Samsung TV Backlight Optical Lens Manufacturer
Optical LED Lens for Samsung TV Backlight
After four months of unremitting efforts, this TV backlight lens is independently developed by our lens optical design team. Unlike the low-cost and low-quality advertising light box backlight lenses, it is a high-quality lens.
Our company pays a lot of attention to the optical performance and performance of the LED lens. In the end, the sample passed the strict verification of the Samsung TV department at one time and was very affirmed by customers.
Design of Optical LED Lens for TV Backlight
According to the different uses of the product and different lighting performance, we need to design lenses with different angles and shapes. The lens design is a very professional job. Our designer team not only needs professional knowledge in optics but also product design. It also needs rich experience in mold manufacturing and plastic injection molding.
Test Mold for Optical LED Lens Manufacturing
From the point of view of the balanced filling of molten plastic, it is impossible to make only one cavity, but to make a symmetrical multi-cavity test mould, so as to ensure the consistent and stable quality of the final plastic product.
The pilot mold also required the same hot runner system as the intended production mould. We need to design reasonable plastic runners to facilitate the glue feeding method for later mass production. Therefore, we can also call this test mold a mass production mould with fewer cavities.
Optical LED Lens Injection Molding Adjustment
In order to achieve the fine adjustment of injection molding conditions, our company usually uses a customized TOSHIBA injection molding machine for injection molding. The clamping force of the 250 Ton injection molding machine can ensure that the parting surface of the mold can fit well. The screw of the TOSHIBA injection molding machine is suitable for the advancement of PMMA, its injection pressure can meet the fine adjustment of 1Pa, and the adjustment and control of the four-stage injection temperature can well meet the characteristics of acrylic raw materials. Dwell time is also an important factor, which adjusts the density inside the product as the molten plastic cools.
When the complete structure of the LED lens is injected, the injection parameters need to be recorded in detail. Then the adjustment technician will adjust and record multiple injection parameters at the same time until the product structure is abnormal, such as flash. This was done to obtain injection molded lens samples under different conditions. Usually, this mold trial process requires our professional and technical staff who are very familiar with lens production to continuously and finely adjust the machine parameters for more than half a day.
Dimensional Inspection and Optical Effect Verification of LED Lens
We need an optical microscope and a quadratic projection measuring instrument to examine these tiny molding dimensions. These dimensional measuring instruments can accurately measure tiny dimensions, and the measurement tolerance can be between +/-0.001mm. It is with their help that we can have a good understanding of how precise the dimensions and tolerances of the manufactured lenses are.
Mass production of Optical LED lenses
We are getting more and more stable on the road to mass production. The mass production mold has gone from the initial 32 cavities to the ramp-up 64 cavities, and now we can even complete the controlled mass production of 160 cavities.
- 1. The stability of injection molding machine, servo machine and oil heating machine. Generally, we need to conduct the product review after the machine is fully automated for 6 hours. All products manufactured during this period need to be scrapped.
- 2. Stability of injection molding environment. The injection molding workshop needs a constant temperature central air conditioner to control the ambient temperature within the range of +/-2°C.
- The stability of raw material supply. Ensure that the same quality of plastic raw materials are uniformly fed into the hopper.
- IPQC quality stability control. A professional lens QC employee is in charge of three injection molding machines, checking the size of 5 shots of products every half an hour, and fitting them to the inspection board to review the optical effect.
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