LED LIGHTING. Hans-Otto Schlothauer March 2012

Transcription

1 LED LIGHTING Hans-Otto Schlothauer March 2012

2 Lighting Lifecycle Luminous efficacy (lm/w) Energy consumption Price Incandescent ~1.500hr <15 Incandescent 100W < 1$ CFL ~15.000hr CFL 20W ~5-10$ LED ~50.000hr LED ~15W ~30-40$ OLED ~20.000hr CFL Compact Fluorescent Lamp HID High Intensity Discharge Lamp (Xenon) EUV Extreme Ultraviolet Lighting < 60 ~13.000$/sm No. 2

3 Australia EU Canada, UK Taiwan Russia, (California) USA, Argentina, South Korea Malaysia India, China Japan LEGISLATION CHANGE REQUIRES LIGHTING EFFICENCY Today: Tomorrow: No. 3

4 LED ENVIRONMENT & TRENDS Market: Legislation: Trends: - Lighting market highly fragmented - Incandescent, replacement market shrinks (higher lifetime) - LED Lighting will dominate the lighting market in coming decade - Maintenance is driver for commercial lighting - OLED will follow - WW different Legislations and no final standards yet (Zhaga, UL, IEC, EN) - More and more lighting appl. will be replaced by LED solutions - Long life time (up to 25y) goal original equipment - Continued LED chip cost reduction, luminance increase No. 4

5 POTENTIAL MATERIALS FOR LED DEVICES LNP* Thermocomp PPA*based compounds High flow High reflection Soldering ability Polycarbonate Transparent grades Diffusion grades FR: FR transparent up to 1mm FXD (Vfx): Diffusion XHT: Higher heat stability SLX: Higher weatherability Valox*/ Flow Non soldering White color (reflection) Konduit*compounds High thermal conductivity Inherent electrical isolative Flame retardant acc. UL94 Valox* Flame retardant acc. UL94 Non-brominated, Non-chlorinated IQ grade available Retrofit LED examples * Trademark of SABIC Innovative Plastics IP BV No. 5

6 Transparency Impact resistance Heat Diffusion Impact resistance FXD Materials for CFL/LED solutions Clarity, Impact resistance, diffusion, flame resistance Flame-retardant Clear Flow XHT Heat resistance Transparency FR SLX UV weathering Konduit* compounds Thermal conductivity Electrical Isolation More design freedom

7 Transparency Impact resistance Heat Diffusion Impact resistance FXD Materials for CFL/LED solutions Clarity, Impact resistance, diffusion, flame resistance Flame-retardant Clear Flow XHT Heat resistance Transparency FR SLX UV weathering Konduit* compounds Thermal conductivity Electrical Isolation More design freedom

8 HOW CAN LEXAN* RESINS SERVE YOU? Potential Applications: LED lightguides LED lenses high reflection resin can offer: Excellent processability Flow availability Improved optical clarity Superior high transmission Heat resistance High Impact/unbreakable Flame-retardant availability Reflectivity > 95% Anti-dust properties (permanent) General Purpose transparent Flameretardant FR transparent General Purpose high reflective 18 MFI, 0.75mm 40 MFI, 0.75mm 60 MFI, LUX2110T 18 MFI, 0.75mm, UV EXRL1005 LUX2010T LUX2910T 8 MFI, LUX MFI, 1.5mm LUX MFI, GWFI 850C 22 MFI, 1.5mm 24 MFI, AD143 BFL4000U BFL2000U * Trademark of SABIC Innovative Plastics IP BV No. 8

9 RESIN LUX2010T, LUX2110T & LUX2910T UL YELLOW CARD No. 9

10 Transparency Impact resistance Heat Diffusion Impact resistance FXD Materials for CFL/LED solutions Clarity, Impact resistance, diffusion, flame resistance Flame-retardant Clear Flow XHT Heat resistance Transparency FR SLX UV weathering Konduit* compounds Thermal conductivity Electrical Isolation More design freedom

11 HOW CAN DIFFUSION (FXD) RESINS SERVE YOU? Potential Applications: CFL bulb LED bulb LED tubes Diffusion Distance Variations A B Combination of standard pigments and specially designed diffusers in LEXAN resin Provides almost limitless options for aesthetic and light management needs Diffuser Loading Variations A B D C D C Distance: D > C > B > A Loading: D > C > B > A Broad spectrum of light management options available Formulas can be custom designed per application needs Available in many grade platforms * Trademark of SABIC Innovative Plastics IP BV No. 11

