EP2776509A1 - Vehicle light bezels - Google Patents
Vehicle light bezelsInfo
- Publication number
- EP2776509A1 EP2776509A1 EP12784252.4A EP12784252A EP2776509A1 EP 2776509 A1 EP2776509 A1 EP 2776509A1 EP 12784252 A EP12784252 A EP 12784252A EP 2776509 A1 EP2776509 A1 EP 2776509A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- vehicle light
- polyamide
- bezel according
- polymer composition
- respect
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 239000000203 mixture Substances 0.000 claims abstract description 37
- 229920000642 polymer Polymers 0.000 claims abstract description 31
- 229920006394 polyamide 410 Polymers 0.000 claims abstract description 14
- 239000002482 conductive additive Substances 0.000 claims abstract 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 13
- 239000006082 mold release agent Substances 0.000 claims description 10
- 229910052751 metal Inorganic materials 0.000 claims description 7
- 239000002184 metal Substances 0.000 claims description 7
- 229910002804 graphite Inorganic materials 0.000 claims description 5
- 239000010439 graphite Substances 0.000 claims description 5
- 229920002292 Nylon 6 Polymers 0.000 claims description 3
- 229920000305 Nylon 6,10 Polymers 0.000 claims description 3
- 229920002302 Nylon 6,6 Polymers 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 3
- 239000003365 glass fiber Substances 0.000 claims description 3
- 239000012760 heat stabilizer Substances 0.000 claims description 3
- 229910000669 Chrome steel Inorganic materials 0.000 claims description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 2
- 229910001220 stainless steel Inorganic materials 0.000 claims description 2
- 239000010935 stainless steel Substances 0.000 claims description 2
- 238000010943 off-gassing Methods 0.000 description 14
- 239000004020 conductor Substances 0.000 description 10
- 239000000463 material Substances 0.000 description 9
- 229910052799 carbon Inorganic materials 0.000 description 8
- NLKNQRATVPKPDG-UHFFFAOYSA-M potassium iodide Chemical compound [K+].[I-] NLKNQRATVPKPDG-UHFFFAOYSA-M 0.000 description 8
- 239000004952 Polyamide Substances 0.000 description 7
- 235000014113 dietary fatty acids Nutrition 0.000 description 7
- 239000000194 fatty acid Substances 0.000 description 7
- 229930195729 fatty acid Natural products 0.000 description 7
- 229920002647 polyamide Polymers 0.000 description 7
- 125000004432 carbon atom Chemical group C* 0.000 description 6
- 150000004665 fatty acids Chemical class 0.000 description 5
- 150000004985 diamines Chemical class 0.000 description 4
- 238000001465 metallisation Methods 0.000 description 4
- IOLCXVTUBQKXJR-UHFFFAOYSA-M potassium bromide Chemical compound [K+].[Br-] IOLCXVTUBQKXJR-UHFFFAOYSA-M 0.000 description 4
- 150000003839 salts Chemical class 0.000 description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 239000005749 Copper compound Substances 0.000 description 3
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- 150000001880 copper compounds Chemical class 0.000 description 3
- GBRBMTNGQBKBQE-UHFFFAOYSA-L copper;diiodide Chemical compound I[Cu]I GBRBMTNGQBKBQE-UHFFFAOYSA-L 0.000 description 3
- 239000000945 filler Substances 0.000 description 3
- 239000000178 monomer Substances 0.000 description 3
- 239000013585 weight reducing agent Substances 0.000 description 3
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 2
- 238000009825 accumulation Methods 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid group Chemical group C(CCCCC(=O)O)(=O)O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical class [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 2
- 239000006229 carbon black Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000000151 deposition Methods 0.000 description 2
- 230000008021 deposition Effects 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- -1 fatty acid metals salts Chemical class 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 239000005431 greenhouse gas Substances 0.000 description 2
- NAQMVNRVTILPCV-UHFFFAOYSA-N hexane-1,6-diamine Chemical group NCCCCCCN NAQMVNRVTILPCV-UHFFFAOYSA-N 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 229920000515 polycarbonate Polymers 0.000 description 2
