The World of LEDs - How Thermoplastics can
support the efficiency of luminaires
Hochschule Hamm Lippstadt, 14. April 2014
Dr. Klaus S. Reinartz, Director Marketing LED EMLA
Bayer MaterialScience AG, 51368 Leverkusen, Deutschland
Our planet from the universe
20% of the electrical power is consumed by general lighting – the
demand will increase by 80% until 2030 (acc. to UNEP, 2009)
Page 2 • Dr. Klaus Reinartz – April 2015
Sustainable and Ecological Lighting
Saving energy and money with LED as light source
Advantages of LED light:
Lower energy costs
Much longer lifetime
Environmentally sound
Excellent performance
Page 3 • Dr. Klaus Reinartz – April 2015
Main Components of a LED based Luminaire
Makrolon® (polycarbonate) can be used for several LED applications
Page 4 • Dr. Klaus Reinartz – April 2015
Secondary Optics
Clear Makrolon® LED grades
Advantages of clear Makrolon® LED
grades:
High light transmission over a broad
range of wavelengths
Excellent long-term heat and high
flux stability
High mechanical stability
Inherently good flame resistance
Exceptional purity to optimize light
transmission
Page 5 • Dr. Klaus Reinartz – April 2015
Secondary Optics
Makrolon® LED grades for a long-term performance
Makrolon
grade
Color
number
MVR
(cm3/10min)
Transmission
(%@2mm)
UV
stabilized
LED2045
000000
61
91
No
LED2245
000000
36
90
No
LED2245
550207
36
89
No
LED2247
550207
36
89
Yes
LED2643
550115
13
89
Yes
AL2447
550396
19
89
Yes
Page 6 • Dr. Klaus Reinartz – April 2015
Secondary Optics
Transmission of selected Makrolon® grades @4mm
Makrolon® LED2245 000000 has the
highest transmission but has a
slightly yellowish appearance
Makrolon® AL2447 550115 has a
crystal clear appearance, but
transmission for thick parts is not
sufficient
Makrolon® LED2245 550207:
High transmission
(>89%@4mm)
No UV absorber
Ice color with high transmission
LED stabilization package
Highest purity level
Page 7 • Dr. Klaus Reinartz – April 2015
Secondary Optics
Transmission of Makrolon® grades versus LED emission
spectrum
White LEDs show a peak in the
blue light around 430 to 460nm
At the wavelength of the blue peak
of the LED the transmission of
Makrolon® is still very high
The absorption of light energy by
Makrolon® strongly increases in
the range below 400nm
Blue / white LEDs do not emit light
in the range of 400nm or below
Light above 500nm is absorbed by
Makrolon if the material does not
contain colorants; any absorption
is solely caused by the additive
Page 8 • Dr. Klaus Reinartz – April 2015
Secondary Optics
Makrolon® LED grades for a long-term performance
Hella, Germany
LEDworx, Austria
LED optics molded from Makrolon® LED2245
LED optics molded from Makrolon® LED2643
Audi, Germany
Makrolon® LED2245 natural
Page 9 • Dr. Klaus Reinartz – April 2015
Light Guides
Clear Makrolon® LED grades
Advantages of clear Makrolon®
grades for light guides:
High light transmission over a broad
range of wavelengths
Excellent long-term heat and high
flux stability
High mechanical stability
Inherent flame retardance
Exceptional purity to optimize light
transmission
Page 10 • Dr. Klaus Reinartz – April 2015
Light Guides
Makrolon® grades with a very high light transmission
Makrolon®
grade
Color
number
MVR
(cm3/10min)
Transmission
(%@2mm)
UV
stabilized
LED2045
000000
61
91
No
LED2245
000000
36
90
No
LED2245
550207
36
89
No
Page 11 • Dr. Klaus Reinartz – April 2015
Light Guides
Makrolon® grades made for special requirements of light
guides
For light guides Makrolon® has to fulfil special requirements:
Transmission and extinction have to watched carefully due to long
pathways
Thermal stability has to be very high over a long period of time to
avoid changes in light transmission
Dispersion of the refractive index over temperature needs to be low
High stability against LED light is needed to avoid loss of transmission
Page 12 • Dr. Klaus Reinartz – April 2015
Diffusors
Diffusive Makrolon® grades to achieve an even light
distribution
Advantages of Makrolon® grades
for light diffusion:
High light transmission
High half-power angle
Strong hiding power of LED light
source
Diffusion products and colors
adjusted to your requirements
Page 13 • Dr. Klaus Reinartz – April 2015
Mechanisms of Light Diffusion
Refraction and Scattering
Technique:
Refraction
surface diffuser plates
Frosted glass with irregular structured surface
(grain size: ca. 10 µm)
Scattering
bulk diffuser plates
Scattering objects within the bulk
(opal glas plates)
Sketch without considering refraction
on the plate surface!
