LED LIGHTING MODULE WITH MOLDED SILICONE OPTICS

Abstract

Lighting modules with lens assemblies that have one or more silicone components, such as silicone optics and / or a silicone lens substrate. The modalities also include attachment features and / or thermal control features that can be used to improve the performance of lighting modules with lens assemblies that have silicone components. Adhesion features and / or thermal control features can be included in the lighting module that has lens assemblies with one or more silicone components.

Description

LED LIGHTING MODULE WITH MOLDED SILICONE OPTICS CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of United States Provisional Patent Application No. 63 / 316,645, filed on March 4, 2022, and entitled LED LIGHTING MODULE WITH MOLDED SILICONE OPTICS, the contents of which are hereby incorporated by reference in their entirety. FIELD OF INVENTION

[0002] The present technology refers to lighting modules, and more particularly to lighting modules with molded silicone optics. BACKGROUND OF THE INVENTION

[0003] Lighting modules with arranged optics are used in various indoor and outdoor applications, such as, but not limited to, pathway or area lighting. Common lighting modules have a complex, multi-part construction. For example, they typically include (i) a printed circuit board (PCB) with light-emitting diodes (LEDs) provided on the PCB in the desired number and arrangement, (ii) a lens that is positioned and fixed onto the PCB, (iii) one or more gaskets to seal the module against the ingress of moisture and particles that could damage the PCB and adversely affect the operation of the LEDs, and (iv) a frame to hold all these parts together. The optics are formed on the lens so that each optic is aligned with an LED when the lighting module is assembled.The lens (and associated optics) is typically molded from an optical-grade plastic material, such as polymethyl methacrylate (PMMA) or polycarbonate (PC). While such lighting modules are relatively easy to add as building blocks to a lighting fixture if additional lumens are needed, their complex, multi-part construction increases material costs, assembly time and cost, and the risk of product failure. BRIEF DESCRIPTION OF THE INVENTION

[0004] The terms “invention,” “the invention,” “this invention,” and “the present invention” used in this patent are intended to have a broad reference to the entire subject matter of this patent and the patent claims below. It is understood that statements containing these terms do not limit the subject matter described herein or limit the meaning or scope of the patent claims below. The embodiments of the invention covered by this patent are defined by the claims below, not by this brief description. This brief description is a high-level overview of different aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below.This brief description is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter shall be understood by reference to appropriate portions of the entire specification of this patent, any or all of the drawings, and each claim.

[0005] The modalities of this disclosure are directed to illumination modules with lens assemblies that have one or more silicone components such as silicone optics and / or a silicone lens substrate. The modalities also include attachment features and / or thermal control features that can be used to improve the performance of illumination modules with lens assemblies that have the silicone components. Adhesion features and / or thermal control features may be included in the illumination module that has the lens assemblies with one or more silicone components. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 is a bottom perspective view of a modal lighting module.

[0007] Figure 2 is a top perspective view of the lighting module in Figure 1.

[0008] Figure 3 is an exploded view of the lighting module in Figure 1.

[0009] Figure 4 is a bottom perspective view of the lighting module of Figure 1 with a lens assembly removed.

[0010] Figure 5 is a top perspective view of the light module of Figure 1 with a printed circuit board removed.

[0011] Figure 6 is a sectional view of the lighting module of Figure 1.

[0012] Figure 7 is a sectional view of Figure 1 taken from the shaded box in Figure 6.

[0013] Figure 8 is a top perspective view of a lens assembly of the lighting module of Figure 1.

[0014] Figure 9 is an exploded view of the lens assembly of Figure 8.

[0015] Figure 10 is a perspective bottom view of the lens assembly of Figure 8.

[0016] Figure 11 is a sectional view of an optic of the lens assembly of Figure 8.

[0017] Figure 12 illustrates an example of an optic of current technology.

[0018] Figure 13 is a bottom perspective view of another lighting module according to modalities.

[0019] Figure 14 is a perspective view of another lighting module according to modalities.

[0020] Figure 15 is a top perspective view of a lens assembly of the lighting module of Figure 14.

[0021] Figure 16 is a bottom perspective view of another lighting module according to modalities.

