Benefits of LED encapsulation include:
Some of the most common LED encapsulation applications include:
Our epoxy and polyurethane resin formulations insulate fragile wire bonds from moisture, thermal shock, vibration, and other potentially damaging conditions. Liquid epoxy is poured into the LED chamber and bracketed to the desired shape. Our high-efficiency ovens then cure the mold. Epic Resins' epoxy manufacturing process exceeds all industry expectations for quality, cost, and dependability.
Epic Resins' expert formulators excel in customizing formulations to fit the specific needs of our customers. If you see an Epic Resins compound that doesn't entirely fit your needs, we'll adjust the formula to work with your unique product properties. Our advanced development and testing labs allow us to create new formulas, so LED lighting manufacturers are certain to find the perfect epoxy or polyurethane compound for their products.
Epic Resins has decades of experience in specialty epoxy and polyurethane resins. Our professional staff uses superior customer service to work with clients to solidify their manufacturing production process. Our expertise provides clients the ability to maximize proactive product development and supply consistency to achieve maximum value, in both short production runs and ongoing industrial bulk supply needs.
Epic S7470 is a series of two component urethane adhesives. This series features a convenient 1:1 volumetric mix ratio with a light paste consistency for easy workability. S7470 has been formulated to provide adhesion to a variety of substrates including plastic and metal surfaces. For example, S7470 can be used in battery bonding, connector potting and as an LED lens adhesive. This series is available in a wide variety of colors, viscosities and gel times.
| Viscosity: | 65,000 - 70,000 cps @ 25°C, 20 RPM |
| Hardness: | 87 – 91 (1 hour @ 135°C) Shore D |
| Application: | End-Cap Adhesives |
Epic S7478 series is a two-component polyurethane potting compound designed for use in high-temperature applications. Epic S7478 is UL 94 V-0 recognized in a thin cross-section without the use of halogen flame retardants and offers a 140°C RTI recognized by UL. The Epic S7478 works extremely well for LED drivers that must meet the requirements of UL 8750 safety standards for LED equipment in lighting products, damp location drivers, electrical encapsulation, signs and many other electrical potting applications. For more technical information on Epic S7478, please view the brochure.
| Viscosity: | 5,000 – 7,000 cps @ 25°C, 20 RPM |
| Hardness: | 75 – 80 Shore A @ 25°C |
| Application: | LED Potting & Encapsulating |
Epic S7253 series of products are two-component polyurethane encapsulation compounds that are recognized by Underwriter's Laboratories as flame retardant materials. The S7253 series of LED potting urethanes are available in a variety of colors and gel times. The S7253 series of polyurethane LED encapsulants have a low mixed viscosity and good thermal conductivity.
S7524 is a transparent, UL 94 V-0 recognized, polyurethane potting compound. This system is unfilled and is excellent for applications requiring low mixed viscosity for better flow into tight tolerance areas. EPIC S7524 would be an excellent choice for White Goods applications, sensor potting, switches and control modules.
| Viscosity: | 170 – 230 cps @ 25°C, 20 RPM |
| Hardness: | 61 – 65 Shore A @ 25°C |
| Application: | LED Potting & Encapsulating |
EPIC R1055/H5083 is a UL recognized vacuum grade modified epoxy system with 180°C RTI. Low mixed viscosity and a long gel time allow this material to achieve 100% penetration of tightly wound coils and tight tolerance spaces in potting applications.
| Viscosity: | 2,300 – 3,300 cps @ 25°C, 20 RPM |
| Hardness: | 85 – 90 Shore D @ 25°C |
| Application: | LED Potting & Encapsulating |
EPIC S7512 is a thermally conductive epoxy potting compound that possesses a long work life and low mixed viscosity to fully encapsulate tight tolerance areas.
| Viscosity: | 4,000 – 5,000 cps @ 25°C, 20 RPM |
| Hardness: | 88 – 91 Shore D @ 25°C |
| Application: | LED Potting & Encapsulating |
EPIC S7513 is a thermally conductive epoxy potting and casting compound with a low coefficient of thermal expansion (CTE) and low mixed viscosity, allowing penetration of intricate areas of electronics applications while reducing stress to delicate components during thermal cycling.
