EIS teams up with device engineers early in the design stage to determine the appropriate material(s) and process necessary to fully manage the thermal challenge. For example, lamination with other materials is frequently required for structural and electrical insulation purposes or to provide a multi-purpose thermal and moisture management layer. Materials can also be custom die-cut to fit the design footprint.
We also specialize in creating retrofit solutions for thermal management needs that become evident once the device is in production.
EIS stocks numerous thermal management materials from 3M™, Chomerics, Laird, and Von Roll that can be electrically conductive or electrically isolating.
LED THERMAL MANAGEMENT
All the advantages of LEDs come with one concern – they heat up. High-brightness diodes, especially in LED clusters, can cause sufficient thermal challenges to impact LED performance.
LED diodes consist of a die semiconductor material impregnated or doped, with impurities to form a p-n junction. Light is projected upward in the LED and heat downward into the base. As heat rises within an LED, light output diminishes. Proper thermal management in designing modules for LEDs, whether on a circuit board or within an enclosure, requires assessing materials and methods for dissipating heat. EIS can recommend appropriate materials and designs to provide the required thermal conductivity and electrical insulation.
Thermal Interference Materials (TIMs) are vital components in all LED lights. TIMs help preserve LED lights and function at maximum capacity by managing the heat produced by the lights. EIS combines and tailors these materials to fit customized and specific needs in any LED application.
TIMs sit between the LED and the heatsink. There they provide high thermal conductivity to efficiently transfer heat emitted from the light source to the heatsink. This is accomplished by displacing the air within the LED. Without TIMs, heat is not transmitted efficiently and LED performance suffers.
LED THERMAL MANAGEMENT CUSTOM CONVERTING
There are a variety of converted materials needed beyond thermal management materials that are critical in the performance, reliability, and safety of LED lighting. Materials used for electrical and fire safety are crucial in LED function by eliminating electrical and fire hazard risks caused by the released heat.
Once the best materials are selected, EIS provides the finished die-cut thermal management component as well.
Integrated direct connected LED luminaire designs are ideal for maximizing cost-effective light efficiency. Flame barrier products (FRB) are used in addition to heatsinks and thermal interface materials at the light fixture housing-enclosure level. FRBs are thin insulation apparatuses made of inorganic materials. These FRB insulation materials provide incredibly high flame and heat resistance in applications such as:
- General-purpose lighting luminaires (including LED)
- Electric and electric hybrid vehicles
- Electrical devices
With excellent heat and flame resistance, FRBs offer arc and track resistance, dielectric strength, flexibility, and convertibility.
EIS also provides EMI/RFI Shielding solutions to lower magnetic interference or radio frequency interference. Although LEDs operate with a direct current, lighting controls and dimming circuits with trebling high frequencies. EMI/RFI management can take several different forms, such as:
- Electrically conductive adhesive transfer tape
- Electrically conductive gaskets (ECG)
- Electrically conductive cushion pad eCAP
- EMI/RFI shielding tape
- Foil and conductive fabric backings
- Electrically conductive & non-conductive adhesives
- EMI/RFI absorbers
- Various magnetic permeability and thicknesses
Making the right choice of electrical insulation, EMI/RFI shielding, and flame-resistant barrier protection is essential for proper thermal management and material selection to make your LED lights as functional and efficient as possible.
Includes phase change materials, adhesives and greases that sit between heat generators and heat sink, pressure-sensitive tapes that mount to heat sinks, thermal fabrics and tapes providing thermal conductivity, and silicone sponge materials for heat absorption. Conductive adhesives and greases are from top suppliers such as 3M, DuPont, Von Roll, and Saint-Gobain.
Adhesive tapes are available for various applications, including bonding, joining, marking, and covering for use in industries and fields such as electrical, automotive, manufacturing, and much more. These tapes eliminate the need for mechanical fasteners, saving both material and process costs. Many tapes are offered, including electrical tape, vibration dampening tape, die-cut foam tape, transfer tape, and more.
Specialty converted coated fabric materials are available in a wide variety of options at Fabrico. Laminated, slit, or die-cut coated fabric products are offered for insulation, surface protection, chemical resistance, and thermal management applications. Fabrics can be laminated with pressure-sensitive adhesives, conductive adhesives and can be die-cut to accommodate EMI/RFI shielding and structural requirements. Specialty converted coated fabric materials are available from top suppliers DuPont, Isovolta, Saint-Gobain, and Von Roll.
Phase change materials (PCM) melt and solidify at certain temperatures while storing and releasing large amounts of energy. EIS supplies PCM such as 3M 8926-02 and Nitto-Denko TR-5925.
CERAMIC & METAL-FILLED ELASTOMER GAP-FILLERS
Gap fillers help to create pathways for efficient heat transfer in between heat-generating mechanisms, heat sinks, heat spreaders, and other cooling devices. Interface Pad 3M 5595 provides excellent thermal conductivity.
Let us help you find thermal management solutions!