Smart Molding International 2-2021

materials 45 www.smart-molding.com C ovestro has developed an in - novative automotive headlight concept for the vehicle lighting of tomorrow. The visionary approach is based on different types of the poly - carbonate Makrolon® and addresses the high demands in terms of func - tionality and aesthetics. Compared with conventional solutions, the new modular design makes do with fewer individual components and reduces as - sembly steps, space requirements and costs. In total, the headlight prototype may drop over 1.5 kilograms of weight, which contributes to reduced emis - sions and greater vehicle range. The development is another example of Covestro’s ambition to become fully circular. This also includes developing products and applications that make the recycling process easier. Thanks to the modular design of the headlight and a focus on a single plastic mate - rial type, the amount of work required for separating, sorting and storing ma - terials in recycling streams is reduced. Apart from pure polycarbonate and a blend with acrylonitrile butadiene sty - rene (ABS), the headlight uses only a scratch-resistant coating for the outer lens cover and metalization on the re - flectors. Advanced technologies and reduced complexity “We work together with car manu - facturers and their suppliers and har - ness our global resources to implement advanced technologies. Examples are heat sinks that are integral to the hous - ing, LEDs, multi-shot molding, in-mold- electronics, sensor integration and more,” explains Jim Lorenzo, Applica - tion Development Engineer at Covestro LLC. “This also includes designing parts and molds that provide the right bal - ance between functionality, aesthetics and cost efficiency.” While traditional automotive headlights have a complex design and usually consist of dozens of components and screws, the design of this modular concept is reduced to a reflector with housing, a collimator lens, a bezel and an outer lens cover. The LED modules for low and high beam and the corresponding reflec - tors are made of the thermally con - ductive polycarbonate Makrolon® TC8030 and the dimensionally stable type Makrolon® DS801, respectively. The production process combines multi-component injection molding with mold-in-place design. Thanks to these materials and the efficient pro - duction technology, the manufacturer can eliminate the additional cost and weight of heat sinks, attachments and other components. Integrated heat management In addition to light sources, the ve - hicle headlights of the future will also integrate technologies such as LiDAR, radar and cameras. This will require the use of thermally conductive ma - terials, in order to dissipate the heat generated by the electronics and light sources. For this purpose, Makrolon® TC8030 integrates heat management directly into the housing of the new headlight concept. The bezel made of different grades of Makrolon® polycarbonates is produced in a three-shot molding process. It hides the advanced driver assistance systems and consolidates the daytime running lights, turn-signals and pedestrian safe - ty lighting into one part. The sensors are hidden behind a LiDAR-transparent panel. The bezel blends cutting-edge performance and aesthetics, includ - ing a “dead front”, seamless appear - ance, a high gloss finish enhanced with laser-etched effects and diffused back- lighting for improved safety and high recognition value. Covestro www.covestro.com An innovative headlamp concept from Covestro for the vehicle lighting of the future requires significantly fewer individual parts than conventional solutions and reduces assembly steps, space requirements, costs and weight. Covestro develops modular innovative design for future vehicle lighting concept Picture: Covestro