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The primary role of the lens in LED applications is also to perform a secondary optical design of the light intensity distribution of the LED source. After receiving the light source, the lens factory analyzes its illuminating form and tailors it according to the customer's light intensity distribution. The most important parameter is the illuminating angle. Obviously, for spotlights, the small angle is generally selected, while the spotlight and light box are You must choose a large angle.
In addition to the angle of illumination, the design also needs to consider parameters such as brightness, spot illumination, uniformity, etc. In addition, there are certain requirements for the material to be yellowed and temperature resistant.
The diversification of lighting plant solutions has led to the diversification of lens products, so it is difficult for lens manufacturers to reduce the cost of lenses for large-scale production. The deeper reason is also the disorderly competition caused by the lack of China's entire LED industry standard.
It is undeniable that some products currently have standardized trends, such as lamps, generally 0.6 meters, 0.9 meters, 1.2 meters in length, MR16, PAR30, PAR38 also have standards, but they are only appearance requirements, specific requirements such as light efficiency, Color temperature still has its own standards, and the lens factory only has tailor-made lenses for each light source and customer requirements.
Now with 100lm light source for streetlights, there are also street lamps with 140lm light source. Obviously, the lenses are different. Hu Lihua stressed.
Indeed, from the current price of lamps, the cheapest can reach 1 yuan / W, the most expensive can even reach 7 dollars / W, the natural lens customers of different grades have different lens requirements.
Many companies are sensitive to price, although our offer is not very high, but some customers are willing to buy cheap lenses made of water. Xue Teng said that it seemed a bit helpless. Indeed, now Zhongshan has a lens offer of 7 points / a, and the general lens offer is a few corners /.
The reporter noticed that these cheap lenses are prone to yellowing in less than half a year, and even the phenomenon of melting at the bottom, seriously affecting the quality of the lamps. Most of the cheap lens manufacturers do not have their own optical R&D team, and lens development relies on plagiarism. There is no IQC and no QC, and there is no quality check. They do not have a clean room, often in an empty iron shed, let alone anti-static, dust-proof treatment in the production process. The finger sleeve is not replaced once every hour to prevent the lens from entering the impurity and the black dot problem affects the appearance.
At the same time, cheap lenses and lens materials produced by regular manufacturers are also very different. Good lenses are generally made of imported materials. The light transmittance of imported materials will be better. For example, the best material in Japan, Mitsubishi's light transmittance can reach more than 90, but the domestic transmittance is only 80. Liang Sheng, director of Hesheng Hardware Lighting Parts Factory, said. The reporter can see from the market that the thicker the lens, the lower the transmittance requirement. Generally, the transmittance of 2 mm acrylic is 93, PC89-90. In addition to the transmittance, some customers have special requirements, such as the requirement to use diffusion material. Or materials with a certain fire rating.
Imported materials perform better in vulcanization and yellowing, can guarantee heat resistance, and have less dust in the production process, and it is not easy to form black spots. Hu Lihua said that based on the internal stress treatment in the production process, the processing method is acrylic baking in a 90-95 oven, and the PC is baked in a 120-150 oven to release internal stress, so their products have a bottom gas. Provide a 3-5 year warranty.
Indeed, injection time is also a key point in ensuring the quality of the lens, because the stress in the lens with a short injection time is not easily released and is easily deformed. According to the reporter's understanding, the lens manufacturers with quality assurance can produce only 8,000-9000 lenses per day. However, some manufacturers who disregard quality in Zhongshan can produce tens of thousands of injections per day.
The most troublesome problem is the problem of internal stress, which is not visible when the lens is just used, but a series of problems such as deformation and yellowing after half a year are followed. As the so-called penny and goods, for low-end lighting factories, as long as the price is low, black spots, half a year later, deformation, yellowing and even light distribution deviations are not a problem.
In addition to the above, the lens factory has high requirements for hardware capabilities. General manufacturers use imported injection molding machines, the best is Japanese and German equipment, and again Taiwan equipment, generally do not consider domestic equipment. Moreover, it is necessary to use an optical injection molding machine, but such an injection molding machine generally has a relatively small specification, and the productivity is much worse for an injection molding machine that is generally used for the production of a mobile phone casing.
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