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ATEX and IEC Ex Flame-proof Explosion Proof Lighting & Equipment
Explosion Proof Lights
Explosion Proof Motors - Motors for Hazardous Locations
Industrial and Vaporproof Emergency Failsafe Lighting
Industrial Cord Reels and Tool Taps
Industrial Work Area Heaters
Machine Vision Lights
QC Series Industrial Portable Lighting - Quick Change Mount
Rig Lights
Stadium lights
String Lights and Temporary Light Stringers
Tank Cleaning Lights
Three Phase Motor Soft Starters
Vapor Proof LED Lights
Variable Frequency Drives (VFDs)
Vehicle Mounting Plates
Workboat Light Fixtures & Lighting Equipment
Yacht Engine Room Lights
Color Changing LED RGB Lighting
Explosion Proof Cord Reels
GOLIGHT Spotlights
Larson FUTURE - Lease Lighting
Remote Area Lighting and Scene Lights
Utility Bucket Mount, Receiver Hitch & Trailer Mount Lighting
Aevum Control Lighting and Equipment - IIoT
Butane and Solvent Extraction Room Lighting and Equipment
DC to DC Transformers and Power Supplies
Explosion Proof Fans & Blowers
Explosion Proof Paint Spray Booth Approved Lights
Explosion Proof String Lights
Explosion Proof Switchgear & Controls
Fleet Service Lights and Lighting Equipment
Industrial Equipment Trailers
Industrial Handlamps & Droplights
ISO 14644/FS-209E Clean Room Lighting
LED Blasting Lights
Night Time Fishing Lights
Portable AC Power Supply Units
Portable Power Distribution Panels
Power Distribution Panels with KVA Transformers
Self-Contained Lighting
Service Pit Lighting
Solar Generators & Solar Powered Lighting
Agricultural Farm Equipment Lighting & Beacons
Explosion Proof Cameras & Surveillance Systems
Explosion Proof Emergency Lights
Explosion Proof Heaters
Garage & Gas Station Canopy Lights
LED Grow Lights
LED Lights
NDT Ultraviolet Lights
Portable Hazardous Location Lighting
Radio Communication Towers and Equipment
Salt Water Processing Equipment
Shelter & Tent Lighting
Thermal Monitoring Cameras and Systems
48V LED Equipment Lights
ATEX Rated Explosion Proof Lights
Automotive Lighting
Class Rated Signals, Alarms, and Systems
Hazardous Location Area Lights and Portable Lighting
HID Equipment Lights
Hot Work Permit Lighting and Equipment
Hunting Lights
Industrial lasers
Industrial Transformers
Light Towers
Outdoor Lighting
Remote Security and Surveillance Systems
Temporary Construction Lights
Vehicle Mounted Spotlights
Equipment & Heavy Machinery LED Light Package Fitouts
Phase Converters - Single to Three Phase
Marine Shore Power Cords and Equipment
24 Volt Military Lights
Disaster Relief / First Responders / Search & Rescue Lighting
Plastic Handcuff Key
110/120 Volt Flood Lights
Post Mount Spotlights
Magnetic Work Lights
Crank-up Light Masts
Intrinsically Safe Lights
Military Flashlights
LED Waterproof Lanterns
Work Area Lights
12 Volt Flood Lights
Boat Spotlights
New Boat Lights
HID Boat Lights
Boat Dock Lights
Remote Control Lights
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Magnetic Control Lights
NEW Lights and New Products
Evaporative Coolers
Police Equipment
AC/DC Transformers
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Military Spotlights 24V
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Military Equipment
Ultralife Batteries
Remote Control Pan Tilt Base
Larson Electronics Spotlights
Larson Electronics Parts
Replacement Lamps
Cords - Brackets
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HID Work Lights
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Acro Lights HID Lights
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Powerlight Flashlight
HID Flashlights
Xenon Flashlights
LED Status Lights
Forklift Lights
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Flashlight Holder
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Magnetic Spotlights
12/24 Volt Spotlights
Gifts For Men
New 12 / 24 Volt Lights
Explosion Proof Accessories and Replacement Parts
Explosion Proof Lighting
Explosion Proof Hand Lamps (Drop Lights)
Explosion Proof Lights - Stand/Dolly
Explosion Proof Tank Lights
Explosion Proof Phones and Intercoms
Explosion Proof Extension Cords
Black Friday & Cyber Monday Specials
Crane Lights
Explosion Proof Light Rentals
General Light Rentals
Light Tower and Light Plant Rentals
Power Distribution Rentals
Power Plant Lighting
Refinery lights
Environmental Services Lights
Aerospace Lights
Chemical Plant Lights
Food Grade Safe Lights
Film and Entertainment Lights
Handheld Meters and Devices
Waste Water Treatment Lights
Mining Lights
Ship Yard Lights
Work Site Lighting

