(Published November 2007) Gerresheimer Wilden is producing Xenon automotive lamp holders for Osram in Dupont’s Zenite LCP resin.

Xenon automotive lamps are gaining in popularity because of their improved beam penetration and durability. However, the lamp holder resin must be adapted to the demanding conditions created by the glow discharge lamp, says Gerresheimer Wilden, with good electrical performance and very low flammability of utmost importance.

“Instead of conventional materials, Osram opted for Zenite 5145 L BK 010 GF 40, a liquid crystal polymer,” says Christian Liebl, project manager in the technical plastic systems unit at the Gerresheimer Wilden Group Technical Competence Centre in Wackersdorf, Germany.

“Injection moulding this innovative material is a very exacting process for both the machine and the mould, but it provides the ideal solution for this application,” he says.

The moulding process involves placing six inserts for the lamp holder into the mould and then overmoulding with the LCP resin. Gerresheimer Wilden says injection pressure and injection speed are the critical factors in achieving a good LCP part; very little holding pressure is required as LCP becomes rigid almost immediately the mould is filled.

Gerresheimer Wilden moulds the parts at its facility at Dy?ina in the Czech Republic, delivering to Osram, where the gas discharge lamp is inserted into the lamp holder and heat-sealed.

www.gerresheimer-wilden.com