INNOVATION | OPTICAL MOULDING


Above: Covestro has developed a new automo- tive headlight concept based on different types of Makrolon polycarbonate, which meets high demands in terms of functionality and aesthetics


Material producer Covestro has developed a new automotive headlight concept. The approach is based on different types of Makrolon PC and meets high demands in terms of functionality and aesthetics. Compared with conventional solutions, the new modular design makes do with fewer individual components and reduces assembly steps, space requirements and costs. In total, the headlight prototype may reduce over 1.5 kg of weight, which contributes to reduced emissions and greater vehicle range. Recycling is also easier. Apart from PC and PC/ABS, the headlight uses only a scratch-resistant coating for the outer lens cover and metalisation on the reflectors. The LED modules for low and high beam and


the reflectors are made of thermally conductive PC Makrolon TC8030 and the dimensionally stable type Makrolon DS801, respectively. The production process combines multi-component injection moulding with mould-in-place design. Due to these materials and efficient production technol- ogy, the manufacturer can eliminate the additional cost and weight of heat sinks, attachments and other components. Future vehicle headlights will also integrate technologies such as LiDAR, radar and cameras. This will require the use of thermally conductive materials, 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 Makrolon grades, is


Right: Trogamid myCX eCO from Evonik has been used by Safilo for premi- um lenses for sunglasses


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produced in a three-shot moulding process. It hides the advanced driver assistance systems and consolidates the daytime running lights, turn-signals and pedestrian safety lighting into one part. The sensors are hidden behind a LiDAR- transparent panel. The bezel blends cutting-edge performance and aesthetics, including a ‘dead front’, seamless appearance, a


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high gloss finish enhanced with laser-etched effects and diffused back-lighting for improved safety and high recognition value. Covestro has aslo developed polycarbonates for LED lights in extreme environments, such as applications in swimming pools. Operating LED lamps underwater puts special demands on the materials involved. In cooperation with Brazilian swimming pool equipment supplier Ecopyre Lighting, Covestro developed an integrated solution using the thermally conductive Makrolon TC. It features high dimensional stability during manufacture and operation of the lights, thereby preventing water ingress. The material’s good thermal conductivity makes it ideal for efficient thermal management in which the heat generated by the LEDs is well dissipated. In addition, the plastic complies with the chemical resistance required for use in swimming pool water. The company adds that highly transparent


Makrolon is also suitable for lenses in explosion- proof lamps, as demonstrated by a recent case study with safety technology supplier R. Stahl. The lights comply with Categories 2 and 3 (for Zones 1 and 21, or 2 and 22) of the EU ATEX directives for industrial environments where highly explosive dust and gas atmospheres may occur during normal operation. These include oil platforms, refineries, and also certain chemical plants. R. Stahl was looking for an optical material solution for LED safety lighting that could be used worldwide. The company selected a Makrolon grade which enables light-focusing optics and is applicable at


elevated temperatures of 60-85℃. Evonik has developed a sustainable transparent polyamide moulding compound for the optics industry. Trogamid myCX eCO is produced partly from a bio-based monomer and entirely with renewable energy. This results in a 50% reduction in the carbon dioxide footprint compared to the qualitatively equivalent premium product pro- duced on a petrochemical basis using conventional energy sources. The compound is a high-purity microcrystalline high performance polyamide specially optimised for the optics industry. It provides transparency of over 90%, good mechani-


IMAGE: COVESTRO


IMAGE: SAFILO


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