[0022] Figure 17 is a bottom view of the lighting module in Figure 16. L / rozn / cznz / q / Yi DETAILED DESCRIPTION OF THE INVENTION

[0023] This document describes lighting modules with improved constructions that allow for simplified assembly, which in turn can reduce assembly time, assembly costs, and material costs. The components and features of the lighting modules described herein can also improve the optical performance of the lighting module compared to traditional lighting modules, including, but not limited to, providing wider illumination distributions, improved uniformity, and improved backlight control. The lighting modules provided herein can also minimize and / or eliminate potential performance problems caused by heat generated by the light sources of the lighting modules.Conveniently, the optics of the illumination modules provided herein can be constructed of silicon, which can improve the fabrication of such optics as well as the performance of the illumination module; however, the optics provided herein are not limited to silicon optics. Other benefits and advantages can be achieved with the systems and methods provided herein, and the aforementioned advantages should not be considered limiting. Lighting module

[0024] Figures 1 to 11 illustrate a lighting module 100 according to different embodiments. The lighting module 100 can be a component of different types of lighting fixtures as desired. In some embodiments, the lighting fixture with the lighting module 100 can be used within an outdoor fixture, such as, but not limited to, a lantern, a spotlight, etc. The lighting module 100 includes a PCB 102 with one or more light sources 104, one or more lens assemblies 106, and one or more mounting mechanisms 108. Optionally, the lighting module 100 includes a frame 110, although in other embodiments the lighting module 100 need not include the frame 110.

[0025] The PCB 102 generally includes a first surface 112 (see Figure 4) and an opposing second surface 114 (see Figure 2). One or more light sources 104 may be provided on the first surface 112. These light sources 104 may include any suitable light source, including, but not limited to, an LED, an organic light-emitting diode (OLED), an incandescent bulb, combinations thereof, or other sources as desired. Furthermore, any number of light sources 104 may be provided on the PCB 102, and when a plurality of light sources 104 are included, the light sources 104 may be provided in different numbers, patterns, and / or arrangements on the PCB 102 as desired. In the modality of Figures 1 to 11, the light module includes a plurality of LEDs as light sources 104 that are arranged in rows of five across the PCB 102.

[0026] Said one or more lens assemblies 106 may be attached to the first surface 112 of the PCB 102 to control the light distribution from said one or more light sources 104. Any number of lens assemblies 106 may be used as desired. In the illustrated embodiment, the lighting module 100 includes three lens assemblies 106.

[0027] Each lens assembly 106 includes at least one optic 116 positioned over a corresponding light source 104, and in certain embodiments, a lens assembly 106 may include a plurality of optics 116. When a plurality of optics 116 is included, the optics 116 may be molded or formed together as illustrated in Figures 8 to 11, for example, or the optics 116 may be independent of each other (discrete). The optics 116 may be formed from any suitable material, including, but not limited to, silicone, glass, and optical-grade plastic materials such as optical-grade acrylics (e.g., optical-grade PMMA) and optical-grade polycarbonate.

[0028] In addition to one or more optics 116, a lens assembly 106 may include a lens 144. The lens 144 includes a lens substrate 146 having a first side 148 (Figure 10) and an opposing second side 150 (Figures 8 and 9). One or more optics 116 are provided in the lens substrate 146 and extend from a first side 148 of the lens substrate 146. Each optic 116 includes an optical cavity 132 (Figures 8 and 9) with an exposed aperture on the second side 150 of the lens substrate 146. When the optics 116 are positioned over the light sources 104, the light sources 104 are received within the optical cavities 132. Any number of optics 116 may be provided in the lens 144 in any arrangement and orientation. In some forms, each optic 116 may be formed separately and secured to the lens substrate 146.In other embodiments, a row of optics 116 is integrally formed and subsequently secured to the lens substrate 146. In still other embodiments, the optics 116 and the lens substrate 146 are integrally formed together to form a monolithic lens assembly 106. In some embodiments, the lens 144 may be constructed of the same material as the optics 116. As a non-limiting example, the lens 144 may be constructed of the same optical-grade silicone as the optics 116. In such embodiments, the lens 144 and the optics 116 may be integrally or separately formed. In other embodiments, the lens 144 may be constructed of a material that is different from that of the optics 116. As an example, the lens 144 may be constructed of a first type of optical-grade silicone or acrylic, and the optics 116 may be constructed of a second type of optical-grade silicone.