| Viscosity: | 2,500 – 3,500 cps @ 25°C, 20 RPM |
| Hardness: | 84 – 87 Shore D @ 25°C |
| Application: | LED Potting & Encapsulating |
EPIC S7515 is an optically clear aliphatic polyurethane that has exceptional UV resistance. Low mixed viscosity and short gel time allow for easy air release and quick turnover of parts in high volume production settings.
| Viscosity: | 500 – 700 cps @ 25°C, 20 RPM |
| Hardness: | 30 – 35 Shore D @ 25°C |
| Application: | LED Potting & Encapsulating |
Epic S7144 series of products are two-component polyurethane LED potting compounds that are formulated in a variety of colors and gel times. The S7144 series of products are designed with a meter mix friendly 3:1 ratio by volume, a Shore A Hardness of 80, and good hydrolytic stability for LED encapsulation applications.
| Viscosity: | 250 – 350 cps @ 25°C, 20 RPM |
| Hardness: | 77 – 83 Shore D @ 25°C |
| Application: | LED Potting & Encapsulating |
Epic S7310 is a black two-component urethane compound featuring low viscosity, a 1:1 volumetric mixing ratio, good resin/hardener compatibility, and good durometer stability after being exposed to elevated temperatures.
Epic S7160 is a two-component clear epoxy system designed for coating or encapsulating a variety of substrates. S7160 features a low viscosity and long pot life to provide air bubble-free castings.
EPIC S7302 is a medium durometer polyurethane potting compound used in applications that are subject to regular thermal cycling between -70°C and 135°C with short excursions up to 160°C. EPIC S7302 has low viscosity allowing excellent penetration as well as good adhesion to both plastic and metal case materials.
| Viscosity: | 2,500 – 3,500 cps @ 25°C, 20 RPM |
| Hardness: | 68 – 72 Shore A @ 25°C |
| Application: | LED Potting & Encapsulating |
EPIC S7475 is a premium, RoHS compliant, polyurethane potting compound that is UL 94 V-0 recognized. Low mixed viscosity allows this material to flow under PCB's and into tight tolerance areas. EPIC S7475 is suited for applications that will see constant thermal cycling due to its very low glass transition temperature and soft durometer.
| Viscosity: | 3,500 – 4,500 cps @ 25°C, 20 RPM |
| Hardness: | 50 – 65 Shore OO @ 25°C |
| Application: | LED Potting & Encapsulating |
EPIC S7527 is a UL 94 V-0 recognized polyurethane potting compound with excellent thermal and electrical properties. EPIC S7527 is outstanding for potting encapsulating sensitive electronics exposed to outdoor environments. EPIC S7527 is designed for use in equipment conforming to UL 8750, the standard for LED equipment for use in lighting products. This polyurethane has undergone extensive UL testing and has achieved a 150°C RTI rating, a rating previously unavailable with flexible polyurethane potting compounds.
| Viscosity: | 3,000 – 4,000 cps @ 25°C, 20 RPM |
| Hardness: | 88 – 92 Shore A @ 25°C |
| Application: | LED Potting & Encapsulating |
EPIC D9980 is a rigid, two-component aliphatic polyurethane designed to be UV stable, optically clear and display minimal color change and high gloss retention after 1,000 hours of accelerated weather testing. EPIC D9980 has been used in applications that operate up to 130°C.
