Lumenharold,
Thanks for the ray tracing image!
I've made a few design changes that should correct some of the problems that you've highlighted. The gap between the two light pipes has been reduced to .020" and it will occur within a hole in a white, plastic housing. The entrance end of the...
Timelord,
You bring up some interesting points. I could conceivably bond a clear silicone rubber pad to the top of light pipe A. The pad could be a few thousandths of an inch thicker than the .030" gap. However, the pad might not be durable enough to withstand a couple thousand cycles of...
Thanks for the response, CorBlimeyLimey. I'm going to build a mockup to test the concept. I'm also going to make the entrance to light pipe A concave so as to better capture the light from the LED.
I'm designing two light pipes in series with each other (see attached sketch). Both will be cylindrical rods of approximately .3" diameter with a few extra features (not shown) for mechanical assembly. Light pipe A will be embedded in a base housing. Its entrance face will sit .020" above a...
