Leader in The Development And Production of Secondary Optics Made of LSR Since 2010

Dr. Christian Todaro

Abstract

1. Liquid Silicone Rubber (LSR): a challenging material for optical components

2. Applications and case studies:

i. Street lighting

• Realization of Street Lighting applications without glass protection: Advantages

• Nactus 6 x 2 SIL: IP and IK properties of LSR

ii. UV Lighting

• KESQ2145XXSR lenses: Transmission properties of LSR

iii. Poultry farm lighting

• SIO3 lenses: Resistance to chemical agents

iv. Stage and Architectural lighting

• Advantages of LSR for the production of large secondary optics

• Case Study: PLL2066XXSR Silicone lenses for color mixing

• Case Study: The new window lens

v. Outdoor lighting

• SIO3 and SIO3 JR: Non-yellowing properties of LSR

vi. Lighting in extreme environments

• Thermal resistance of LSR

vii. Aerospace lighting

• LSR Stress resistance in harsh conditions

3. The production process

4. New Products

5. Khatod : history of our company since 1985

Silicone (LSR)A challenging material for optical components

The demand for better optical performance combined with newshapes makes the Liquid Silicone Rubber (LSR) an excellentsolution to provide optical clarity, durability and design freedomsuch as to enable even the realization of micro-structures incompact shapes.

LSR provides high temperature stability, 94% light transmissionand excellent UV and blue light stability. As for the productionprocess, LSR is processed by injection molding for themanufacturing of complex shapes, micro-structures and opticaltextures.

Street Lighting

Realization of Street Lighting applications without glass protection

AdvantagesHigh temperature resistance up to 200°C

IK RESISTANCE

IP RESISTENCE

Flexibility, easy to mount

Low absorption over a wide range of wavelength

High optical stability and transparency

UV-resistant, low yellowing factor

Realization of Street Lighting applications without glass protection

37 standard beam angles available on stock

85 customized beam angles available

Realization of Street Lighting applications without glass protection

NACTUS 2X6 LSR: IP AND IK PROPERTIES OF THE LSR

UV Applications

KESQ2145XXSR lenses: Transmission properties of LSR

Khatod’s KESQ2145NASR Lens

UV Lighting: enhancing LSR transmission

Khatod’s LSR optics can reach 90% transmittance at290nm (UVA-UVB) wavelenght

UV APPLICATIONS Main Applications

UV gluing

UV curing

UV marking

UV drying of printing inks and lacquers

Currency inspection

Forensic analysis - urine, protein stains

Leak detection using fluorescent dyes

Fluorescing minerals and gems detection

Indoor Lighting

Outdoor Lighting

Poultry Farms and Horticultural Lighting

Poultry and Horticulture farms: examples of resistance to chemical agents

LSR material withstands several acids and chemical solutions. The resistance to a selection of chemicals is shown in the following table. The data refer to a transparent vulcanizate having a approx. 50 shore hardness, which confirms the suitability of Silopren® LSR for use with the chemicals in the following list.

Poultry and Horticulture farms: examples of resistance to chemical agentsChemical Test temperature °C Silopren®- LSR Change in Shore-hardness Swelling, Vol.-%

Acetone 20 2050 -8 33Ammonia, 25% aqueous solution 20 2050 3 4Baysilone Fluid M10 (100cSt at 25°C) 150 2050 -10 72Carbon tetrachloride 20 2050 -40 192Chloroform 20 2050 -12 218Cyclohexane 20 2050 -10 10Ethanol 20 2050 -5 10Ethyl acetate 20 2050 -11 113Glacial acetic acid 20 2050 -2 128Glycol 20 2050 0 0Hydrochloric acid 20%ig 20 2050 0 0Methanol 20 2050 -3 8Methyl ethyl ketone 20 2050 -10 80Methylene chloride 20 2050 -10 103Mineral oil ASTM Nr.2 150, 72 h 2050 -4 9Mineral oil ASTM Nr.3 150, 72 h 2050 -12 42n-Butanol 20 2050 -8 19Nitric acid 10%ig 20 2050 0 0Olive oil 100 2050 0 0Petroleum ether 20 2050 -10 237Phosphoric acid 50%ig 20 2050 0 0Sodium hydroxide solution 20%ig 20 2050 0 0Sulphuric acid 20%ig 20 2050 0 1Trichloroethylene 20 2050 -13 150Vaseline 100 2050 -8 14Xylene 20 2050 -20 127

Swelling of Silopren LSR by chemicals (immersion 8 days)

Poultry and Horticulture farms: examples of resistance to chemical agents

Here is a list of commonly-used disinfectants used in poultry farms:• Quaternary ammonium compound• Halogens• Alcohols• Oxidizing agents• Phenols• Aldehydes

Khatod silicone lenses are high-resistant with most of the above materials and enable safe use of luminaries under those conditions.

Stage and Architectural Lighting

Stage Lighting: advantages of LSR for the production of large secondary optics

THE CAUSE The need for larger secondary optics comes from the market trend to use bigger LED clusters and from the continuous pursuit of narrower beams.

THE SOLUTION Silicone LSR allows to create larger optics by minimizing production costs. The Silicone production process is considerably more advantageous both in terms of volume (production capability) and final costs compared to the traditional polymers despite the higher cost of LSR as a raw material.

