{"id":7679,"date":"2018-02-02T08:00:51","date_gmt":"2018-02-02T14:00:51","guid":{"rendered":"https:\/\/www.ulprospector.com\/knowledge\/?p=7679"},"modified":"2023-06-06T12:45:26","modified_gmt":"2023-06-06T18:45:26","slug":"pe-automotive-plastics-led-headlights","status":"publish","type":"post","link":"https:\/\/ulprospector.ul.com\/7679\/pe-automotive-plastics-led-headlights\/","title":{"rendered":"LEDs and Plastics Help Light the Way for Tomorrow\u2019s Vehicles"},"content":{"rendered":"<figure id=\"attachment_7680\" class=\"thumbnail wp-caption alignright\" style=\"width: 225px\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/01\/7_Chevy-Silverado-truck-headlamp-225x300.jpg\" alt=\"Chevy Silverado truck headlight - see more innovations in automotive plastics in the Prospector Knowledge Center!\" width=\"225\" height=\"300\" \/><figcaption class=\"caption wp-caption-text\">The 2019 Chevrolet Silverado truck\u2019s headlamps, which are divided into three zones, offer a good example of the complexity packed into today\u2019s lighting systems.<\/figcaption><\/figure>\n<p>Automakers and their suppliers are always seeking bright ideas when it comes to lighting. The recent CES 2018 technology show in Las Vegas and the North American International Auto Show (NAIAS) in Detroit revealed just how much attention is being paid to headlamp and taillight systems, internal ambient lighting in vehicles and other such features.<\/p>\n<p>Just as with trends in other consumer products such as smartphones, wearables and the like, automotive OEMs want to differentiate their products from the competition while retaining an identifiable brand language. For the most part, they also are aiming to pack more features and value into smaller, sleeker packages to project the image of seamless simplicity.<\/p>\n<p>When it comes to vehicles, certain trends remain constant \u2014 the need for uncompromised safety and excellent performance, all at a justifiable cost, and increasingly at lighter weights. Longer-term trends involve the consolidation of both componentry and manufacturing processes to achieve all the above.<\/p>\n<p>CES, with its growing spotlight on automotive tech, focused more on connectivity between consumer and vehicle with a slew of interactive touch-screen and voice-activated interfaces, and on electric and autonomous vehicles, with their batteries, cameras, lasers, and sensors. These trends also have major implications for the use of plastics and polymers.<\/p>\n<p>At the Detroit show, meanwhile, new-product introductions and futuristic concept vehicles ruled the day, stretching the minds of even the most imaginative. Variations on LED lighting configurations were prominent. Let\u2019s briefly illuminate some of those trends.<\/p>\n<h3>Various LED Lamp Styles<\/h3>\n<p>The growing use of light-emitting diode, or LED, lights in vehicle headlamp systems is generally taking one of two forms \u2014 configurations of fewer, high-powered LED systems that create a more spatial, voluminous effect underneath the headlamp cover; or use of more, lower-powered LEDs that can be arrayed to create a more sparkling, jeweled effect.<\/p>\n<p>LEDs are hotter at the P-N junction at the circuit board where electrons are converted to photons. As such, the LED \u201cbulb\u201d is not hot; rather, the electronics behind the bulb are hot. Heat sinks \u2014 typically aluminum but, increasingly, thermally conductive polymers \u2014 are needed, therefore, to take the heat away from this portion of the electronics at the circuit board. (By contrast, halogen runs hotter at the bulb itself.)<\/p>\n<p>There also are light pipes and light blades:<\/p>\n<ul>\n<li>Light pipes are thin, linear runs of clear material that that offer no 3D effect but which can be made either to project a homogenous light with diffusion techniques, or can give a sequence of discrete bright\/hot-spots. The latter also can be deployed for distinctive \u201cglitzy\u201d and \u201cjeweled\u201d styling effects.<\/li>\n<li>Light blades, meanwhile, are usually small, flat surfaces of clear material that can be stacked side by side to create more of a 3D visual effect when lit. The light blades provide a 2D \u201cplane of light\u201d to be illuminated, whereas the light pipes provide a one-dimensional \u201cline of light.\u201d The plane aspect provides a dramatic effect and when layered, creates an additional dimension, yielding the 3D effect.