[0029] Optionally, the lens 144 may include one or more light-extraction features to extract light from the lens 144. Such light-extraction features may be provided on any side 148, 150 of the lens substrate 146 and / or within the lens substrate 146 to interrupt any internal reflection conditions so that light may be redirected downward and out of the lens substrate 146. In some embodiments, the light-extraction features include a textured surface provided on at least one side 148, 150 of the lens substrate 146. Such a textured surface may be formed by embossing, sandblasting, combinations thereof, and / or other suitable techniques as desired.In some embodiments, light-extraction features may comprise particles provided on the lens substrate 146, optical prisms, bubbles, combinations thereof, and / or other types of light-extraction features as desired. Such light-extraction features can improve the optical performance of the illumination module 100 by minimizing light that would otherwise be lost due to internal reflection, which can improve lumens per watt, reduce pixilation, and / or minimize contrast between optics 116. The type, orientation, and density of the extraction features can be varied to control the distribution of output light.

[0030] Different fastening features may be used to assemble the lighting module 100, including, but not limited to, mechanical fasteners and / or chemical fasteners as desired. In the embodiment illustrated in Figure 1, the fastening features include holes 107 that are defined in the frame 110 (and optionally on a plate 168) to receive mechanical fasteners (e.g., bolts, screws) that in turn engage with corresponding holes 109 in the PCB 102. However, as mentioned, in other embodiments, other fastening features may be used, including, but not limited to, clips, snaps, hooks, snap-fit ​​connectors, combinations thereof, and / or other suitable mechanisms or features as desired. Fastening mechanisms

[0031] One or more locking mechanisms 108 may be used to secure the lens assemblies 106 to the PCB 102. Different types of locking mechanisms 108 may be used, and in some embodiments, a plurality of types of locking mechanisms 108 may be used. The locking mechanisms 108 may secure the lens assemblies 106 to the PCB 102 and prevent or minimize movement of the lens assemblies 106 relative to the PCB 102. Such locking mechanisms 108 may be particularly suitable for (but not limited to) illumination modules 100 with silicon lens assemblies 106 and may attach the lens assemblies 106 to the PCB 102 to maintain the proper position, physically press the lens assemblies 106 against the PCB 102, and / or, failing that, hold the lens assemblies 106 in place on the PCB 102.The fastening mechanisms 108 can also allow for a simplified construction of the illumination module 100, which can omit gaskets, frames, and other components that have traditionally been required. Figures 16 and 17, by comparison, illustrate a prior art illumination module 1601 with lens assemblies 1606 supported between an upper frame 1611 and a lower frame 1613. As illustrated in Figure 17, gaskets 1603 are required around each lens assembly 1606 to seal the illumination module 1601. However, as illustrated, these additional components require additional assembly compared to disclosure illumination modules.

[0032] Referring to Figures 3 to 5, in some embodiments, the fastening mechanisms 108 may include one or more adhesives. Although the adhesive can be applied directly to the PCB 102, in the illustrated embodiments, adhesive tape 164 is used to secure the lens assemblies 106 to the PCB 102. The adhesive tape 164 includes a first side 167 (Figures 3 and 5) that adheres to the PCB 102 and a second side 169 (Figure 4) that adheres to the lens assemblies 106. In certain embodiments, the adhesive tape 164 may be a double-sided tape and / or a double-coated tape, including, but not limited to, a silicone / acrylic double-coated tape.Non-limiting examples of suitable adhesive tapes include, but are not limited to, those sold under the trade name 3M™ Silicone / Acrylic Double Coated Tapes 9731-050, 9731-085, and 9731-100 by 3M Company and those sold under the trade name FS-2256h Silicone / Acrylic Double Sided Tapes by DST Tapes, Inc.

[0033] Referring to Figures 1 to 7 and as best illustrated in Figures 6 and 7, in different In the L / rozn / cznz / q / Yi embodiments, the fastening mechanisms 108 may include a compression component 166 designed to physically press the lens assemblies 106 against the PCB 102. In the embodiment illustrated in Figures 1 to 7, the compression component 166 is a plate 168 having an outer frame 176 and crossbars 178 extending through the outer frame 178 to define holes through which light can pass. Fastening features 180 on the crossbars 178 (or at other locations) may engage with the holes 182 in the PCB 102 such that the plate 168 applies pressure to the lens assemblies 106; however, other techniques may be used to fasten the plate 168 so that it applies pressure to the lens assemblies 106.In some embodiments (see Figure 13), the crossbars 178 are located close to the optics 116 (and the associated light sources 104) in such a way that the crossbars 178 can serve to influence the directionality of the light coming out of an optic 116. The crossbars 178 can be designed to have any improvement in shape and surface to direct the emitted light as desired.

