Patent ID: 8891171

Claim:
A high sag thick lens for use with an illumination apparatus having a light source, the lens including: a first outer lens part having opposite first and second surfaces, the first surface of the first outer lens part defining a first curved optical active surface of the lens that refracts incoming light rays from the light source, the second surface of the first outer lens part including a plurality of first elongated baffles; a second outer lens part having opposite first and second surfaces, the first surface of the second outer lens part defining a second optical active surface of the lens that refracts the incoming light rays from the light source, the second surface of the second outer lens part including a plurality of second elongated baffles; and a lens core part forming an interior of the lens and that is embedded between the first outer lens part and the second outer lens part, the lens core part having opposite first and second surfaces, the first surface of the lens core part including a plurality of third elongated baffles and the second surface of the lens core part including a plurality of fourth elongated baffles; where the second surface of the first outer lens part and the first surface of the lens core part are fused together with the first elongated baffles being intertwined with the third elongated baffles, and where the second surface of the second outer lens part and the second surface of the lens core part are fused together with the second elongated baffles being intertwined with the fourth elongated baffles, and where the first outer lens part, the second outer lens part and the lens core part have a same refractive index and are made of a single solidified injection-moldable plastic material that entirely fills the interior of the lens in a gapless manner to prevent refraction of the incoming light rays from the light source by any one of the elongated baffles inside the lens.