Akboru Elektrik, a Turkish supplier of lighting systems for pools, hot tubs and gardens, selected Therma-Tech thermally conductive polymers from PolyOne to replace aluminum for heat sinks in LED swimming pool lighting.
The transition from metal to plastics increased the expected useful lifetime of the lights by 200%, according to PolyOne.
"PolyOne was able to formulate the material we wanted, and provided excellent support to our company during the design and manufacturing phases of the product's introduction," said Zafer Alkan, General Manager of Akboru Elektrik.
LED lights are much more efficient than incandescent bulbs at transforming electrical power into light, but still generate considerable heat. As a result, aluminum heat sinks are often used to draw heat away from the diode to extend its performance over time.
However, aluminum parts are heavier and more costly to manufacture, and present fewer design options than moldable conductive polymers.
PolyOne's Therma-Tech thermally conductive materials provided Akboru Elektrik with the solution to oxidation problems on metal heat sinks. The manufacturer estimates the switch to this polymer tripled the LED lighting products' useful life and reduced part weight by 50%.
Daily production rates for this lighting were also increased by up to 25%, and secondary operations needed to complete the aluminum parts were eliminated, reducing costs by more than 20% per unit.
"Our Therma-Tech materials are rapidly becoming an industry standard for metal replacement in LED lighting systems, and we are pleased that Akboru Elektrik collaborated with us on this successful product launch," said Holger Kronimus, Vice President Europe and General Manager, Specialty Engineered Materials, Europe at PolyOne.