All SUPPORT

This article provides some knowledge about adhesion test, including the process and the certificated level.

Internal Structure Design of Automotive Lighting

The internal structure design in automotive lighting is a strict and complex engineering process, as it includes many components to deliver functions such as illumination, heat dissipation, sealing, and vibration resistance. The detailed knowledge on the internal structure design of automotive lighting is given below.

1. Light Source Module

LED Module: Most of the automotive lighting, which has been in use today, is used as a source of light LEDs. This shall ensure that the LED modules have a good heat dissipation design for long service life and stable operation. Common designs to dissipate heat are normally aluminum heat sinks and materials with high thermal conductivity.
Light Source Socket: Used for fixing the light source position to hold the light source stably and conveniently for replacement. The bulb socket is usually made from high-temperature-resistant materials.

2. Optical Design


Reflectors and Lenses: These are used to concentrate and steer light in such a way as to realize the required lighting effect. Normally, reflectors will be plastic or metal with a coating of silver or aluminum, and the lenses likely contain plastics of high transparency like PC (polycarbonate) or PMMA (polymethyl methacrylate).
Optical Engine: Bin of LEDs and lenses to shape the light beam and throw light.

3. Thermal Management Design


Heat Sinks: This is the part of the system that absorbs the heat and dissipates it as it builds while the light source is running. Heat sinks used in LED lights are typically of aluminum alloy material.
Thermal Conductive Materials: Fine materials of high efficiency of thermal conductivity are installed between the LED module and the heat sink to improve efficiency in heat dissipation.


4. Circuit Design


Driving Circuit: It is used to switch, brighten, and change modes of the light source. Equipped with overheat protection, over-voltage protection, and short circuit protection functions.
Connectors: Connect the inner circuit of the Light with the vehicle circuit; to ensure a stable power supply.


5. Sealing and Waterproof Design


Sealing Rings: Used to seal between different parts of the Light, to prevent water and dust from entering. Common materials are Silicone and Rubber.
Waterproof Breathable Valves: Balances the pressure difference between the inside and outside of the Light. Prevents water vapor from entering and allows internal air to escape.


6. Mounting Structure


Mounting Brackets: Fixing the light on the vehicle body, holding its position fixed. Most mounting brackets need to have anti-vibration functions to adapt to vibrations in the course of vehicle operation.
Adjustment Mechanisms: Some lights are designed with angle adjustment mechanisms that enable adjusting the angles and directions of light to meet different lighting demands.


7. Housing and Decorative Parts


Light Housing: Houses the internal components and is normally made of heat-resistant UV-resistant plastic, such as PC or PMMA, or even glass.
Decorative Frames: Beautify the light and offer additional protection.


8. Safety and Testing


Standard Compliance: The light design should be according to international standards, such as ECE or DOT, and pass all the related safety requirements for on-road applications.
Testing and Validation: Optical performance, heat dissipation resistance, durability, and waterproofing, among other things, are tested to guarantee product quality and performance steadiness.


Designing an interior structure of automotive lamps involves comprehensive optical, thermal, electrical, and mechanical features. This will require an accurate design and a very strict test to make sure that its performance and durability meet the standards.

Knowledge of PP Housing for Automotive Lights

Polypropylene is one of the most significant materials used in the designing and manufacture of automotive light housing. With superior mechanical properties and processing characteristics, PP finds favor with most. Here is detailed knowledge about PP housing for automotive lights:

Material Characteristics:


Strength and Impact Resistance: The PP materials have demonstrated good strength and impact resistance, which are very protective against external impacts. As automotive light parts are exposed frequently, this is very important.
Heat and Cold Resistance: PP shows stable property performance at high or low temperatures, and thus is suitable for use under different climatic conditions.
Processability: PP is easy to process and mold. So, although complex in shape and precise in dimensions, with the injection molding method, it can be realized.


