Contract No. NMP2-CT

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1 1 Training i material Contract No. NMP2-CT

2 2 Presentation ti 4 Technology Integration Demonstration Contract No. NMP2-CT

3 Objectives 3 To apply the knowledge developed and collected within the project to an industrial demonstrator. The PEGASUS methodology can apply to any plastic car component but this demonstrator is based on a completely new rear part of a Smart* car. - Integrated t rear quarter panel and complete rear lamp assembly * Smart is a Daimler AG company

4 Demonstration Rear panel / fender design 4 Product Design Rear lamp Fender Fender with integrated rear lamp

Demonstrator Steps 5 Technology integration:

5 Demonstrator Steps 5 Technology integration: Design Rear light assembly Moulding of rear panel Painting Assembly Testing Economic and environmental impact Incorporating: Intrinsic colouring nano-pigments, conductive pathways, overmoulding, de-bond on command adhesive

Product development: Design 6 Product design: To design the new component

The functional requirements were fed into the IDEE and the optimal materials and

IDEE supports mould design based on simulations such as MouldFlow, processing

6 Product development: Design 6 Product design: To design the new component integrating i the different parts. The functional requirements were fed into the IDEE and the optimal materials and processing routes identified. IDEE supports mould design based on simulations such as MouldFlow, processing parameters, Life Cycle and cost analysis. Product manufacturing: To manufacture the newly designed component using the new materials developed within the project and the options obtained from IDEE analysis.

Design 7 Product development: Process performance evaluation: The

determined and compared against a benchmark.

7 Design 7 Product development: Process performance evaluation: The Raw materials technical, economic and environmental aspects were determined and compared against a benchmark. End of life Production The new part was designed to replace an existing car component. This allowed comparison of the results with the existing part where all the information is already available. Use phase Implementation

8 8 Technology integration ti LEDs in Automotive Lighting

Technology integration LEDs in Automotive Lighting 9 LEDs used instead of conventional lights, this has become increasingly popular during the project for the

repair Significant reduction in energy consumption (compared to conventional lamps) Better for the environment, LEDs contain no mercury or heavy metals Pegasus

9 Technology integration LEDs in Automotive Lighting 9 LEDs used instead of conventional lights, this has become increasingly popular during the project for the following reasons: LEDs considered as alternative lighting due to space and cost savings Expected LED-life is comparable to part-life, no need for intermediate repair Significant reduction in energy consumption (compared to conventional lamps) Better for the environment, LEDs contain no mercury or heavy metals Pegasus new technology: Conductive path and Over Moulding Lines of injected conductive polymer, connect pins from the plug to the LEDs LEDs are overmoulded for increased integration

micro injection machine) was designed to

10 Technology integration Mould for LEDs overmoulding 10 Issues related to the integration of temperature and pressure sensitive LEDs in polymer processes required investigation. A simple mould (designed to be used in a micro injection machine) was designed to evaluate LEDs resistance to injection moulding temperatures and pressures. LEDs placed inside the p cavity

temperatures and pressures Tolerances in

11 Experiments showed that: Technology integration LEDs withstand injection temperatures and pressures Tolerances in LEDs dimensions are acceptable. LED trials 11 A compound from EU Sixth Framework project PolyCond, contract number NMP2-CT , was the one that presented the best results with maximum output intensity of the LEDs.

12 Technology integration LEDs Layout 12 LED array had to: Fit existing part geometry Cover entire area Meet brightness regulations Number of LEDs needed Red/orange Amber Turn - 7 to 14 Stop 5 to 10 - Rear fog 10 to 20 -

13 13 Technology integration ti Conductive pathway

Technology integration - Conductive Path 14 Studies with

entire conductive path with a conducting polymer.

geometry meant that the conductive pathway would be too

A metallic insert will be used to connect the LEDs but the

14 Technology integration - Conductive Path 14 Studies with LED overmoulding proves that it is possible to inject the entire conductive path with a conducting polymer. Metallic pins from the plug However, in this case the part geometry meant that the conductive pathway would be too narrow for a complete solution. A metallic insert will be used to connect the LEDs but the path from this insert to the metallic pins of the plug will be injection moulded using conductive polymer.

15 15 Technology integration ti Part design

16 Technology integration - Part Design 16 Bright blue areas are new developments to the housing for the integration into the fender. The PMMA lenses had to be trimmed to fit the new housing. Plug Lines of conductive path

17 Technology integration Part Design 17 Pegasus new technology: Debond-on-command After injection moulding of the housing part (with the LEDs and the conductive path), the debond - on - command glue is applied to the housing. It is then placed in contact with the lens, thus obtaining the Rear-Light part.

18 Technology integration Part Design 18 Existing Rear-Light Number of Individual Parts: 8 Lens/cover PMMA - 225,72g Housing PC/ABS - 362,66g Positioner PMMA - 23,5g Light separator PA6/MT30-16,6g Lamps Foam ring 25,35g EPDM - 12,93g Metallic conductor Aluminium - 41g Lamps support PP T20-48,5g

19 Technology integration FINAL PART Part Design Lens/Cover Injection Housing Injection Processing Sequence 12 Steps 19 Welded Part Assembled to Foam Ring and Lamps Support (Lamps previously placed) Welding of Housing and Lens/Cover Positioner and Light Separator assembled to Housing Existing Rear- Light Nickel Bath to Housing Positioner Injection Light Separator Injection Assembly and Fixation of Metallic Conductor in Lamps Support (Fixation by pins deformed by means of heat) Metallic Conductor Production Lamps Support Injection Foam Ring Extrusion

20 Technology integration Part Design 20 LED Rear-Light Number of Individual Parts: 5 Lens/cover PMMA - 179,64g LED with powerpathes Conductive path Aluminium - 21,92g PC/PBT - 10,7g Housing PP - 257,12g

