Therma-Tech™ for LED Lighting Systems

8.5 in
8.25 in
CMYK
Case Study - EM - LED Lighting Kruuneteknikka.indd
TR 1: 8.2500" x 11.6875"
TR 2: 8.5000" x 11.0000"
BL: 8.7500" x 11.9375"
REMAY 80545
Digital/IAM
Asset No. 80545-P1
Case Study
Engineered Materials
Therma-Tech™ Solutions Brighten the Future
for LED Lighting Innovators
Transitioning from metal to a PolyOne solution meets performance
targets and improves manufacturing efficiency and sustainability.
Situ a tio n
The use of Light Emitting Diode (LED) technology in place of incandescent,
halogen and fluorescent lighting systems is rapidly emerging as an important new
trend in residential and commercial lighting. Factors driving the demand growth
of LEDs in these applications include the need for improved energy efficiency,
eco-conscious brand owners and legislators, and the widespread push to reduce
electrical consumption and greenhouse gas emissions.
11 in
Therma-Tech formulations provide designers with greater
freedom to achieve required thermal conductivity, and
also meet important dielectric, mechanical, flammability,
dimensional stability and creep resistance requirements.
Perhaps best of all, Therma-Tech material processes like
conventional thermoplastics, expanding part design freedom,
simplifying manufacturing, and reducing total systems cost.
T h e P o ly O n e D if fe r e n ce
Kruunutekniikka Oy, a Finnish manufacturer of lighting
components, sought a heat exchanger material solution that
would facilitate cooling of these components without the
need for aluminum. Coolics™ (www.coolics.fi), a patented new
thermal interface from Kruunutekniikka, has been developed
with the use of customized Therma-Tech materials that offer
thermal conductivity in plane from 2.7 to 21 W/m.K (ASTM
E1461).
Therma-Tech materials also provide the required flammability
performance with a glow wire resistance of 850°C/0.8mm (IEC
60695-2-12), plus the high dimensional stability necessary for
100
100
100
100
50
50,40,40
SLUR
0
100
100
100
100
50
50,40,40 100,100 100,100
100
100
100
100
50
50,40,40 100,100
50
100
100
100
100
50
50,40,40
50
50
100
100
100
100
50
50,40,40
75
75,66,66
100
100
100
100
50
50,40,40
25
25,19,19
11.6875 in
For an LED lighting system to be an effective alternative
to traditional lighting, it must be designed to dissipate the
excess heat generated by LEDs. Materials such as aluminum
have traditionally been used for this purpose, but cast
aluminum is both heavy and expensive to manufacture. In
contrast, Therma-Tech™ thermal management polymers from
PolyOne are formulated to meet the exacting performance
requirements of thermal interface components, including
sockets, heat sinks, transfer pads and trim, with improved
design and manufacturing flexibility.
8.5 in
8.25 in
CMYK
Case Study - EM - LED Lighting Kruuneteknikka.indd
TR 1: 8.2500" x 11.6875"
TR 2: 8.5000" x 11.0000"
BL: 8.7500" x 11.9375"
REMAY 80545
Digital/IAM
Asset No. 80545-P2
them to be directly overmolded on LED packages.
PolyOne’s sales and technical team listened carefully to Kruunutekniikka’s stated needs and requirements for this innovative
thermal interface. Addressing the challenge, experts from PolyOne worked closely with Kruunutekniikka and proposed a
combination of two customized Therma-Tech grades offering the features required for the application.
Therma-Tech solutions also gave Kruunutekniikka an economic advantage versus the die-cast aluminum parts it had been
using for its lighting system heat exchangers and components.
D elivering a Value- A dde d So lu tio n
Close collaboration between PolyOne and Kruunutekniikka resulted in a thermoplastic solution that met critical performance
needs and optimized the manufacturing process, which resulted in cost savings of more than 10 percent.
Lower Material Usage: The selected Therma-Tech solutions are 33 percent less dense than die-cast aluminum, so the
amount of material required per unit decreased accordingly.
Improved Manufacturing: By using the injection moldable Therma-Tech formulation rather than traditional die-cast aluminum,
Kruunutekniikka was able to realize substantial cost savings during high-volume production. The process switch also
accelerated production startup time. In addition, die casting requires secondary steps to achieve net shape, and these steps
were eliminated by switching to the injection molding process.
Sustainability: Production scrap generated during injection molding of Therma-Tech can be fully recycled as part of an in-line
process, which helped Kruunutekniikka to meet its sustainability goals.
Working in close collaboration with PolyOne, Kruunutekniikka is able to drive growth in the emerging solid-state LED lighting
market with a cost-effective solution that meets its goal of enabling a lower environmental impact.
PolyOne offers specialized solutions that are targeted at helping customers meet performance and sustainability goals, improve
manufacturing efficiency, and maximize value in every way possible.
11 in
CONTA CT INFORMATION
Americas
Asia
Europe
U.S.–Avon Lake OH
+1 866 POLYONE
China–Shenzhen
+86 (0) 755 2969 2888
Germany–Gaggenau
+49 (0) 7225 6802 0
Argentina–Buenos Aires
+0054 11 4200 5917
China–Suzhou
+86 (0) 512 6823 24 38
Spain–Barbastro
+34 (0) 9 7431 0314
Brasil–Campinas
+55 19 3206 0561
India–Mumbai
+91 9820 194 220
Turkey–Istanbul
+90 (0) 212 549 2256
Mexico - Toluca
+52 722 2790200
Thailand–Singapore
+65 (0) 6861 9325
w w w. p o l y o n e . c o m
PolyOne Americas
PolyOne Asia
PolyOne Europe
33587 Walker Road
Guoshoujing Road No. 88
6, Giällewee
Avon Lake, Ohio 44012
Z.J Hi-Tech Park, Pudong
L-9749 Fischbach
United States
Shanghai, 201203, China
Luxembourg
+1 440 930 1000
+86 (0) 21 5080 1188
+32 (0) 83 660 211
Copyright © 2013, PolyOne Corporation. PolyOne makes no representations, guarantees, or warranties of any kind with respect to the Information contained in this document about its accuracy, suitability for particular
applications, or the results obtained or obtainable using the information. Some of the Information arises from laboratory work with small-scale equipment which may not provide a reliable indication of performance or
properties obtained or obtainable on larger-scale equipment. Values reported as “typical” or stated without a range do not state minimum or maximum properties; consult your sales representative for property ranges
and min/max specifications. Processing conditions can cause material properties to shift from the values stated in the Information. PolyOne makes no warranties or guarantees respecting suitability of either PolyOne’s
products or the Information for your process or end-use application. You have the responsibility to conduct full-scale end-product performance testing to determine suitability in your application, and you assume all
risk and liability arising from your use of the Information and/or use or handling of any product. POLYONE MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, IMPLIED WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, either with respect to the Information or products reflected by the Information. This literature shall NOT operate as permission, recommendation, or
inducement to practice any patented invention without permission of the patent owner.
100
100
100
100
50
50,40,40
SLUR
0
100
100
100
100
50
50,40,40 100,100 100,100
100
100
100
100
50
50,40,40 100,100
50
100
100
100
100
50
50,40,40
50
50
100
100
100
100
50
50,40,40
75
75,66,66
100
100
100
100
50
50,40,40
25
25,19,19
11.6875 in
Product choices often vary by region due to differences in regulatory and agency requirements,
availability and other key factors. Please contact your nearest sales office for assistance in
choosing the right solution for your locale.