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Often the physical properties of materials can limit design freedom, however thanks to our specialised range of optical materials from vendor partner Dow Corning, this issue can be mitigated.

Optical materials are used in the manufacture of items such as mirrors, windows and prisms and are designed to reflect, transmit, detect and transform light.

Included in our diverse range of optical materials are mouldable optics, optical coatings and optical encapsulants. Dow Corning optical materials go beyond the limits of traditional optical materials whilst proving to not only offer excellent optical properties but more resistance to impact damage and degradation from UV, heat and environmental extremes.

Dow Corning optical materials push design boundaries by enabling LED sources to feature more complex shapes, micro-scale optical structures, multifunction parts and even undercuts that are difficult to achieve with organic polymers or glass.

 

Mouldable Optics

Mouldable Optics can boost the long-term performance of a design beyond the capability of traditional optical materials. With unique optical properties, they are most resistant to impact damage and degradation from UV, heat and environmental extremes – a key benefit of modern optical materials compared to traditional means. Mouldable Optics are also beneficial to the end user in the sense that it allows them to explore more complex designs whilst simplifying the manufacturing process.

Dow Corning MS-1002 is a mouldable silicone optic designed to produce fine detail with good resistance to environmental aging. MS-1002 has a medium viscosity for injection moulding, good mould flow and transparency with better heat resistance than plastic and appearing lighter than glass. There is also the option to easily mould this material into complex shapes.

The award-winning MS-2002 is a white reflective material which enables creativity and flexibility in designing and manufacturing light reflectors. MS-2002 Mouldable Silicone optic offers minimum colour change with heat or UV exposure and ensures high performance in challenging conditions such as high humidity. It is fast curing, and has high viscosity and high Shore A hardness.

 

Optical Coating

Optical coatings are made up of a combination of thin film layers, designed to enhance transmission or reflection properties within an optical system. The performance of an optical coating is ultimately based upon the number of layers, which includes the thickness of the individual layers as well as the refractive index difference at the layer interfaces.

Dow Corning CI-2001 White Reflective Optical Coating provides even more freedom to go beyond the design limitations of traditional materials. This reflective coating can enhance light output and efficiency in reflectors, lightboxes, mixing chambers, backlight units and other surfaces, while ensuring high resistance to environmental aging. CI-2001 offers many additional benefits including additional protection from humidity, moisture and thermal stress and excellent insulation again high voltages whilst minimising processing costs. At the same time, CI-2001 eliminates the need for special storage, handling and ventilation.

 

Optical Encapsulants

Optical Encapsulants serve to enhance light output and efficiency in lighting applications. These silicone based products have great compatibility with LED substrates whilst offering superior thermal stability. With a number of additional benefits including their ability to sustain their physical and electrical properites over a wide range of temperature, humidity and other harsh environmental conditions, optical encapsulants are an incredibly advantageous material.

Dow Corning JCR 6122 is a two-part, transparent, medium modulus LED encapsulant with very low viscosity and high transparency. JCR 6122 has been designed to meet the challenging needs of the LED market, with features including high adhesion, high purity, moisture resistance, thermal stability and optical transmittance.

EI-1184 is a unique optics encapsulant which can perform multiple functions. EI-1184 offers greater cost efficiency and a lower overall total cost of ownership whilst providing superior protection from moisture, thermal stress and shock and impact. Additional benefits include minimal yellow and degradation while maintaining consistent light quality over the product light-span.

 

Concluding Thoughts

Designed to meet the challenging needs of the optical market, Dow Corning mouldable optics, optical coatings and optical encapsulants are a great choice to address tough industry demands whilst guaranteeing a competitive edge.

Encompassing advanced silicone technology, users of Dow Corning optic materials can enjoy a range of benefits including optimised efficiency, simplified and speed processing properties, resisted yellowing and physical degradation whilst protecting sensitive LED electronics from thermal cycling stress to perform reliably at extreme temperatures ranging from -45°C to 200°C.

To make an enquiry about any of our Optical Materials, contact Ellsworth Adhesives Europe via email: infoeurope@ellsworth.com or alternatively call 01355 321122.

Shop our extensive range of optical materials here. 