- 239000004417 polycarbonate Substances 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- KIDHWZJUCRJVML-UHFFFAOYSA-N putrescine Chemical compound NCCCCN KIDHWZJUCRJVML-UHFFFAOYSA-N 0.000 description 2
- 239000001993 wax Substances 0.000 description 2
- 229910017083 AlN Inorganic materials 0.000 description 1
- PIGFYZPCRLYGLF-UHFFFAOYSA-N Aluminum nitride Chemical compound [Al]#N PIGFYZPCRLYGLF-UHFFFAOYSA-N 0.000 description 1
- 229910052582 BN Inorganic materials 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- 229910001369 Brass Inorganic materials 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- VMQMZMRVKUZKQL-UHFFFAOYSA-N Cu+ Chemical compound [Cu+] VMQMZMRVKUZKQL-UHFFFAOYSA-N 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229920003189 Nylon 4,6 Polymers 0.000 description 1
- 240000007594 Oryza sativa Species 0.000 description 1
- 235000007164 Oryza sativa Nutrition 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical group OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 239000001361 adipic acid Substances 0.000 description 1
- 235000011037 adipic acid Nutrition 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
- 150000003842 bromide salts Chemical class 0.000 description 1
- GHWVXCQZPNWFRO-UHFFFAOYSA-N butane-2,3-diamine Chemical group CC(N)C(C)N GHWVXCQZPNWFRO-UHFFFAOYSA-N 0.000 description 1
- 235000013539 calcium stearate Nutrition 0.000 description 1
- 239000008116 calcium stearate Substances 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000011231 conductive filler Substances 0.000 description 1
- 150000001879 copper Chemical class 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 229910000365 copper sulfate Inorganic materials 0.000 description 1
- ARUVKPQLZAKDPS-UHFFFAOYSA-L copper(II) sulfate Chemical compound [Cu+2].[O-][S+2]([O-])([O-])[O-] ARUVKPQLZAKDPS-UHFFFAOYSA-L 0.000 description 1
- OPQARKPSCNTWTJ-UHFFFAOYSA-L copper(ii) acetate Chemical compound [Cu+2].CC([O-])=O.CC([O-])=O OPQARKPSCNTWTJ-UHFFFAOYSA-L 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 150000001991 dicarboxylic acids Chemical class 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000007717 exclusion Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- XMBWDFGMSWQBCA-UHFFFAOYSA-N hydrogen iodide Chemical compound I XMBWDFGMSWQBCA-UHFFFAOYSA-N 0.000 description 1
- 238000005286 illumination Methods 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- UTOPWMOLSKOLTQ-UHFFFAOYSA-M octacosanoate Chemical compound CCCCCCCCCCCCCCCCCCCCCCCCCCCC([O-])=O UTOPWMOLSKOLTQ-UHFFFAOYSA-M 0.000 description 1
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 1
- WGOROJDSDNILMB-UHFFFAOYSA-N octatriacontanediamide Chemical compound NC(=O)CCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCC(N)=O WGOROJDSDNILMB-UHFFFAOYSA-N 0.000 description 1
- 239000012188 paraffin wax Substances 0.000 description 1
- 235000019809 paraffin wax Nutrition 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 235000019271 petrolatum Nutrition 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920006375 polyphtalamide Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 235000009566 rice Nutrition 0.000 description 1
- CXMXRPHRNRROMY-UHFFFAOYSA-N sebacic acid Chemical compound OC(=O)CCCCCCCCC(O)=O CXMXRPHRNRROMY-UHFFFAOYSA-N 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 239000000344 soap Substances 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 125000000383 tetramethylene group Chemical group [H]C([H])([*:1])C([H])([H])C([H])([H])C([H])([H])[*:2] 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L77/00—Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Compositions of derivatives of such polymers
- C08L77/06—Polyamides derived from polyamines and polycarboxylic acids
Definitions
- This invention relates to vehicle light bezels, also referred herein as bezel.
- Bezels are known and are usually made from polycarbonate or polyesters, such as poly(butylene terephtalate) (PBT).
- PBT poly(butylene terephtalate)
- US2010/00227182 describes a bezel comprising a thermoplastic polyester.
- As bezels are near a light source, such as headlights, rear lights, fog lamps, daytime running lights (DRL) and interior lights, it is required that they can withstand heat. Withstanding heat implies that the heat deflection temperature (HDT) of a bezel has to be sufficient, as well as low outgassing is necessary.
