Automotive Lighting Technology, Transparent Plastic and Automotive Lightweight
Automotive Lighting Technology, Transparent Plastic and Automotive Lightweight
2016-10 "Tongguang Media" "Modern Plastics"
1Vehicle Lightweight
as a physical means of transportation in the economic field and daily life is beyond doubt. The important direction of development is comfort, safety, intelligence and economy. With the improvement of global awareness of non-renewable energy protection and environmental requirements, low energy consumption and low emissions have become the most important technical tasks besides safety and intelligence. The world is vigorously promoting power technology and developing new energy vehicle technology. Whether it is fuel vehicles, hybrid vehicles, pure electric vehicles, etc., weight reduction is always the same theme. The use of high-strength steel, magnesium alloy, aluminum alloy metal, etc. The low specific gravity, fiber reinforced composite materials, hard foam coating reinforcement, plastic instead of steel, new composite stamping and welding, etc. are used to reduce the weight of the car on the premise of ensuring safety.15-53%comparison results, many research institutions and enterprises have made a lot of achievements in materials, technology, technology, design and so on.
the test results of Ford Motor Company's Quanshun car in Europe show that:fuel consumption per 100 kilometers under the condition of meeting the Euro IV standardYand its own qualityx(kg)the following relationships are met:Y = 0.003X +3.3434, the weight of the whole car is reduced10%, fuel utilization efficiency can be improved6%~8%, exhaust emissions are reduced by about5%, raw material costs can be reduced by about10%. The decrease in fuel consumption means at the same timeCO2, nitrogen oxides(NOx)plays an important role in reducing fuel consumption and carbon emissions in environmental protection requirements.A large number of test results for various types of vehicles show that the fuel consumption of vehicles has a certain linear relationship with the quality of vehicles. Therefore, reducing the weight of automobiles, that is, reducing fuel consumption by means of lightweight, has become the most popular research topic in the automobile industry. At present, the lightweight of automobiles has become an important way for automobile enterprises to deal with the energy conservation and emission reduction policies of governments of various countries. The EU has approved an agreement to strengthen carbon dioxide standards2020, carbon dioxide emissions per unit mileage of new cars in the EU must be controlled at every kilometer.95grams. If according to combustion-The emission level corresponds to approximately 100km of fuel consumption.4liters. According to the European Environment Agency (EEA),2012is132.2grams/km, compared20099%,202028.1%. Japanese automobile companies have also always listed lightweight as a very important guiding program in the overall design of automobiles. According to regulations, Japanese cars mainly pay car weight tax, car tax, etc. These taxes and fees are related to the weight of the car body and the size of the displacement. The heavier the car body and the larger the displacement, the more money you pay. For example, the weight tax, the use of a long time, the weight of the luxury car exhaust emissions is larger, almost every year to pay.8Yen , and the new mini car only needs to be handed in.1.2million yen, the difference between the two6times. In recent years, the Chinese government has also introduced a series of energy-saving and emission-reduction measures, such as actively encouraging the development of new energy vehicles, limiting the average fuel consumption of car companies, and so on.
2Lighting Technology, Transparent Plastic and Lightweight Automobile Because of professional reasons, the automotive industry is mainly involved in the automotive interior and exterior lighting technology with transparent plastic instead of inorganic glass technology. This article will share some ideas with you on automotive lighting technology, transparent plastic and lightweight.
Automotive lighting or optical systems mainly include window glass, windshield, car lights, atmosphere lights, etc.
2.1substitute material
PC(polycarbonate)20century80s, the energy crisis prompted Japan to formally put forward the concept of lightweight cars and design new models that effectively save energy consumption and raw materials. The injection molding process is used to produce automobile headlights, which improves the degree of automation and further improves the lightweight design level of enterprise lamps.PCdue to its strong impact resistance, it is equivalent250times of inorganic glass was first used instead of glass in the headlight cover. The reflector and the bracket body were all made of plastic injection molding, lampshade and the lamp body are assembled by adhesive bonding or welding, which reduces the weight of traditional glass lamps by up20-60%. In addition, the decorative function part of the car lamp modeling makes usePCexcellent optical and coloring performance, using transparent coloredPCmaking decorative strips, or spraying primer and aluminizing for flexible application; Aluminum plating of reflector die castings is changedPC,BMC,PEEK,LCP, reduces the quality by up80%, and the production process is greatly simplified. It is relatively complicated to change the luminous color of the bulb in the lamp, and the indicator light needs to emit a specific color of light, and use colored transparencyPCorPMMAis very convenient for the injection molding process. Among these transparent colored plastics, the heat resistance and weather resistance of the color masterbatch are very important. When used as an external part, most of the surface coated hard film is used.PC, thus further improving scratch resistance and weather resistance, brighter than glass lenses, more resistant to breakage, better shape precision plastic. And it can absorb impact energy and vibration energy to reduce the damage to the human body during a collision and improve the safety factor of the car. Parts such as reflectors and decorative rings are electroplated or aluminized. In car lights, except for heat dissipation components, they can basically be replaced by plastic parts, and the weight reduction technology is relatively mature.