Page 14 • Dr. Klaus Reinartz – April 2015
Characterization of a Diffusor Sheet
Measuring the diffusion properties with a single beam
Glass
fiber
Advantages:
Single method to compare materials
Relatively quick measurement
Intensity
Detector
Mask with
small hole
Disadvantages:
Method may deliver different results if
different apparatuses are used
Single beam measurements do not
represent the performance in the real
luminaire due to not measuring backreflection
Angle
α
Light
output
Light
input
Glass
fiber
Light
source
Page 15 • Dr. Klaus Reinartz – April 2015
Light
Diffusor/
Sample
Recommendation
Material comparison should always be done
on the same machine using the same setup
Final assessment of different materials
should always be done in the final luminaire
Typical Translucent Makrolon® Grades
Makrolon®
grade
Color
number
MVR
(cm3/10min)
Transmission
(%@2mm)
Half Power Angle
(°@2mm )
2407
021180
19
83
4
2407
021172
19
77
22
2407
021182
19
57
50
2407
021173
19
52
57
* All properties are shown in intensity related quantities, not with cosine corrected
“luminosity” values! The result may be influenced by the individual measurement setup
Page 16 • Dr. Klaus Reinartz – April 2015
Typical Translucent Makrolon® Colors
Transmission [%]
Transmission [%]
Transmission vs. wavelength
Color 021172
Color 021173
Wavelength [nm]
Transmission [%]
Transmission [%]
Wavelength [nm]
Color 021180
Wavelength [nm]
Page 17 • Dr. Klaus Reinartz – April 2015
Color 021182
Wavelength [nm]
Typical Translucent Makrolon® Colors
Polar Diagrams
-15
1.0
0
15
-30
0.8
30
-45
0.6
10F336/1mm
021180
1mm
10F336/2mm
021180
2mm
10F336/3mm
021180
3mm
10F336/4mm
021180
4mm
Lambert Ideal
45
-75
75
60
-60
-75
90
-15
0
-30
-45
0.6
a.u.
a.u.
-90
0.8
15
10F338/1mm
021173
1mm
10F338/2mm
021173
2mm
10F338/3mm
021173
3mm
10F338/4mm
021173
4mm
Lambert Ideal
75
30
45
-90
90
-15
-30
0.8
-45
0.6
60
-60
0.0
1.0
0.4
-60
0
15
10F340/1mm
021182
1mm
10F3340/2mm
021182
2mm
10F340/3mm
021182
3mm
10F340/4mm
021182
4mm
Lambert Ideal
30
45
60
0.4
-75
75
-75
75
0.2
-90
90
a.u.
0.2
a.u.