12 Transmission, Haze, Clarity (%) REQUIREMENTS FOR RETROFIT LIGHT BULBS CFL retrofit light bulb Requirements (bulb): UL mm** RTI listed > 100C transmission/diffusion performance Impact Mercury containment LED retrofit light bulb Requirements (bulb): Light management - high transmission with hiding power Light Fastness UV/Thermal Stability RTI listed > 100C GWFI 650C & BPT 125C(Europe) FR UL94 1.5mm**(NAFTA) General Purpose FXD173R, FXD123R, FXD143R LUX2114, LUX2614 Extrusion FXD103R Flame Retardant FXD9810 LUX9612 & LUX9616 Low Temp Ductility FXD1414T Outdoor Extreme UV resistant SLX2471T & 2271T Optical Properties of Various Lexan FXD Formulations 100 Optical Properties of Various LEXAN* FXD Formulations LED retrofit tubes Requirements: UL 94 < 1mm** (Nafta) GWFI 650C, BPT 125C (Europe) High transmission Lightsource not visible Extrusion grade Color 1 Color 2 Transmission Haze Clarity Color 3 Color 4 Color 5 Color 6 Color 7 Color 8 Color 9 Color 10 **(depends on w all thickness) * Trademark of SABIC Innovative Plastics IP BV No. 12

13 Transparency Impact resistance Heat Diffusion Impact resistance FXD Materials for CFL/LED solutions Clarity, Impact resistance, diffusion, flame resistance Flame-retardant Clear Flow XHT Heat resistance Transparency FR SLX UV weathering Konduit* compounds Thermal conductivity Electrical Isolation More design freedom

14 HOW CAN LEXAN* SLX RESINS SERVE YOU? Potential Applications: UV light UV weathering Outdoor / Street Lighting applications UV PROTECTIVE LAYER Lexan SLX resin UV weathering Clarity, color and gloss Toughness Chemical resistance Eliminates UV coating Diffuse lighting As molded: In hot chamber for 2900 hours: 175W MH lamp 120 o C on the refractor 55 o C ambient Lexan * SLX resin UV PC resin * Trademark of SABIC Innovative Plastics IP BV No. 14

15 Delta YI Haze (%) XENON ARC WEATHERING: YI AND HAZE LEXAN* SLX RESINS LOWER HAZE AND YELLOWNESS AFTER UV EXPOSURE Hours UV PC resin SLX resin T3 (SLXxy7zT) Hours ISO A protocol ~1800 hours = 1 yr Florida exposure This information should be used as indicative only. The true performance can only be determined under conditions as in the final application. No. 15

16 Impact Energy (J) Brittle LEXAN * SLX VS. UV STABILZED PC RESIN Ductile Lexan SLX25x1T 20 UV-stab PC resin Exposure energy (kj/m2) Xenon Arc Exposure Lexan SLX Resin: Better Retention of Colour, Transparency, Ductility than standard UV PC Resin Modified G26 protocol 3000 kj/m2 = ~1 year Florida exposure This information should be used as indicative only. The true performance can only be determined under conditions as in the final application. 16 No. 16

17 Transparency Impact resistance Heat Diffusion Impact resistance FXD Materials for CFL/LED solutions Clarity, Impact resistance, diffusion, flame resistance Flame-retardant Clear Flow XHT Heat resistance Transparency FR SLX UV weathering Konduit* compounds Thermal conductivity Electrical Isolation More design freedom

18 HOW CAN LEXAN* FR RESINS SERVE YOU? Potential Applications: with Clear FR needs (UL) Requirements Flame-retardant Clear Flow UL 94 V0 1.5mm (Naf ta)** GWFI 650C, BPT 125C (Europe) High transmission Lightsource not visible Transmission/Wavelength diagram nm ~ 430nm LED bulb LED spotlights LED tubes UL94 1.5mm** High transparency 430nm Flow UL 94 1mm** (NAFTA) GWFI 650C, BPT 125C (Europe) High transmission Lightsource not visible Transmission/Wavelength diagram nm ~ 430nm Extrusion grade Potential Benefits: Excellent processability Standard PC type optical properties Good practical impact strength Heat resistance like PC Flame resistance at thin walls -Clear UL94 5VA -Clear and Diffusion UL94 V0 Almost limitless color capability Global availability Compliance with ECO protocols (non-brominated, non-chlorinated and non phosphorus) Thin wall V0 clear Eco FR A Unique Enabler 5VA clear F1 Rating outdoor ** depends on wall thickness application * Trademark of SABIC Innovative Plastics IP BV No. 18

