Cost reduction of LED luminaires with Covestro’s Makrolon® polycarbonate

LEDs have been a hot ticket item in the lighting industry, and understandably so. Not only are LEDs energy efficient and long-lasting, they also offer superior performance. Because of these benefits, many lighting designers and manufacturers turn to them for use in their products—creating a need for materials that can effectively contribute to this long-term performance.

When PowerSecure Lighting needed a flame retardant material for LED lamp components used in its Solais® products, it turned to Covestro LLC. Bayblend® FR3010 polycarbonate/acrylonitrile butadiene styrene (PC+ABS) blend from Covestro turned out to be the ideal match for the Solais® trackhead and module family lines. These products are used in a variety of applications, including high-end retail, commercial, hospitality, health care and more.

Bayblend® FR3010 PC+ABS blend was used in PowerSecure Lighting`s Solais® trackhead and module family lines. (Photo credit: PowerSecure Lighting)

Lightweight Bayblend® FR3010 PC+ABS blend was used to mold two components—one that holds the lamp fan to allow for cooling of the module and power supply, and another that forms the electrical enclosure around the power supply. While not visible at first glance, these components play a crucial role in ensuring optimal product performance.

Unlike the material previously used in these components of the LED luminaires, Bayblend® FR3010 PC+ABS blend met the UL 94 5VA flammability requirement—which was necessary due to PowerSecure Lighting’s use of unisolated power supplies. The flame retardant properties of Bayblend® FR3010 PC+ABS blend were beneficial to the overall design and functionality of the products, keeping them safe and long-lasting.

As LED lighting OEMs and products designers continually work to optimize their products, Covestro is with them every step of the way to ensure they’re equipped with the right materials to make their concepts a reality.

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