Foaming agents’ structures simultaneously increase strength and decrease weight.
Our cellular foaming agents help you cut weight, conceal surface defects and improve cycle times. Tested and proven across a wide range of polymers and applications, these foaming agents can be relied upon time and time again to make your manufacturing jobs easier and your end product more appealing.
Explore below to learn more about the value our foaming agents can bring to your business.
OnCap™ Chemical Foaming Agents
Maintain finished part integrity with 50% less material by adding chemical foaming agents to your process.More
OnCap™ PolyFoam foaming agents
OnCap™ PolyFoam™ blowing and foaming agents reduce density, increase dimensional stability and improve surface appearance in structural parts.More
Excelite™ foaming technology
These agents add an exceptional surface finish and greater production control for vinyl extrusion applications like construction and digital printing.More
LED Manufacturer Innovates and Saves with Polymer Heat Sinks
Shift from metal drives improved product line for component manufacturer
In the rapidly evolving market for light emitting diode (LED) products, manufacturers need to innovate or risk quickly falling behind. Finland’s Kruunutekniikka Oy seized an opportunity for such an innovation: reengineering the critical heat sink that protects heat-sensitive LED components.
While LED light bulbs can use up to 80 percent less energy than incandescent bulbs and can last more than 20 years, they generate a substantial amount of heat that must be dissipated with a heat sink.
Manufacturers typically build heat sinks from die-cast aluminum – effective but costly to buy and work with. As an injection molding contractor with expertise in lighting components, Kruunutekniikka knew it could provide improved manufacturability and performance in LED lighting by producing non-metal heat sinks at scale.
The company’s product engineers developed specifications that included thermal conductivity in plane from 4 to 21 W/m.K (in compliance with ASTM E1461); glow wire resistance of 850°C/0.8mm (IEC 606095-2-12); and enough dimensional stability to allow it to be overmolded directly on LED components.
They just needed to find the right material.
The search led Kruunutekniikka’s design engineering team to PolyOne. A collaborative team from the two companies looked at potential options before developing a material that combined two grades of PolyOne’s Therma-Tech™ thermal management compounds.
PolyOne engineered compounds that combined the heat transfer and cooling capabilities of metals with the design freedom, weight reduction and cost advantages of conventional thermoplastics.
The team tested the formulation and phased it into production, and Kruunutekniikka’s Coolics™ brand quickly adopted the material throughout its line of customized LED cooling systems. The material added immediate benefits including: complex designs at lower costs than metal; lighter weight; inherent corrosion resistance; adaptability for ingress protection up to IP67; high heat resistance; compliance with UL94 V-0 flammability standards; and options for either electrically conductive or insulating properties.
As a result of the collaboration, Kruunutekniikka realized a cost savings of more than 10% through a variety of means:
- Reduced material usage: The Therma-Tech formulation required 37 percent less material due to its lower density compared with aluminum.
- Improved manufacturing: The company realized substantial savings during high-volume production thanks to a switch from die casting to injection molding. In addition, the change in material eliminated secondary steps needed to achieve net shape with die casting. Startup times also were reduced.
- Achieved new sustainability goals: Production scrap from the injection molding process can be fully recycled as part of an in-line process, which helped the company meet its sustainability goals.
By replacing metal with engineered thermal composites, Kruunutekniikka has been able to drive growth in the emerging solid-state LED lighting market with a solution that is innovative, sought after, cost effective and consistent with the company’s ongoing effort to facilitate sustainable practices.
To learn more about the benefits of custom engineered thermoplastics, contact an expert at PolyOne today!
PolyOne is a leading producer of cast acrylic sheet for cabin windows, fighter canopies, windscreens, wing-tip lenses, outer laminates and insturment panels for general aviation and military aircraft.
Polycast Poly 2000™ Stretched Acrylic Sheet (MIL P 25690) - Product Bulletin
Aerospace industry advantages and typical values of Polycast Poly 2000™ stretched acrylic sheet
Polycast™ Cell Cast Acrylic Solutions for Aerospace - Industry Bulletin/Overview
Polycast™ aerospace solutions, regulatory compliance, product properties and approvals/specifications
Polycast has been manufacturing cast acrylic sheet for over 50 years and is presently the principal supplier of acrylic sheet meeting U.S. Military Material Specifications MIL-PRF-5425, MIL-PRF-8184 and Mil-PRF-25690 to the United States aerospace industry. PolyOne has developed an enhanced crazed-resistant material and MIL-PRF-8184 has been revised to recognize the improved performance of this material.
Commonly Asked Questions
WHAT ARE PHTHALATES?
A class of commonly used...
CAN I MIX EPIC WITH OTHER INKS OR ADDITIVES??
Yes! Of course you can!
Aerospace manufacturers trust PolyOne cast acrylic sheets to meet the exacting demands required in high performance environments. Our acrylic sheets can be modified to change physical, chemical or optical properties to meet the requirements and specifications of militaries and aviation authorities. Uniquely manufactured and formulated, these sheets meet both the present, and future needs, of our aerospace industry customers.
Polycast™ Aerospace Grade Sheet
Polycast AQ acrylic sheet meets even the most stringent demands of commercial and military aircraft manufacturers.More
Polycast™ UV-SC™ - UV Blocking & Solar Heat Control Cell-Cast Acrylic Sheet
Block out significant amounts of near-infrared radiation while maintaining high visible light transmission.More