19 OPTICAL PROPERTIES OF LEXAN* RESINS LUX961L, LUX2614 and LUX2114 MFR C; 1.2kg MFR C; 1.2kg MFR C; 1.2kg UL94 V2@ 0.75mm LUX2114 LUX2114 LUX2114 LUX2114 LUX2114 UL94 V2@ 0.75mm LUX2614 LUX2614 LUX2614 LUX2614 LUX2614 UL94 V0@ 1.5mm LUX9610 LUX9612 LUX9612 LUX9616 LUX9616 LUX9616 Thick. Item NA9E155T WH8E508X WH8E490x WH8E491x WH8E492x WH5E140X 3mm 2mm 1.5mm 1.0mm %T DLD (deg.) % Haze % T DLD (deg.) % Haze %T DLD (deg.) % Haze % T DLD (deg.) % Haze LUX-series from clear to diffusion Products with broad optical properties suitable to cover LED diversified applications No. 19

20 LEXAN* FR RESINS LUX. Cd/m 2 Viewangle WH8E491X WH8E492X WH8E490X Angle D.L.D. measurement curve based on 1.5mm color chip * Trademark of SABIC Innovative Plastics IP BV No. 20

21 LEXAN* RESIN LUX961L UL Yellow Card All Color Listings, Including RTI Rating * Trademark of SABIC Innovative Plastics IP BV No. 21

22 LEXAN* RESIN LUX2114 & LUX2614 UL YELLOW CARD * Trademark of SABIC Innovative Plastics IP BV No. 22

23 FR Resins LEXAN* FR RESINS A NEW GENERATION A new family of Flame Retardant Polycarbonate Copolymer Resins Current developmental portfolio look Potential Benefits 1.5mmV0 18MFI EXRL0792 3mm 5VA 1.2mm V0 F1 3mm 5VA 1mm V0 F1 Product Entitlement Flame Retardance-V0 Flame Retardance-5VA Initial Color Color Stability Impact Processability 10MFI 5MFI EXRL0706 EXRL0747 New FR Resin Existing Clear FR PC Benefits Confirmed by Validation Customers * Trademark of SABIC Innovative Plastics IP BV Improved flame resistance thinner wall V0 performance over standard clear FR PC New flame resistance capability 5VA performance over clear FR PC Compliance with ECO protocols (non-brominated, non chlorinated, nonphosphorus and no Teflon added) Standard PC type optical properties Improved melt flow and process capability over existing clear FR PC Color capability No. 23

24 OPTICAL PROPERTIES OF LEXAN* RESIN EXRL0706 & EXRL0747 Thickness Item NA8E061T WH8F013X WH7E317X WH6E305X WH5E143X WH4E202X Transmission% mm DLD Haze% Transmission% mm DLD Haze% Transmission% mm DLD Haze% Transmission% mm DLD Haze% From clear to diffusion Products with broad optical properties suitable to cover LED diversified applications * Trademark of SABIC Innovative Plastics IP BV No. 24

25 UL YELLOW CARD LEXAN* RESIN EXRL0747 & EXRL706 RTI rating generic, measurement ongoing 2Q2012 No. 25

26 UL YELLOW CARD LEXAN* RESIN EXRL0702 RTI rating generic, measurement ongoing No. 27

27 OPTICAL PROPERTIES OVERALL LEXAN* LUX GRADES *PAC/EUR GWFI 850C Grade LUX2114* LUX2614* LUX9610/2/6 FR V2 0.75mm V2 0.75mm V0 1.5mm Grade EXRL0792 EXRL0706 EXRL0747 FR V0 1.5mm V0 1.2mm V0 1.0mm MVR MVR Optics (T% vs DLD) Optics (T% vs DLD) Transparency(%) WH8E508 WH8E490 WH8E491 WH5E492 WH5E140 Transparency(%) WH8F013X 12.7 WH7E317X 19.8 WH6E305X 30.5 WH5E143X 53WH4E202X Optics Based on 1.5mm DLD(Degree) Well Optics Based on 1.0mm Coverage DLD (Degree) No. 28

28 Transparency Impact resistance Heat Diffusion Impact resistance FXD Materials for CFL/LED solutions Clarity, Impact resistance, diffusion, flame resistance Flame-retardant Clear Flow XHT Heat resistance Transparency FR SLX UV weathering Konduit* compounds Thermal conductivity Electrical Isolation More design freedom