[0034] Figures 14 and 15 illustrate another example of a lighting module 1400 with a lens assembly 1406 that is substantially similar to lens assembly 106 except that lens assembly 1406 further includes one or more mechanical retention features 174 such as those included in the clamping mechanisms 108. Lens assembly 1406 also includes channels 154 that are different from those of lens assembly 106 but will be discussed in detail later. In certain embodiments, the mechanical retention features 174 may be fixed or integrally formed with the lens assembly 106, and the mechanical retention features 174 may have different profiles suitable for mating with complementary features on the PCB 102 (e.g., holes and / or other features as desired).As non-limiting examples, the mechanical retention features 174 can be T-shaped, arrow-shaped as illustrated in Figures 14 and 15, and / or have other profiles as desired.

[0035] As mentioned, in certain embodiments, a lighting module may include only one type of fastening mechanism 108, although in other embodiments a lighting module may use a plurality of fastening mechanisms 108. By way of non-limiting examples, a lighting module 100 uses both an adhesive tape 164 and the compression component 166, the lighting module 1300 uses only a compression component 166, and the lighting module 1400 uses only the mechanical retention features 174. Other types and / or different combinations of fastening mechanisms 108 may be used as desired, including, but not limited to, screws, bolts, clips, snaps, snap-fit ​​features, combinations thereof, and / or other features or mechanisms as desired. Silicone optics

[0036] Lens assembly 106 may be provided with optics 116 having any geometry depending on the desired light distribution of the illumination module 100, and the modalities of the present disclosure should not be limited to the particular optic geometry described and illustrated herein.

[0037] Figure 11 illustrates one embodiment of an optic 116 that can be used in embodiments of the illumination modules 100 contemplated herein. The optic 116 has a base surface 118 in which an optical cavity 132 is defined by the inner surface 134. In use, the optic 116 is positioned over a light source 104 such that the light source 104 emits light into the optical cavity 132. The optic 116, in turn, can refract, reflect, or otherwise alter the directionality of some of the emitted light such that the light is emitted from the optic 116 in a desired pattern or distribution. In the illustrated form, the optics include a first portion 120 that defines a first side 124 of optics 116 and a second portion 122 that defines a second side 126 of optics 116. The first portion 120 and the second portion 122 may be formed integrally or separately and subsequently fixed together.The first portion 120 is generally designed to receive light rays from the light source 104 and refract or, failing that, emit the light rays in a direction toward the first side 124 of the optics 116 (see, for example, light ray 138). The second portion 122 may be designed to reflect and refract the light that has been initially emitted from the light source 104 toward the second side 126 of the optics 116 back toward the first side 124 of the optics 116. In the illustrated embodiment, the second portion 122 may include totally internally reflective surfaces 145 AB that reflect the light rays and direct them out of the second portion 122 of the optics 116 and toward the first side 124 of the optics (see, for example, light rays 140, 142). However, to reiterate, the optics 116 for use in the lighting modules disclosed in this document can have any geometry and are not limited to the specific geometry shown in Figure 11.The optical geometries shown in United States Patent Application Serial No. 17 / 686,785, filed on March 4, 2022, and entitled OPTIC WITH TOTAL INTERNAL REFLECTION AND REFRACTION FOR BACK LIGHT CONTROL, which is incorporated herein by reference, may be suitable in some applications.

[0038] Figure 12 illustrates an example of a current art optic 1216. Similar to optic 116, optic 1216 has a first portion 1220 and a second portion 1222. However, optic 1216 also includes a tail portion 1223 and an air pocket 1225. The inclusion of a tail portion 1223 and an air pocket 1225 has historically been necessary to accommodate optics that have excess or negative taper (as present in optic 1216) and that are made of traditional optical materials (e.g., glass, plastic, etc.), which are rigid. The excess makes it difficult to remove the optic from its optical mold. Moreover, since traditional optical materials are rigid, optics made from them are not flexible and therefore cannot be removed from the optical mold without breaking or otherwise damaging the optic. Thus, a tail portion 1223 is generally formed with the optics.The outer wall of tail portion 1223 is formed with a taper angle β, or curve, which allows the optics to be removed from the optical mold. However, the inclusion of tail portion 1223 adversely affects the ability of optics 1216 to control light (and thus the efficiency of the illumination module) because light can escape through the tail portion, where it is effectively lost for any useful purpose. Furthermore, although portions 1220 and 1222 of optics 1216 have a negative curve, the inclusion of tail portion 1223 causes the entire optics 1216 to have a positive curve.

