Bayer MaterialScience Pushes LED Lighting Application Development Foreward with New Products

Bayer MaterialScience provides solution for Fraen's Optics Division:
Fraen's Optics Division wanted to produce a high-performing optic for use in light emitting diode (LED) lighting to meet the general illumination market's needs, as well as the company's own performance targets. With the help of Bayer MaterialScience LLC, Fraen was able to find the key to its latest product, the Twelve LED Troffer Reflector, which produces the beam pattern needed to replace the recessed fluorescent light with an LED solution.

Fraen's Optics Division injection molds a flame-retardant grade of Bayer's Makrolon® polycarbonate to form the Twelve LED Troffer Reflector. The optical efficiency of the Makrolon polycarbonate material allowed Fraen to develop a reflector that delivers a pleasing, diffuse illumination that is suitable for use in a wide range of lighting applications and fixtures, including general interior lighting, troffer fixtures and low bay commercial and architectural fixtures.

The material Fraen used, Makrolon 6265X polycarbonate, is a high-flow resin with easy release properties. The grade has earned Underwriter Laboratories' (UL) 94 V-0 rating at 1.5 mm. In addition to supplying its plastic, Bayer also provided Fraen Corporation with technical expertise.

"Not only were we impressed with the properties of this plastic, we were also able to process it using our existing machinery — without having to make any modifications or upgrades — which was beneficial from a manufacturing perspective," said David Cohen, executive vice president and chief operating officer of Fraen's Optics Division. David continues, "Bayer personnel assisted us with specifications and performance criteria."

"As a leading provider of materials for the LED lighting market, we are always inspired by the challenge of helping our customers bring new products to market," said Kevin Dunay, market segment leader, Electrical/Electronics (EE) Polycarbonates, Bayer MaterialScience LLC. "The Twelve LED Troffer Reflector is the latest example of how Bayer works collaboratively with its customers."

The Twelve LED Troffer Reflector is available directly from Fraen's Optics Division or through its designated distributors.

New polycarbonate grade can replace aluminum in LED heat sinks:
The light emitting diode (LED) market is booming as consumers switch from incandescent bulbs to more energy efficient LEDs. Lighting designers and manufacturers are looking for materials to help make the bulb transition a smooth one. Bayer MaterialScience LLC is launching a new grade of thermally conductive plastic to help lighting manufacturers meet consumer demand quickly and cost-effectively.

Makrolon® TC8030 polycarbonate, which joins a selection of heat-resistant Bayer plastics developed for LED applications, is targeted for use in LED heat sinks for replacement lamps or next-generation luminaires. Compared with aluminum, a common material in heat sinks, this grade of Makrolon offers similar thermal performance while helping reduce costs and enhance design freedom. Using this material can save costs by eliminating assembly steps, improving production efficiency and reducing capital investments. Because Makrolon TC8030 plastic is injection molded, it gives designers the freedom to create non-traditional shapes, use in-mold decoration and optimize joining techniques.

"Bayer is working continuously to provide innovative materials for lighting applications," said Kevin Dunay, market segment leader, Electrical/Electronics (EE) Polycarbonates, Bayer MaterialScience LLC. "Being in front of market trends allows us to develop materials that meet the evolving needs of manufacturers and designers."

About Fraen Corporation:
Fraen's Optics Division specializes in the design, development and manufacture of optics for high-powered LEDs. Fraen offers a wide range of standard products for all major LED makers as well as innovative custom optical solutions. Fraen's other businesses include its Advanced Manufacturing Division, which manufactures stepper motors; its Custom Manufacturing Division, which specializes in lit plastic parts and complex stampings; and Fraen Machining Corporation, which manufactures precision-turned metal components.

About Bayer MaterialScience LLC:
Bayer MaterialScience LLC is one of the leading producers of polymers and high-performance plastics in North America and is part of the global Bayer MaterialScience business with approximately 14,700 employees at 30 production sites around the world and 2010 sales of 10.2 billion euros. The company 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. Sustainability is central to Bayer MaterialScience LLC's business and is based around the key areas of innovation, product stewardship, excellence in corporate management, social responsibility and respect for the environment.