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LED designers have achieved a number of advantages by choosing a PC (rather than glass and PMMA), including greater impact and heat resistance, increased flammability levels, and increased design flexibility. Although glass and PMMA compete with PCs for their high light transmission and weather resistance, the latest professional PCs are rapidly closing the gap. As a candidate for LED devices As the adoption rate of LED lighting continues to rise, lighting manufacturers are pursuing materials other than traditional materials for lighting applications to drive innovative designs and shapes, increase efficiency, and overcome ongoing cost barriers. Although traditionally manufacturers use polymethyl methacrylate (PMMA) in solid state lighting (SSL) applications - followed by glass. Polycarbonate resins (PCs) are now increasingly becoming lenses, lampshades, tubes, conduit columns, diffusers and reflectors. Today, approximately 90% of the replacement LED lamps for alternative incandescent lamps are made of PC materials. LED designers have achieved a number of advantages by choosing a PC (rather than glass and PMMA), including greater impact and heat resistance, increased flammability levels, and increased design flexibility. Although glass and PMMA compete with PCs for their high light transmission and weather resistance, the latest professional PCs are rapidly closing the gap. As a candidate for LED devices, polycarbonate poses a huge challenge to glass and PMMA and is driving advances in residential, commercial and outdoor LED designs. PCs open the residential market Many countries have begun to transition away from traditional lighting sources, thanks to consumers' high attention to energy conservation and emission reduction, and government regulations to promote the phasing out of inefficient bulbs. However, in order to completely replace incandescent lamps and compact fluorescent lamps (CFLs), LEDs must address cost issues, and cost remains one of the main obstacles to entry into the mass residential market. As demand grows, consumers need to see and understand the benefits of technology that has a longer lifespan. Durability and impact resistance are important criteria in a residential environment, as it is common for residents to drop lights when installing lights or to improperly handle replacement lamps. The impact resistance provided by the PC is measured in kJ/m2 (kJ/m2) when the sample is broken by bending shock in the laboratory, which is significantly higher than that of glass and PMMA. In actual impact measurement, the performance of PC exceeds 10 times that of PMMA and 30 times that of glass. LED devices produced using PCs are also safer than those produced using PMMA, which performs poorly in terms of flame retardancy and heat resistance. According to the UL 94 standard, some PCs have achieved a 5VA rating, which is the highest level of flame retardancy. On the other hand, PMMA is UL rated UL 94, which is the lowest in the rankings. In addition, PCs can be used continuously at temperatures up to 130C, while PMMA can only reach 90C. Table 1 summarizes the key features of PC and PMMA for reference by solid-state lighting product developers. Table 1. Comparison of PC and PMMA specifications Producing softer solid-state lighting To increase the demand for LEDs in residential environments, lighting designers must also address the quality issues of LED lighting to make lighting softer and closer to incandescent bulbs. A diffusing material with a creamy or matte finish shields the LED light source, helping to evenly distribute light and reduce glare. If there is no diffusion, the LED light source will produce glaring white highlights. At the same time, designers must balance the relationship between the aesthetic needs of soft white light and light transmission. Too much diffusion can mean excessive illuminance loss, which reduces bulb efficiency. The PC excels at making a delicate balance between diffusion and light propagation. A new generation of polycarbonate can shield hot spots without affecting light transmission. When used in an LED dome or lens cover, the PC provides effective diffusion without the need for secondary lenses or components, eliminating cost, complexity and weight. Diffusers made with PMMA typically require multiple components, adding weight and complexity to the LED design. Table 2 shows the transmission and light scattering provided by the PC level available to today's LED designers. The transparent grade of SABIC's LEXAN LUX C resin delivers 1 mm 91.5% light transmission, a significant improvement over the traditional PC's 89%, second only to 92% PMMA. For lighting applications that require greater diffusion, the LEXAN LUX C resin diffusion stage diffuses light (shown in Table 2) to light scattering (DLD) or observs half the angle of incident light without significantly reducing light transmission. . Table 2. Transmittance and Light Scattering of Transparent and Diffused PC Grades Creating uniformity and uniformity of illumination also presents difficulties for industrial and commercial LEDs, but PCs have proven effective in these environments. Intematix, a manufacturer of LED lighting fluorescent materials and optics, selected SABIC's transparent, diffused and reflective grades of LEXAN LUX resin to make the ChromaLit linear lighting system (Figure 1). ChromaLit uses remote phosphor technology, which uses a phosphor assembly that is separate from the blue LED energy source to produce better light diffusion. The separation of the phosphor from the energy source produces better illumination