Silicone Technology: Possibilities for the New Lighting Hugo da Silva Global Market Manager – Next Generation Lighting

Dow Corning Corporation

Silicone Technology: Possibilities for the New Lighting Hugo da Silva Global Market Manager – Next Generation Lighting

Dow Corning Corporation

Who is Dow Corning?

Dow Corning is …..  A global leader in silicones and high purity silicon  More than 7,000 products/services

 Approx 25,000 customers  Approx 10,000 employees  Strong and healthy financially: $6billion sales 2010  Investing in our future and our customers’ futures: geographic, manufacturing, innovation  Transforming our business to deliver:  Efficiency, Innovation and Sustainability  4-5% of sales is spent on R&D  More than 5,000 active patents  Formed in 1943  A joint venture of The Dow Chemical Company and Corning Incorporated

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Dow Corning Worldwide

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What is a Silicon(e)?

Silicones are… Quartz Carbon

Silicon Metal

Silica (SiO2)

Silicon (Si)

Terrestrial abundance 1. Oxygen 49.5% 2. Silicon 25.7% 3. Aluminum 7.5% 4. Iron 4.7% ・・・・・・ 14. Carbon 0.03%

Methylchloro Silanes

Methyl Siloxanes

Silicone

• Fluids • Lubricants • Emulsions • Resins • Compounds • Elastomers or rubbers 7

Characteristics of silicones

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Fascinating Silicone The missing link

• Combining the characteristics of plastics and glass

Serving customers’ diverse needs…

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LEDs in General Illumination • LEDs hold the possibility for significant energy saving in lighting, efficiency has been always the strong push to change technology in the lighting industry • LEDs holds the potential of replacing all existing technologies, never possible before • First Step: Initial LED implementation expected to occur using incumbent lighting systems(so called LED retrofit) - AC power source -Exiting structure(e.g.E27, A, E, MR16 sockets) - Luminaires w/ modules; new luminaire designs

• Second Step: Full exploitation of LED attributes may require luminaires and systems designed to access the complete set of LED attributes - Optimized around the application, and lighting profile of an LED source - Easier for new constructions(building Integration) or application that does not require a lot of structural changes(e.g. Street Lighting)

General Lighting Market Drivers and Challenges • Market Drivers – – – – –

Efficacy, energy efficiencies Reliability, long lifetimes Cost savings: cost for replacement, maintenance, labor, energy Green consciousness: replacement of fuel, regulations Fixture design and manufacturing

• Technical Challenges (SSL) – Efficacy, energy efficiencies: LEDs with higher efficiencies, efficiency of product design, incl. thermal management, efficiency of power management system, luminaire efficiencies – Product reliability with long lifetime, quality issues – Cost savings: achieve low CoO to expand market penetration, improvements in HB LED price/performance, yield, production efficiency, standardization of interfaces/components – Development of performance, testing and labeling standards – Education of consumers and technicians – Competing lighting technologies: fast-growing CFL market share and mind share – Lifetime may be too long to generate next demand in short-term Source: Strategies Unlimited 2010

Materials Sciences and SSL • The role of materials sciences in the development of solid-state lighting (SSL) is profound, examples include:  Device manufacturing: as semi-conductors, for photonics and electronics; phosphors; dielectrics; metals; getters;  substrates:; as preferred crystal growth substrates; as foils, PCB, laminates and flexi-circuits;  optical elements: lenses, coupling agents; waveguides; luminaires;  Assembly agents: adhesives; potting compounds; barrier layers; interfacial agents; protection; thermal management;

• However, these would well apply to any optical technology, but SSL is a response to society’s drive for more sustainable and efficient technology… 13

Materials Needs for LEDs • Materials development and improvements are instrumental in driving overall cost of ownership down and improving performance to aid in general market adoption • Use of LEDs in lamps and luminaires frequently requires materials that are: – Optically transparent and able to withstand intense light sources – Thermally stable and able to withstand elevated operating temperatures – White and able to reflect light without excessive losses – Protective of sensitive electronic components

Why Silicones in LED General Lighting?

How Are Silicones Special?

High & low temp use

Material

High Temp

Silicones

+150 to 200°C

Epoxies

+150 to 180°C

Urethanes

+115 to 125°C

Acrylics

+85 to 125°C*

Flexible to -45 to -115°C

-60°C 16

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Fascinating Silicone For Electronics

Why silicones excel in electronics 1. 2. 3. 4. 5.

