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Second generation, high performance polyester compound for LED TV applications

Solvay Specialty Polymers : 28 November, 2014  (New Product)
Solvay Specialty Polymers has unveiled an enhanced version of its Lavanta high-performance polyester (HPP) for production of light-emitting diodes (LEDs) for televisions and backlight unit applications. The second-generation product – Lavanta 5115 WH 224 – provides significantly improved processability while maintaining its high heat and light stability.
Lavanta 5115 WH 224 is a 15% glass fibre-reinforced polycyclohexylene terephthalate (PCT) compound developed specifically for LED electronic packaging applications that utilise surface mount technology. The injection moulding grade provides enhanced processability versus other available PCTs which results in higher yields and shorter cycle times. It can be moulded at a lower temperature (125C) than competitive PCTs and still maintains 100% of its maximum crystallinity. Cooler moulds enable cycle times to be reduced, resulting in lower energy use and reduced cost.
Lavanta 5115 WH 224 has high reflectivity (greater than 95%) with excellent whiteness retention even after thermal and light ageing. This gives it excellent reliability for LEDs that operate at high junction temperatures up to 150C. Lavanta 5115 WH 224 replaces competitive materials including polyphthalamides (PPA) like PA6T and PA9T, which can only operate up to 120C. The new PCT grade also has lower moisture absorption and excellent dimensional stability compared to PPA.
The second-generation Lavanta HPP also boasts strong mechanical properties, including tensile strength of 78MPa and elongation of 1.6%. This mechanical performance allows for easy ejection from the tool and improved yields during assembly.
The material is commercially available and being used by key moulders in Taiwan and China for television and backlight applications. Solvay plans to expand the Lavanta HPP product series with an enhanced version with even greater whiteness and whiteness retention while maintaining the excellent processing capabilities.
Lavanta HPPs are an extension of Solvay’s high-performance polyester line which includes materials like Xydar liquid crystal polymer (LCP) for electronic components such as connectors.
“This second-generation material is an important achievement because it exceeds the processing requirements of the LED industry, enabling moulders to maximize productivity and achieve greater efficiencies,” said Glenn Cupta, global business development manager for electrical/electronics for Solvay Specialty Polymers. “The enhanced processability is achieved without sacrificing the excellent initial whiteness and whiteness retention of the material.”
Cupta noted the growing trend among television manufacturers to use fewer LEDs to reduce cost. This is accomplished by sending higher amperage (current) through the LED, resulting in significantly higher junction temperatures above 100C and greater brightness. Previously used materials are unable to withstand the higher heat and light output, discolouring prematurely in applications such as reflector cups.
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