Patent ID: 7994529

Claim:
A method of forming a lighting apparatus comprising: providing a light emitting diode (LED) die mounted on a submount, the LED die having a top surface; molding an outer lens onto the submount having the LED die such that the outer lens abuts at least two edges projecting from the top surface of the LED die and forms a layer above the top surface of the LED die using a first silicone having a first index of refraction, the outer lens forming a recess, relative to a top surface of the outer lens, above the top surface of the LED die; and after molding the outer lens, molding an inner lens within the recess using a second silicone having a second index of refraction higher than the first index of refraction, a shape of the inner lens acting to collimate light emitted by the top surface by total internal reflection (TIR), and a shape of the outer lens affecting a side emission pattern of light not internally reflected within the inner lens.