[0039] In some embodiments, the lens assembly 106 and / or its subcomponents (for example, the optics 116 and / or a lens substrate 146) covered herein may be formed from optical-grade silicone, which may result in improved producibility and performance of the lens assembly. In certain embodiments, at least the optics 116 covered herein may be formed from optical-grade silicone, which may result in improved producibility and performance of the optics 116. In some embodiments, the optical-grade silicone materials may have a refractive index of approximately 1.39 to 1.43, and values ​​in between. Additionally or alternatively, the optical-grade silicone materials may have a durometer in the range of 50 to 90 Shore A.Non-limiting examples of optical-grade silicone materials that may be suitable for optics 116 and / or lens substrate 146 may include silicone sold under the trade name SILASTIC™ MS-1002 Moldable Silicone from The Dow Chemical Company, silicone sold under the trade name SILASTIC™ MS-4002 Moldable Silicone from The Dow Chemical Company, or silicone sold under the trade name SILOPREN™ LSR 7180 from Momentive Performance Materials Inc.

[0040] In contrast to optic 1216, and referring to Figure 11, optic 116 is formed from optical-grade silicone and does not include a tail portion 1223 or an air pocket 1225. Although optic 116 also includes an excess in its design, the silicone material from which it is made has a degree of flexibility that allows optic 116 to be pulled / detached from an optical mold without damaging the optic 116. Thus, forming optic 116 from a silicone material eliminates the need to include irrelevant features in the optic (i.e., the tail portion 1223), allowing the entire optic 116 to have a negative curvature (e.g., progressively increasing in length from the base surface 118 to a lower end 128) and eliminating the resulting inefficiencies that arise from including such features.

[0041] The optics 116 mentioned above are provided for illustrative purposes and should not be considered limiting. Rather, the lens assembly 106 may have optics 116 that have different shapes, profiles, and geometries as desired. Thermal control

[0042] As best illustrated in Figures 8 and 9, in certain embodiments, the lens assembly 106 includes one or more thermal control features that can reduce the impact of heat generated by the light sources 104 on the other components of the illumination module 100. Such thermal control features can be particularly useful with optics 116 and / or lens substrates 146 formed from silicone to minimize deformation of the optics 116 and / or lens substrates 146 by controlling and / or eliminating heat that might otherwise cause the silicone to deform (e.g., by expanding outward or bulging). However, such thermal control features are not limited to silicone components.

[0043] In some embodiments, said one or more thermal control features of the lens assembly 106 include one or more channels 154 and / or a venting feature 156. As illustrated in Figures 8 and 9, said one or more channels 154 may be defined on the second side 150 of the lens substrate 146. In certain embodiments, two or more channels 154 may intersect as illustrated in Figures 8 and 9; however, in other embodiments, the channels 154 need not intersect, and the channels 154 may be provided in any scheme as desired. As an example, Figure 15 illustrates lens assembly 1406, which is substantially similar to lens assembly 106 except that the channels 154 are formed in a mesh pattern and do not intersect each other.In certain embodiments, the channels 154 are in communication with, and extend from, the optical cavities 132 in which the light sources 104 reside to carry away the heat generated by the light sources 104 within the optical cavities 132. In some embodiments, and as best illustrated in Figure 7, the channels 154 can extend in a plane that is offset above a plane of the light source 104 to provide improved ventilation of the hot air from the optics 116. In such embodiments, the channels 154 offset above the light source 104 can allow the air that heats up inside the optical cavity 132 to escape naturally from the optical cavity 132 (for example, because the channels 154 are in the highest area to which the air can move).

[0044] The vent feature 156 may allow air to be vented through the lens substrate 146 from the second side 150 to the first side 148. Optionally, one or more channels 154 may extend from the optical cavities 132 to the vent feature 156 so that hot air can be released from the illumination module. Referring to Figures 8 and 9, in certain embodiments, the vent feature 156 may include a vent hole 158 extending through the lens substrate 146 and a vent member 160 covering the vent hole 158. The vent member 160 may be made of different materials. In some embodiments, the vent member 160 is a semipermeable member that may be permeable to air but impermeable to moisture, thereby minimizing moisture ingress into the lens assembly 106.In some embodiments, a vent cavity 162 is defined on the second side 150 of the lens substrate 146, the vent hole 158 may be defined in the vent cavity 162, and the vent member 160 may be positioned within the vent cavity 162. In this way, the vent member 160 does not contribute to the thickness of the lens assembly 106 such that the second side 150 of the lens substrate 146 remains spliced ​​with the underlying adhesive tape 164 and / or the PCB 102.