29 HOW CAN LEXAN* XHT RESINS SERVE YOU? Potential Applications: Heat resistance LED spotlights LED flashlights LED lightguides or lenses High heat resistance: Color stability Higher RTI rating Flame retardant clear V0 down to 2mm Two shot molding with other materials Direct metallizable Excellent flow for thin wall parts Electrical applications at high use temp * Trademark of SABIC Innovative Plastics IP BV No. 30

30 Tensile Strength Retention WHY ANOTHER HIGH HEAT PC? XHT vs competitive high heat clear grades Flow HDT Specific Gravity Impact Initial Color Metallization Color Stability RTI Lexan XHT other HH PC PMMI PAR Pleximid UPolymer UV Weathering Benefits Confirmed by Customers Tensile strength retention at 150 o C 120% 100% 80% 60% 40% 20% 0% Std PC XHT Comp HHPC Time of exposure (hrs) Heat Ageing against Comp PC at 140 o C BPI PC Control XHT BPI PC BPI PC BPI PC BPI PC XHT Comp PC XHT XHT XHT XHT Hr Hr Hr Hr Hr High use temperatures (140 o C+) + Clarity + Color stability = XHT High heat + Clarity + Processability (flow, release) = XHT No. 31

31 Transparency Impact resistance Heat Diffusion Impact resistance FXD Materials for CFL/LED solutions Clarity, Impact resistance, diffusion, flame resistance Flame-retardant Clear Flow XHT Heat resistance Transparency FR SLX UV weathering Konduit* compounds Thermal conductivity Electrical Isolation More design freedom

32 HOW CAN LNP Konduit* COMPOUND SERVE YOU? Potential Applications: Heat-sink Evolution LED Efficiency LED spotlight Requirements: LED bulb UL 94 V0 (Nafta) UL 94 HB (RoW) Break-down voltage: 4KV Dielectric strength 1.2m drop test HDT>100C High thermal conductivity: working temp <75C Thermal cycle test HWI=4 / HAI=3 CTI=4 Paintable For external surface >65C, RTI req. * Trademark of SABIC Innovative Plastics IP BV No. 33

33 LNP* KONDUIT* COMPOUNDS Konduit* Compounds are compounds that exhibit superior thermal conductive performance. The unique feature of this compound is its ability to fulfill the requirements needed for the LED Lighting heat sink and driver housing applications. Available in black, gray or white colors Thermal conductivity up to 10W/mK (electrical isolative) Thermal conductivity up to 15W/mK (electrical conductive) Features & Potential Benefits in LED Socket: Reduce working temperature by metal+plastics hybrid design - increase operating efficiency and life span Inherent electrical isolative pass 6KV breakdown test Comply with safety regulations like Underwriter s Laboratory (UL) Design freedom of injection molding Better productivity compare to die-cast Al Potentially system cost reduction through improved productivity Eliminate painting process with PX09322 * Trademark of SABIC Innovative Plastics IP BV No. 34

34 Konduit Compounds (Light color) Konduit Compounds (Dark color) LNP KONDUIT* COMPOUND PRODUCT TREE PX08321 T/r K ~2.6W/m-K PA6 based PX08322 UL94-V0@1.2mm, T/r K ~2.1W/m-K, RTI=120C, F1 PPS based 0X10324 UL94-V0@1.2mm, T/r K ~3.5W/m-K, RTI =130C Electrically conductive PA6 based PX11311 PX11313 UL94-V0@1.0mm, T/r K ~1.2W/m-K UL94-V0@1.0mm, T/r K ~1.5W/m-K PPS based OX11314 UL94-V0@0.8mm, T/r K ~1.5W/m-K, RTI =130C Compliance with ECO protocols (non-brominated, non chlorinated) * Thermal conductivity measured with Netzsch Nanoflash, Through-plane with a 3 mm thick plate No. 35

35 PREDICTIVE SUPPORT CAPABILITY FOR LED HOUSING DESINGn Aluminum Insert CAD capability (WTC) 1) Model LED housing geometry. 2) Suggest design changes to increase surface area-enhance thermal performance CAD capability Konduit Housing Thermal Design Thermal design (WTC) 1) Surface area optimization 2) Temperature prediction 3) Heat flux prediction Processing expertise (CTC) 1) Feed system optimization. 2) Prediction of Fill time 3) Prediction of Pressure switchover 4) Prediction of Temperature 5) Prediction of Warpage. Processing Expertise Structural design Structural design(wtc) 1) Deflection prediction due to CTE difference between KONDUIT,ALUMINUM 2)Thermal stress prediction 3) Heat flux prediction No. 37

