Silicone LED Prescription Optics for Regulated Lighting Applications

Abstract

A unitary silicone prescription optic has a molded silicone body comprising: a front surface configured as a light exit; an integral reflector configured to receive and reflect light from an LED light source; and an integral attachment portion configured to mount the molded silicone body within a housing. The unitary silicone prescription optic has many advantages over conventional optic systems.

What is claimed is: 
     
         1 . A unitary silicone prescription optic, comprising:
 a molded silicone body, comprising:
 a front surface configured as a light exit; 
 an integral reflector configured to receive and reflect light from an LED light source; and 
 an integral attachment portion configured to mount the molded silicone body within a housing. 
   
     
     
         2 . The unitary silicone prescription optic of  claim 1 , wherein the prescription is for a vehicle exterior lamp. 
     
     
         3 . The unitary silicone prescription optic of  claim 1 , wherein the front surface of the molded silicone body is a refractive face with a molded contour to produce a requisite light spread and light intensity. 
     
     
         4 . The unitary silicone prescription optic of  claim 1 , wherein the front surface of the molded silicone body includes horizontal or vertical flutes or pillows. 
     
     
         5 . The unitary silicone prescription optic of  claim 1 , wherein the reflector is a total internal reflector (TIR) providing greater than 55% efficiency of light collection and distribution. 
     
     
         6 . The unitary silicone prescription optic of  claim 1 , wherein the reflector is a total internal reflector (TIR) providing greater than 75% efficiency of light collection and distribution. 
     
     
         7 . The unitary silicone prescription optic of  claim 1 , wherein the reflector is a total internal reflector (TIR) providing 85% efficiency or greater of light collection and distribution. 
     
     
         8 . The unitary silicone optic of  claim 1 , wherein the attachment portion is at a periphery of the molded silicone body. 
     
     
         9 . The unitary silicone optic of  claim 8 , wherein the attachment portion comprises a reinforcing structure molded with the molded silicone body, the reinforcing structure imparting structural strength to the attachment portion. 
     
     
         10 . A prescription lamp, comprising:
 a unitary molded body molded from silicone, comprising:
 a front surface configured as a light exit; 
 an integral reflector molded to meet a prescription light output; and 
 an integral attachment portion; 
   an LED light source, the integral reflector receiving and reflecting light from the LED light source; and   a housing configured to mount the unitary molded body to a structure, the integral attachment portion attached directly to the housing without an additional seal member.   
     
     
         11 . The prescription lamp of  claim 10 , wherein the structure is a vehicle and the prescription light output is for an exterior vehicle lamp. 
     
     
         12 . The prescription lamp of  claim 10 , wherein the front surface of the unitary molded body is a refractive face with a molded contour to produce a requisite light spread and light intensity. 
     
     
         13 . The prescription lamp of  claim 10 , wherein the front surface of the unitary molded body includes horizontal or vertical flutes or pillows. 
     
     
         14 . The prescription lamp of  claim 10 , wherein the front surface is coating-free. 
     
     
         15 . The prescription lamp of  claim 10 , wherein the integral reflector is a total internal reflector (TIR) providing greater than 55% efficiency of light collection and distribution. 
     
     
         16 . The prescription lamp of  claim 10 , wherein the integral reflector is a total internal reflector (TIR) providing greater than 75% efficiency of light collection and distribution. 
     
     
         17 . The prescription lamp of  claim 10 , wherein the integral reflector is a total internal reflector (TIR) providing 85% efficiency or greater of light collection and distribution. 
     
     
         18 . The prescription lamp of  claim 10 , wherein the attachment portion is at a periphery of the unitary molded body. 
     
     
         19 . The prescription lamp of  claim 18 , wherein the attachment portion comprises a reinforcing structure molded with the unitary molded body, the reinforcing structure imparting structural strength to the attachment portion. 
     
     
         20 . A lamp with a single-stage optic, the lamp comprising:
 a unitary molded body molded from silicone, comprising:
 a front surface configured as a light exit; 
 an integral reflector molded to meet a prescription light output; and 
 an integral attachment portion; 
   a light source; and   a housing configured to mount the unitary molded body to a structure.