region in the cavities. Each subsequent injection-molding shot may at least partially over-mold the article region formed in the preceding shot. Each subsequent shot may be prior to full cooling of the article region formed in the previous shot.

Abstract: An LED light fixture includes a heat-sink, a circuit board thereon with a plurality of spaced LED light sources, and a one-piece optical member with a plurality of secondary lenses over corresponding LED light sources and having a lens flange surrounding the lenses and integral with each lens. The optical member includes a polymeric carrier portion surrounding the lenses, overlapping with and molded onto the lens flanges across such overlapping, and extending therefrom to a peripheral edge portion. The optical member has an outer surface infused with an ultraviolet inhibitor to increase long-term weathering performance. The infused outer surface includes an outer layer of each lens and extends to form an outer layer of the lens flanges and therebeyond to form an outer layer of the carrier portion. The invention also includes a method of manufacturing such infused optical member.