<\/li>\n<\/ul>\n<p>Light blades and light pipes can be made of PC, acrylic or liquid silicone. Headlamp lens covers these days are nearly all polycarbonate, while tail lamp covers, which do not require impact resistance, are often acrylic.<\/p>\n<p>Looking ahead, the imminent rise of autonomous, self-driving vehicles will necessitate the widespread use of lasers, radars, cameras and sensors on each such vehicle. These are the devices that will detect other objects, and their distance and speed, to ensure collision avoidance and safe operation.<\/p>\n<h3>Mechanical vs. solid-state LiDAR<\/h3>\n<p>Today\u2019s self-driving vehicles often employ LiDAR, which stands for Light Detection and Ranging \u2014 a remote sensing method that uses light in the form of a pulsed laser that can detect, locate and measure objects and their variable distances. LiDAR systems can be mechanical (e.g., one design is an encased, \u201cspinning top\u201d type of device that offers accurate, 360-degree detection), or solid state (which is non-mechanical, but has a limited field of view, and hence requires multiple fixed sensors to capture all necessary angles).<\/p>\n<p>While many self-driving vehicles today use mechanical LiDAR systems \u2014 which you sometimes see attached obtrusively to a bar across the roof like a ski rack \u2014 automakers are actively exploring integrating solid-state LiDAR into vehicle headlamps, tail lamps and other vehicle positions to streamline the vehicle\u2019s appearance while still giving the required 360-degree view.<\/p>\n<p>Both types of LiDAR systems ratchet up the need for purity in the lens material and in whatever encloses these highly sensitive sensors, notes Paul Platte, senior marketing manager \u2013 automotive in the North American polycarbonates group for materials supplier Covestro LLC. The optical purity aspect is vital so the LiDAR sensors operate without hindrance to their ability to send and receive signals. Driver and pedestrian safety depends on it.<\/p>\n<p>Another aesthetic consideration is automakers\u2019 desire to disguise LiDAR sensors in visible light \u2014 so they are essentially invisible to the naked eye behind opaque-looking covers \u2014 while being fully transparent to the necessary LiDAR frequencies, Platte said.<\/p>\n<h3>Headlamp bling<\/h3>\n<p>Several vehicles on the Detroit show floor exhibited aesthetic flair:<\/p>\n<ul>\n<li>The <strong>2018<\/strong> <strong>BMW X2 compact SUV crossover<\/strong> showed brushed metallized accents above and below the lamp underneath the clear cover, yielding a bright reflective effect, while retaining the brand\u2019s signature C-shaped LED configuration. The automaker describes it this way: \u201cLED headlights with cornering lights\u00a0illuminate the road when you&#8217;re traveling at speed. With the LED fog lights, they create a distinctive appearance, and complete the connection between coupe styling and X characteristics.\u201d<\/li>\n<li>The latest <strong>Audi Q5 Quattro<\/strong> on display featured not only headlights with extensive light piping, but also a large, metal-looking front grille, or license plate surround, made from a polycarbonate\/polyester blend.<\/li>\n<li>The headlamps on the <strong>2018 Lincoln MKZ<\/strong> luxury sedan, meanwhile, used a high-flow, LED-grade polycarbonate to achieve its distinctive style. It features a thick, curving band of clear plastic \u2014 approximately 1-inch deep by 3\/8 inches thick by 18 inches long \u2014 that twists like a ribbon of taffy from underneath the lamp to the upper corner of the fixture, yielding a distinctive 3D visual effect.<\/li>\n<li>The award-winning <strong>2019 Dodge Ram 1500<\/strong> truck comes with three different headlight style options, including a plated look and what it labeled \u201ca Bi-LED AFS,\u201d for adaptive front lighting system that optimizes distribution of\u00a0lightfrom the headlights according to driving circumstances. With AFS, depending on vehicle speed and steering input, the\u00a0system\u00a0points the low-beams headlights in the direction the driver intends to travel.<\/li>\n<li>The <strong>2019 Chevrolet Silverado<\/strong> truck\u2019s headlamps also demonstrate the complexity of some of today\u2019s lighting systems. For starters, the lamp is divided into three separate \u201czones,\u201d with the top having the primary high\/low beam elements while the middle (in the vertical stack) has a white light bar transitioning to the lower section (in the vertical stack), which has a horizontal colored light bar. All this is achieved with the appearance of a smooth, outer surface of PC. Additionally, to obtain these aesthetics, many of the components have geometrical complexity, leading to material, design and manufacturing challenges.