Abstract

As automotive lamps are highly integrated, the heat generated from bulbs reduces the light quantity and lifespan of the bulbs. Numerous studies have been actively conducted worldwide on heat dissipation designs and material modifications for heat release. In this study, an analysis was carried out of the mechanical, thermal, and morphological characteristics of Polybutylene Terephthalate (PBT) and Polyamide (PA6) matrix composites containing alumina filler; further, their flowability and injection moldability were also studied. The PA6 matrix that was subjected to an addition of 60% alumina was selected as the sample. To compare the performances of the selected composites with that of the fog lamp reflector manufactured with conventional PBT, fog lamp reflectors were fabricated. When 60% alumina was added, the thermal conductivity was improved. Thus, the maximum temperature of the lamp reflector was reduced, and the heat was transferred to the surroundings; this was in contrast to the fog lamp reflector fabricated with conventional PBT.

Highlights

  • As automotive lamps are highly integrated, the heat generated from bulbs reduces the light quantity and lifespan of the bulbs [1]

  • The mechanical, thermal, and morphological characteristics of polymer matrix composites containing alumina according to the alumina content were compared for their application to automotive lamp reflectors, and their flowability and injection moldability were analyzed

  • A fog was observed at the position of BT2, and the value was 74.4 ◦ C for the Polybutylene Terephthalate (PBT) reflector and 77 ◦ C for the lamp reflector was fabricated through injection molding using PA6 (60) selected based on the analysis

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Summary

Introduction

As automotive lamps are highly integrated, the heat generated from bulbs reduces the light quantity and lifespan of the bulbs [1]. To minimize the deformation of the reflector caused by thermal shocks, many studies have been actively conducted worldwide on heat dissipation design and material change for heat release [3,4,5,6]. As for studies on the geometry of the reflector, research has been conducted on the geometry that improves the heat dissipation performance by designing radiation fins on the reflector. The mechanical, thermal, and morphological characteristics of polymer matrix composites containing alumina based on the alumina content were compared for their application to automotive lamp reflectors, and their flowability and injection moldability were analyzed. When 60% alumina was added, the thermal conductivity was improved and the maximum temperature of the lamp reflector was reduced and the heat was well transferred to the surroundings, compared to the fog lamp reflector fabricated with conventional PBT

Materials and Specimen Fabrication
Characterization
Analysis of Mechanical Characteristics
Analysis of Thermal Conductivity Test Results
Analysis of Flowability Test Results
Spiral of the PBTthe and PA6 compounds according to theduring
Thermogravimetric
Microstructures of the Composites
Reflector
Reflector Fabrication Using Injection Molding
Polycarbonate chambers were constructed to
Findings
Conclusions

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