- HDT heat deflection temperature
- Outgassing is also referred to as fogging and is in the context of this application understood to be the deposition of volatile compounds, originating from the plastic composition of a bezel and volatilized by heating of the lamp and/or LED units under operating condition, on cold spots such as the lens and reflector, or other areas affecting the visual appearance or headlamp illumination performance.
- Measures applied to reduce fogging include, for example, exclusion of solvents in the
- Another solution relates to special designs of the moulded part, or of the mirror optic system as a whole, as a result of which an internal air flow is induced when the vehicle is moving and the material contributing to fogging is guided away from the critical part, thus resulting in reduced deposition of the material contributing to fogging on that part.
- Bezels are parts that are usually relatively heavy, such as for example between 200 and 300 g per bezel. Weight reduction has a positive influence on fuel consumption in cars, and thus it is desirable to have less heavy bezels.
- the parts are also quite large, it is usually necessary to prepare bezels with relatively large thickness, as otherwise the mould is not completely filled, due to flowing properties of the material used.
- a vehicle light bezel produced from a polymer composition comprising at least 30 wt% of polyamide-410 with respect to the total composition, combines the properties of dimensional stability and allowing for less wall thickness, which allows bezels to be much lighter in weight. This has been exemplified in the examples below.
- An advantage of a bezel according to the invention is that the surface quality is high, as well as high dimensional stability. Moreover, bezels with lower wall thickness can be prepared, which allows for less heavy bezels. Also less orange peel is observed on the surface of a bezel according to the invention. Another advantage is that the outgassing limit, i.e. the temperature at which no outgassing is observed, of the bezel according to the invention is high.
- Polyamide-410 is here understood to be a polyamide containing monomer units derived from a dicarboxylic acid with 10 carbon atoms and a diamine with 4 carbon atoms.
- the dicarboxylic acid 1 ,10 decandioic acid is used.
- the diamine preferably 1 ,4-butanediamine is used.
- PA-410 may comprise up to 30 wt. % of further monomeric units, for example dicarboxylic acids with more or less than 10 carbon atoms or diamines with more or less than 4 carbon atoms, with respect to the total amount of polyamide.
- the PA-410 used in the bezel according to the invention comprises at least 80 wt.
- % with respect to the total amount of polyamide of monomer units derived from dicarboxylic acid with 10 carbon atoms and a diamine with 4 carbon atoms, more preferably at least 90 wt. % with respect to the total amount of polyamide, even more preferably at least 95 wt. % with respect to the total amount of polyamide, even more preferably at least 99 wt. %, most preferably at least 99.9 wt. %, with respect to the total amount of polyamide.
- the bezel according to the invention preferably is produced from a polymer composition comprising at least 40 wt% of polyamide-410 with respect to the total composition, more preferably at least 50 wt % of polyamide-410, and most preferred at least 60 wt% of polyamide-410.
- the bezel according to the invention can also comprise a further polymer in the polymer composition, such as polyamides and/or polyphtalamides.
- the further polymer is for example chosen from the group of polyamide-610, polyamide-6, polyamide-66, polyamide-46 and aromatic copolyamides.
- Polyamide-610 as further polymer has the advantage that the surface quality remains high.
- Polyamide-6 or polyamide-66 as further polymer have the advantage that these are readily available.
- Even more preferred is a further polymer being a copolyamide, based on monomeric units of adipic acid, terephtalic acid, hexamethylene diamine and diaminobutane. This has the advantage that the temperature resistance is improved, as well as moisture uptake is decreased.
- the amount of a further polymer may be for example at least 5 wt%, preferably at least 10 wt% with respect to the total amount of polymer
- the amount may be preferably at most 50 wt%, more preferably at most 40 wt% with respect to the total amount of polymer composition.
- Polyamide-410 can be prepared as for example described in
- the bezel according to the invention can be prepared by injection molding, which is a technique known in the art.
- the bezel according to the invention may have a shiny surface, as well as a matt surface.
- Surface class A has been observed for bezels according to the invention.
- Surface class A surfaces is a term used in automotive design to describe a set of freeform surfaces of high efficiency and quality.