04/05/17 The State of Carbon Fiber for Thermal Dissipation in LEDs

Article - April 7, 2016 By

120VAC LED Flood Light on Adjustable 200lb. Grip Magnetic Base - 6, 1-Watt LEDs - 50' SOOW Cord

The State of Carbon Fiber for Thermal Dissipation in LEDs

Light emitting diodes (LEDs) require efficient heat sinks in order to operate consistently. In an attempt to remedy concerns surrounding the efficiency of such components and to create a solid foundation for high-powered LED variants, manufacturers have been exploring new materials with exceptional thermal dissipating properties.

Specifically, researchers have veered away from metals (copper and aluminum), and have started to focus on non-metals (thermoplastics, carbon fiber and graphite), as well as combinations of metal and non-metal materials.

An example of this breakthrough comes from Korea Electronics Technology Institute. Scientists from the organization released a case study that showed the thermally conductive attributes of carbon nano-fibers (CNFs) in LEDs. The researchers used the material to create a new type of heat sink that is lightweight and inexpensive without compromising performance. The results of the study showed that CNF-mixed epoxy, when applied to LED heat sinks, can improve thermal conductivity by up to 140 percent.

Carbon Fiber Heat Dissipation Properties

Carbon fiber has superior thermal management features. It boasts low thermal resistance- up to 40 percent lower than mainstream aluminum. The material can reach heat resistance thresholds as high as 400 degrees Celsius. This makes it applicable for high-powered LED luminaries in extreme temperature environments. Previously, die-cast aluminum was the heat sink material of choice; but from a manufacturing perspective, the material was difficult and complex to work with, which caused scaling issues for industrial lighting businesses.

Below are the general properties of carbon fiber:

• Corrosion resistance

• Electrical conductivity

• Fire resistance

• Exceptional thermal conductivity

• Non-poisonous

• Low coefficient of thermal expansion

The robust material is also up to 25 percent lighter than aluminum and is equipped with a higher strength-to-weight ratio, compared to conventional metals, giving designers more flexibility to incorporate other components in the fixtures. It is crucial to consider that large and heavy lamps pose serious risks during installation. Furthermore, such negative features contribute to poor wind and vibration resistance. Heavy fixtures are also more difficult to transport in bulk.

Carbon Fiber as a Secondary Component

Carbon fiber is very versatile, and can be combined with other materials to create effective heat dissipating components. Teijin, a Japan-based synthetic fibers technology company, is a pioneer in the application of carbon fiber mixtures in LEDs. The group created a material called Raheama: a thermal-management sheet that is composed of 50-200 micrometer fibers from a graphite fiber stock that measures roughly eight micrometers. It is a carbon fiber heat-conductive filler that conducts high temperatures more efficiently than metals (such as copper or silver).

Raheama contains low thermal coefficient expansion rates- lower than ceramics, making it suitable for applications where stability is needed. The company designed the carbon fiber filler specifically for LEDs. Scientists used the material with polycarbonate sheets to create a heat sink that can disperse heat on the same level as aluminum, without the added weight. It comes in two variants- R-A201 and R-A301. The first option is suitable for components that require high level molding, while the latter contains high heat radiation properties.

Another material that was traditionally used for heat sinks in LEDs was copper. The metal was effective in mitigating heat, but the material was also expensive. It has a coefficient of 16.6 (10-6 m/m K), compared to carbon fiber- which can reach as low as zero. Low coefficient of thermal expansion is important in heat dissipation, because it allows the component to tolerate varying levels of heat without warping or expanding. Recently, manufacturers have combined copper with carbon fiber and/or other graphitic products to increase a heat sink’s tolerance to high temperatures.

By comparison, mixing aluminum and carbon is not recommended, because the combination creates a galvanic couple, which causes rapid corrosion. Because of this, copper is suitable for such pairings. Carbon fiber conductivity is known to present problems in marine environments, due to its ability to facilitate galvanic corrosion in fittings.

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