Eliminating a Vexing Problem — Fog on Headlights

Imagine an automotive lamp that is fog free and weighs less than a conventional one. Hyundai Mobis did more than imagine. It developed new materials that fend off fog and slash weight by 20 percent.

It took only 18 months start of finish for Hyundai Mobis along with Initz (SK Chemical’s subsidiary), a Korean materials supplier, to develop substances with no gas emi

ssions. Furthermore, it is produced locally, while before it had been imported.

There is more to lamp fog than mist getting on it. Fog is created when gases emitted from plastic parts inside the lamp stick to the wall, leading to discoloration. This leads to a safety hazard as it affects light distribution. Gases are formed at high temperatures, which are often present in headlamps.

Global makers have been quite aware of the problem. They addressed it by altering the lamp’s internal structure. This seemed an easier fix than developing new materials, a challenging endeavor.

The inside of a lamp will heat to as high as 200 degrees Celsius, with a big differential between inside and outside temperatures. Added to the mix, it is imperative that the lamp resist humidity and high rigidity to keep its parts from being shaken by strong vibrations.

To address these requirements, Hyundai Mobis added glass fiber to the existing plastic to produce enough rigidity and also added high-molecular weight additives. The result was a material that met humidity and rigidity requirements without producing gases.