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INNOVATION | OPTICAL MOULDING : O


Right: Dow has developed Dowsil EI-2888 primerless silicone


encapsulant, an optically-clear silicone for pro- fessional LED lighting that cures at room temperature


Langwald, Business Development Director Automotive. “For automo- tive, this includes new light concepts for vehicle head- lights. These LSR active safety features, such as glare-free headlights, are considered to be highly innovative. The future development of autonomous vehicles will also prompt demand for more integrated LSR electronic components under the hood and within the vehicle interior. “LSR involves using thinner, more


durable and safer materials and integrating electronics, mechatronics and optics. The reason why LSR works so well for automotive applications is the material is weather and UV resistant, can withstand high and low temperatures, and damp- ness. LSR also enables manufacturers adopting this technology to achieve component geometries and technical features not previously possible, such as moulding microstructures on the surface of an LSR headlight.”


Moulding LSR requires greater precision and


Below: Four thermo-optical resins from SABIC have been added in the materials database of the Zemax OpticStudio, the industry- standard in software for designing


optical systems


process stability. “Machines with direct-drive servo motors, including the IntElect series, are designed to achieve extremely precise shot control with the low-viscosity material,” says Langwald. “Units can be modified with a special screw geometry and non-return valve (activeLock) to achieve high repeatability with the precision LSR requires. Being able to combine LSR with technical plastics to create one fully bonded component is another exciting development. It will be feasible to com- bine two, three or more individual materials into one seamless, robust component, which offers vehicle designers huge opportunities. For LSR applications, the high precision IntElect range


offers the perfect solution in terms of precision and repeatability. IntElect S machines boast injection speeds of up to 500 mm/s. The standard IntElect line goes up to 200 mm/s.” Dow has developed Dowsil EI-2888 primerless silicone encapsulant, an optically-clear silicone for professional LED lighting that


cures at room temperature. The company says that the advanced silicone technology provides good optical performance without compromise


and offers unique rheological properties for use with light fixtures in a variety of shapes and forms. Designed for explosion-proof and high ingress protection-rated luminaires, the company says that Dowsil EI-2888 is also cost-effective to buy and use as its patented composition does not contain platinum – unlike other silicone solutions currently available on the market. “LED luminaires in harsh environments need


protective materials that are reliable, easy to apply, and that provide robustness of cure,” says Konstan- tin Sobolev, Strategic Marketing Manager for Dow. “Dowsil EI-2888 primerless silicone encapsulant eliminates a time-consuming processing step and reduces waste that can occur if curing is compro- mised by surface contaminants or moisture. This low-viscosity silicone also dispenses readily and adheres reliably without sacrificing optical proper- ties. Dowsil EI-2888 is an excellent choice for many professional applications, including explosion proof lighting, outdoor displays, and flexible and rigid LED strips.” A two-part protective material with a 1:1 mix


ratio, Dowsil EI-2888 cures at room temperature with optional heat acceleration. The UL 94 compli- ant, 100% polydimethylsiloxane (PDMS) silicone provides even curing and is insensitive to inhibi- tion, a typical issue for platinum catalyst, and material reversion, a traditional problem in en- closed spaces at high temperatures. It can be applied with automated static or dynamic metered mixing, manual mixing, or with flow, pour or needle dispensing equipment. The self-priming encapsu- lant adheres to a variety of substrates and supports the design of innovative LED luminaires in IP-rated enclosures. Four thermo-optical resins from SABIC have been added to the materials database of the Zemax OpticStudio, the industry-standard in software for designing optical systems. These


22 INJECTION WORLD | September 2019 www.injectionworld.com


PHOTO: SABIC


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