- the bezel according to the invention may also be treated by for example metallization to at least one surface, to provide a metal look.
- Metallization is usually vacuum metallization either via direct or indirect metallization. This results in a bezel comprising at least one surface having a metal layer. This has the advantage that the bezel can also serve as a reflector for the light source.
- the metal layer may be selected from the group of aluminum, chrome, and stainless steel.
- the bezel according to the invention may also comprise other materials in the polymer composition, such as heat-stabilizers, mold-release agents, pigments, thermal conductive materials, electrical conductive materials and fillers.
- Fillers include for example minerals, glass fibers and carbon fibers. Typical amount of fillers are for example amounts between 10 to 30 wt%, with respect to the total composition. Preferably, the filler is glass fiber in an amount between 10 to 30 wt% with respect to the total composition.
- Heat-stabilizers may be copper compounds and a salt containing a halogenide acid group, for example an iodide or a bromide salt.
- suitable copper compounds include copper (I) halogenides, preferably copper iodide (Cul) and further copper salts like for instance copper acetate, copper sulfate and cupper stearate.
- copper (I) halogenides preferably copper iodide (Cul) and further copper salts like for instance copper acetate, copper sulfate and cupper stearate.
- the salt containing an halogenide acid group preferably potassium bromide (KBr) of potassium iodide (Kl) are used. Most preferably a combination of copper iodide and potassium iodide (Cul/KI) is used.
- the amount of Cu preferably is between 10 - 500 ppm, based on the total of the composition, more preferably between 1 - 100 ppm, even more preferably 10 - 70 ppm.
- Thermal conductive materials include for example, aluminium, aluminium oxide, copper, magnesium, magnesium oxide, brass, carbon, silicon nitride, aluminium nitride, boron nitride, zinc oxide, graphite, ceramic fibre and the like.
- thermally conductive materials may be in the form of granular powder, particles, whiskers, short fibres, flake, platelet, rice, strand, or spherical-like shapes or any other suitable form.
- the thermal conductive material is preferably present in an amount between 1 to 10 wt% with respect to the total polymer composition, more preferably between 2 and 7 wt% with respect to the total polymer composition.
- the thermal conductive material are expanded graphite platelets, or PITCH-based carbon fibres, as these are also electrical conductive.
- PITCH-based carbon fibre having an aspect ratio of about 50:1 can be used.
- PITCH-based carbon fibres contribute significantly to the heat conductivity.
- expanded graphite platelets are present in an amount between 2 and 7 wt%, as this keeps the dielectrical strength high and thus leaves the bezel insulating. This amount also reduces the risk for electrical charge and discharge and consequent damage brought to LED electronics systems and/or other electronic parts.
- PITCH-based carbon fibres PAN-based carbon fibres as well as carbon black may be employed. Electrical conductive materials have the advantage that dust accumulation is reduced. PAN-based carbon fibres have a larger contribution to the mechanical strength.
- Pigments include for example carbon black and nigrosine.
- the polymer composition of the bezel according to the present invention contains less than 1 wt. % more preferably less than 0.5 wt. %, even more preferably less than 0.3 wt. %, even more preferably less than 0.2 wt. %, even more preferably less than 0.1 wt. % of a mold release agent, with respect to the total composition.
- a mold release agent is a chemical compound that facilitates the release of a part from a mold, preferably by creating a slip effect between the surface of the part and the surface of the mold cavity.
- mold release agents include fatty acids, fatty acid metals salts, fatty acid esters, fatty acid amides, fatty acid soaps, (modified) paraffin waxes, (modified) polyolefin waxes.
- the mold release agents are chosen from the group of fatty acids, such as for example metal salts of stearates especially sodium, zinc or calcium stearate or montanate, and polyetheylene wax and an fatty acid amide such as ethylen-bis-stearamide or combinations thereof.
- the polymer composition does not contain any mold release agent at all.
- the bezel according to the invention produced from the polymer composition comprising PA-410, still show very good mold release characteristics, but also have a very good surface quality.
- the outgassing limit also remains high, as the presence of a mold release agent is disadvantageous for outgassing.
- the bezel according to the invention is no longer fully based on fossil carbon, since polyamide-410 may be at least partly based on renewable resources. This is especially an advantage, even if the polymer composition of the bezel only contains a fraction of polyamide-410 and also a further polymer.
