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Mike Likes:
Clever engineers create LED lamp in CD format

An innovative, extremely flat LED lamp from EDC GmbH opens a whole new range of possibilities for energy-efficient light design. The "F|light" (not a typo) lighting design is perfectly suited to those situations where there is little space for lamps or when special design solutions are needed. Based in Langenhagen, Germany, near Hanover, the company manufactures this product using Makrolon OD2015, a special transparent polycarbonate from Bayer MaterialScience. The design concept is a no-brainer when you consider that EDC is a manufacturer of music and video CDs and DVDs looking to diversify a little.

The special feature of the LED lamp is a flat substrate made of a special high-performance plastic. At just 1.8 mm, it is as thin as a CD and can be round or square. During injection molding, tiny dimples (1.4 mm wide and 1.2 mm deep) are incorporated into the substrate to take the numerous little LEDs. "The polycarbonate's outstanding reproduction accuracy enables much higher precision in forming the dimples than can be achieved with other transparent plastics," says Axel Wetzchewald from the LED program at Bayer MaterialScience.

Breakproof and dimensionally stable
This polycarbonate material grade was specifically developed for light conductors, optical systems, and lenses, and provides a very high level of light transmission even with greater coating thicknesses. It is also shatterproof and boasts excellent dimensional stability across a wide range of temperatures. This enables the finely structured lights to be manufactured with great precision.

ECD has opted not to use conventional circuit board technology in the construction of the LED lamp. "All of the electronic elements required to operate the tiny LEDs, such as resistors and conductor tracks, are thinly printed onto the transparent substrate," explains Eckehard Schulz, project manager for new technologies at EDC. This is where the excellent print quality of Makrolon OD2015 really pays off. It is also possible to add microstructures for routing the light. This special design even allows light to escape at the edge -- an additional optical effect that can have a sweet appeal in some applications.

The lighting disk can also be fitted with flat auxiliary lenses or integrated optical systems that focus or diffuse the LED light as required. Diffusers, lens plates, or reflectors can be combined or integrated to achieve uniform illumination. This gives rise to diverse potential applications for F|light in living rooms and kitchens, designer lights, and shop and office lighting. Being lightweight, the lamp is also ideal for mobile applications including cars, motor homes, and the aviation industry.

Bayer MaterialScience has developed a broad range of polycarbonate materials for LED lamps. You can learn more about them by clicking here.

Click here for the EDC F|light brochure (PDF). Click here to go to the EDC products/services Web page.

Source: Bayer MaterialScience

Published September 2014

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