Some key points about lenses, as explained by an LED lens manufacturer.

Release Date:

2022-01-04 12:50

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LED lens manufacturers define a lens as an optical component whose surface is part of a sphere, made from transparent materials such as glass, crystal, or plastic. The materials and types of lenses include the following:

      LED lens Manufacturers regard a lens as an optical component whose surface is part of a sphere, made from a transparent material such as glass, crystal, or plastic. The materials and types of lenses include the following:

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　　1. LED lens – silicone lens:

　　A. LED lens The manufacturer believes that, due to its high-temperature resistance, (Or reflow soldering), silicone gel is often used to directly encapsulate LED chips.

　　 B. Conventional silicone hydrogel lenses are small in size, with diameters ranging from 3 to 10 millimeters.

　　2. Polymethyl methacrylate lens

　　A. Optical-grade PMMA (polymethyl methacrylate, commonly known as acrylic).

　　B. Plastic material: Advantages—high production efficiency (can be manufactured via injection molding and extrusion); high light transmittance (approximately 93% at a thickness of 3 mm). Disadvantages—operating temperature should not exceed 80°C (heat deflection temperature is 92°C).

　　3. PC lens

　　A. Optical-grade polycarbonate material.

　　B. Plastic material: Advantages—high production efficiency (can be manufactured via injection molding and extrusion); slightly lower light transmittance (approximately 89% at a thickness of 3 mm). Disadvantages—operating temperature should not exceed 110°C (heat deflection temperature is 135°C).

　　4. Glass lens

　　Optical materials: advantages include high transmittance (97%), excellent thermal stability, and more. Disadvantages include limited shape options, brittleness, difficulty in achieving mass production, low manufacturing efficiency, and high costs.

　　LED lens The manufacturer believes that a single lens can be directly encapsulated. (Or bonded) onto the LED chip leadframe, forming an integral unit with the LED. In theory, the LED chip emits light in a 360-degree pattern; however, when mounted on the LED leadframe, it is fixed and encapsulated, resulting in a beam angle of approximately 180 degrees (with a small amount of side‑emitted light beyond this range). Additionally, some stray light remains within the chip itself. Consequently, all of the chip’s emitted light can be captured in a single pass. The lens effectively converges light, allowing one to obtain 180°, 160°, 140°, 120°, and so on. The primary lens is typically made from materials such as PMMA, PC, optical glass, or silicone.

　　LED lens The manufacturer believes that the secondary lens and… LEDs are two distinct components, yet they are inseparable in practical applications. The secondary lens functions to collimate the light emitted from the LED source into a desired beam angle ranging from 5° to 160°; the resulting light distribution can be circular, elliptical, or rectangular. Secondary lens materials are typically optical-grade PMMA or PC, with glass used only in specialized applications at present. However, as glass‑molding technologies become more widespread, the secondary lens market is poised for a material revolution, with optical glass set to replace optical PMMA or PC.

　　 LED lens Manufacturers argue that this contrasts with lenses and reflector cups. While both operate on the same basic principle, lenses offer superior control because every ray of light is precisely directed and utilized, whereas a significant portion of the light in a reflector remains uncontrolled and does not strike the reflector surface; consequently, the light distribution pattern of a reflector is less sharp than that of a lens.


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