PET lightweights LED lighting module in Audi Q7

  • PET based, glass fiber reinforced polymer
  • Heat deflection temperature of 250°C
  • Material overcomes heat distortion and outgassing

ZKW Group, a manufacturer of premium lighting systems for motor vehicles, is using a PET based, glass fiber reinforced polymer to produce the lighting module for the new Audi Q7. Arnite XL-T of Royal DSM resists extreme thermal loads and overcomes challenges such as heat distortion and outgassing.

High thermal loadings of over 235°C as a challenge

Headlights are a key distinguishing feature for a car’s identity and currently LED lighting is the cutting edge of automotive headlamp design. LED, HID and Halogen lighting systems, often combined in one headlight assembly, offer very good performance but also place more restrictions on the use of materials and design. Sunlight radiated into the multiple LED/HID lenses can create localized increases in thermal loadings in excess of 235°C and can cause heat distortion and outgassing of both functional and aesthetic components.

To overcome these challenges, expensive high performance polymers can be used. Or alternatively, additional metal heat shields can be employed. But they do add weight and cost as well as restricting design parameters.

Audi Q7

Arnite XL-T of Royal DSM is used for the lighting module of the new Audi Q7

PET based, glass fiber reinforced polymer

Arnite XL-T, a PET based, glass fiber reinforced polymer with a heat deflection temperature (HDT) of 250°C, overcomes the challenges of heat distortion and outgassing. The thermally conductive material features low outgassing and very good textured surface finish. Due to its special crystallization behavior, a very good surface finish can be obtained, even in glass fibre reinforced grades/variations/options. With its extended thermal conductivity, the material outperforms high heat resistant thermoplastics such as polyether sulfon (PES), polyetherimides (PEI) and polyphthalamides (PPA).

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