- a bezel is a relatively heavy part of a vehicle and therefore these products contribute strongly to the production of green house gases.
- Employing PA410 in bezels which is at least partly based on monomers originating from natural resources already provides an important decrease in the production of green house gases for bezels and vehicles in general.
- the bezel according to the invention allows for recycling as it has a high thermal stability, and shows very high outgassing limit compared to other bio-based materials.
- the minimum thickness required for a bezel is usually determined by the choice of material. Good flowing material allows for thinner parts, which is beneficial for weight reduction.
- State of the art bezels made from polycarbonate for example usually have a thickness around 2.5 mm when pressures around 150 bar are used to fill the mold.
- the bezel according to the present invention surprisingly shows that thicknesses of less than 2 mm can be used, while still obtaining sufficient filling of the mold. This allows for substantial weight reduction per bezel.
- Heat deflection temperature under load (0.45 MPa) was measured according to ISO 7501/-2. Water absorption was measured according to ISO 62 at 100% relative humidity. Outgassing limits were measured on injection molded plates of 80x80x2mm. A plate was inserted in a thermally isolated clean oven. Within 10 cm above the plate, a mirror of 70x70mm was placed. The mirror was cooled to 60 °C by air in a controlled manner. The plate was heated for 4 hours at a constant temperature in a controlled manner. Each test was performed on a new specimen and several temperatures were measured. The maximum temperature at which no deposit was visible on the mirror is denoted as the outgassing limit. The experiments were performed in duplo. The results are shown in Table 1.
- Table 1 clearly shows that the material comprising polyamide-410 combines a high HDT, which is a measure for heat resistance, together with high outgassing limit and low moisture absorption.
Landscapes
- Chemical & Material Sciences (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
The invention relates to a vehicle light bezel produced from a polymer composition comprising at least 30 wt% of polyamide-410 with respect to the total composition. Preferably, the vehicle light bezel is produced from a polymer composition further comprising a thermal conductive additive.
Description
VEHICLE LIGHT BEZELS
This invention relates to vehicle light bezels, also referred herein as bezel. Bezels are known and are usually made from polycarbonate or polyesters, such as poly(butylene terephtalate) (PBT). US2010/00227182, for example, describes a bezel comprising a thermoplastic polyester. As bezels are near a light source, such as headlights, rear lights, fog lamps, daytime running lights (DRL) and interior lights, it is required that they can withstand heat. Withstanding heat implies that the heat deflection temperature (HDT) of a bezel has to be sufficient, as well as low outgassing is necessary. Outgassing is also referred to as fogging and is in the context of this application understood to be the deposition of volatile compounds, originating from the plastic composition of a bezel and volatilized by heating of the lamp and/or LED units under operating condition, on cold spots such as the lens and reflector, or other areas affecting the visual appearance or headlamp illumination performance. Measures applied to reduce fogging include, for example, exclusion of solvents in the
composition; thinner designs for the moulded parts, thus reducing the amount of material contributing to fogging; and insulating the part by applying a coating. Another solution relates to special designs of the moulded part, or of the mirror optic system as a whole, as a result of which an internal air flow is induced when the vehicle is moving and the material contributing to fogging is guided away from the critical part, thus resulting in reduced deposition of the material contributing to fogging on that part.
Moreover, as bezels are visible parts in the automotive industry, the surface quality has to be high. Outgassing is not desired as it deteriorates the surface quality, reduces light transmission of lenses and increases light reflection losses of light reflecting area's, such as reflectors.
Bezels are parts that are usually relatively heavy, such as for example between 200 and 300 g per bezel. Weight reduction has a positive influence on fuel consumption in cars, and thus it is desirable to have less heavy bezels. However, as the parts are also quite large, it is usually necessary to prepare bezels with relatively large thickness, as otherwise the mould is not completely filled, due to flowing properties of the material used.
It is thus an object of the present invention to provide vehicle light bezels that combine both dimensional stability, low outgassing properties, while being lighter in weight than those known in the prior art.