<\/li>\n<\/ul>\n<p><img decoding=\"async\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/01\/1_Tail-lamp-display-curious-visitor-at-CES.jpg\" alt=\"Tail lamp display at CES - see more innovations in automotive plastics in the Prospector Knowledge Center!\" \/><\/p>\n<p><strong>Automotive lighting displays at CES 2018 generated a lot of interest on the show floor.<\/strong><\/p>\n<p><img decoding=\"async\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/01\/3_BMW-X2-headlamp.jpg\" alt=\"BMW X2 headlamp - - see more innovations in automotive plastics in the Prospector Knowledge Center!\" \/><\/p>\n<p><strong>The new BMW X2 compact SUV crossover features brushed metallized accents under the headlight cover and both above and below the brand\u2019s distinctive headlamps.<\/strong><\/p>\n<p><img decoding=\"async\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/01\/4_Audi-Q5-license-plate-surround.jpg\" alt=\"Audi Q5 grille - see more innovations in automotive plastics in the Prospector Knowledge Center!\" \/><\/p>\n<p><strong>The latest Audi Q5 Quattro displayed a large, metal-looking license plate surround made from a polycarbonate\/polyester blend.<\/strong><\/p>\n<p><img decoding=\"async\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/01\/6_2019-Dodge-Ram-1500-truck-headlamp.jpg\" alt=\"\" \/><\/p>\n<p><strong>The 2019 Dodge Ram 1500 truck comes with three different headlight style options, including with AFS, an adaptive front lighting system that adjusts lighting brightness and direction based on driving circumstances. <\/strong><\/p>\n<p><img decoding=\"async\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/01\/8_VWs-I.D.-Crozz-concept-EV-with-lighted-log.jpg\" alt=\"VW ID Crozz - see more innovations in automotive plastics in the Prospector Knowledge Center!\" \/><\/p>\n<p><strong>On the front of the I.D. Crozz, Volkswagen\u2019s concept EV crossover coupe, a solid light bar connects the right and left headlamps, while also lighting the VW logo in the center.<\/strong><\/p>\n<p><img decoding=\"async\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/01\/12_Nissans-XMotion-concept-SUV_side-view.jpg\" alt=\"Nissan XMotion concept SUV - see more innovations in automotive plastics in the Prospector Knowledge Center!\" \/><\/p>\n<p><strong>Nissan\u2019s XMotion concept SUV combines futuristic design with minimalist Japanese elements, along with abundant use of soft ambient interior lighting.<\/strong><\/p>\n<p><img decoding=\"async\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/01\/14_MB-Smart-concept-front-display_at-CES.jpg\" alt=\"Smart concept car at CES 2018 - see more innovations in automotive plastics in the Prospector Knowledge Center!\" \/><\/p>\n<p><strong>Some electric vehicles, such as this Mercedes-Benz Smart Car concept, transform the front-end space that previously had to house the radiator into a sort of digital bulletin board.<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: center;\">All photos by Robert Grace<\/p>\n<h3>Tapping into ambient lighting<\/h3>\n<p>Lighting \u2014 especially on concept vehicles \u2014 plays a role in applications well beyond headlamp and tail light systems. Volkswagen\u2019s concept EV crossover coupe shown in Detroit, the <strong>I.D. Crozz<\/strong>, included an illuminated VW front logo as well as a solid, wide light bar connecting the right headlamp to the logo and left headlamp. The Crozz also features a significant amount of ambient lighting inside the vehicle.<\/p>\n<p>Nissan\u2019s impressive-looking concept SUV called the <strong>XMotion<\/strong> (pronounced \u201cCross Motion\u201d), features soft ambient lighting that glows through the Japanese maple ribs of the minimalist dashboard. Beyond being just an aesthetic accent that offers a personalization feature, Platte said, ambient lighting also projects a sense of space and can make interiors look bigger.<\/p>\n<p>The LEDs used in automotive lighting systems have lamp inner volumes that run cooler than their traditional counterparts, but their heat source is hot, and too much heat can lower the LEDs\u2019 life expectancy. That creates another plastics opportunity, Platte said in an interview on the NAIAS show floor.