IACS CO., LIMITED (Yiwu Fuwei e-commerce firm)

First, the material type of high power LED lamp bead lens

  1. High power LED lamp bead silicone lens

a. Because silicone is resistant to high temperatures (and can also be reflowed), it is often used to package directly on LED chips.

b. The general silicone lens is small in volume and has a diameter of 3-10 mm.

  2. High power LED lamp bead PMMA lens

a. Optical grade PMMA (polymethyl methacrylate, commonly known as: acrylic).

b. Plastic materials, advantages: high production efficiency (can be completed by injection molding, extrusion); high transmittance (93% penetration at 3mm thickness); disadvantages: temperature can not exceed 80° (heat distortion temperature 92 degrees) ).

3. High power LED lamp bead PC lens

a. Optical grade Polycarbonate (PC) polycarbonate.

b. Plastic materials, advantages: high production efficiency (can be completed by injection molding, extrusion); light transmittance is slightly lower (the penetration rate is about 89% at 3mm thickness); disadvantage: the temperature can not exceed 110 ° (heat deformation temperature 135 degree).

4. High power LED lamp bead glass lens

Optical glass material, advantages: high light transmittance (97%), high temperature resistance, etc.; Disadvantages: single shape, fragile, difficult to achieve mass production, low production efficiency, high cost. However, at present, very few manufacturers in China have begun to develop glass molding processes, and use glass casting to produce glass lenses, which can produce lenses of various shapes and special surfaces. In addition, mold production, product consistency, high precision, and can greatly improve production efficiency, effectively reduce the cost of glass lenses, coupled with the high light transmittance, glass lens is bound to become optical plastic high-power LED An alternative to lenses. However, the current high prices of such production equipment are difficult to popularize in the short term. In addition, the disadvantages of glass compared to PMMA and PC materials are more fragile, and more research and exploration are needed. In the improved process that can be realized now, the non-fragile properties of the glass can only be improved by coating or tempering treatment, although after these treatments The light transmittance of the glass lens will be reduced, but it will still be much larger than that of the ordinary optical plastic lens. Therefore, the prospect of glass lenses will be broader.

Second, the application classification of high-power LED lamp bead lens

  1. Primary lens

a. The primary lens is directly encapsulated (or bonded) on the LED chip holder and integrated with the LED.

b. The LED chip (chip) theoretically emits 360 degrees, but in fact the chip is fixed and packaged on the LED holder, so the maximum illumination angle of the chip is 180 degrees (there is also a small amount of residual light in the range of more than 180°), and the chip There will also be some stray light, so that all the light of the chip can be effectively concentrated by one lens and different light angles such as 180°, 160°, 140°, 120°, 90°, 60°, etc., but different There is a certain difference in the light extraction efficiency of the LED at the exit angle (the general rule is: the greater the angle, the higher the efficiency).

c. The primary lens is generally made of PMMA, PC, optical glass, silica gel or the like.

  2. High power LED lamp bead secondary lens

a. The secondary lens and the LED are two separate objects, but they are inseparable when applied.

b. The function of the secondary lens is to converge the illumination angle of the LED light source again to any desired angle between 5° and 160°. The distribution of the light field can be mainly divided into: circular, elliptical and rectangular.

c. Secondary lens materials are generally optical grade PMMA or PC; glass is currently only selected under special circumstances. However, with the popularization and popularization of the glass molding process, the secondary lens will usher in a material revolution, and the optical glass will replace the optical grade PMMA or PC.