Design and Manufacturing



Injection Molding: PP automobile light housing is usually manufactured by injection molding. The injection molding process allows mass production with efficiency while providing precision and uniformity to the product.
Structural Design: While designing PP automobile light housing, structural strength, ease of installation, and compatibility with other components are to be considered. For example, good design for clamps or bolt holes will ensure that they can be securely fixed to the vehicle body.
Light-Weight Design: Modern automotive design concentrates on long weighting. The PP material by itself is light, and a thin-wall structure can further minimize the weight of lights.


Applications



Headlight Lamps and Taillamps: PP housing finds huge usage in the manufacturing of car headlamps or headlights and taillamps, providing them with robust support and protection.
Fog Lights and Side Marker Lights: The housings of fog lights and side marker lights also utilize PP material-based housings, which are likely to perform satisfactorily in every type of environmental condition.
Internal Structural Support: In some instances, the PP housings will offer essential internal structural support to automotive lights by guaranteeing the stability and fixation of the internal components.


Advantages and Challenges

Advantages:


Cost-Effective: PP material itself is not very costly and is economically processable.
Durability: Long-life PP material ensures good performance during the vehicle's whole life cycle.
Processing Flexibility: Different product shapes and functions can be produced for different requirements.


Difficulties:


Chemical Stability: PP has poor stability in certain chemical environments, for example, in strong acids and alkalis; as a result, the environment of use should be taken into consideration.
UV Stability: PP tends to age with long-term exposure to ultraviolet light. The addition of UV stabilizers or surface treatment can improve its weather resistance.


Surface Treatment


Coating and Plating: The PP automotive light housing can be coated or electroplated for surface decoration and to improve durability.
Texture and Color: Different kinds of surface effects and colors can be obtained by changing the texture of the injection mold or adding different masterbatches.


In summary, with the excellent properties and economic benefits of PP materials, such materials would be therefore highly suited for the manufacture of automotive light housings. By considering its characteristics and limitations in design and application, high-quality, durable automotive light housing can be processed.
 

In this page, we are going to introduce mpld injection system, including the relevent knowledge about the channel, the cross-sectional shape of runners, the distribution forms of runners, and the gate location and form for injection.

Knowledge of Motorcycle and Automotive Light Lens PMMA

PMMA, also called acrylic, is a widely used plastic material in producing auto-lamp lenses. Here is the associated knowledge related to the PMMA lamp lens:

Advantages


High Transparency and Clearness: PMMA has 92% high transparency, which is close to that of glass. It is thus considered to be an ideal material used in manufacturing lamp lenses.
Resistance to UV rays: PMMA is highly resistant to UV rays. Thus, turning yellow over time of the lens will be less, and so its clarity remains unaffected.
High mechanical strength: PMMA is very hard and rigid, which allows it to withstand certain external mechanical impacts and not break so easily.
Workability: This material can be easily cut, drilled, engraved, and polished. This feature makes PMMA suitable for producing complex shapes of lamp lenses.


Applications

With its excellent properties in optical performance and workability, PMMA has a wide application in automobile headlights, taillights, and turn signal lights. It is especially used where high transparency and clearness are necessary in light lenses.

Maintenance and Care



Cleaning: Clean the PMMA lens with mild soapy water. Do not use cleaners that contain alcohol since it will hurt the material.
Protection: Apply scratch-resistant and UV-resistant protective film onto the PMMA lens surface to prolong lifespan and durability.


Summary

PMMA housings are considered to be the ideal choice for carrying out the function of lighting lenses within the automobile domain, in that they guarantee perfect transparency and excellent optical properties. In regard to abrasion resistance with poor chemical resistance, the proper use of surface treatments and maintenance can advantageously exploit the merits of PMMA to satisfy very stringent requirements necessary in lamp lenses.
 

