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Optimizing LED heat management

Covestro polycarbonate provides heat management for LED luminaire

Optimizing LED heat management

A heat sink is crucial for LED luminaires, helping to dissipate heat. Aluminum, a popular material for this component, has disadvantages that include its weight, appearance and tendency to corrode.

Makrolon® TC8030 polycarbonate is used for the housing of SLP Lighting’s CircLED™ high bay fixture, acting as a heat sink. (Photo: SLP Lighting)
Makrolon® TC8030 polycarbonate is used for the housing of SLP Lighting’s CircLED™ high bay fixture, acting as a heat sink. (Photo: SLP Lighting)

Task

With the drawbacks of aluminum in mind, SLP Lighting selected a Covestro material to provide efficient cooling for its new CircLED™ product. CircLED™ is an 18-inch round high bay fixture for general high bay applications such as auditoriums, exhibit halls, factories, distribution centers and warehouses.

Challenge

The housing of the CircLED™ acts as a heat sink for the lighting luminaire. Most fixtures of this type have heavy die cast aluminum housings, but CircLED™ utilizes lightweight, thermally conductive Makrolon® while still providing thermal management for up to a 200 watt LED engine.

Solution

The CircLED™ housing is injection molded at SLP Lighting’s manufacturing plant in Missouri with thermally conductive Makrolon® TC8030 polycarbonate from Covestro. The material provides strong heat-transferring capability, enabling the design to maintain an acceptable steady state temperature. Covestro worked closely with SLP Lighting, providing part and mold design support, substantial CAE thermal simulations and physical testing to validate material performance in the application.

Case Profile

Supplier

Covestro LLC

Industry

Lighting LED

Application

CircLED™

Makrolon® polycarbonate - the state of the art material for a broad range of design applications that possesses phenomenal properties

  • Developed specifically for LED applications, Makrolon® TC8030 polycarbonate offers high thermal conductivity.
  • The material is lightweight, therefore reducing the weight of the LED luminaire.
  • Makrolon® LQ2887 polycarbonate has earned the Underwriters Laboratories 94 flame class rating of V-0 at 2.0 mm.
  • This grade provides enhanced design freedom, allowing designers to create non-traditional shapes and optimize joining techniques.
  • Makrolon® LQ2887 polycarbonate can be used to in-mold LEDs on the printed circuit board in the heat sink assembly to reduce costs.
Find out more about Makrolon®
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