Over the past years, sales of LED packages have increased by over 50% per year and performance also improved in double digit percentages. This tremendous growth was driven mainly by the switch to LEDs for LCD (liquid chrystal display) backlighting and by developments in the lighting industry. LED manufacturers are looking for materials that deliver high reliability, enabling smooth high volume production and excellent light output. DSM has responded to this need with the introduction of Stanyl ForTii LED LX, an LED-specific grade of Stanyl ForTii high temperature polyamide with halogen-free flame retardant grades for demanding applications.
High-flow Stanyl ForTii LED LX is a mineral-filled grade, and its excellent UV resistance sets a new standard for LED packages. Stanyl ForTii LED LX delivers a good reliability performance over time and, more specifically, high initial reflectivity, as well as excellent mechanical strength.
Its high flow properties make it suitable for use in high cavity tools. This enhanced reflectivity of Stanyl ForTii has an immediate effect on the LED package light output and enables LED suppliers to improve their key specifications.
Stanyl ForTii LED LX outperforms competitive PPAs thanks to its specific polymer structure. High reliability and LED lifetime are further enabled through its excellent adhesion to silicones and epoxy encapsulates as well as the metallic lead frame, avoiding chip degradation due to moisture or air diffusion through interfacial delamination phenomena.
Approximately 20% of the world’s electricity consumption is used for lighting applications. This provides a significant opportunity to cut both emissions and electricity costs. Today’s Light Emitting Diodes (LED) consume about 70-80% less energy than conventional lamps. At the same time, they increase service life and design flexibility. Since LED solutions are rapidly becoming more affordable, LED lighting is being adopted increasingly in many applications around the world. Over the past few years engineering plastics have become the incumbent solution for LED.
Strong track record in LED lamps
LEDs with high power densities make thermal management the key focus area in LED lighting design. Without appropriate thermal management, LEDs will gradually lose brightness, change their color spectrum over time and present higher failure rates.
Today, DSM’s Stanyl TC is the material of choice for the Lighting industry. It combines a unique high mechanical performance with excellent thermal management, while increasing design flexibility. With Stanyl TC, designers can reduce weight of lamps, while increasing electrical safety and productivity in manufacturing. Total system costs can be reduced by up to 30-40% compared with cast aluminum.
Life Cycle Analysis shows that in carbon footprint, Stanyl TC has a major advantage compared to traditional die casting materials. CO2 emissions for a typical heatsink in Stanyl TC are up to 85% lower than an equivalent die cast aluminum heatsink.
The benefits of Stanyl TC have now been recognized by almost all top lighting players, who have adapted the material in a wide range products such a as reflector lamps (MR16, GU10, & PAR), conventional bulbs (A lamps) and LED modules.
Stijn Meijers, Global Segment Manager for Lighting said: “DSM is strongly committed to the lighting industry. This is demonstrated by our growing portfolio of material solutions for lighting, developed for a wide range of high-performance applications such as highly reflective grades for LED packages or thermally conductive grades to enable improved thermal management. By using our industry-specific material portfolio, our customers are able to gain a number of significant benefits including greater efficiency, weight saving, higher flexibility in manufacturing, and a smaller carbon footprint.”