Automotive Lamp ABS Housing

Automotive Lamp ABS Housing is a kind of plastic material used in producing automotive lights and is famous for its powerful advantages. Here is some detailed knowledge about automotive Lamp ABS Housing

1. Material Properties

Strength and Resistance to Impact: The ABS material is of high strength, and those impacts from the outside are well protected, which is important for components like automotive lamps that are often exposed.
High Temperatures and Low Temperatures Resistance: It remains stable in both high and low temperatures, making the material suitable for use in various climate conditions.
Processability: This material is easy to mold and is manufactured into complex shapes and precise dimensions through injection molding.


2. Design and Manufacturing


Injection Molding: ABS automotive lamp housing is generally injection molded. The Injection molding process facilitates systematic mass production without compromising on the uniformity and accuracy of the product. 
Structural Design: While designing the ABS automotive lamp housing, the structural strength, easy installation, and assemblage of the component with other parts should be taken into consideration. For example, reasonable clips or bolt holes should be designed so that the lamp housing can be firmly attached to the body of the vehicle.
Lightweight Design: The modern auto design emphasizes lightweight construction. This is inherently supported by ABS material, and thin-wall structures further reduce the weight of automotive lamps.


3. Applications


Headlamps and Tail Lamps: The use of ABS housing finds wide application in the manufacturing of headlamps and tail lamp housings due to its high mechanical strength and resistance against impact.
Fog Lights and Side Marker Lights: The fog lights and side marker lights also have housings made of ABS material, which are expected to function reliably in all kinds of environmental conditions.
Internal Structural Support: The ABS Housings sometimes serve as an internal structural support inside the Automotive lamp to provide stability and fixation to internal components.



4.Advantages


Cost-Effective: The cost of ABS material is relatively inexpensive, and the processing costs are reasonable.
Durability: ABS itself provides very excellent durability, and it sustains good performance during the whole life cycle of the vehicle.
Flexibility in processing: It holds a diversity of product shapes and functions in accordance with different requirements.


5.Challenges


Chemical Stability: Poor stability of ABS in specific chemical surroundings such as strong acid and housing has to be taken into automotive consideration during the use environment.
UV Stability: It has been reported that ABS tends to be embrittled after being exposed to UV for a very long time. The addition of UV stabilizers or surface treatments may enhance weather resistance.


6. Surface Treatment


Painting and Coating: Painting or electroplating can be performed on the ABS automotive lamp housing to improve appearance and durability.
Texture and Color: Changes in various surface textures and colors can be achieved by revamping the injective mold's texture or through the addition of masterbatches.


In summary, the use of ABS material in making lamp housing is perfect due to its performance and economic benefits. If considering the properties and limitations of design and application, it can result in high-quality and durable automotive lamp housing.

Ultrasonic welding is a well-known technology applied in light manufacturing. Creating high-frequency ultrasonic vibration, applied to two different pieces made of plastic, welds them together and results in a perfect bond. Here is some information to figure out ultrasonic welding.


Principle

The frequency of ultrasonic welding is between 20 and 40 kHz. These very high-frequency vibrations can pass through the surfaces between the two plastics, producing high temperatures and softening the surface of plastics. Once the vibrations are stopped, this melted material cools and solidifies to bring out the joint.

 Advantages

Fast and high Efficiency: The process of ultrasonic welding is done within a few seconds, which is suitable for large-scale production.
High Strength: The formed joints are of high mechanical strength, hence able to bear large forces.
No Additives: After using ultrasonic welding, no adhesives or other auxiliary materials are therefore necessary. In that case, it can decrease costs and reduce pollution.
High precision: This technique is allowed to bond highly precisely, so it's applicable for complex, fine components.
Environment Friendly: Ultrasonic welding doesn’t emanate any toxic gases. Thus, it is environment-friendly.


Applications

Ultrasonic welding has wide applications in bonding several plastic components in lights. Some of the applications include


Bonding Lenses and Housings: Can bond transparent or semi-transparent lenses to the housing
Fixing Lenses and Reflectors: Fix the optical lenses and reflectors in place
Assembling Internal Components: Fixtures used to attach internal brackets, heat sinks, and light guides.


