English
Español
عربى
русскийIn the production process of LED dual-lamp cup dual-light lens, from the selection of raw materials to the precision manufacturing of molds, to injection molding and demolding, every step embodies the wisdom and sweat of engineers and craftsmen. However, when the lens emerges from the mold, its surface often has tiny flaws and unevenness. Although these subtle details are inconspicuous, they have an unignorable impact on the optical performance of the lens. The last process - fine grinding and polishing of the lens with extremely fine polishing powder and soft polishing cloth has become a key step in determining the final quality and performance of the lens. This process is not only a test of technology, but also an extreme pursuit of patience and meticulousness.
In the design of LED dual-lamp cup dual-light lens, optical performance is the core indicator to measure its quality. The surface smoothness of the lens directly affects the propagation path and efficiency of light, and then affects the lighting effect and driving safety. A lens with a rough surface will not only reduce the transmittance, increase the scattering and reflection of light, but also may produce glare and interfere with the driver's vision. Therefore, grinding and polishing the lens surface to a mirror-like smoothness and brightness is a necessary means to improve the optical performance of the lens and ensure the lighting effect.
Before fine grinding and polishing, the lens needs to be initially trimmed and polished to remove excess materials such as gate marks and flash generated during the injection molding process, and to initially refine the surface roughness. This step usually includes mechanical trimming and manual trimming to ensure the basic shape and dimensional accuracy of the lens. After the initial trimming, although the lens surface is relatively flat, there are still tiny scratches and unevenness, which need to be further refined by fine grinding and polishing.
Selection of polishing powder: Polishing powder is a crucial material in the process of fine grinding and polishing, and its particle size and composition directly affect the polishing effect. For LED dual-lamp cup dual-light lens, extremely fine polishing powder should be used to ensure that new surface defects are not introduced while removing tiny scratches. The particle size of polishing powder is usually measured in microns (μm), and the finer the polishing powder, the smoother the surface. In addition, the composition of the polishing powder also needs to be selected according to the lens material and optical requirements to achieve the best polishing effect.
Selection of polishing cloth: The polishing cloth is a medium that carries the polishing powder and is in direct contact with the lens surface. High-quality polishing cloth should be soft, wear-resistant, and not easy to deform to ensure that the lens surface will not be damaged during the polishing process. Commonly used polishing cloth materials include flannel, silk cloth, and non-woven fabrics. It is very important to choose a suitable polishing cloth according to the lens material and polishing requirements.
Polishing equipment and process parameters: Fine grinding and polishing usually use special polishing equipment, such as polishing machines, grinders, etc. These equipment achieves precise polishing of the lens surface by controlling process parameters such as polishing force, rotation speed, and polishing time. During the polishing process, the polishing force and angle need to be continuously adjusted to avoid over-polishing or under-polishing. At the same time, the polishing powder and polishing cloth need to be replaced regularly to maintain the polishing effect and efficiency.
Monitoring and adjustment of the polishing process: Fine grinding and polishing is a process that requires patience and meticulousness. During the polishing process, it is necessary to constantly observe the changes on the lens surface and adjust the polishing force, angle, and particle size of the polishing powder to ensure that the polishing effect meets the design requirements. In addition, it is necessary to regularly use optical instruments to detect the roughness and transmittance of the lens surface to evaluate the polishing effect and adjust the polishing strategy.
After fine grinding and polishing, the lens must undergo strict quality inspection to ensure that its optical performance and appearance quality meet the design requirements. Quality inspection usually includes the following aspects:
Surface roughness detection: Use a surface roughness measuring instrument to detect the roughness of the lens surface to ensure that it is within the specified range. Surface roughness is an important indicator to measure the smoothness of the lens surface and directly affects the optical performance of the lens.
Transmittance detection: Use a spectrophotometer to measure the transmittance of the lens to ensure that its transmittance in the visible light range meets the design requirements. Transmittance is one of the key indicators to measure the optical performance of the lens and directly affects the lighting effect and driving safety.
Imaging quality detection: Use a high-resolution camera and test chart to evaluate the lens's focusing ability and imaging clarity. Imaging quality is an important indicator to measure the optical performance of the lens and directly affects the lighting effect and visual experience.
Appearance quality inspection: Carefully inspect the appearance of the lens to ensure that there are no defects such as scratches, cracks, and bubbles. Appearance quality is a direct reflection of lens quality and one of the focuses of consumer attention.
Fine grinding and polishing is not only a technical job, but also an art. It requires craftsmen to have rich experience and superb skills, and to be able to flexibly adjust polishing strategies and process parameters according to the material, shape and optical requirements of different lenses. At the same time, fine grinding and polishing is also a process that requires patience and meticulousness, requiring craftsmen to maintain a high degree of concentration and patience during the long polishing process. It is this persistence in technology and pursuit of art that makes each LED dual-lamp cup dual-light lens appear mirror-like smooth and bright, becoming a lighting partner trusted by drivers.
Fine grinding and polishing are an indispensable part of the production process of LED dual-lamp cup dual-light lenses. It not only concerns the optical performance and lighting effect of the lens, but also reflects the respect for technology and the pursuit of art. Through rigorous process control and strict quality inspection, each lens can become a lighting partner trusted by drivers, escorting night driving safety.
