Thermal Management in the LED Lighting Industry

The light-emitting diode (LED) is one of today’s most energy-efficient and rapidly-developing lighting options. These systems are used throughout a number of industries that demand reliability and longevity. Increasingly the LED lighting industry needs durable solutions that can perform well in harsh conditions. LEDs may reach temperatures as high as 3,000-6,000 degrees Kelvin. The junction temperature at the semiconductor has a direct impact on performance. Poor LED thermal management can lead to reduced light output, color shift and reduced lifetime of the LED.

In order to keep LEDs cool to the touch and protect components within lighting, LED lighting needs innovative thermal management solutions. An additional thermal management challenge is compaction and shrinking designs. To protect these smaller designs throughout the lighting industry, effective LED thermal management is a design requirement. Gap fillers, dielectric pads and other thermal interface materials are used to maintain optimal operating temperatures, preventing premature failure and maintain preferred surface temperatures.

Polymer Science, Inc. offers a complete line of P-THERM® Thermal Interface Materials that are designed to efficiently and effectively aid in LED lighting and other electronic designs. We offer a multitude of thermal gap fillers, as well as, dielectric pads for all of your LED lighting needs. 

Dielectric Pads

Our P-THERM® ECIs offer good dielectric and thermally conductive properties without the worry of flow from wax-based products or mess associated with thermal grease.  The natural tack of the materials mitigate movement during assembly. Pads are a cost effective method to manage the heat generated by LED components.

Thermal Gap Fillers

Polymer Science provides a comprehensive range of thermally conductive gap filler materials in both silicone and non-silicone formulations. Our P-THERM® gap filler materials are available in a variety of thermal conductivities, hardnesses and thicknesses to meet the thermal management needs of advanced LED lighting designs. 

Our materials have been designed to achieve the desired heat management properties, ensuring that components are kept at optimized operating temperatures for improved performance and longevity. Gap fillers offer good surface wetting and conform to irregular surfaces.

Polymer Science is able to supply P-THERM® Gap Filler materials on rolls, providing maximum material yield. With a range of options available, we can provide customized solutions that are tailored to the specific needs of LED lighting manufacturers, helping them achieve the best performance and reliability for their products.

Two-Part Dispensable Gap Fillers

P-THERM® two-part dispensables offer a lightweight and thin bond line that is highly effective in compact LED lighting systems. Dispensables offer a durable solution especially compared to thermal grease which can bleed out or migrate over time. Dispensables can aid thermal management in the LED lighting industry offering weight reduction, minimal thickness profile and low thermal resistance. These gap fillers are preferred across many industries where designs are becoming more compact.

Two-part dispensable gap fillers are ideally suited to the most intricate LED designs and complex manufacturing processes as well. The curing time and viscosity can be adjusted which benefits many LED manufacturing processes. Dispensables can help reduce material waste and improve efficiency. For both performance and manufacturing, dispensable gap fillers are an effective solution for the LED lighting industry.


Generally, LED lighting is both more energy efficient and has a longer lifespan than traditional bulbs. Polymer Science’s P-THERM® products meet the demands for durability, design flexibility and the environmental benefits associated with LED lighting. As LED technology continues to advance, our staff is eager to work with our current partners and new industries. 

Some of the applications and manufacturers we help: 

Aviation Lighting


Traffic Signals

Automotive Lighting


Residential and Commercial Lighting


Electronic Displays

Polymer Science Advantages

At Polymer Science we offer the LED lighting industry and all of our clients exceptional support. Our advantages include a lower minimum order quantity and customization of width on rolls to minimize waste. We offer short lead times to help manufacturers reduce downtime and increase productivity. Our eco-friendly facility reflects our commitment to sustainability and environmental responsibility. We also offer design support to help you achieve the best possible performance and select the ideal thermal management solution for LED lighting systems.