It has now surprisingly been found that a vehicle light bezel produced from a polymer composition comprising at least 30 wt% of polyamide-410 with respect to the total composition, combines the properties of dimensional stability and allowing for less wall thickness, which allows bezels to be much lighter in weight. This has been exemplified in the examples below.
An advantage of a bezel according to the invention is that the surface quality is high, as well as high dimensional stability. Moreover, bezels with lower wall thickness can be prepared, which allows for less heavy bezels. Also less orange peel is observed on the surface of a bezel according to the invention. Another advantage is that the outgassing limit, i.e. the temperature at which no outgassing is observed, of the bezel according to the invention is high.
Polyamide-410
Polyamide-410 is here understood to be a polyamide containing monomer units derived from a dicarboxylic acid with 10 carbon atoms and a diamine with 4 carbon atoms. Preferably as the dicarboxylic acid 1 ,10 decandioic acid is used. As the diamine preferably 1 ,4-butanediamine is used. PA-410 may comprise up to 30
wt. % of further monomeric units, for example dicarboxylic acids with more or less than 10 carbon atoms or diamines with more or less than 4 carbon atoms, with respect to the total amount of polyamide. Preferably the PA-410 used in the bezel according to the invention comprises at least 80 wt. % with respect to the total amount of polyamide of monomer units derived from dicarboxylic acid with 10 carbon atoms and a diamine with 4 carbon atoms, more preferably at least 90 wt. % with respect to the total amount of polyamide, even more preferably at least 95 wt. % with respect to the total amount of polyamide, even more preferably at least 99 wt. %, most preferably at least 99.9 wt. %, with respect to the total amount of polyamide.
The bezel according to the invention preferably is produced from a polymer composition comprising at least 40 wt% of polyamide-410 with respect to the total composition, more preferably at least 50 wt % of polyamide-410, and most preferred at least 60 wt% of polyamide-410.
The bezel according to the invention can also comprise a further polymer in the polymer composition, such as polyamides and/or polyphtalamides. The further polymer is for example chosen from the group of polyamide-610, polyamide-6, polyamide-66, polyamide-46 and aromatic copolyamides. Polyamide-610 as further polymer has the advantage that the surface quality remains high. Polyamide-6 or polyamide-66 as further polymer have the advantage that these are readily available. Even more preferred is a further polymer being a copolyamide, based on monomeric units of adipic acid, terephtalic acid, hexamethylene diamine and diaminobutane. This has the advantage that the temperature resistance is improved, as well as moisture uptake is decreased. The amount of a further polymer may be for example at least 5 wt%, preferably at least 10 wt% with respect to the total amount of polymer
composition. The amount may be preferably at most 50 wt%, more preferably at most 40 wt% with respect to the total amount of polymer composition.
Polyamide-410 can be prepared as for example described in
WO00/09586. Bezel
The bezel according to the invention can be prepared by injection molding, which is a technique known in the art. The bezel according to the invention may have a shiny surface, as well as a matt surface. Surface class A has been observed for bezels according to the invention. Surface class A surfaces is a term used in automotive design to describe a set of freeform surfaces of high efficiency and quality.
The bezel according to the invention may also be treated by for example metallization to at least one surface, to provide a metal look. Metallization is usually vacuum metallization either via direct or indirect metallization. This results in a bezel comprising at least one surface having a metal layer. This has the advantage that the bezel can also serve as a reflector for the light source. The metal layer may be selected from the group of aluminum, chrome, and stainless steel.
The bezel according to the invention may also comprise other materials in the polymer composition, such as heat-stabilizers, mold-release agents, pigments, thermal conductive materials, electrical conductive materials and fillers. Fillers include for example minerals, glass fibers and carbon fibers. Typical amount of fillers are for example amounts between 10 to 30 wt%, with respect to the total composition. Preferably, the filler is glass fiber in an amount between 10 to 30 wt% with respect to the total composition.
Heat-stabilizers may be copper compounds and a salt containing a halogenide acid group, for example an iodide or a bromide salt. Good examples of suitable copper compounds include copper (I) halogenides, preferably copper iodide
(Cul) and further copper salts like for instance copper acetate, copper sulfate and cupper stearate. As the salt containing an halogenide acid group preferably potassium bromide (KBr) of potassium iodide (Kl) are used. Most preferably a combination of copper iodide and potassium iodide (Cul/KI) is used. The copper compound and the salt suitably are present in the polymer composition for the bezel according to the invention in a molar ratio of Cu : halogenide = 1 : 5 - 15. The amount of Cu preferably is between 10 - 500 ppm, based on the total of the composition, more preferably between 1 - 100 ppm, even more preferably 10 - 70 ppm.
