Covestro: Advanced polycarbonate materials for lighting

Lighting the way to improved LED solutions

San Diego, April 25, 2016 — Lighting designers and manufacturers are increasingly turning to LED lighting to replace traditional lighting – and for good reasons. LEDs are more energy efficient, have a longer service life, are environmentally sound and offer excellent performance. With these outstanding characteristics, LEDs are used in a wide variety of both indoor and outdoor applications in commercial, industrial and residential settings. Covestro’s broad portfolio of polycarbonate resin, sheet and film materials for the LED market provides manufacturers with a range of solutions for their lighting needs.

At booth #4956 during LIGHTFAIR International, April 26-28 in San Diego, Covestro will showcase materials and technologies for lighting applications.

Lighting applications such as LED lamps and luminaires often require heat-resistant materials that can be formed into complex designs. For lenses and secondary optics, Covestro’s family of Makrolon® LED polycarbonate grades meets these challenges while providing higher purity and light transmission when compared with standard grades.

Makrolon® LED2643 clear polycarbonate is used in LED lighting applications requiring high lumen efficiency and heat stability. This grade is impact resistant and has a UL 94 flame class rating of V-2 at 0.75 mm. Makrolon® LED2245 polycarbonate, another clear material option, features higher light transmission with easy release and excellent flow properties.

Covestro also offers a variety of reflective white (RW) polycarbonate grades with high efficiency in reflecting visible light. These materials can be injection molded into almost any shape, allowing a high degree of design freedom. Both Makrolon® RW6265X polycarbonate and Makrolon® RW6267X polycarbonate are flame-retardant, low-viscosity grades with easy release and a UL flame class rating of V-0 at 1.5mm. These characteristics, combined with added ultraviolet (UV) stabilizers, make Makrolon® RW6267X polycarbonate an excellent choice for applications with higher UV exposure.

Heat management is a crucial component in LED lamps and luminaires. For these applications, Covestro offers a line of thermally conductive (TC) polycarbonate grades that provide thermal management coupled with design freedom and a lighter weight than metals. Used in LED heat sinks for lamps or next-generation luminaires, Makrolon® TC8010 polycarbonate is the newest addition to Covestro’s portfolio of thermally conductive grades. Makrolon® TC8030 polycarbonate, also used in these applications, features increased thermal conductivity with a UL 94 flame class of V-0 at 2.0 mm, and a f1 listing.

In addition to polycarbonate injection molding resins, Covestro offers a variety of polycarbonate sheet products for use in luminaires and outdoor lighting applications. These materials provide energy efficiency without sacrificing design freedom and feature superior impact strength and higher flammability resistance over acrylic diffusers. Makrolon® Lumen XT polycarbonate sheet utilizes a textured surface along with advanced diffusion technology to eliminate hot spots. With a variety of diffusion levels and both warm (LW) or cool (LC) hues, it provides designers with flexibility to maximize both the aesthetics and performance of light fixtures. Makrolon® DX-NR polycarbonate sheet, specifically designed for use as a lighting lens in outdoor applications, offers advanced UV-resistance technology for long-lasting weather resistance.

Covestro also offers an extensive portfolio of innovative films for light management. Makrofol® LM polycarbonate films are available in a variety of surface finishes and thicknesses for diffusing, guiding and reflecting light. Applications include lamp shades and covers for ceiling lamps, mixing boxes and reflectors for down lights and diffuser lenses for LED strips. Makrofol® LM stands out with its high transparency, break resistance and heat-deflection temperature of up to 135 C. Covestro’s portfolio of diffuser films features translucent products with a high light scatter as well as highly transparent materials with a low light scatter. These films convert the point-shaped light from LEDs into even, whole-surface light. Designers and OEMs looking for specialty films can count on Covestro for several options, including lenticular films. These films can be used in conjunction with a finely imprinted grid of lenses to direct light as a function of the angle and optically merge the points of light from individual LEDs into a band.

Covestro’s newest polycarbonate film, Makrofol® DE 1-4 060023, is optimized to be most stable against LED light. This translucent, UV-stabilized film features lower yellowness index and haze while retaining higher light transmission than standard Makrofol® DE grades. The film offers high glow wire test results and is UL 94 V-2 rated.

LIGHTFAIR International attendees can also experience first-hand a variety of applications utilizing Covestro’s materials for LED lighting.

When searching for an optically clear material that met stringent UL 94 5VA requirements for its ALBA Series luminaires, TerraGlo Lighting turned to Makrolon® polycarbonate to mold the 3-mm-thick inner lens cover. Makrolon® FR7087 is a transparent, flame-retardant polycarbonate resin that has been proven in demanding applications, particularly LED lighting and electrical enclosures.

For use in its luminaires, Kenall Lighting chose Makrolon® LED polycarbonate grades designed specifically for a LED light source. These specialty grades optimized the function and benefits of Kenall’s luminaires, and offered improved light transmission and efficiency when compared with competitive products. Kenall utilized Makrolon® polycarbonate for secondary and tertiary optics within parking garages and its high bay product line.

Lumenova™ selected Makrolon® polycarbonate when it needed a material that was not only bright, but also energy and cost efficient for its R20, BR40 and BR30 reflector lamps. These lamps are rated with the highest lumen output in their respective categories and are great replacements for inefficient incandescent BR and CFL lamps. Makrolon® RW6267X polycarbonate, found in the lamp’s optical mixing chamber, is a flame-retardant, low-viscosity grade that allows for high reflectance without the need for additional secondary operations.

Covestro’s booth will also feature lineal troffers and diffuser lenses used in high bays, cove lighting and sheet panels that have been cold bent to 90 degreees. These applications utilize Makrolon® DX-NR polycarbonate sheet diffusor and Makrolon® Lumen XT polycarbonate sheet diffusor. Makrolon® Lumen XT polycarbonate sheet’s high diffusion and transmission properties provide maximum fixture performance and aesthetics coupled with greater design freedom. Makrolon® DX-NR polycarbonate sheet’s advanced UV-resistance technology provides long-lasting weathering performance. It features a non-reflective texture on the UV-resisant side of the sheet that enhances both aesthetics and performance.

Attendees of LIGHTFAIR International are invited to visit Covestro’s booth #4956 to speak with experts and learn more about Covestro’s material technology for lighting applications.

About Covestro LLC:

Covestro LLC is one of the leading producers of high-performance polymers in North America and is part of the global Covestro business with 2015 sales of EUR 12.1 billion. Covestro manufactures high-tech polymer materials and develops innovative solutions for products used in many areas of daily life. The main segments served are the automotive, electrical and electronics, construction, medical and sports and leisure industries. The Covestro group has 30 production sites around the globe and employed approximately 15,800 people at the end of 2015.

Find more information at www.plastics.covestro.com, www.sheets.covestro.com, or www.films.covestro.com.

Covestro Contact:

John Skabardonis, Phone: +1 412-413-5444
John.Skabardonis@covestro.com

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This press release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG. 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 Covestro’s public reports which are available on the Covestro website at www.covestro.com. Covestro assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

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