Light Emitting Diode (LED) Potting Applications and LED Encapsulants

Optically Clear LED Encapsulation ResinsEpoxy Resin and Polyurethane Compounds for Peerless LED Encapsulation

The demand for LED encapsulants is expected to continue its meteoric rise, fueled by the explosive growth of LED lighting. In 2013, LED lighting was 18% of a $66 billion global lighting market. By 2020, it's expected to comprise 70% of a $100 billion global market.* Packaged LED lighting will dominate the demand.

*Per data cited by General Electric in a 2013 article in Forbes.

Epic Resins specializes in quality LED encapsulation for any industry or application

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.

Order LED Encapsulants     See Our LED Brochure

Epic Resins has been at the forefront of LED encapsulation technologies for decades. One component of our quality is the extensive technical training of our epoxy and polyurethane specialists. Our specialists ensure your epoxy or polyurethane compound lasts as long as the LED light itself. For reliable, cost-effective LED encapsulation, Epic Resins is the answer.

Custom-Made Resins for LED Lighting Manufacturers

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 from the ground up, 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.

Why Epic Resins?

Contact the LED encapsulating resin manufacturers at Epic Resins to get the best polymer for your needs.

LED Encapsulating Compounds Available at Epic Resins:

Epic S7478 - 2 Component Polyurethane LED Potting Compound

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.

Epic S7253 - 2 Component Polyurethane Encapsulation Compound

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.

Epic R1055/H5083 - Modified Epoxy System

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.

Epic S7512 - Thermally Conductive Epoxy

EPIC S7512 is a thermally conductive epoxy potting compound that possesses a long work life and low mixed viscosity that helps to fully encapsulate tight tolerance areas.

Epic S7513 - Thermally Conductive Epoxy

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.

Epic S7144 - 2 Component Polyurethane LED Potting Compound

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.

Epic S7310 - 2 Component Urethane Potting Compound

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 - 2 Component Epoxy Compound

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 - Medium Durometer Polyurethane

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.

Epic S7475 - RoHS Compliant Polyurethane

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.

Epic S7527 - UL 94 V-0 Recognized Polyurethane

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 that will be 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.

LED Encapsulation Improves Applications in Innumerable Industries

Epic Resins LED potting formulations are dynamic. We engineer epoxy and polyurethane solutions varied in hardness, pot life, thermal integrity, temperature tolerance, viscosity and more. Whatever type of LED encapsulation you require, Epic Resins can deliver. We’ve devised polyurethane potting compounds for automotive lights, LED signs, and LED embedded indicators, including Epic S7511.

The chemical engineers at Epic Resins frequently develop custom blend polyurethane compounds that prevent mechanical failure and moisture damage, extending the life of the LED. For applications requiring extreme thermal resistance, we also have epoxies for LED encapsulation.

LED Encapsulant polyurethane compoundOther common LED encapsulation applications include

Request more information and data sheets on industrial LED encapsulation resins & polyurethanes from Epic Resins.

Epic Resins epoxy resin formulations and applications

Epoxy Resin Materials

  • 1 component
  • 2 component
  • Polyurethane potting compounds
  • Electrical potting compounds
  • Thixotropic epoxy compounds
  • Anhydride cure
  • Battery potting compounds
  • Adhesives and bonding materials
  • Polyurethane elastomer
  • Flame Retardant Polyurethane
  • Electronic encapsulation
  • Low hardness polyurethane
  • Aliphatic polyurethane compound
  • UL-Recognized potting compound
  • Thermally conductive epoxy

Benefits of polyurethanes over silicone potting

  • Lower cost of materials results in a more economical polymer
  • Better bond strength to substrates and cases
  • Durable and efficient in optimal operating temperatures range
    • Low temperature: -60°
    • High temperature: 150°C
  • Higher chemical resistance to more chemical compounds
  • Reduced water vapor permeability increases water-resistance of sensitive components
  • More flexible formulation allows polyurethanes to be formulated soft or rigid
  • More strength, elongation, and abrasion resistance
  • Reduced outgassing from material
separation and air filter adhesives
 