Thermal conductive materials include for example, aluminium, aluminium oxide, copper, magnesium, magnesium oxide, brass, carbon, silicon nitride, aluminium nitride, boron nitride, zinc oxide, graphite, ceramic fibre and the like.
Mixtures of such thermally conductive materials are also suitable. The thermally conductive material may be in the form of granular powder, particles, whiskers, short fibres, flake, platelet, rice, strand, or spherical-like shapes or any other suitable form. The thermal conductive material is preferably present in an amount between 1 to 10 wt% with respect to the total polymer composition, more preferably between 2 and 7 wt% with respect to the total polymer composition.
Preferably, the thermal conductive material are expanded graphite platelets, or PITCH-based carbon fibres, as these are also electrical conductive. For example, PITCH-based carbon fibre having an aspect ratio of about 50:1 can be used. PITCH-based carbon fibres contribute significantly to the heat conductivity. The presence of expanded graphite platelets as thermal conductive material in the present invention results in lower outgassing behaviour of the bezel during use, better performance and makes the bezel anti-static, which is beneficial against dust accumulation.
Most preferred, expanded graphite platelets are present in an amount between 2 and 7 wt%, as this keeps the dielectrical strength high and thus leaves the bezel insulating. This amount also reduces the risk for electrical charge and discharge and consequent damage brought to LED electronics systems and/or other electronic parts.
As electrical conductive materials PITCH-based carbon fibres, PAN- based carbon fibres as well as carbon black may be employed. Electrical conductive materials have the advantage that dust accumulation is reduced. PAN-based carbon fibres have a larger contribution to the mechanical strength.
Pigments include for example carbon black and nigrosine.
Preferably the polymer composition of the bezel according to the present invention contains less than 1 wt. % more preferably less than 0.5 wt. %, even more preferably less than 0.3 wt. %, even more preferably less than 0.2 wt. %, even more preferably less than 0.1 wt. % of a mold release agent, with respect to the total composition. A mold release agent is a chemical compound that facilitates the release of a part from a mold, preferably by creating a slip effect between the surface of the part and the surface of the mold cavity. Examples of mold release agents include fatty acids, fatty acid metals salts, fatty acid esters, fatty acid amides, fatty acid soaps, (modified) paraffin waxes, (modified) polyolefin waxes. Preferably, the mold release agents are chosen from the group of fatty acids, such as for example metal salts of stearates especially sodium, zinc or calcium stearate or montanate, and polyetheylene wax and an fatty acid amide such as ethylen-bis-stearamide or combinations thereof. Most preferably the polymer composition does not contain any mold release agent at all. With the low amount or even with the total absence of the mold release agent, the bezel according to the invention, produced from the polymer composition comprising PA-410, still show very good mold release characteristics, but also have a very good
surface quality. A low amount or even with the total absence of the mold release agent, the outgassing limit also remains high, as the presence of a mold release agent is disadvantageous for outgassing.
Another important improvement is that the bezel according to the invention is no longer fully based on fossil carbon, since polyamide-410 may be at least partly based on renewable resources. This is especially an advantage, even if the polymer composition of the bezel only contains a fraction of polyamide-410 and also a further polymer. A bezel is a relatively heavy part of a vehicle and therefore these products contribute strongly to the production of green house gases. Employing PA410 in bezels which is at least partly based on monomers originating from natural resources already provides an important decrease in the production of green house gases for bezels and vehicles in general. Moreover, the bezel according to the invention allows for recycling as it has a high thermal stability, and shows very high outgassing limit compared to other bio-based materials.
The minimum thickness required for a bezel is usually determined by the choice of material. Good flowing material allows for thinner parts, which is beneficial for weight reduction. State of the art bezels made from polycarbonate for example usually have a thickness around 2.5 mm when pressures around 150 bar are used to fill the mold. The bezel according to the present invention surprisingly shows that thicknesses of less than 2 mm can be used, while still obtaining sufficient filling of the mold. This allows for substantial weight reduction per bezel.