With modern advances in technology, and electronic products becoming ever smaller, the use of thermal management materials has become essential to electronics device manufacturers to address and mitigate the thermal demands of today’s electronic devices.

A broad range of Thermal Management Materials are available in the market place – from thermally conductive adhesives and encapsulants, to thermal pastes and greases.

In the first blog post of 2018, we’ve outlined the different types of thermal materials on the market, and shared the standout products within each category.

 

Thermally Conductive Adhesives

Thermally Conductive Adhesives have been developed specifically for applications where heat transfer is essential. This type of thermal management material offers enhanced thermal stability, chemical resistance and higher temperature properties.

Robnor ResinLab PX449TC is an example of a flame retardant thermally conductive adhesive with high adhesion, high electrical insulation characteristics and good chemical and water resistance. This adhesive is most appropriate for the bonding and sealing of electric components, most circuit board components and plastics and substrates.

PX628H is another thermally conductive adhesive from Robnor ResinLab with excellent adhesion to a wide variety of substrates. With high impact resistance, this adhesive has a long pot life and convenient mix ratio to ensure maximum strength when bonding metal and composite parts.

 

Thermally Conductive Encapsulants

Thermally Conductive Encapsulants are designed to dissipate heat from sensitive electronic components and extend the life span of devices whilst providing environmental protection.

Dow Corning TC-4605 thermally conductive encapsulant is a two component silicone rubber material, offering excellent dielectric properties. Curing with heat, TC-4605 forms as a rubber that is elastic, thermally conductive, flame retardant and repairable.

Dow Corning TC-6011 cures at room temperature to provide an impressive flowability and workability. With good adhesion and reliability, TC-6011 can be applied with manual mixing and potting and automated or manual needle dispensing.

 

Adhesive Pastes

Adhesive pastes create a robust mechanical attachment without the need for screws and clips. As a result of this, device size and weight can be reduced and the product can be kept in line with the trend towards small electronics.

Robnor ResinLab TCP091 silicone-free paste has been specially formulated to provide efficient and reliable heat transfer across the interface between electronic components. Developed to optimise performance, TCP091 is a general purpose, versatile compound with good thermal conductivity and excellent dielectric properties at all frequencies.

 

Thermal Greases

Commonly used as an interface between heat sinks and heat sources to eliminate air gaps or spaces for maximum heat transfer, thermal greases are advantageous for use in high thermal performance applications where minimal bondline thickness is essential. Functioning immediately after application, thermal greases can compensate for voids easily. Additional advantages of thermal greases include thermal resistance, bond line thickness, re-workability and a lower overall cost.

One of the most popular thermal greases available is LORD CoolTherm™ TC-501 Thermal Grease, a solvent-free silicone thermal interface material which provides high thermal conductivity and low thermal resistance for applications in which superior heat dissipation is required. Featuring high reliability, TC-501 eliminates pump-out, provides excellent resistance to moisture and temperature cycling. TC-501 achieves thin bondlines of 25-50 microns (1-2 mils) whilst minimising the thermal pathway and maximising heat flow.

 

Thermal Gap Fillers

Thermally Conductive Gap Fillers are growing in popularity with large volume applications and heat sinks. Available in various levels of softness and conductivity, thermal gap fillers increase heat transfer efficiency with voids and air pockets acting as a thermal insulation for heat transfer between the heat source and sink.

Dow Corning TC-4525 Thermally Conductive Gap Filler is a soft an compressible silicone material which dissipates heat from electronic devices like printed circuit boards by conducting it to a heat sink such as an aluminium housing. Well suited for automated dispensing using standard meter mix equipment, TC-4525 has excellent thixotropic properties and an enhanced processing experience thanks to its smooth dispensability and assembly.

 

To make an enquiry about any of our Thermal Management Materials, contact Ellsworth Adhesives Europe via email: infoeurope@ellsworth.com or alternatively call 01355 321122.

If you are still unsure which Thermal Management Material is best suited to your electronic device, don’t hesitate to contact ‘The Glue Doctor’ who can assist you with your choice.

Shop thermal management materials here. 

UV Light Curing is a speed curing process in which high intensity ultraviolet light is used to create a photochemical reaction that instantly cures inks, adhesives, coatings and other materials.