This process is best suited for thermoplastic materials, which include:


Polycarbonate PC
Polymethyl Methacrylate PMMA
Polypropylene PP
Acrylonitrile Butadiene Styrene ABS


Steps of Operation
Workpiece preparation: Put the plastic parts in the fixture of the ultrasonic welding machine.
Setting Parameter: Setting the parameters of the ultrasonic welding machine, such as the vibration frequency, vibration amplitude, time of welding, and pressure.
Start Welding: Turn on the ultrasonic welding machine to operate the welding.
Cool and Remove: At the end of welding, cool down the material and let it solidify before removing the workpieces.

Maintenance
Equipment Checks: The ultrasonic machine is checked regularly so that the machine runs smoothly.
Cleanliness of Welding Head: The welding head is cleaned regularly so that impurities do not accumulate, which will affect welding quality.
Test Bond Strength: To assure the quality of welding, all normal test bond strengths are carried out.

Conclusion

In automobile light manufacture, ultrasonic welding technology can be applied because it is a very fast process with the capability of developing welds that are high in strength and precision. Being a very correct material combination in conjugation with a correct set of operating parameters, ultrasonic welding will go on to make high-quality bonds that come up to the stringent requirements in manufacturing automotive lights.
 

Polycarbonate (PC) light lenses are mostly used in cars and motorcycle lights. Here is some information about PC light lenses:

1. Feature of Polycarbonate Material


High Transparency: PC material has high transparency close to the glass, which is crucial for the light omit coming out.
Strong Ability Against Hitting: PC material doesn’t easily get broken while being hit, ensuring the safety of the headlights.
Ability Against High Temperature: PC material stays steady in high-temperature environments, preventing getting broken due to the heat from the lights.
Lightweight: PC material is lighter than traditional glass, helping reduce the weight of the vehicle and the cost of fuel.
UV Resistance: After UV treatment, PC material reduces UV damage, prolonging the lifetime of the light lens.


2. Producing Process of PC Light Lens


Molding By Injection: PC light lenses are mostly produced by injection, which can shape the lenses in complex shapes and precise dimensions.
Surface Treatment: To increase durability, PC light lenses often receive surface treatments like coating with UV-resistant and anti-scratch.
Dyeing and Coloring: PC light lenses can be dyed in various colors, fitting for different kind of shapes and designs.

3. Advantages of Using PC Light Lens


Great Safety: For vehicle safety, the high impact resistance of PC light lenses makes them less likely to shatter in accidents.
Design Flexibility: PC material allows designers to create various light lens shapes to improve the vehicle's creative look.
Less Cost: Despite the high cost of PC material, its features and long lifetime make it a high-efficiency material.
Environmental Friendliness: PC material is recyclable, causing less pollution to the environment.


4. Ways of Care


Regular Cleaning: Use a neutral detergent and a soft cloth to clean PC light lenses. To avoid cleaners containing abrasives or corrosive chemicals to prevent surface damage.
Prevent Scratches: To avoid scratching the light lens surface with sharp or hard objects and try to park in areas where falling objects are unlikely.
Regular Inspection: Regularly check the mounting condition and surface of the light lens. Promptly repair or replace any problematic lens to ensure performance and safety.



5. Future Development Trends
With technological advancements, the performance of PC materials continues to improve. In the future, we may see PC light lenses with even higher transparency, stronger impact resistance, and greater durability. Additionally, the development of smart lighting technology will drive the application of PC light housings in integrating more functions, such as automatic dimming and smart displays.

Conclusion
PC light lenses play an irreplaceable role in the manufacture of automotive and motorcycle lights. Their superior performance and broad application prospects make them a key material in the development of future lighting technology.