45
0.2
1.0
0.0
10F337/1mm
021172
1mm
10F337/2mm
021172
2mm
10F337/3mm
021172
3mm
10F337/4mm
021172
4mm
Lambert Ideal
30
0.4
0.2
0.0
15
-45
0.6
0.4
0
-30
0.8
60
-60
-15
1.0
0.0
-90
90
Optical data are available on request for optical engineering
Page 18 • Dr. Klaus Reinartz – April 2015
Typical Translucent Makrolon® Colors
Transmission vs. Half Power Angle
60
Half power angle [°]
50
40
021180
30
021172
021173
021182
20
10
0
0
10
20
30
40
50
Transmission Ty [%]
60
70
80
90
Optical data are available on request for optical engineering
Page 19 • Dr. Klaus Reinartz – April 2015
Diffusive Reflection
Makrolon® grades to improve the reflection of light
Advantages of Makrolon® grades for
diffusive reflectors:
High reflectivity (>94%)
High temperature stability
Mechanical strength
Page 20 • Dr. Klaus Reinartz – April 2015
Typical Makrolon® Grades for Diffusive
Reflectors
Makrolon®
grade
Color
number
MVR
(cm3/10min)
Total
reflectance (%)
UV stabilized
RW2407
012363
19
96,5
Yes
RW2407
010226
19
94,5
Yes
RW6267X
012363
19
96
Yes
RW6265X
010226
19
94
No
RW6267X
012268
19
95
Yes
Page 21 • Dr. Klaus Reinartz – April 2015
Specular Reflection
Advantages of Makrolon® grades for
specular reflectors:
High gloss surface allowing excellent
reflectivity of metal layers
Good adhesion of metallic surface to
base polymer
Best surface quality due to specially
developed production cycle
Low thermal expansion coefficient
Page 22 • Dr. Klaus Reinartz – April 2015
Typical Grades for Specular Reflectors
Product grade
MVR
(cm3/10min)
Vicat
temperature
(°C)
CLTE parallel
(10-4/K)
CLTE transversal
(10-4/K)
Makrolon® 2405
19
143
0,65
0,65
Makrolon® GF8004
10
144
0,50
0,55
Bayblend® T90 MF-20
12
130
0,40
0,56
Apec® 1695
45
158
0,70
0,70
Apec® 2095
8
203
0,70
0,70
Page 23 • Dr. Klaus Reinartz – April 2015
Heat Management
Optimizing the efficiency of LEDs by effective cooling
Advantages of Makrolon® grades for
heat sinks:
Reduced weight of LED light engines
Strong heat-transferring capability
High level of design freedom
Cost-effective production
Easy processing through high
viscosity
Page 24 • Dr. Klaus Reinartz – April 2015
Makrolon® Grade for Heat Sinks
High thermal conductivity for very good heat transfer
Product grade
Makrolon® TC8030
Color number
Thermal conductivity
(W/m*K)
999900
20 (1)
13 (2)
(1)
ISO 22007-2
(2) ASTM E 1461-01
Page 25 • Dr. Klaus Reinartz – April 2015
Heat Transfer
Difference between incandescent and LED light sources
Conduction + Convection
Unlike traditional light sources, LED heat dissipation depends mainly on conduction
and convection. Heat produced by LED light source has to be conducted away
efficiently to ensure optimal performance of a replacement lamp or luminaire
Page 26 • Dr. Klaus Reinartz – April 2015
LEDs for Lighting
Convert electrical power to light and heat
Junction Temperature Tj
• LEDs emit 70% of electrical power as heat
30%
Light
Silicone cover
LED chip
Input Power
LED package
70%
Heat
PCB
Heat sink
• Heat degrades the LED chip leading to
reduced light output (degradation)
• Maximum allowed temperature for the LED
package is defined by the junction
temperature (Tj)
Typical values
• Maximum allowed
Tj = 125°C
• Long term continuous use Tj = 85°C
The higher the junction temperature, the shorter the lifetime
of the LED replacement lamp or luminaire
Page 27 • Dr. Klaus Reinartz – April 2015
Makrolon® TC8030
PAR 30 – Similar Performance vs. Aluminum
Thermocouple attached to back plate
Enclosed
Fixture
Open Air Test
Heat Sink
Material
Back
Plate(°C)
Makrolon
TC8030
79.2
Average of 5 Purchased
Aluminum Lamps
Enclosed in
Can Light
Page 28 • Dr. Klaus Reinartz – April 2015
80.2
Open Air
Delta vs.
