Switching to conductive polymer triples lifetime of LED pool lighting

Akboru Elektrik, a leading 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. Collaborating with PolyOne enabled Akboru Elektrik to make a transition from metal to polymer that increased the expected useful lifetime of the lights by 200 percent, supporting the company’s goals to reduce part weight and improve manufacturing and logistics efficiency.

“Our company is always on the lookout for innovative new materials to help us improve our manufacturing efficiency and the quality of our products”, explained Zafer Alkan, general manager of Akboru Elektrik. “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”.

LED lights are much more efficient than incandescent bulbs at transforming electrical power into light, but still generate considerable heat. The diodes that produce light in LEDs are sensitive to high temperatures. 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 increased by up to 25%, and secondary operations needed to complete the aluminum parts were eliminated, reducing costs by more than 20% per unit.