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MATERIALS | ENGINEERING PLASTICS


Right: Covestro showed this headlamp concept made in PC and PC/ ABS at K2019


Novel lighting Covestro also displayed a novel concept headlight produced in different types of polycarbonate or PC/ABS (apart from the siloxane scratch-resistant coating) that incorporate specific functional attributes as well as simple recycling. Paul Platte, Senior Marketing Manager, Automotive with Covestro in the US, says the headlight incorporates no fewer than nine novel technologies that facilitate assembly and also disassembly, since only the electronics need to be removed before the thermoplastic parts can be recycled all together into new PC-based blends. The headlamp includes an outer lens in polycar-


bonate that is laser welded to a frame in a Bay- blend PC/ABS blend (eliminating any adhesive bonding) that is part of a two-component mould- ing, the other component being the housing/ reflector in a thermally conductive compound. All electronics are placed either in or on the housing/ reflector, Platte says, so heat is conducted directly


into the conductive material, eliminating the need for aluminium heat sinks. One LED chip is insert moulded into place. “The compound is not as conductive as aluminium, but we can keep the LEDs at within two degrees of where they would be with aluminium,” he says. This leads to a reduction of 40% in weight and a 20% cost reduction. One of the new materials used in the headlamp


is Makrolon DS 801, which is claimed to provide particularly high dimensional stability. This is a filled material but, by using variotherm mould tempera- ture control technology, it is possible to achieve surface roughness to match an unfilled grade. Makrolon LED 2245 ST is used for the opaque headlamp bezel, providing good aesthetics as well as the transparency to radar required for the LIDAR system. This is achieved with Makrolon LED 2245 ST. A further polycarbonate with good light diffusion forms part of another two-component moulding used to evenly spread out light from a strip of some 70 LEDs.


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Polymeric materials in the European cable industry 2020


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• What factors affect industry structure and market demand • Polymeric compounds demand in the market • Strategic and structural change re-shaping the cable industry


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PHOTO: PETER MAPLESTON


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