PMMA (polymethyl methacrylate), commonly known as acrylic or plexiglass, is an amorphous, fragrant, non-toxic and transparent thermoplastic. It has excellent physical and mechanical properties, dielectric and electrical insulation properties, excellent optical properties and other advantages. withPCis widely used in injection molding production of light guide bars, lenses, etc. After modification and coating,PMMAis not only widely used in automobile interior and exterior decorations, automobile lights and other parts that improve the beauty of automobiles, but also has been gradually applied to the manufacture of side windows, sunroofs, triangular windows, rear windows, interior atmosphere lights,HUDstructural and functional components such as head-up displays play an active role in reducing the quality of the car and improving the performance of the car in all aspects. For example, we are in"ABB"and other large-scale applications in automobiles8N(PMMA)and Bayer's2245,2045is used in the production of light guide bars and lenses. When transparent plastic is used for windows and sunroofs and windshields, it is lighter than traditional glass40%~50%, such as Buick's new generationGL8usesPCis manufactured, it is relieved that44440%(3kg). This has played a positive role in reducing fuel consumption and is conducive to environmental protection. Because plastic is easy to process, it is suitable for designing and manufacturing windows with great curvature, so as to meet the needs of designers with different modeling designs. At the same time,PMMAof its stable and clear and transparent characteristics to ultraviolet rays is excellent. At present4,5,6mmEvonikPMMAraw materials for windows have been passed through the European Union.ECER43"Uniform Provisions on Certification of Safety Glass and Materials" regulatory certification testing.
LSRliquid silicone rubber, optical grade liquid silicone injection molding lens, as a new optical material, has the transparency second only to glass, and is stable and does not change color under long-term exposure to high temperature or ultraviolet rays, has certain flexibility, scratch resistance and crack resistance. In particular, the low viscosity characteristics of the material can pass through a very thin filling path or fill a very small space structure, which means that it can be used to form some special-shaped matrix high-precision lenses, and this is the newAIrequired for lighting, small in size and light in weight,.
2.2Process Design, since the shape required by the designer can be easily manufactured, the data obtained from reliability and durability tests can be linked, effective assessment of fatigue strength of lamp components and implementation of equal life design. Under the vehicle life requirements, in addition to wearing parts, the life of other parts also tends to approach, prevents unnecessary long life of some lamp parts, can also reduce consumables and weight.
2.3New Light Sources LED, laser and other lamp source technologies, glass lenses in car lights are also being replaced by plastic lenses on a large scale, especiallyLEDthe production of lamp source has become economical, the working temperature of lens can be greatly reduced, the molding efficiency of injection lens is high, the energy consumption in the production process is low, the process is less, and the pollution is less than that of glass lens. In particular, complex parts can be obtained by injection molding, which can be directly assembled or welded with each other, thus reducing the number of assembly parts and installation cost. The weight is only the 1/5 of plastic lens, the shock and vibration intensity requirements of the steering mechanism are significantly reduced in the follow-up steering headlights. Similarly, due to the development of light source and light guide strip technology, the atmosphere lamp adopts three colors or multiple colors.LEDcombination of adjustable lighting designs the interior layout through the atmosphere light guide strip, and the atmosphere effect of tens of millions of colors can be set at will, while the size and weight are only about one tenth of the traditional atmosphere structure.OLEDon indicator lights and decorative lights has also become richer, lighter and more three-dimensional. The taillight shown in the following figure is adopted.OLEDandLEDcombination technology, low power consumption and light weight.
2.4Changes Caused by Development of Automotive Electronics Technology , under the current situation that the proportion of automotive electronics and electricity is gradually increasing, new design technologies can be used, and then achieve the purpose of replacing mechanical functions with electronics, and finally can effectively reduce mechanical parts and weight. At present, Marelli, Hella, OSRAM, including Mercedes-Benz, BMW, Audi, and other companies have launched someADBheadlights, some of which have been put into mass production applications, from Audi9beam,84pixels, to the tested1024pixel intelligent projection headlights, the once popular high-end follow-up steering or directional lighting have been added with more accurate pixel lighting technology elements, and even directly replaced by iteration, without complex mechanical steering mechanism, replaced by high pixel electronic lighting system, low heat generation, light weight and higher safety.
Above
the geometric multi-beam LED headlights (MULTIBEAM LEDs) currently used in Mercedes-Benz models have 84 independently controlled LED light-emitting units. The new technology reduces this number to 3, but each LED light-emitting unit contains 1024 controllable light spots. In this way, the new smart pixel LED headlights can more accurately illuminate the road ahead.
3Lighting, Transparent Plastic Technology and New Energy Vehicles
car lightweight is not only suitable for traditional fuel vehicles, for new energy electric vehicles, reducing the weight of the body and achieving vehicle lightweight is also very important, because it is related to the main battery life of new energy vehicles. Relevant research in the field of lightweight technology shows that the reduction of weight directly means the increase of cruising range. Such as pure electric vehicles If the weight of the whole vehicle is reduced10kg, the driving range can be increased2.5km, to improve the driving range of electric vehicles, in addition to strengthening the battery and drive system, weight reduction is the key. As we mentioned above, the continuous development of lighting technology, simplified structure and materials replaced by plastic have greatly reduced the weight of lights. What is the difference between the development of new lighting technology for traditional power vehicles and new energy vehicles? In addition to the most important benefits of weight reduction on cruising range, the low energy consumption of the new lighting technology will significantly reduce the consumption of the lighting system on the power storage system, so that more power will be used to drive the cruising range, especially the newLEDor laser headlights pixelated technology changes, car headlights do not need reflective bowls, the layout can be more flexible and compact, weight loss and its own low power consumption characteristics are more advantageous. We are planning to develop large-scale special injection molding machines, and study the technology of transparent plastic instead of glass windows and even the overall roof. If it can be applied in a mature and economical way, in addition to simplifying the manufacturing process and reducing the energy consumption of the manufacturing itself, it will contribute more to the overall weight reduction of the car. Will exceed50Kgabove.
conclusion, statistics show that,20165.56billion tons of oil, about half of which is consumed by cars. With the shortage of resources and the deterioration of the environment, energy conservation and emission reduction has become the main theme of the current development of the automobile industry. As a strategic industry in my country, new energy has become an important measure to realize the sustainable development strategy of the automobile industry. Lighting and transparent plastic alternative technologies will also contribute to the lightweight journey of energy saving and emission reduction.