[0045] A collection of exemplary embodiments is provided later, including at least some explicitly listed as “Embedments” that provide further description of a variety of exemplary embodiments in accordance with the concepts described herein. These embodiments are not intended to be mutually exclusive, exhaustive, or restrictive; and the disclosure is not limited to these exemplary embodiments but encompasses all possible modifications and variations within the scope of the stated claims and their equivalents.

[0046] Mode 1. A lens assembly for a lighting module, the lens assembly comprises: a lens comprising a substrate with a first side and a second side, wherein an optic extends from a first side of the lens and includes an optical cavity exposed on the second side of the lens, wherein the optical cavity is configured to receive a light source and wherein the second side of the lens defines a channel extending from the optical cavity.

[0047] Mode 2. The lens assembly according to any of the above or below modes or combination of modes, wherein the lens comprises an opening configured to receive a light source, and wherein the optics extend over the opening.

[0048] Mode 3. The lens assembly according to any of the above or below modes or combination of modes, wherein the lens comprises a ventilation feature configured to provide ventilation to the optical cavity.

[0049] Mode 4. The lens assembly in accordance with any of the above or below modes or combination of modes, wherein the ventilation feature is configured to provide ventilation through the lens from the second side to the first side.

[0050] combination of Option 5. modalities, The assembly where the lens channel is of any of the above or below modalities or extends from the optical cavity towards the ventilation feature.

[0051] Option 6. The lens assembly according to any of the above or below modalities or combination of modalities, wherein the ventilation feature comprises a ventilation hole extending through the lens substrate and a ventilation member covering the ventilation hole.

[0052] Modality 7. The lens assembly according to any of the above or below modalities or combination of modalities, wherein the optics comprise silicone.

[0053] Mode 8. A lighting module comprising: a printed circuit board with at least one light source; a lens assembly comprising a lens with at least one silicon optic; and a clamping mechanism connecting the lens to the printed circuit board and such that at least one silicon optic is provided over said at least one light source.

[0054] Mode 9. The lighting module of any of the above or below modes or combination of modes, wherein the clamping mechanism comprises an adhesion mechanism that adheres the lens to the printed circuit board and in such a way that said at least one silicone optic is provided over said at least one light source.

[0055] Mode 10. The lighting module of any of the above or below modes or combination of modes, wherein the adhesion mechanism comprises adhesive tape.

[0056] Mode 11. The illumination module of any of the above or below modes or combination of modes, wherein the clamping mechanism maintains a relative location between an optical cavity of said at least one silicon optic and said at least one light source.

[0057] Mode 12. The illumination module of any of the above or below modes or combination of modes, wherein the clamping mechanism comprises one or more mechanical retention features extending from the lens assembly.

[0058] Mode 13. The lighting module of any of the above or below modes or combination of modes, wherein said one or more mechanical retention features are arrow-shaped projections or T-shaped projections, and wherein said one or more mechanical retention features are configured to engage with one or more defined holes in the printed circuit board.

[0059] Modality 14. An optic for a lighting module, the optic comprises: a base surface; a lower end opposite the base surface; a first side; and a second side opposite the first side, wherein the optic comprises a negative curvature in a direction from the base surface to the lower end, and wherein the optic comprises silicone.

[0060] Mode 15. The optics of any of the above or below modes or combination of modes, wherein the optics further comprises: a first portion comprising an outer surface and a cavity defined in the base surface having a cavity surface, wherein the cavity is configured to receive a light source and comprises a cavity axis, wherein the first portion is configured to refract the first light rays from the light source, and wherein the first portion defines a first side of the optics; and a second portion formed integrally with the first portion and defining a second side of the optics.

[0061] Mode 16. The optics of any of the above or below modes or combination of modes, wherein the cavity surface comprises a non-linear curvature.

[0062] Mode 17. The optics of any of the above or below modes or combination of modes, wherein the second portion comprises a total internal reflection surface configured to reflect the second light rays from the light source towards the first side of the optics.

[0063] Mode 18. The optics of any of the above or below modes or combination of modes, wherein the total internal reflection surface is a first total internal reflection surface, and wherein the second portion comprises a plurality of total internal reflection surfaces.

[0064] Modality 19. The optics of any of the above or below modalities or combination of modalities, wherein the silicone of the optics has a refractive index of approximately 1.39 to 1.43, and values ​​between them.

[0065] Modality 20. The optics of any of the above or below modalities or combination of modalities, wherein the silicone of the optics has a durometer in the range of 50 to 90 shore A.

