LED light fixture including optical member with in-situ-formed gasket and method of manufacture

A method for manufacturing an optical member for an LED light fixture of the type including a mounting surface supporting at least one LED light source and the optical member, the method comprising the steps of:

• providing an optical-member carrier piece with a back side for facing the mounting surface, the back side having a groove positioned to surround the at least one LED light source, the groove including a plurality of spur-grooves extending inwardly from an inner edge of the groove;
• and
• forming a resilient compressible gasket with a plurality of inward projections therealong by injecting a thermoplastic elastomer (TPE) into the groove and the spur-grooves.

A method for manufacturing an optical member for at least one LED light source supported with respect to a mounting surface, the method comprising:

• providing a groove and a plurality of spur-grooves formed in an optical-member back side positionable to face the mounting surface, the groove being configured to surround the at least one LED light source and the spur-grooves which extend inwardly from the groove to terminate with a distal end which is spaced from an inner edge of the groove;
• and
• injecting a thermoplastic elastomer (TPE) into the groove through injection gates which are at the distal ends of the spur-grooves.

An LED light fixture comprising:

• a mounting surface supporting at least one LED light source;
• and
• an optical member having a back side facing the mounting surface and having a lens corresponding to the at least one light source, the back side having a groove surrounding the at least one LED light source and at least one spur-groove extending inwardly from an inner edge of the groove, the groove and the at least one spur-groove being filled with a resilient compressible gasket.