| Viscosity: | 300 – 600 cps @ 25°C, 20 RPM |
| Hardness: | 75 – 80 Shore D @ 25°C |
| Product | UL Recognized | Mix Ratio by Weight (A:B) | Mix Ratio by Volume (A:B) | Mixed Viscosity @ 25°C, 20 RPM (cps) | Gel Time @ 25°C | Glass Transition Temp. (Tg) |
| Epoxies | ||||||
| R1055/H5083 | Yes | 100:18 | 3.25:1 | 2,300 - 3,300 | 300 - 360 Min (100 Grams) | 70 - 80 °C |
| S7512 | No | 100:9 | 100:22.1 | 4,000 - 5,000 | 150 - 260 Min (100 Grams) | 48 - 52 °C |
| S7513 | No | 100:14.2 | 4:1 | 2,500 - 3,500 | 100 - 250 Min (100 Grams) | 40 - 45 °C |
| Polyurethanes | ||||||
| D9980-01 | No | 100:97 | 1:1 | 300 - 600 | 10 - 20 Min (100 Grams) | 19 - 24 °C |
| S7144 | No | 100:43 | 3:1 | 250 - 350 | 25 - 35 Min (100 Grams) | (-21) - (-65) °C |
| S7302 | No | 100:19.5 | 4:1 | 2,500 - 3,500 | 45 - 55 Min (100 Grams) | (-70) - (-65) °C |
| S7475 | Yes | 100:17 | 4:1 | 3,500 - 4,500 | 40 - 50 Min (100 Grams) | -55 °C |
| S7478 | Yes | 100:8.52 | 100:12 | 5,000 - 7,000 | 25 - 35 Min (100 Grams) | (-5) - (-10) °C |
| S7515 | No | 51.5:100 | 1:2 | 500 - 700 | 5 - 10 Min (13 Grams) | 25 - 30 °C |
| S7524 | Yes | 100:58.4 | 2:1 | 170 - 230 | 20 - 35 Min (100 Grams) | (-19) - (-15) °C |
| S7527 | Yes | 100:16.7 | 5:1 | 3,000 - 4,000 | 30 - 50 Min (100 Grams) | (-2.5) - (-1.52) °C |
| Product | Coefficient of Thermal Expansion (CTE)(EXP‑6) in/in °C | Dielectric Strength (volts/mil) | Dissipation Factor (100 kHz) | Volume Resistivity (ohm‑cm) | Shore Hardness @ 25°C |
| Epoxies | |||||
| R1055/H5083 | 43 - 47 | 550 @ 0.080" | 0.020 - 0.022 | 1.90e+15 - 2.10e+15 | 85 - 90 D |
| S7512 | 34 - 37 | 410 @ 0.100" | 0.015 - 0.025 | 2.00e+15 - 2.50e+15 | 88 - 91 D |
| S7513 | 35 - 45 | 510 @ 0.100" | 0.020 - 0.040 | 1.50e+15 - 2.00e+15 | 84 - 87 D |
| Polyurethanes | |||||
| D9980-01 | 85 - 95 | 385 @ 0.100" | 0.014 - 0.018 | 1.00e+15 - 1.20e+15 | 75 - 80 D |
| S7144 | 190 - 210 | 420 @ 0.125" | 0.042 - 0.046 | 1.10e+13 - 1.20e+13 | 77 - 83 A |
| S7302 | 175 - 190 | 365 @ 0.125" | 0.020 - 0.030 | 2.40e+12 - 2.80e+12 | 68 - 72 A |
| S7475 | 355 - 365 | 472 @ 0.095" | 0.010 - 0.011 | 2.70e+12 - 2.80e+12 | 50 - 65 OO |
| S7478 | 100 - 130 | 450 @ 0.100" | 0.040 - 0.070 | 1.50e+12 - 2.00e+15 | 75 - 80 A |
| S7515 | 200 - 250 | 340 @ 0.100" | 0.040 - 0.060 | 1.00e+11 - 1.50e+11 | 30 - 35 D |
| S7524 | 285 - 295 | 422 @ 0.102" | 0.105 - 0.125 | 1.80e+12 - 2.00e+12 | 61 - 65 A |
| S7527 | 165 - 175 | 855 @ 0.033" | 0.025 - 0.032 | 3.10e+14 - 3.40e+14 | 88 - 92 A |
Epic Resins has decades of experience in epoxy and polyurethane resins. We will work directly with you to recommend or develop formulations with the specific characteristics your product requires. With our advanced testing procedures, formulations and fast turnaround times, you're sure to find what you need with us.