Stage Lighting: advantages of LSR for the production of large secondary optics

Example of a customized 9-LED cluster with 6 different color LEDs

The New PLL2066XXSR Series

Standard color mix LED available on the market

Thanks to this innovative optics you will be free to build up your own Multicolor or Dynamic White LED cluster as well as to use

these optics with standard clusters available on the market.

Stage Lighting: advantages of LSR for the production of large secondary optics

Silicone TIR LensFlange diameter: 70mmTotal height: 57mm

The New PLL2066XXSR Series

Stage Lighting: advantages of LSR for the production of large secondary optics

Beam angle: 6.3°

Field angle 11.3°Efficiency 88%

Polar diagram with PLL2066NASR lens

Case studyRGBW & Dynamic

White lens for Windows & Doors

applications

Source 4 Color LEDs in single row

Beam Angle Minor axis: as narrow as possible; major axis 160° - 180°

MaterialOptical Grade Silicone

Pockets for connectors and/or components

Fixing Plastic frame and screws

IP 65/66

IK10

Low Profile: Only 23X23X698mm (non-invasive)

RGBW lens for Windows & Doors applications

Mechanical dimensions Fixed LEDs Alignment

Height: 30mm

Base: 50mm

RGBW lens for Windows & Doors applicationsPhotometry

Beam3° x 100° FWHM 7° x 170° at 10%

Efficiency65% considering black

side walls for better beam precision

RGBW lens for Windows & Doors applications

Color Mix All the LEDs on Blue and Green Blue and Red Red and Green Red – Green – Blue White and Blue

Aerospace and Special Applications

Aerospace and special applications: stress resistance in harsh conditions

LSR material is characterized by flexibility and excellentstress resistance. Its IK10.2 compliance and the resistanceto a wide range of temperatures (-40°C up to 200°C) make it the perfect solution for aerospace applications.

Aerospace and special applications: stress resistance in harsh conditions

Khatod SIO3 Lenses used for indoor illumination of Boeing 777 aircrafts

Outdoor lighting

Outdoor lighting: non-yellowing features of LSR

Outdoor lighting: non-yellowing features of LSR

Outdoor lighting: non-yellowing features of LSR Yellowness change over 6,480 h @ 150 °C – consistent yellowness index even

at high temperature with longer time

Outdoor lighting: non-yellowing features of LSR Yellowing change over 6,480 h @ 150 °C – consistent yellowing index even

at high temperature with longer time

The Production process

LSR: A QUICK OVERVIEW

LSR is a bi-component material.A special plate pump brings the two materials

with the right proportion into an injection machine

Production process and mold construction

The two components remain separated until reach the mixer andthen injected into the mold. Curing starts into the mixer at roomtemperature and will continue inside the mold in a temperature-controlled environment.

Production process and mold construction

The curing process is carried out at around 150°C temperature. For a correct process, the mold cavities are under vacuum.

Production process and mold construction

100% Inside Tooling

Resistance to extreme temperatures

Resistance to extreme temperatures: outdoor

Optics / Lens Material

Maximum Operating Temperature

PMMA Operating temperature up to 85°

PMMA HT Operating Temperature up to 120°

PMMI/TT70 Operating temperature up to 160°

POLYCARBONATE

Operating Temperature up to 120°

Ultra Clear Silicone

Operating Temperature -100°/200°C

OPERATING TEMPERATURE

Our SIO3 lenses can work with 500Watts COBs having

36mm LES. The high temperature released at the

junction will not affectmechanical and optical features of the optics.

Moreover the silicone lens isable to absorb the generatedheat and release it outdoor.

Resistance to extremetemperatures

Khatod: our History since 1985

The Awards: a history of success from all over the world 2014: ELEKTRA AWARD

Won with SIO3 Silicone Lenses

2015 SAPPHIRE AWARDS Won with SIO3 Silicone Lenses

2019: SAPPHIRE AWARDS Won with NACTUS 6x2 SIL

2014: ASSODEL AWARD Won with SIO3 Silicone Lenses

2015: EM BEST OF INDUSTRY AWARDS IN BEST OPTICS INNOVATION Won as Best Optics Innovator with SIO3, GAIA, NEMA lenses, EASY Reflectors

2018: EM BEST OF INDUSTRY AWARDS Won as Best Optics Innovator

2019: EM BEST OF INDUSTRY AWARDS IN BEST OPTICS INNOVATION Won as Best Optics Innovator, NACTUS 6x2 TIR, NACTUS 24 mini

2016: EM BEST OF INDUSTRY AWARDS IN BEST OPTICS INNOVATION Won as Best Optics Innovator, with SIR50, SIO3, GAIA lenses

Khatod: our history 1985

New Products Silicone Lens Diameter 50

mm

Silicone Lens Diameter 65

mm

Dynamic White Silicone Lens 70mm

UV Silicone lens 20 mm

Applications for the new Silicone LensesDynamic White Museums and Galleries

UV Curing Operation Theatres

USASales office & Stock

HeadquarterMilan, Italy

RussiaSales office

IndiaSales office & Stock

JapanSales office

FranceSales office

United KingdomSales office

BrazilSales office

Sales and Stock

THANK YOU!