There are a wide selection of light curable materials on the market – from adhesives and coatings to maskants and potting compounds. UV curing now has an increasingly greater importance in the modern manufacturing sector and has been deemed as the smart solution for equipment manufacturers.

Light guides are a key component for efficient UV curing as they transmit UV and visible energy from a source mounted inside of a spot-curing unit to the curing area. Several factors should be considered when choosing a light guide for your system which will be outlined in this blog.

Light Guides Overview

A broad range of light guides are on offer, manufactured by our vendor partner Dymax. These light guides deliver high intensity UV light efficiently from UV spot lamp curing systems and are available in a long-lasting liquid or fibre form in single and multi-legged configurations or various lengths.

Liquid light guides are optical instruments consisting of a light conducting liquid core within plastic tubing. They are the most economical method for manufacturers aiming to deliver high intensity UV light to adhesives and coatings. Liquid light guides are also available in two-pole, three-pole and four-pole configurations to allow UV curing of multiple points simultaneously.

There are several benefits of using a liquid light guide including excellent cold light properties, ensuring no danger of individual fibre breakup as well as no transmission of infrared radiation.

Liquid light guides are the standard light guides offered by Dymax however Quartz Fibre light guides are also available as an alternative when maximum transmittance efficiency is essential. Additional advantages include greater flexibility in the curing process and easy customisation.

Factors to consider when selecting a Light Guide

Many factors should be considered when selecting the most suitable light guide for your manufacturing process including length, diameter, multi-pole, connection and curing intensity versus distance.

 

DIMENSIONS

Light guides are usually one metre long, however a wide variety of other lengths are on offer if your application requires a more custom length.

Dymax Single pole light guides are available with 3mm, 5mm or 8mm inside diameters.

3mm – The standard size

5mm – Delivers a higher intensity

8mm – Allows for more curing power thanks to its larger light guide opening which captures more of the light emitted from the bulb.

MULTI OR SINGLE POLE? 

Light which is emitted from spot lamps can be channelled through a single pole light guide or split between multiple pole light guides. Each pole of a multi-pole light guide emits equal intensity (typically +/- 10% for liquid filled light guides), and are available liquid-filled or quartz fibre with all sharing a common shutter. Standard Dymax multi-pole lightguides incorporate integrating rods to cure multiple points simultaneously with a more balanced output from pole to pole. On the other hand, single pole light guides offer a higher minimum initial intensity (W/cm²) and typical intensity at 2000 hours(W/cm²), ensuring light is delivered with much greater strength and depth to the target object.

CONNECTION

Two types of connectors are used in UV light guides, “Wolf” and “D”, both of which are available from Dymax. It is important to note “D” connectors are an industry standard and compatible with all existing Dymax lamp designs, whilst “Wolf” connectors have been designed for the previous generation of Dymax lamps (PC-3, PC-3 Ultra and 3010-EC). “Wolf” connectors remain fully compatible with all light guides.

INTENSITY V DISTANCE

When taking into consideration curing area/intensity versus distance, the UV and visible light emitted from a light guide separates. Therefore, intensity decreases and curing area increases with distance from the end of the light guide.

Light Guide Accessories

A number of accessories are available for use with light guides including the single light guide mounting stand, acrylic light guide mounting stand and light guide stand expansion kit which can enhance the UV curing process.

Filter mount assemblies can be purchased to broaden the life of light guides and are more efficient than glass fibre optics for transmission in the visible range.

Optical bandwidth Cool Blue™ filters extend liquid light guide life and offer additional curing options for applications requiring UV light cure.

Shop our full range of Light Guides here. 

Concluding Thoughts

By using Dymax light guides when UV curing adhesives, sealants and coatings you can be assured of a more rapid and controlled cure.

Dymax light guides have been manufactured with a robust mechanical design and incorporate top of the range technology to minimise degradation of light intensity whilst transmitting the highest light intensity available for UV curing.

To make an enquiry about any of our Light guides, contact Ellsworth Adhesives Europe via email: infoeurope@ellsworth.com or alternatively call 01355 321122.

If you are still unsure which light guide is best suited to your UV curing materials and equipment, don’t hesitate to contact ‘The Glue Doctor’ who can assist you with your choice.