Headlight Lens Solutions for High-Lumen Output Systems

As LED technology continues to evolve, high-lumen output headlight systems will be commonplace on top-tier bikers and motorcycle aftermarket lighting upgrades, as they are offered at 3,000 to 6,000 lumens/lamp. But a lumen rating alone will not ensure effective lighting along roadway. The headlight lens makes a crucial difference in the path raw light takes to become an effective, safe, legal headlight beam pattern. High lumens, with an unoptimized lens equal to, cause wasted energy, non-flat glare and hot spots.

At Danyang Yeya Opto-Electronic Company Limited, our specialties are LED multifunctional lighting products - the lens is designed to match with high lumen systems. Below are four key lens solutions for high output applications.

1. Free-Form Optics for Uniform Beam Distribution

High-lumen LED chips emit light from a very small surface area which produce extreme luminance if not well controlled – which is often the case to create blinding hotspots. This is not possible with either a smooth or a parabolic lens. Instead, free-form optics, which breaks up the surface of the lens in a number of small segments with slightly different shapes, are needed.

These "free-form" lenses bend the light from portions of the LED chip into zones of the road, resulting in a uniform light pattern, no dark spots, and assured that there will not be too bright a spot. Holding to the principle of going OTL (One Time Look), Danyang Yeya's engineering team utilizes high-tech optical simulation software to design free-form lenses for achieving superior uniformity, so that a 5,000 lumen system can offer comfortable and fatigue-free light for the rider while eliminating glare from oncoming traffic.

2. Aspheric Lens Geometries for Collimated Projection

The high-lumen output types often utilize projector type optics (concave aspheric lens) which together produce an inverted image of the LED chip and the cutoff shield onto the road. Aspheric lenses are lenses whose radius of curvature changes from the center to the periphery, which reduces spherical aberration, a characteristic seen in higher output systems, that results in blurring at the cutoff line.

Danyang Yeya can create sharp, blue-free cutoff lines, satisfying ECE standards or SAE/DOT requirements, even at lumen output in excess of 4,000 lumens, by employing precision molding of aspheric lenses. These lenses also deliver a collimated beam which enhances the down road view, without boosting the total power used.

3. High-Clarity Polycarbonate with Anti-Yellowing Coatings

The high-lumen systems can also produce a lot of heat, particularly if several LED chips are fired under high-intensity. Eventually, the effects of heat and UV radiation create polycarbonate lenses that yellow, haze or even crack, which results in lower transmission and pattern distortion of the beam.

Danyang Yeya knows the answer to this problem in two stages. We first choose top quality optical-grade poly-carbonate that has high thermal stability. Secondly, we apply a multi-layer hard coating, which is composed of UV-absorbers and thermal stabilizers. This coating absorbs more than 99% of all damaging UV radiation and is not subject to surface degradation by heat cycling. With > 90% of light transmission after years of use in the high output systems, what has been achieved is a lens that maintains efficiency and is a wise investment.

4. Custom Lens Tooling for Optimized Etendue Matching

Systems with high lumens come in a variety of sizes and configurations of LEDs (diameter, quantity) and reflectors (design and angles) and beam angles (angles designed). There is no one particular lens geometry that will suit any combination. To achieve maximum efficiency, the optics parameter called etendue, which is the product of source area and emission angle, has to be matched with the optics of the lens (its design).

Danyang Yeya is able to develop custom OEM/ODM lens solutions, using existing mold or new development tool. Our professional engineers measure your LED module etendue, and a customized lens is designed to be used to gather and focus more than 85% of light. For motorcycle safety lights, Toyota auxiliary lights, ATVs, forklifts, we custom mould the lens in such a way to achieve the most curvature, diameter and focal length needed for your high lumen system. We promise reasonable price, quick delivery and precise quality control from raw materials to finished product.

Summary

Headlight systems with high lamp luminous output require equally high performance lens systems. Uniform beam distribution is achieved with free form optics, sharp cutoff lines with aspheric geometries, still high light output over time for polycarbonate with anti-yellowing coatings, and custom tooling configures optics to your specific LED setup. Phelps Model Engineering have merged their engineering knowledge, quality-first production and fast OEM/ODM with Danyang Yeya Opto-Electronic Company Limited to bring the ultimate headlight lenses, which allow for the refractivity of your high lumen system. Call us today to find out what we can do for your project.