<\/p>\n<p>He noted that resins such as Covestro\u2019s thermally conductive Makrolon-brand polycarbonate often can effectively replace aluminum as a heat sink in headlamps. The injection-moldable PC not only offers design freedom but also is lighter weight than aluminum, which he said frequently is over-specified as to heat management for that application.<\/p>\n<p>Additionally, electric vehicles that don\u2019t require a radiator can use that front-grille real estate as a digital bulletin board of sorts to convey information and even to personalize the vehicle. The <strong>Mercedes-Benz Smart Car concept<\/strong> at CES, for example, flashed text welcoming the driver by name.<\/p>\n<p>All these innovative uses of display screens, sensor covers and lighting offer significant opportunities to polymer makers to serve the diverse needs of today\u2019s \u2014 and tomorrow\u2019s \u2014 increasingly intelligent, interactive and autonomous vehicles.<\/p>\n<h3>Need to search for automotive approved plastics?<\/h3>\n<p>Automotive Plastics Search in Prospector can help you quickly find plastics approved for automotive applications from more than 70 automotive OEMs.<\/p>\n<p><a role=\"button\" href=\"https:\/\/www.ulprospector.com\/automotivesearch\/?utm_source=Knowledge-Center&amp;utm_medium=CTA&amp;utm_campaign=Professional\" target=\"_blank\" rel=\"noopener\"><br \/>\nLearn more<br \/>\n<\/a><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Automakers and their suppliers are always seeking bright ideas when it comes to lighting. The recent CES 2018 technology show in Las Vegas and the North American International Auto Show (NAIAS) in Detroit revealed just how much attention is being &hellip; <a href=\"https:\/\/ulprospector.ul.com\/7679\/pe-automotive-plastics-led-headlights\/\">Continued<\/a><\/p>\n","protected":false},"author":23,"featured_media":7681,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"episode_type":"","audio_file":"","podmotor_file_id":"","podmotor_episode_id":"","cover_image":"","cover_image_id":"","duration":"","filesize":"","filesize_raw":"","date_recorded":"","explicit":"","block":"","itunes_episode_number":"","itunes_title":"","itunes_season_number":"","itunes_episode_type":"","footnotes":""},"categories":[21],"tags":[230,247,274],"ppma_author":[1244],"class_list":{"0":"post-7679","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-plastics-2","8":"tag-trade-show-review","9":"tag-application","10":"tag-design","11":"entry"},"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Automotive plastics: LEDs light the way for innovation<\/title>\n<meta name=\"description\" content=\"Automotive plastics continue to evolve. 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He has broad global experience and for more than 35 years has worked as a journalist, editor-in-chief, publishing executive and key connector of like-minded parties. He has launched successful publications and C-level events on three continents. While with Crain Communications Inc., he oversaw the relaunch of the 100-year-old European Rubber Journal in London and helped to start Urethanes Technology magazine there. \u00a0In 1988 Bob returned to Akron, Ohio, to serve as founding editor of Plastics News, an award-winning, weekly business newspaper. In 2005 he oversaw the editorial launch of the bilingual (Chinese and English) PN China e-newsletter and website. For more than a decade at PN he also held the titles of associate publisher, editorial director and conference director, and most recently served as business development director. A long-time affiliate member of the Industrial Designers Society of America, Bob has organized numerous design-focused events, earned a Personal Recognition Award from IDSA in 2013, and constantly strives to help bridge the gap between the design and manufacturing communities. In 2014 he left Crain and created RC Grace LLC in Akron, Ohio, as a consultancy that aims to help companies to enhance their branding and market presence, find business partners, connect with design resources (here or in Asia), secure funding and advance their growth initiatives. Email Bob or visit his website at www.rcgrace.com to learn more about how he can help you.\",\"sameAs\":[\"http:\\\/\\\/ulprospector.com\"],\"url\":\"https:\\\/\\\/ulprospector.ul.com\\\/author\\\/robert-grace\\\/\"}]}<\/script>\n<!-- \/ Yoast SEO plugin. -->","yoast_head_json":{"title":"Automotive plastics: LEDs light the way for innovation","description":"Automotive plastics continue to evolve. 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