Solvay Specialty Polymers, Alpharetta, Ga., has unveiled an enhanced version of its Lavanta high-performance polyester (HPP) for the production of LEDs for televisions and backlight unit (BLU) applcations. This second-generation HPP injection molding grade is said to provide significantly improved processability, resulting in higher yields and shorter cycle times, while maintaining its high heat and light stability properties.
Lavanta 5115 WH 224 is a 15% glass fiber-reinforced polycyclohexylene terephthalate (PCT) compound specifically developed for LED electronic packaging applications that utilize surface mount technology. It can be molded at a lower temperature (257 F/125 C) than competitive PCTs and still maintains 100% of its maximum crystallinity. According to global business development manager Glenn Cupta, this material is an important achievement because it exceeds the processing requirements of the LED industry. He says the trend among television manufacturers is to use fewer LEDs to reduce cost. This is accomplished by sending higher amperage through the LED, resulting in significantly higher junction temperatures about 212 F/100 C and greater brightness. Previously used materials are unable to withstand the higher heat and light output, discoloring prematurely in applications such as reflector cups.
Lavanta 5115 WH 224 has greater than 95% reflectivity with excellent whiteness retention even after thermal and light aging. This gives it excellent reliability for LEDs that operate at high junction temperatures up to 302 F/150 C. The material replaces competitive materials including polyphthalamides (PPAs) like PA6T and PA9T, which can only operate up to 248 F (120 C). This PCT is also said to have lower moisture absorption and excellent dimensional stability compared to PPA. It boasts strong mechanical properties—which allows for easy ejection from the tool--including tensile strength of 11,312 psi and elongation of 1.6%.
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