Third, high-power LED lamp bead lens specification classification

  1. Penetrating (convex lens)

a. When the LED light passes through a curved surface of the lens (the two convex surfaces have two curved surfaces), the light will refract and condense, and the angle will also change when the distance between the lens and the LED is adjusted (the angle is inversely proportional to the distance), The optically designed lens spot will be very uniform, but due to the lens diameter and lens mode limitations, the light utilization rate of the LED is not high and the edge of the spot has a relatively obvious yellow edge (the reason for the yellow edge is not repeated);

b. Generally used in large angle (50 ° or more) concentrating, such as table lamps, bar lights and other indoor lighting;

  2. Reflex type (cone or cup type)

a. The design of the lens is concentrating in front of the concentrating light, and the tapered surface can collect and reflect all the side light, and the overlapping of the two kinds of light (the same angle) can get the most perfect light utilization. With a beautiful flare effect;

b. It is also possible to make some changes on the surface of the conical lens, which can be designed as a mirror surface, a frosted surface, a bead surface, a striped surface, a thread surface, a convex surface or a concave surface to obtain different spot effects.

3. Lens module

a. It is to complete a single multi-head lens by injection molding a plurality of single lenses. According to different requirements, it can be designed as a 3, 1, 5, or even dozens of lens modules. It is also possible to pass two separate lenses. The brackets are combined.

b. This design effectively saves production costs, achieves consistent product quality, saves space in the lighting mechanism, and is easier to achieve "high power" and other characteristics.

Fourth, the design and mold processing of high-power LED lamp bead lens

  1. First of all, depending on the light source (high-power LED lamp bead), different brands of high-power LED lamp beads (such as CREE, Lumileds, Seoul, Osram, Everlight, Edison, Changsen source, etc.), its chip structure and packaging, Light characteristics, etc. will be different, resulting in the same lens with different specifications of the brand LED difference; so requires targeted development (mainstream brand-oriented), in order to achieve the actual needs;

  2. Design and optical simulation using optical design software (such as Code V, ZEMAX, TracePro, ASAP, LighTools, etc.) and mechanical modeling software (such as Pro/E, UG, SOLIDWORKS, etc.), continuously optimized to obtain the corresponding optical lens

3. The LED lens itself is a precision optical component, so its precision for the mold is extremely high, especially the processing precision of the optical surface of the lens is 0.1 μm. Generally, the processing of such high-precision molds must have the following equipment: ultra-precision processing machine (such as: PRECITECH NANOFORM 350), CNC integrated processing machine, precision grinding machine, precision milling machine, drilling machine, CNC precision spark machine, surface profiler, interferometer Wait.

4. The most precise part of the mold is the optical mold. First, the special mold steel (such as: Swedish S136 mirror steel) must be heat treated to 55° to complete the rough embryo. After the nickel plating on the rough embryo, the ultra-precision processing machine is used. Obtained by surface machining.

Fifth, the material and production of high-power LED lamp bead lens

  1. As an optical grade product, LED lenses have strict requirements on light transmission, thermal stability, density, refractive index uniformity, refractive index stability, water absorption, turbidity, and maximum long-term operating temperature. Therefore, the material of the lens must be selected according to the actual situation. In principle, optical grade PMMA is chosen, and optical grade PCs can be selected if there are special requirements. At present, the Japanese Mitsubishi PMMA material is the best (VH001 is a frequently selected grade), and Mitsubishi's branch in China, Nantong Liyang, will be slightly less;

  2. It must be equipped with a dust-free workshop of 10,000 or higher level. The operators must wear anti-static clothing such as anti-static clothing, finger-sets, and masks, and regularly inspect and clean the workshop.

3. Professional optical injection molding machines such as Toshiba, Demag, Haitian, Zhenxiong and other injection molding machines must be in place, and the injection molding process must be strictly controlled to obtain qualified products.

4. Product inspection: no bubbles, no dents, no creases, no flow lines, no crescents; shape accuracy Rt<0.005 Surface roughness Ra<0.0002.

5. The product must be packaged in anti-static, dust-proof PVC and must be completely sealed. The temperature and humidity must be strictly controlled. It is best not to store it for more than one year.

Yiwu Fuwei e-commerce firm is a very professional Led manufacturer who produces high quality outdoor led light. Our popular products are solar led lights, UFO lights, underwater lights and so on. If you have any question about the led product, please feel free to contact us.