Exploration And Optimization Of Influencing Factors Of Optical Property Of LSR Injection Molding LED

Optical grade LSR is a highly transparent thermosetting material,which has the characteristics of high light transmittance,wide operating temperature range,good resistance to UV stability,good fluidity and so on.The product is formed by injection technology,with short molding cycle,large design freedom,good microstructure replication,low yellowing index and excellent mechanical properties.It is widely used in automotive lighting,road traffic and other fields.Product performance is determined by structural design,molding process and material properties.Molding quality is one of the key factors that affect the optical performance of products,which including dimensional accuracy,curing uniformity,air holes and sutures.To control the optical performance of the product,not only the excellent structural design but also the optimization of the injection molding process is needed.At present,traditional optical simulation can only be aimed at product structure design,but it cannot form a system solution that takes injection molding into account,resulting in errors between simulation and actuality.In view of the shortcomings of traditional optical simulation,this subject based on the consideration of structural design,molding process and material properties to build a co-simulation platform for injection molding optical performance.Using LED as a model,the feasibility of co-simulation was verified,the effect of LSR injection molding on total luminous flux,illuminance and light intensity were studied.Based on this platform,the LSR molding LED process was optimized and designed to reduce the error between simulation and actuality on the basis of improving the optical performance of the product.The main contents of this article are as follows:(1)Constructed an injection molding optical performance co-simulation platform,clarified its technical principles,and provided a relatively complete solution for optical performance simulation.With the elliptical LED as the research object and the actual optical performance error as the reference,the effectiveness of the co-simulation based on Moldex3D,UG,TracePro was verified,and the feasibility of the engineering application was determined(2)The influence of LSR injection molding on the optical performance of LED products with key size parameters was studied,which provided a reference for the application of lighting fields,such as high-power integrated self-adjusting automotive headlamp design.Above all,the influence of different shaft length ratio and aspect ratio on the total LED luminous flux,illuminance and light intensity was explored,and then the co-simulation technology was used to analyze the different shaft length ratio and aspect ratio LEDs.The influence rule of dimensional accuracy caused by LSR injection molding on the optical performance of LEDs with different shaft length ratios and aspect ratios is obtained.(3)Based on the co-simulation platform,the injection molding process design was analyzed and optimized,which improves the optical performance of the actual product and reduces the development cost and cycle time.In order to avoid premature crosslinking and flashing in LSR injection molding,the rule of influence of volume flow rate and filling degree on the scorch index versus mold temperature and filling degree on the pressure of mold cavity were studied with the charring index and mold pressure as the characteristic parameters.Through orthogonal test method,the molding process parameters that affect the dimensional accuracy are optimized,and a better parameter combination is obtained;The mold cooling system,heating system and temperature isolation design are optimized.The LED dimensional accuracy is improved through process optimization.After co-simulation analysis and verification,the optical performance of the product is improved after molding.