[0066] Modality 21. A lens assembly for an illumination module, the lens assembly comprises: a lens comprising a substrate with a first side and a second side, wherein an optic extends from a first side of the lens and includes an optical cavity exposed on the second side of the lens, wherein the optical cavity is configured to receive a light source and wherein the second side of the lens defines a channel extending from the optical cavity.

[0067] Modality 22. A lighting module comprising: a printed circuit board with at least one light source; a lens assembly comprising a lens with at least one silicon optic; and an adhesion mechanism that adheres the lens to the PCB and such that at least one silicon optic is provided over said at least one light source.

[0068] Modality 23. A lens assembly for a lighting module, the lens assembly comprising: a lens comprising a substrate with a first side and a second side, wherein the lens comprises an orifice configured to receive a light source; and optics provided on the first side of the lens and positioned over the orifice configured to receive the light source, wherein the lens comprises a ventilation feature configured to provide ventilation through the lens from the second side to the first side.

[0069] Modality 24. A lighting module comprising: a printed circuit board with at least one light source; a silicone lens assembly comprising a lens with at least one optic; and an adhesion mechanism that adheres the silicone lens assembly to the PCB and such that said at least one optic is provided over said at least one light source.

[0070] Modality 25. An optic for a lighting module, the optic comprises: a base surface; a first portion comprising an outer surface and a cavity defined in the base surface having a cavity surface, wherein the cavity is configured to receive a light source and comprises a cavity axis, wherein the cavity surface comprises a nonlinear curvature, wherein the first portion is configured to refract the first light rays from the light source, and wherein the first portion defines a first side of the optic; and a second portion integrally formed with the first portion and defining a second side of the optic, wherein the second portion comprises a total internal reflection surface configured to reflect the second light rays from the light source towards the first side of the optic, wherein the optic comprises silicon.

[0071] Modality 26. An optic for a lighting module, the optic comprises: a base surface; a lower end opposite the base surface; a first side; and a second side opposite the first side, wherein the optic comprises a negative curvature in a direction from the base surface to the lower end, and wherein the optic comprises silicone.

[0072] Throughout this description, for explanatory purposes, numerous specific details are established to provide a complete understanding of many aspects and modalities disclosed in this document. However, it will be evident to someone experienced in the subject that many aspects and modalities can be practiced without some of these specific details. In other cases, familiar structures and devices are shown in diagram or schematic form to avoid obscuring the underlying principles of the aspects and modalities described.

[0073] The different aspects, modalities, implementations, or characteristics of the described modalities may be used separately or in any combination. In particular, it should be appreciated that the different conceptual elements of the figures may be combined without departing from the essence or scope of the invention.

[0074] The use of the terms “a” and “an” and similar referents in the context of describing the invention (especially in the context of the following claims) should be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by the context. Directional references such as “above,” “below,” “top,” “bottom,” “left,” “right,” “front,” and “rear,” among others, are intended to refer to the orientation as illustrated and described in the figure(s) to which the components and directions are being referenced. The terms “comprising,” “having,” “including,” and “containing” should be construed as open terms (i.e., meaning “including, but not limited to”), unless otherwise indicated.Throughout this disclosure, a part number with a letter refers to a specific instance of an item, and a part number without an accompanying letter refers to the item generically or collectively. Thus, as an example (not shown in the drawings), device “12A” refers to an instance of a device class, which may be collectively referred to as “12” devices, any one of which may be referred to generically as a “12” device. Mention of value ranges herein is intended simply as a shorthand method for referencing each individual value falling within the range, or gradients thereof, unless otherwise stated herein, and each individual value is incorporated into the specification as if it were individually mentioned herein.All methods described herein may be carried out in any suitable order unless otherwise stated herein or otherwise clearly contradicted by the context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illustrate embodiments of the invention and does not impose a limitation on the scope of the invention unless otherwise claimed. Nothing in the specification should be construed as indicating any element not claimed as essential to the practice of the invention.

[0075] As used herein, the term “substantially” refers to the full or near-full extent or degree of an action, characteristic, property, state, structure, element, or result. For example, an object that is “substantially” enclosed would mean that the object is either completely or nearly completely enclosed. The exact permissible degree of deviation from absolute completeness may, in some cases, depend on the specific context. However, the proximity to completeness will be such that it will have the same overall result as if full completeness were achieved.