Optically Clear Polymer Formulations for LED Encapsulation
Polyurethane Compounds Uniquely Designed to Benefit LED Lighting Systems Epic Resins leads the way in innovati…
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LED Encapsulation and Potting Compound Product Brochure
Epoxy Resin Adhesives and Polyurethane Potting Compounds for LED Manufacturers Epic Resins specializes in e…
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Optically Clear Polymers
LED Encapsulation Brochure
R1055/H5083
Modified Epoxy System
EPIC R1055/H5083 is a UL recognized vacuum grade modified epoxy system with a 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
S7512
One-Component Polyurethane
EPIC S7512 is a thermally conductive epoxy potting compound that possesses a long work life and low mixed viscosity that helps to fully encapsulate tight tolerance areas.
Mixed Viscosity 4,000 – 5,000 cps @ 25°C, 20 RPM
Hardness 88 – 91 Shore D @ 25°C
Application LED Potting & Encapsulating
S7513
One-Component Epoxy
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
D9980
Two-Component Epoxy
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.
Mixed Viscosity 300 – 600 cps @ 25°C, 20 RPM
Hardness 75 – 80 Shore D @ 25°C
Application LED Potting & Encapsulating
S7144
One-Component Polyurethane
EPIC S7144 possesses excellent hydrolytic stability, making this product an excellent choice for use in outdoor LED signage where moisture protection is required.
Mixed Viscosity 250 – 350 cps @ 25°C, 20 RPM
Hardness 77 – 83 Shore D @ 25°C
Application LED Potting & Encapsulating
S7302
Two-Component Polyurethane
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.
Mixed Viscosity 2,500 – 3,500 cps @ 25°C, 20 RPM
Hardness 68 – 72 Shore A @ 25°C
Application LED Potting & Encapsulating
S7475
Two-Component Polyurethane
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.
Mixed Viscosity 3,500 – 4,500 cps @ 25°C, 20 RPM
Hardness 50 – 65 Shore OO @ 25°C
Application LED Potting & Encapsulating
S7478
Two-Component Polyurethane
EPIC S7478 is a flexible, thermally conductive, polyurethane that is UL 94 V-0 recognized in cross-sections as thin as 3 mm and maintains a UL RTI rating of 140°C. EPIC S7478 is useful in applications that generate a significant amount of heat and require environmental protection.
Mixed Viscosity 5,000 – 7,000 cps @ 25°C, 20 RPM
Hardness 75 – 80 Shore A @ 25°C
Application LED Potting & Encapsulating
S7515
One-Component Epoxy
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.
Mixed Viscosity 500 – 700 cps @ 25°C, 20 RPM
Hardness 30 – 35 Shore D @ 25°C
Application LED Potting & Encapsulating
S7524
Two-Component Polyurethane
EPIC 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.
Mixed Viscosity 170 – 230 cps @ 25°C, 20 RPM
Hardness 61 – 65 Shore A @ 25°C
Application LED Potting & Encapsulating
S7527
Two-Component Epoxy
EPIC S7527 is a UL 94 V-0 recognized polyurethane potting compound with excellent thermal and electrical properties. EPIC S7527 is outstanding for potting and encapsulating sensitive electronics that will be 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.
Mixed Viscosity 3,000 – 4,000 cps @ 25°C, 20 RPM
Hardness 88 – 92 Shore A @ 25°C
Application LED Potting & Encapsulating
LED Potting Encapsulants Brochure

Thermally Conductive Epoxy LED Potting

Polyurethane LED potting compound S7144For applications requiring heat transfer, Epic Resins’ epoxy LED potting compounds are engineered for thermal conductivity. They prevent moisture and contamination across a broad temperature range. Regardless of your thermal conductivity or moisture prevention needs, the potting specialists at Epic Resins will help you choose optimal materials for your LED encapsulation.

Solid-State Lighting is the illuminating technology of the future, but tests indicate that SSL technology can be unreliable. Epic Resins has conducted Hammer testing and determined numerous ways improve SSL integrity with better driver design. Selection of appropriate compound is imperative in controlling two common SSL failures: board-level corrosion and solder joint fatigue in the driver circuit.

View our interactive online LED encapsulation potting brochure.

Contact the LED potting material formulators at Epic Resins today for more information on our excellent encapsulating and thermally conductive sealing compounds.