uniformity. The ChromaLit linear system delivers natural, uniform, high-quality light that can be converted to 215 lm/w or as high as 163 lm/W when used with the most efficient blue LEDs. Design Flexibility for Commercial Lighting Commercial and industrial LED luminaire manufacturers face many of the same challenges as the residential market. The lighting design must be practical, attractive and lightweight, while also providing high light efficiency and light uniformity. To meet these complex standards, manufacturers are looking for materials that offer design flexibility in which glass and PMMA lag behind PCs. In particular, PCs can be used to produce sharp corners and notches - this design feature further enhances PMMA's weakness in impact strength. In addition, PMMA does not maintain a high degree of durability and hardness in ceiling LED applications like a PC, as shown in Figure 2. PCs can also be used in snap fit applications compared to other materials such as glass. Unlike adhesive assemblies, LED lights and luminaires made with snap-on connections can be easily removed without damaging the parts, reducing life cycle costs and environmental impact. See Table 3 for more information on life cycle impact. Table 3. Environmental impact and life cycle comparison of LEXAN resin and PMMA Another fundamental obstacle faced by commercial LED designers is the release of light inside the optical system, which reduces light output while generating unnecessary heat. Reduce equipment reliability and service life. Lenses made of PC have a high refractive index that helps optimize light extraction, and can also integrate reflectors into LED modules for thinner lenses and lighter designs. With PC lenses, PC reflectors can also be effectively integrated into optical systems. By using lenses and mirrors, the illumination of the LED module is maximized and the PC is significantly better than PMMA. PCs also offer manufacturers the choice of processing methods, from injection molding and blow molding to extrusion, to support in-mold coloring to form dynamic and curved shapes. Although PMMA can also be processed in a variety of ways, given the global warming and total energy requirements, PC materials have a clear advantage in terms of sustainability and life cycle impact (see the carbon entry in Table 3). Increasing Outdoor LED Performance LEDs are increasingly used in architectural lighting, exterior and street lighting, and automotive applications. While facing many of the same challenges as residential and industrial environments, outdoor LED designs must address the effects of long-term exposure to the sun, rain, wind, heat, humidity, and cold. Although PMMA outperforms PC in terms of weather and ultraviolet (UV) radiation resistance, PCs have made progress in these areas. For example, SABIC's LEXAN SLX resin is specifically designed to reduce the gap between PC and PMMA in outdoor applications. LEXAN SLX resin resists yellowing due to UV exposure and maintains its gloss, color stability and mechanical properties more than five times longer than standard PCs. Standard PCs are degraded by UV radiation, reducing the ductility of the components and making them brittle. The outdoor illumination lens of Figure 3 shows a yellowing comparison of components made with LEXAN SLX resin and standard PC after 2900 hours of exposure to ultraviolet (UV) light. To capture the difference, the lens was placed in a hot chamber equipped with a 175 W metal halide (MH) lamp and placed on a refractor at 120 ° C for 2900 hours. The evolution of polycarbonate The advancement of PC technology has significantly improved the applicability of PCs to LEDs. Material manufacturers such as SABIC have invested in the development of PC materials to increase design freedom through lighter weight, better mechanical properties, higher aesthetics and lesser secondary operations. Figure 4 compares SABIC's LEXAN LUX resin grade to thermal aging of a standard PC with UV additives. When tested at 130 ° C for 5000 hours, the standard PC showed a larger color shift than the two grades of LEXAN LUX resin tested (2180T and 2110T) - expressed by the increase in the increase in the y or the yellow index . Due to the extremely long life of LED devices (up to 10-15 years), lifetime is also a key factor in LED components and materials. As shown in Figure 5, SABIC's LEXAN LUX resin grade is better than standard PCs after 2000 hours of heat aging. Using polycarbonate Although the difference in refractive index (RI) must be taken into account, designers and OEMs can develop products in a way that develops products with PMMA and glass. Although the same predictive modeling tools can be used, SABIC can also provide a two-way scattering distribution function (BSDF) file that allows product engineers to predict the results of their design for transparent and diffuse materials. In addition, PCs can be processed using the same type of molding machine as PMMA - injection molding machines, extruders and blow molding machines. Using a UL 94 compliant PC can also reduce product development time and potentially eliminate the need for equipment burn testing. Although the future of LED technology is bright, it is still at a relatively early stage of development, and has not yet achieved a large-scale market breakthrough, which has become the main form of lighting in residential, commercial and outdoor environments. However, manufacturers and engineers are facing these challenges, and exciting new designs appear every day. Addressing the complex and ever-changing specifications of the LED industry requires constant investment in new and improved PC materials.