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Application and Advantages of Lens Technology in LED Lighting

01 Role and Classification of Lenses

◆ Basic Introduction to Lenses

Lenses, as optical components, play a vital role in LED lighting. Fabricated based on light refraction principles, they are made of transparent materials such as glass or crystal. The refractive surfaces are typically two spherical surfaces or one spherical surface paired with a flat plane, capable of forming real and virtual images. In LED lighting, lenses are widely used and generally fall into two categories: convex lenses and concave lenses. Convex lenses are thicker at the center and thinner at the edges, existing in three forms: biconvex, plano-convex, and concave-convex. Concave lenses are the opposite, with three forms: biconcave, plano-concave, and convex-concave.

◆ Materials and Applications
Lens materials vary and include silicone, PMMA, PC, and glass, each with unique advantages and limitations for different scenarios:

• Silicone Lenses: Known for high-temperature resistance and compatibility with reflow soldering, they are often directly encapsulated on LED chips. Compact in size (typically Ø3-10mm), they enhance light extraction efficiency and optimize illumination by modifying light field distribution.

• PMMA Lenses: Made of optical-grade polymethyl methacrylate (acrylic), they offer high production efficiency (via injection/extrusion molding) and excellent transmittance (~93% @3mm thickness). However, their thermal resistance is limited (<80°C; heat deflection temperature: 92°C).

• PC Lenses: Composed of optical-grade polycarbonate, they balance production efficiency with good heat resistance (operating temp: ≤110°C; heat deflection temp: 135°C). Transmittance is ~89% @3mm thickness.

• Glass Lenses: Crafted from optical glass, they deliver superior transmittance (up to 97% @3mm) and thermal stability. Drawbacks include bulkiness, fragility, complex mass production, and higher costs.

High-power LED systems often combine lenses with reflectors to achieve critical functions like light concentration and guidance, significantly improving luminous efficacy through optimized light distribution curves.

◆ Classification and Specifications
Lenses are categorized as primary or secondary based on their role and light control:

• Primary Lenses: Directly integrated with LED chip packaging (using PMMA, PC, glass, or silicone). They collimate light emitted by the chip (theoretically 360°, practically ≤180° after packaging) into specific angles (e.g., 180°, 160°, 140°, 120°, 90°, 60°).

• Secondary Lenses: Separate from the LED source but used in tandem to further focus light into angles between 5°–160°. Light distribution can be circular, elliptical, or rectangular. Materials typically include PMMA or PC, with glass used for specialized applications.

02 Design and Production of Lenses

◆ Design and Mold Processing
LED lens design must align with light source characteristics, utilizing precision machining and high-quality materials:

• Source-Specific Design: Variations in LED chip structures, packaging methods, and beam profiles necessitate tailored development for mainstream brands.

• Optical Simulation: Non-aspheric optical surfaces are engineered using optical design software for light path simulation.

• Precision Manufacturing: As high-precision optical components, lenses demand mold accuracy ≤0.1μm and lens eccentricity ≤3μm, requiring ultra-precision machining equipment.

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◆ Advantages of LED Lenses
Compared to traditional luminaires, lenses provide:

• More uniform and efficient light distribution.

• Enhanced visual performance.

• Superior beam control vs. lampshades, especially for narrow-angle applications.

◆ Light Loss and Design Optimization
Design considerations include:

• Light Transmittance & Loss: Shell/lens transmittance and stray light loss must be minimized to meet standard light distribution requirements.

• Beam Diffusion: For high-power LED lamps (e.g., bulb lights), lenses diffuse parallel beams to comply with standards.

• Modular Design: Rectangular lens units enable compact, orderly arrangements to achieve target light distribution.