Examples
Heat deflection temperature under load (0.45 MPa) was measured according to ISO 7501/-2. Water absorption was measured according to ISO 62 at 100% relative humidity. Outgassing limits were measured on injection molded plates of
80x80x2mm. A plate was inserted in a thermally isolated clean oven. Within 10 cm above the plate, a mirror of 70x70mm was placed. The mirror was cooled to 60 °C by air in a controlled manner. The plate was heated for 4 hours at a constant temperature in a controlled manner. Each test was performed on a new specimen and several temperatures were measured. The maximum temperature at which no deposit was visible on the mirror is denoted as the outgassing limit. The experiments were performed in duplo. The results are shown in Table 1.
Table 1 Outgassing limit
Table 1 clearly shows that the material comprising polyamide-410 combines a high HDT, which is a measure for heat resistance, together with high outgassing limit and low moisture absorption.
Claims
Vehicle light bezel produced from a polymer composition comprising at least
30 wt% of polyamide-410 with respect to the total composition.
Vehicle light bezel according to claim 1 in which the polymer composition comprises at least 40 wt% of polyamide-410 with respect to the total composition.
Vehicle light bezel according to claim 1 or 2, in which the polymer composition comprises at most 1 wt% of a mold release agent, with respect to the total composition.
Vehicle light bezel according to any of the claims above, in which the polymer composition comprises a further polymer.
Vehicle light bezel according to claim 4, in which the further polymer is chosen from the group of polyamide-6, polyamide-66 and polyamide-610.
Vehicle light bezel according to any of the claims above, in which the polymer composition comprises a heat stabilizer.
Vehicle light bezel according to any of the claims above, in which the polymer composition further comprises 10 to 30 wt% glass fibers, with respect to the total composition.
Vehicle light bezel according to any of the claims above, in which the polymer composition further comprises a thermal conductive additive in an amount of between 1 to 10 wt% with respect to the total composition.
Vehicle light bezel according to claim 8, in which the thermal conductive additive is expanded graphite platelet.
Vehicle light bezel according to any of the claims above, further comprising at least one surface having a metal layer.
Vehicle light bezel according to claim 9, in which the metal layer is selected from the group of aluminum, chrome, and stainless steel.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP12784252.4A EP2776509A1 (en) | 2011-11-10 | 2012-11-09 | Vehicle light bezels |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP11188557 | 2011-11-10 | ||
| EP12784252.4A EP2776509A1 (en) | 2011-11-10 | 2012-11-09 | Vehicle light bezels |
| PCT/EP2012/072274 WO2013068536A1 (en) | 2011-11-10 | 2012-11-09 | Vehicle light bezels |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| EP2776509A1 true EP2776509A1 (en) | 2014-09-17 |
Family
ID=47172625
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP12784252.4A Withdrawn EP2776509A1 (en) | 2011-11-10 | 2012-11-09 | Vehicle light bezels |
Country Status (2)
| Country | Link |
|---|---|
| EP (1) | EP2776509A1 (en) |
| WO (1) | WO2013068536A1 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR102234377B1 (en) * | 2014-07-31 | 2021-03-31 | 엘지이노텍 주식회사 | Lamp for vehicle |
| FR3069047A1 (en) * | 2017-07-17 | 2019-01-18 | Valeo Vision | LIGHT DEVICE OF A MOTOR VEHICLE COMPRISING A POLAR ADDITIVE |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| NL1009846C2 (en) * | 1998-08-12 | 2000-02-15 | Dsm Nv | Polyamide product from polytetramethylene diacid amide. |
| US20100227182A1 (en) | 2009-03-03 | 2010-09-09 | E.I. Du Pont De Nemours And Company | Thermoplastic molded vehicle light bezel |
-
2012
- 2012-11-09 WO PCT/EP2012/072274 patent/WO2013068536A1/en not_active Ceased
- 2012-11-09 EP EP12784252.4A patent/EP2776509A1/en not_active Withdrawn
Non-Patent Citations (1)
| Title |
|---|
| See references of WO2013068536A1 * |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2013068536A1 (en) | 2013-05-16 |
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