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Drawing from previous studies published in SAE, a software program describes physical progress of water intrusion into or released from a lamp assembly. This program, based on test data, calculates condensation quantity and clearing time. It calculates moisture exchange between a lamp assembly and ambient, considering the moisture contained in the air inside of the lamp and moisture stored on the wall surface or in the materials. This program is applicable to different scenarios, such as initial humidity conditions of a lamp assembly, lamp size, type, venting type and test performance specifications. The significance of the program application in guiding test performance will also be addressed.

The effect of water vapor transfer from plastic materials commonly used in automotive lighting assemblies can be experimentally measured. This is accomplished by isolating this phenomenon from other mechanisms effecting water vapor concentration in the lamp. Quantifying this effect helps to address design considerations for liquid water and water vapor egress in the lighting assembly. The relevance of the current moisture clearing type test required in the industry is discussed in light of the empirical results for this effect.

Plastic automotive lamp assemblies are vented by a variety of methods to reduce the likelihood of condensation forming in the lamp and to prevent water ingress lamp warranty returns. Previously, it has been shown that the humidity in a vented automotive lamp can be described empirically by a decreasing exponential (i.e. decay). It was also shown that this formula by applying Fick’s Law of Diffusion, particularly the exponential constant (k), can be related to basic physical properties of the lamp system. Specifically, the exponential constant is a ratio of the product of a characteristic cross-section area of the vent and the permeability of water vapor over the product of the lamp volume and a characteristic length of the vent. This description was shown to be less accurate at time t greater than 30 minutes and additional details of the vented lamp system were proposed for better fit to the experimental data.

Certain conditions promote water vapor to condense on available surfaces within an automotive lighting assembly. Certain surfaces are more susceptible to water condensation than others. This is due partially to temperature gradients in the lamp and possibly water vapor concentration gradients. This study demonstrates that humidity gradients exist in an automotive lamp. How humidity gradients affect the likelihood of surface condensation for a particular interior surface of a lamp will also be addressed.

Evaluating thermal concerns is often addressed during the automotive lamp design process. The thermocouple device is used frequently for temperature measurements to locate and quantify hotspots that arise in the automotive lamp assembly. This study seeks to review the techniques used for thermocouple temperature measurement. Common techniques are described in detail and evaluated. An experiment coupled with computer simulation is introduced and performed that tests accuracy and compares the methodology and results of the different thermocouple measurement techniques. The technique that most directly measures both inside (exposed to light source) and outside (away from light source) surface temperature is demonstrated to have advantages. Correlation to heat deflection temperature and thermal damage such as warp and metalization blemish (haze) is described.