Makrolon
TC8030 (°C)
Back
Plate (°C)
Delta vs.
Makrolon
TC8030 (°C)
54.2
+ 1.0
57.0
+ 2.8
Makrolon TC8030 initial performance is similar to
aluminum and is expected to improve over the long
term from elimination of the TIM
Makrolon® TC8030
Simulation of Conductivity vs. Case Temperature
Simulation at 6W
Page 29 • Dr. Klaus Reinartz – April 2015
Makrolon® TC8030
Improved Performance with Integration
Printed
Circuit
Board (PCB)
Thermal
Interface
Material
(TIM)
Heat Sink
Current technology with aluminum heat sink
In-Mold LED on heat sink assembly of PCB*
• Improved performance by elimination of thermal grease or adhesives
Lower thermal resistance reduces operating temperature improving LED color and life
Removes risk of thermal pumping of TIM over time increasing long term durability
Better quality and longer life can lead to increased sales
in a highly competitive marketplace
Page 30 • Dr. Klaus Reinartz – April 2015
Summary
Page 31 • Dr. Klaus Reinartz – April 2015
Material Options for LED Lighting
Makrolon® Products to Meet Your Design Needs
Makrolon LED
clear or
Makrolon 2407 in
diffusion colors
for lenses
Makrolon TC
alternative to
aluminum die
casting
Makrolon with UV
protection
Makrolon RW for
reflectance without
secondary operations
Bayer has a wide range of products for indoor and outdoor
replacement lamp and luminaire components
Page 32 • Dr. Klaus Reinartz – April 2015
Material Options for LED Applications
Makrolon® Products to Meet Your Design Needs (selected
grades!)
Makrolon® LED 2045 / Makrolon® LED2245 / Makrolon® LED2643
Makrolon® FR7087
Makrolon® 6717 / Makrolon® ET3113 / Makrolon® ET3127 / Makrolon® ET3227
Makrolon® LED2045 / Makrolon® LED2245
Makrolon® 2407 021180 / Makrolon® 2407 021172 / Makrolon® 2207 021177
Makrolon® RW2407 012353 / Makrolon® RW2407 012363
Makrolon® TC8030
Page 33 • Dr. Klaus Reinartz – April 2015
Further Information
Homepage:
http://www.plastics.bayer.com/
eNewsletter:
http://www.materialscience-products.bayer.com/en/Newsletter/LEDNewsletter.aspx
LED brochure:
http://www.plastics.bayer.com/~/media/Product%20Center/PCS/Images/5_Library/
Broschueren/LED%20Brochure/MS00069823_LED-Brosch.ashx
Page 34 • Dr. Klaus Reinartz – October 2014
Contact Data
Dr. Klaus S. Reinartz
Director Marketing LED EMLA
Bayer MaterialScience AG
BU Polycarbonates
Building B207
51368 Leverkusen, Germany
Phone:
Email:
Page 35 • Dr. Klaus Reinartz – October 2014
+49-214-30-32403
klaus.reinartz@bayer.com
Forward-Looking Statements
This presentation may contain forward-looking statements based on current
assumptions and forecasts made by Bayer Group or subgroup management.
Various known and unknown risks, uncertainties and other factors could lead to
material differences between the actual future results, financial situation,
development or performance of the company and the estimates given here.
These factors include those discussed in Bayer’s public reports which are
available on the Bayer website at www.bayer.com.
The company assumes no liability whatsoever to update these forward-looking
statements or to conform them to future events or developments.
Page 36 • Dr. Klaus Reinartz – October 2014
Thank you!
Page 37 • Dr. Klaus Reinartz – April 2015