New Car Lighting-Mercedes Benz EQE






The Benz EQE was officially launched.
In terms of appearance design, the EQE inherits the bow-shaped body of the flagship EQS of the EQ family, with a body length of 4969 and a drag coefficient of only 0.22. In addition, it is equipped with an NCM811 power battery with a total capacity of 96.1 kWh, and the CLTC comprehensive working condition is up to 752 kilometers.




The front face of the EQE also basically follows the design of the EQS, with soft front lines and a closed air intake grille. The sports shape of the diversion groove below is very conspicuous, and with the thick chrome decoration, it is very handsome.






Let's look at the lights.



Mercedes-Benz's current choice of lamp technology is basically in the same line, what is used for S, what is used for E. Therefore, this EQE can also be equipped with DLP 1.3 million pixel headlights, which can perform refined anti-glare functions and ground projection functions. However, it is estimated that, like other models, DLP should be an optional function, and the projection content should currently only have meteor shower lighting effects. In addition to using a lens as the main light source for the high-end model, the low-end EQE uses a reflector bowl technology.



However, unlike the fuel version of the headlight design, the daytime running lights in the fuel version of the S, E and C headlights are three dots, two dots and one dot respectively, with obvious inheritance. In the EQS of the EQ series, the headlights are also decorated with three-point daytime running lights, but this EQE has changed the family style, without the same penetration as the EQS, and the daytime running lights have been changed to upper and lower light guides.




In addition to the transparent effect, there are three levels of ridges on the outside under the limited thickness, and the entire surface is designed with grid-like patterns. It is a matrix arrangement of the Mercedes-Benz logo.
The interior decorative frame has a surface treatment similar to wood grain, and the texture is very good.



The taillight part is EQ family-style 3D spiral shape, very similar to EQS. It does not use particularly advanced technology, but is only designed in a very unique optical scheme.




When it comes to Mercedes-Benz, we have to mention its interior lamp design. The interior design is very luxurious. No matter what class of model it is, the interior is the existence of the same class. The same is plastic, why is Mercedes-Benz designed so beautifully.







 


~~THE END~~

Ranking Of September new car Lighting





1 ST 


Renault R5 Turbo 3E Concept

Reason:
How will headlights develop in the future? Renault gave its own answer: replacing the headlights directly with GOPRO is a cool solution in the era of autonomous driving. There are also pink, blue and yellow LED light strips on the front and rear of the car that flash as the car drifts, adding to the 1980s and 90s video game vibe.






 


 2 ND


Jeep Wagoneer S Concept

Reason:
The innovative design of the 7-hole Jeep logo: it can no longer be a hole, but it must be "7" repetitions of the same element. Just like BMW's headlights, it can no longer be an angel's eye, but it must be a second repetition of the same element. Graphics and elements, in the replacement of design, there is always one to be inherited.



Sort of like a dam, the light pours down from the upper stream like a river, and casts it on the decorative panels.




 


 3 RD


Citroen Oli Concept

Reason:
The French have great idea. I can't design this peculiar lamp shape.












OTHERS


BMW XM

In the M mass production version, the double kidney grille lights are retained, so that it can be recognized from a distance at night that this is a BMW. The taillights are much more restrained than the concept version. The side creatively incorporates the three slashes of the M logo. The interior canopy atmosphere light also incorporates the three colors of the M logo.










 

BMW X1

The X1 is replaced with barb-shaped headlights similar to those of the 3 Series, and a floating nameplate is used on the side, which is eye-catching. The tail light only emphasizes the position light, and the other function lights are simplified. It's good.






Dacia Manifesto Concept

Who says headlights have to have two? The exposed LED has its own wild beauty.






 

Ford Mustang








 

GAC AION Hyper SSR

Both the front and rear lights feature extremely smooth outlens, which seems to be a new trend emphasizing minimalist technology.










 

Jeep Avenger
 



There are more and more lights with X-shaped elements. Maybe everyone likes the X-Men?




