Illuminating optical lens for light emitting diode (LED)

A method for assembling an illuminating optical lens system for use with a light emitting diode (LED) comprising the steps of:

• (a) providing an LED mounted on a circuit board;
• (b) providing a lens comprising (i) a base defining a circumferential rim on a plane having a bottom surface around a longitudinal axis (A-A) adapted to mount to the circuit board;
• (ii) an integral refractive outer surface of the lens extending around and angled towards the longitudinal axis (A-A) from the base;
• (iii) an integral refractive inner surface of the lens extending from the base forming a cavity shaped and sized to receive the LED;
• and (iv) a plurality of grooved sections formed on the bottom surface of the base portion, each of the plurality of grooved sections having a plurality of grooves that extend radially of the longitudinal axis;
• (c) applying adhesive to at least one of the lens or the circuit board around the LED for mounting the lens to the circuit board;
• (d) mounting the lens to the circuit board over the LED wherein the LED is positioned within the cavity formed by the inner surface of the lens;
• wherein the integral refractive outer and inner surfaces each define a predetermined geometry adapted to direct and focus light emitting from the LED to a predetermined path;
• and
• wherein the lens is fabricated with a tolerance range of the inner surface within 0.15 mm of the LED.

A luminaire system comprising:

• (a) a plurality of light emitting diode (LED) units mounted on a circuit board;
• (b) a plurality of illuminating optical lenses each mounted over and around an LED wherein each lens comprises (i) a base defining a circumferential rim on a plane having a bottom surface around a longitudinal axis (A-A);
• (ii) an integral refractive outer surface of the lens extending around and angled towards the longitudinal axis (A-A) from the base;
• (iii) an integral refractive inner surface of the lens extending from the base forming a cavity shaped and sized to receive the LED;
• wherein the base is adapted to be mounted on the circuit board, and (iv) a plurality of grooved sections for receiving an adhesive formed on the bottom surface of the base portion, each of the plurality of grooved sections having a plurality of grooves that extend radially of the longitudinal axis, wherein the integral refractive outer and inner surfaces each define a predetermined geometry adapted to direct and focus light emitting from the LEDs to a predetermined path;
• and wherein the lens is fabricated with a tolerance range of the inner surface within 0.15 mm of the LED.