Power Electronics

Polycarbonate Grade Can Replace Aluminum In LED Heat Sinks

The light emitting diode (LED) market is booming as consumers switch from incandescent bulbs to more energy efficient LEDs. Lighting designers and manufacturers are looking for materials to help make the bulb transition a smooth one. Bayer MaterialScience LLC is launching a new grade of thermally conductive plastic to help lighting manufacturers meet consumer demand quickly and cost-effectively.

Makrolon® TC8030 polycarbonate, which joins a selection of heat-resistant Bayer plastics developed for LED applications, is targeted for use in LED heat sinks for replacement lamps or next-generation luminaires. Compared with aluminum, a common material in heat sinks, this grade of Makrolon offers similar thermal performance while helping reduce costs and enhance design freedom. Using this material can save costs by eliminating assembly steps, improving production efficiency and reducing capital investments. Because Makrolon TC8030 plastic is injection molded, it gives designers the freedom to create non-traditional shapes, use in-mold decoration and optimize joining techniques.

This material has a preliminary UL 94 flame class rating of V-0 at 2.5 mm, with an official UL listing expected by the end of March 2012. It is currently available in a black color, but additional colors can be achieved through film insert molding or painting.

A demonstration lamp is a functional PAR30 with a heat sink molded from Makrolon TC8030 and a lens molded from Makrolon LED2643, a material with improved light transmission properties when using an LED light source. Makrolon LED2643 has a UL 94 flame class rating of V-2 at 1.5 mm and is f1 rated for outdoor use (in accordance with UL 746C).

Bayer MaterialScience LLC
Part Number: Markalon

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