Electrically conducting or non-conducting Thermal management capabilities Optical clarity and light transmittance Adhesion, flexibility, and resilience Resist heat and cold, thermal shock, oxidation, moisture, chemicals, and ultraviolet radiation; perform reliably under harsh conditions 6. More durable than many organic materials; perform longer 7. Flowing, wetting, adhesion, and cure properties that speed and simplify processing; repairable

Dow Corning and the LED Lighting Market • The properties of silicone materials are a natural fit for LED lighting applications • Silicone applications for Lighting are one of the top corporate global priorities

• Dow Corning has made substantial infrastructure additions to support LED expansion • Dow Corning is targeting alignment and collaboration with leading LED / lighting producers around the world to enable the lighting revolution

Where Silicones have been used?

Designing Green with Silicone Materials lower U façade values than mechanically fixed facades

Rooftop planting

evergreen plant shield against sun and wind

weathersealants -> air tightness

automated ventilation control & lighting control using natural light

Photovoltaic energy Collective thermal solar systems

double or triple pane low-e glazing

double skin façade active façade

window Installation system

lighting control using motion detection sensors

higher energy efficiency with bonded doors and windows

LED Development and Manufacturing Materials

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Example of Applications(LED Package)

Example of Applications(Lamps)

Conformal coating

Conformal coating

Remote Phosphor technology has many patents from different companies, Dow Corning is not responsible for the use of this technology , or any IP related subject.

Example of Applications(LED Luminaires) Conformal coating

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Silicones Innovation for Secondary optics

Optical Materials Moldable Optical lenses

Remote Phosphor; Diffuser

Light Guides

White Reflector

Silicones benefits across the entire lighting value chain - Thermal stability - Easy processability -Transparency - Lower cost of ownership - Photo stability - Enhanced Protection - Enhanced light output efficiency - Enhanced reliability and lifetime 26

Thermal Stability of Silicone 200h thermal aging test (4mm thickness) Methyl silicone Phenyl silicone Epoxy

Typical Organic materials used for optical systems in lamps and luminaires, and Silicone resin aged at 200o C for 24 hours

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Features/Benefits of Silicones FEATURES • Good transparency • Medium viscosity for injection molding • Good mold flow for excellent feature reproduction • Easy mixing of additives BENEFITS • Lighter than glass • Easily molded into complex and big shapes • Allow very detailed shapes unlike other optical materials • Better heat resistance than plastic • Less yellowing than some plastic

POTENTIAL USES • Primary or secondary lenses • Light pipes • Light guides • Other optic devices • Remote phosphor designs

Dow Corning® MS-1002 Moldable Silicone Dow Corning® MS-1003 Moldable Silicone

Injection Molding Optical Parts - Benefits • Injection molding is the recommended method of manufacture for these materials • Benefits of injection molding with Silicones: – Precision applications • Micrometer-sized features

– Complex shapes • Undercuts, precise optical lens features, etc.

– Short cycle times (specially in big parts, enables faster production)

– Less steps in production e.g. No melting process, easier to release from mold allowing faster production that might lead to cost reduction.

– No waste(liquid materials) – Possibility of overmold Friendly to use with other materials in a overmold Process(e.g. Glass overmolded on top)

Silicones Innovation for Thermal Interface Materials

Dispensable / Printable Pad Concept • A fabricated pad is one that is coated onto some kind of liner, cured and then cut into pieces for use such as a gap pad (below left). • A dispensable pad is a pad that applied to the application substrate in it’s wet state and cured in place (below right). Pad may be screen/stencil printed or dispensed.

Printable Thermal Pads for LED Lighting

Dispensable Pad Benefits Lower Cost of Ownership – Material is less expensive than fabricated pad (30% – 60%) – Increased throughput may further lower cost of ownership Improved Thermal Performance – Better conformity to surface unevenness – No fiberglass carrier = lower thermal resistance & better compression – Can attain thinner bond lines than fabricated pad Easy To Use – Dispensed or printed through a variety of manual or automated processes Reliable – Soft, compliant, stress relieving, shock dampening Re-workable – Easily removed for rework Versatile – Use as printable pad or dispense like a traditional liquid gap filler

What are the next steps?

Thank You! My contact information: Hugo da Silva Tel.: +32 496121475 mailto:[email protected] www.dowcorning.com/lighting

The information provided in this presentation does not constitute a contractual commitment by Dow Corning. While Dow Corning does its best to assure that information contained in this presentation is accurate and fully up-to-date, Dow Corning does not guarantee or warranty the accuracy or completeness of information provided in this presentation. Dow Corning reserves the right to make improvements, corrections and/or changes to this presentation in the future.

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