Jeep Recon Concept





Pagani Utopia

This peanut eye is so embarrassing. There are also fog lights hanging on the tip, so I'm afraid it will break if you touch it.





The barrel-like taillights are handsome.


Volkswagen Gen.Travel Concept





Volkswagen ID Buzz

The overall design follows the characteristics of the ID family, and the ambient lighting design of the lens bezel is well differentiated from other brothers.













~~THE END~~

What is Ingress protection (IP)?

IP code or ingress protection code is defined by the International Electrotechnical Commission (IEC) under the international standard IEC 60529 which classifies and provides a guideline to the degree of protection provided by mechanical casings and electrical enclosures against intrusion, dust, accidental contact, and water. It is published in the European Union by the European Committee for Electrotechnical Standardization (CENELEC) as EN 60529.

The standard aims to provide users more detailed information than vague marketing terms such as waterproof. For example, a cellular phone rated at IP67 is "dust resistant" and can be "immersed in 1 meters of freshwater for up to 30 minutes". Similarly, an electrical socket rated IP22 is protected against insertion of fingers and will not become unsafe during a specified test in which it is exposed to vertically or nearly vertically dripping water. IP22 or IP2X are typical minimum requirements for the design of electrical accessories for indoor use.

The digits indicate conformity with the conditions summarized in the tables below. The digit 0 is used where no protection is provided. The digit is replaced with the letter X when insufficient data has been gathered to assign a protection level. The device can become less capable, however it cannot become unsafe.

Protection against solid objects
0 – No protection/ No test required
1 – Protected against objects greater than 50mm diameter
2 – Protected against objects greater than 12.5mm diameter, such as a finger
3 – Protected against objects greater than 2.5mm
4 – Protected against objects greater than 1.0mm such as wire
5 – Ingress of dust is not totally prevented but dust does not enter in harmful quantities to interfere with the correct operation or impair safety
6 – No ingress of dust permitted

Protection against water
0 – No protection / No test required
1 – Protected against falling drops of water
2 – Protected against drops falling at 15° in 4 fixed positions
3 – Low pressure spray – similar to shower head at up to 60° from vertical tested using an oscillating tube with an arc of 60° for ten minutes
4 – Low pressure spray – similar to shower head – as per numeral 3 but 180° for 10 minutes
5 – Medium pressure jet – 6.3mm diameter, similar to garden hose – from any angle for 3 minutes at a distance of 2.5-3 metres.
6 – High pressure jet – 12.5mm diameter, similar to fire hose – from any angle for 3 minutes at a distance of 2.5-3 meters.
7 – Immersion – for temporary immersion in water under set conditions – 1 metre for 30 minutes
8 – Protected against the effects of continuous immersion in water, ingress of water in quantities causing harmful effects shall not be possible. Conditions should be more severe than for numeral 7.
9 – Steam clean, high pressure, high temp jet wash to DIN40050 (German Std), extends BS EN 60529:1992

IP Enclosures at Deltron

At Deltron Enclosures, we can offer IP54 enclosures, which are suited to light duty environments that may require some level of protection from dust.

For more demanding applications, we also manufacture IP66 and IP68 enclosures. These are suited to industries mentioned previously in this article, where the applications are located in tough environments and therefore ingress protection is a priority.

In addition, our IP66 and IP68 enclosures are available in a heavy duty version for a durable enclosure. They are often used for deep water applications, or when the engineer requires resilient casing for the electronic components.

WHAT ARE E-MARK?
In order for lighting products to be traded on the European market, they must meet certain requirements in the areas of safety, health and the environment. For example, with regard to the safety of drivers of vehicles and their surroundings when it comes to lighting, regulations have been drawn up by the Economic Commission for Europe: ECE. Directives (indicated with the letter R) lay down, for example, the amount of light, visibility, flashing frequency, etc. of headlights, rear lights, flash units, work lights, etc.