36 KONDUIT* COMPOUND UPDATED UL YC INCLUDING f1 RATING (PA6 BASED) Light colors Dark colors No. 38

37 KONDUIT* COMPOUND UL YC PA6 based CONTINUED Light colors Dark colors * * Note: Natural color appears black No. 39

38 KONDUIT* COMPOUND UL YC PPS BASED MATERIALS Light colors Electrical isolative Dark colors Electrical conductive * * Note: Natural color appears black No. 40

39 Impact resistance Transparency Heat resistance High reflectivity New FR PC (Lexan) FR solutions up to 1mm (UL94 V0) Chlorine, Bromine free Flow Diffuse availability FR Lenses Lightguides Reflectors Diffusion Diffuse appearance Transmission/diffuse Tailor-made solutions FR solution up to 1.5 mm CFL Lighting bulbs LED light bulbs LED extruded tubes FXD UV weathering Clarity, colour and gloss Toughness Chemical resistance Eliminates UV coating SLX Outdoor Lighting applications Street lightings Materials for CFL/LED solutions Clarity, Impact resistance, diffusion, flame resistance * Trademark of SABIC Innovative Plastics IP BV LED light bulbs LED extruded tubes LED spotlights High heat resistance Clarity Metallization aesthetics & aging colour stability on heat aging Improved flow/impact compared to other high heat PC XHT Thermal conductivity Electrical isolation High conductivity FR UL94 V0 up to 1.2mm Design freedom colors Konduit* compounds Heat sink spot lights Heat sink Retrofit LED application Lenses Flashlights Lightguides Spotlights

40 BROAD PORTFOLIO OF HIGH PERFORMANCE RESINS Resin Blends/Compounding Forward Integration PC Cycoloy* PC/ABS SF&S (Sheet/Film) Cycolac* ABS Geloy* ASA Noryl* PPE ULTEM* PEI VALOX* PBT Geloy* PC/ASA Xenoy* PC/PBT Noryl GTX* PPE/PA Nylon Ultem ATX* PC/PEI PC PEI LNP (Specialty Compound) PC ASA ABS PPO PEI PBT PTFE Carbon Fiber Glass Color PS PA PP PEEK * Trademark of SABIC Innovative Plastics IP BV No. 42

41 SABIC - Global Disclaimer THE MATERIALS, PRODUCTS AND SERVICES OF SABIC INNOVATIVE PLASTICS HOLDING BV, ITS SUBSIDIARIES AND AFFILIATES ( SELLER ), ARE SOLD SUBJECT TO SELLER S STANDARD CONDITIONS OF SALE, WHICH CAN BE FOUND AT AND ARE AVAILABLE UPON REQUEST. ALTHOUGH ANY INFORMATION OR RECOMMENDATION CONTAINED HEREIN IS GIVEN IN GOOD FAITH, SELLER MAKES NO WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, (i) THAT THE RESULTS DESCRIBED HEREIN WILL BE OBTAINED UNDER END-USE CONDITIONS, OR (ii) AS TO THE EFFECTIVENESS OR SAFETY OF ANY DESIGN INCORPORATING SELLER S PRODUCTS, SERVICES OR RECOMMENDATIONS. EXCEPT AS PROVIDED IN SELLER S STANDARD CONDITIONS OF SALE, SELLER SHALL NOT BE RESPONSIBLE FOR ANY LOSS RESULTING FROM ANY USE OF ITS PRODUCTS OR SERVICES DESCRIBED HEREIN. Each user is responsible for making its own determination as to the suitability of Seller s products, services or recommendations for the user s particular use through appropriate end-use testing and analysis. Nothing in any document or oral statement shall be deemed to alter or waive any provision of Seller s Standard Conditions of Sale or this Disclaimer, unless it is specifically agreed to in a writing signed by Seller. No statement by Seller concerning a possible use of any product, service or design is intended, or should be construed, to grant any license under any patent or other intellectual property right of Seller or as a recommendation for the use of such product, service or design in a manner that infringes any patent or other intellectual property right. SABIC Innovative Plastics is a trademark of SABIC Holding Europe BV * Trademark of SABIC Innovative Plastics IP BV No. 43