[0076] This document describes preferred embodiments of this invention, including the best mode known to the inventors for carrying out the invention. The invention is susceptible to various modifications and alternative constructions, and certain exemplary embodiments thereof are shown in the drawings and have been described in detail above. Variations of those preferred embodiments, within the essence of the present invention, may become apparent to those skilled in the art upon reading the foregoing description. The inventors expect that skilled craftspeople will employ such variations as appropriate, and the inventors do not intend the invention to be practiced in any manner other than that specifically described herein.Consequently, it should be understood that the invention is not intended to be limited to the specific form or forms disclosed, but rather, this invention includes all modifications and equivalents of the subject matter mentioned in the appended claims as permitted by applicable law. Furthermore, any combination of the elements described above in all possible variations thereof is encompassed by the invention unless otherwise stated herein or clearly contradicted by the context.

[0077] The preceding description, for explanatory purposes, used specific nomenclature to provide a complete understanding of the modalities described. However, it will be evident to someone experienced in the subject that the specific details are not required in order to practice the modalities described. Therefore, the above descriptions of specific modalities are presented for illustrative and descriptive purposes. They are not intended to be exhaustive or to limit the modalities described to the precise forms disclosed. It will be evident to someone experienced in the subject that many modifications and variations are possible in view of the above teachings.

Claims

1. A lens assembly for a lighting module, the lens assembly comprising: a lens comprising a substrate with a first side and a second side, wherein an optic extends from a first side of the lens and includes an optical cavity exposed on the second side of the lens, wherein the optical cavity is configured to receive a light source and wherein the second side of the lens defines a channel extending from the optical cavity.

2. The lens assembly according to claim 1, wherein the lens comprises an orifice configured to receive a light source, and wherein the optics extend over the orifice.

3. The lens assembly according to claim 1, wherein the lens comprises a ventilation feature configured to provide ventilation to the optical cavity.

4. The lens assembly according to claim 3, wherein the ventilation feature is configured to provide ventilation through the lens from the second side to the first side.

5. The lens assembly according to claim 3, wherein the channel extends from the optical cavity to the ventilation feature.

6. The lens assembly according to claim 3, wherein the venting feature comprises a vent hole extending through the lens substrate and a vent member covering the vent hole.

7. The lens assembly according to claim 1, wherein the optics comprise silicone.

8. A lighting module comprising: a printed circuit board (PCB) with at least one light source; a lens assembly comprising a lens with at least one silicon optic; and a clamping mechanism connecting the lens to the PCB and such that said at least one silicon optic is provided over said at least one light source.

9. The lighting module according to claim 8, wherein the clamping mechanism comprises an adhesion mechanism that adheres the lens to the PCB and such that said at least one silicone optic is provided over said at least one light source.

10. The lighting module according to claim 9, wherein the adhesion mechanism comprises adhesive tape.

11. The lighting module according to claim 8, wherein the clamping mechanism maintains a relative location between an optical cavity and said at least one silicon optic and said at least one light source.

12. The lighting module according to claim 8, wherein the clamping mechanism comprises one or more mechanical retention features extending from the lens assembly.

13. The lighting module according to claim 12, wherein said one or more mechanical retention features are arrow-shaped projections or T-shaped projections, and wherein said one or more mechanical retention features are configured to engage with one or more defined holes in the PCB.

14. An optic for a lighting module, the optic comprises: a base surface; a lower end opposite the base surface; a first side; and a second side opposite the first side, wherein the optic comprises a negative curvature in a direction from the base surface to the lower end, and wherein the optic comprises silicon.

15. The optics according to claim 14, wherein the optics further comprises: a first portion comprising an outer surface and a cavity defined in the base surface having a cavity surface, wherein the cavity is configured to receive a light source and comprises a cavity axis, wherein the first portion is configured to refract the first light rays from the light source, and wherein the first portion defines a first side of the optics; and a second portion integrally formed with the first portion and defining a second side of the optics.

16. The optics according to claim 15, wherein the cavity surface comprises a non-linear curvature.

17. The optics according to claim 15, wherein the second portion comprises a total internal reflection (TIR) ​​surface configured to reflect the second light rays from the light source towards the first side of the optics.

18. The optics according to claim 17, wherein the TIR surface is a first TIR surface, and wherein the second portion comprises a plurality of TIR surfaces.

19. The optics according to claim 14, wherein the silicone of the optics has a refractive index of approximately 1.39 to 1.43, and values ​​between them.

20. The optics according to claim 14, wherein the silicone of the optics has a durometer in the range of 50 to 90 shore A.

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