21 LED Rear-Light Technology integration Part Design Metallic Conductor Production Processing Sequence 5 Steps 21 FINAL PART Metallic Conductor and Led s Welding Lens/Cover Position in the Extracted Part and dassembly by Debond on Command Glue Position of Set Welded and Pins Plug like inserts in the mould Housing Injection Conductive Path Injection by Auxiliary Unit Simultaneous = 1 Step

Technology integration Moulding process 22 C-Frame Housing part cavity Injection side of the machine C-Frame structure Secondary injection unit (for the conductive

22 Technology integration Moulding process 22 C-Frame Housing part cavity Injection side of the machine C-Frame structure Secondary injection unit (for the conductive path) Ejection side of the machine Main injection unit (for the housing part) Rotating central block of fthe mould ld( (rotation ti of 180º) Conductive path cavity

23 Technology integration Moulding process LEDs are placed inside the mould by a robot 3 2 Themouldclosesandthehousingis injected (by main injection unit) simultaneously to the injection of the conductive polymer (by secondary injection unit) 4 3 The mould opens and the central block rotates 180º Steps 1 and 4 are simultaneous 4 - The housing part (with the LEDs and the conductive path) is ejected and the cycle re-starts

24 Technology integration Moulding process 24

25 Technology integration next steps 25 Light cluster automated moulding process operational during June Prototype manufacture to be carried out Parts supplied for demonstrator and testing

26 Technology integration contacts Ferrie van Hattum (U.Minho.) 26

27 27 Moulding of rear panel Contract No. NMP2-CT

28 Demonstration - Manufacturing Parts designed d using the outputs t from the project in order to perform process evaluation. 28 This included findings from flow line studies. The polymer was intrinsically coloured using the orange nano-pigment compound developed during Pegasus. Several options of integrating the rear lamp into the fender were possible.

29 Tool Design: Demonstration - Moulding tool 29

30 30 Painting Contract No. NMP2-CT

Due to time constraints the panels will be given the

under development in the project would have been used.

advantages such as eliminating solvents, less wastage

31 Due to time constraints the panels will be given the standard conventional clear coating currently used by SMART. Demonstration - Painting 31 Ideally, a powder coating under development in the project would have been used. Once fully developed these coatings will offer advantages such as eliminating solvents, less wastage and smaller paint shops. Clear Coat Hydro based paint Black substrate Clear Coat Kunststoff Eingefärbt(MIC)

32 32 Assembly Contract No. NMP2-CT

33 Demonstration Light cluster fitting 33 The integration ti of the rear lamp into the fender could been done in a number of ways. To allow for this the mould was produced with different inserts so that the following integration possibilities could be trialled: Over molding Clipping Screwing Gluing (with de-bond on command functionality) The demonstrator will have the light assembly clipped to the rear panel for the main testing program

34 34 Performance testing Contract No. NMP2-CT

35 Demonstration Performance testing ti 35 The evaluation of the parts are made in four categories: Dimensional testing Functional testing Dimensional testing after functional tests Recycling T ti i t t i l SMART t d d d t i t ti l Testing is to typical SMART standards and to international standards for Europe, USA, Japan and Canada.

Demonstration Dimensional i evaluation 36 Dimensional Testing A

fixed to the car 3D data is collected by a probe perpendicular to

order to compare the different sets of production parameters and the

36 Demonstration Dimensional i evaluation 36 Dimensional Testing A special frame was designed to fix the part in the same way as it is fixed to the car 3D data is collected by a probe perpendicular to the surface The measurement results are stored in a database in order to compare the different sets of production parameters and the different ways of integrating ti the rear lamp into the fender Measurement frame

37 Demonstration Functional testing ti A range of physical and endurance tests are carried out on the integrated rear lamp and panel, including: Lamps Driving/Field tests Life tests Panel Driving/Field tests Punch/Scratch/Crash tests General Vibration Stability Temperature Change Resistance Thermal / Humidity Resistance Impermeability Resistance to salt spray Freezing and de - icing 37

38 Demonstration Dimensional Dimensional testing Repeated on rear panel after functional testing to ensure there are no changes. testing ti and Recycling 38 Recycling Panels are to be assessed for effectiveness of recyclability

39 Demonstration Summary The demonstration rear quarter panel including light cluster will be produced by the end of June The demonstrator was designed in the Integrated Design Engineering Environment (IDEE) developed during Pegasus. It also made use of the following innovative materials and processing techniques developed by Pegasus: Nano-pigments Over moulding Conductive pathway De-bond on command adhesive. The initial testing will be completed by December 2010 with full The initial testing will be completed by December 2010 with full testing completed by April 2011.

40 Demonstration - contacts 40 Contact-Functional t ti Testing Daimler AG Matteo Vicedomini Engineering EP/REA - HPC X334 Mercedes-Benz Cars Development Benz-Strasse - Tor 16 D Sindelfingen Telefon: Telefax: matteo.vicedomini@daimler.com

41 Demonstration - contacts 41 Contact-Tooling t Schneider Form GmbH Felix Hinken Vertriebsleiter / Sales Director Kirchheimer Str. 181 D Dettingen/Teck Telefon: +49 (0) / Telefax: +49 (0) / f.hinken@schneider-form.de

42 Demonstration - contacts 42 Contact-Quality t Assurance QS-Grimm GmbH Klaus Rauber Project Management Werner v. Siemens-Strasse Strasse 5 D Offenburg-Elgersweier Telefon: +49 (0) 781 / Telefax : +49 (0) 781 / klaus.rauber@qs-grimm.de

Production costs reduced dramatically by innovative multi-component technology

LED lamps in a single step Production costs reduced dramatically by innovative multi-component technology State of the art LED products combine a long service life and operating safety with minimal energy