LED Lens Buffer LSR Component

# LED Lens Buffer LSR Component

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Product Overview

LED Lens Buffer LSR Components are precision-molded silicone rubber parts manufactured by 橡楚（湖北）橡胶有限公司, designed to provide reliable cushioning, sealing, and stress absorption between LED lenses and LED module housings for a wide range of lighting applications. Liquid Silicone Rubber (LSR) is the ideal material for this component, as it combines excellent low-temperature flexibility, high-temperature resistance, and optical stability unmatched by most conventional elastomers.

As a specialized manufacturer of LSR products, we engineer LED Lens Buffer LSR Components to solve common pain points in LED assembly: thermal expansion mismatch between glass/polycarbonate lenses and aluminum/PCB substrates, mechanical vibration damage during transportation and operation, and moisture ingress that degrades long-term LED performance. Our buffer components maintain consistent compression set resistance over tens of thousands of thermal cycles, preventing lens shifting, light leakage, and premature component failure. Each part is molded to tight tolerances to ensure compatibility with standard LED module designs, and can be customized to fit unique form factors for specialized lighting projects.

Our production facility is located at 湖北省鄂州市鄂城区经济开发区凡口街道内河巷54号, where we follow standardized manufacturing processes to deliver consistent, high-quality LSR components for global export markets.

Technical Specifications

Material Properties

Our LED Lens Buffer Components are made from 100% cured injection-molded liquid silicone rubber, formulated specifically for optical and electronic applications. Key material properties are as follows:

Physical Performance

All performance values below are tested at 23°C / 50% RH per ASTM D412 standards:

Process Parameters

We produce our LSR components via high-precision liquid injection molding (LIM) to ensure tight dimensional consistency:

• Standard dimensional tolerance: ±0.05 mm for features under 10 mm; ±0.1 mm for features 10-50 mm
• Minimum wall thickness: 0.3 mm
• Maximum part dimension: 300 mm (custom larger sizes available for special projects)
• Surface finish: As-molded matte; custom polished finish available on request
• Curing process: In-mold heat curing, no post-curing required for standard applications; optional post-curing for low-volatility requirements

Product Advantages

1. Excellent Thermal Stability for Long-Term LED Performance

Unlike thermoplastic buffers or organic rubber alternatives, our LSR buffer components maintain consistent mechanical properties across the full operating temperature range of high-power LED systems. They resist thermal degradation even with continuous exposure to temperatures up to 200°C, and do not become brittle at sub-zero temperatures for outdoor low-temperature lighting applications. Low compression set ensures the buffer maintains consistent cushioning pressure over the 50,000+ hour service life of LED modules, preventing loosening and lens shifting over time.

2. Low Stress Absorption to Protect Optical Components

LED lenses (especially glass lenses for high-power applications) are prone to cracking from mechanical shock and thermal expansion stress between different materials. Our LSR buffer’s low modulus and high elasticity effectively absorb thermal expansion stress from ambient temperature changes and vibration from external sources (such as roadway traffic for street lighting, or building movement for architectural lighting). This reduces the risk of lens cracking and extends the overall service life of the LED assembly.

3. Integrated Sealing Performance

In addition to cushioning, our LED Lens Buffer LSR Components provide excellent IP-rated sealing against moisture, dust, and atmospheric contaminants. LSR is inherently hydrophobic and resistant to UV degradation, so it does not absorb water or degrade from long-term outdoor exposure. This eliminates the need for a separate sealing gasket in most LED module designs, simplifying assembly and reducing overall component costs.

4. Customizable Form and Function

We can mold LED Lens Buffer Components to nearly any custom shape, including annular gaskets, rectangular bumpers, and complex contoured profiles to match unique lens and housing designs. We can adjust hardness, transparency, and surface finish to meet specific application requirements, from low-profile buffers for slim panel lights to high-compression buffers for large outdoor street lighting lenses.

Applications

LED Lens Buffer LSR Components are suitable for a wide range of LED lighting applications across multiple industries:

1. Outdoor Lighting: Street lights, high-mast lighting, flood lights, and architectural facade lighting. The component’s UV and weather resistance ensures long-term performance in exposed outdoor environments, preventing moisture ingress and lens damage from temperature fluctuations.
2. Indoor Commercial Lighting: Downlights, panel lights, track lighting, and high-bay warehouse lighting. The buffer absorbs vibration from ventilation systems and foot traffic, maintaining lens alignment and preventing light leakage over time.
3. Automotive Lighting: Headlight auxiliary lenses, taillight seals, and interior ambient lighting components. LSR’s resistance to automotive fluids and wide operating temperature range meets the demanding requirements of automotive electronic systems.
4. Specialized Lighting: Stage lighting, horticultural grow lights, and underwater lighting. For underwater applications, the LSR buffer provides excellent water resistance and hydrostatic pressure absorption to protect optical components.
5. Consumer Electronics Lighting: Smartphone flash lenses, smart display backlight modules, and wearable device lighting components. The low-profile, precision-molded design fits compact form factors while providing reliable cushioning.

Selection Guide

Hardness Selection

Choosing the correct hardness for your LED Lens Buffer depends on your application requirements:

• 10-20 Shore A: Recommended for large lenses (over 100 mm) and applications with high vibration or large thermal expansion mismatch. Higher elasticity provides maximum stress absorption.
• 20-35 Shore A: General-purpose grade for most standard indoor and outdoor LED applications, balancing cushioning performance and structural support.
• 35-50 Shore A: Recommended for small precision lenses (under 30 mm) and applications requiring high dimensional stability and low compression, such as automotive headlight lenses.

Size Specifications

We offer standard off-the-shelf sizes for common LED lens diameters: 20 mm, 30 mm, 50 mm, 75 mm, and 100 mm annular buffers. For custom sizes or non-circular lens designs, we accept custom tooling and production orders based on your 2D/3D CAD drawings. Minimum order quantities apply to custom tooling projects.

Material Grade

We offer three standard material grades to meet different application requirements:

• Standard Electronic Grade: General-purpose grade for most indoor and low-power outdoor applications, compliant with RoHS and REACH.
• Low-Volatility Grade: Formulated for enclosed LED assemblies to minimize silicone outgassing, which can cause fogging on lens surfaces. Recommended for high-power enclosed LED modules and automotive lighting applications.
• Food-Grade / Medical-Grade: Compliant with FDA 21 CFR 177.2600 and ISO 10993 for medical lighting and food-processing lighting applications.

Quality Assurance

At 橡楚（湖北）橡胶有限公司, we implement strict quality control throughout the entire production process, from raw material incoming inspection to final finished product testing. Our production system is certified to ISO 9001, and we follow all quality management requirements of this standard to ensure consistent product quality.

Our standard quality control checks include:

1. Raw material inspection for mechanical properties and purity before production
2. In-process dimensional inspection every 2 hours to maintain tolerance compliance
3. Final visual inspection for 100% of parts to exclude surface defects or molding flaws
4. Batch testing of compression set and hardness to verify conformance to technical specifications

All our products comply with international environmental regulations including RoHS 2.0 and REACH SVHC requirements. For orders over 5000 pieces, we can provide third-party test reports upon request.

For inquiries about custom specifications, bulk orders, or technical support, contact us at:

• Address: No. 54, Neihe Alley, Fankou Street, Economic Development Zone, Echeng District, Ezhou City, Hubei Province, China
• Phone: +86 18071171144
• Email: churubber@163.com