History of Automobile Headlights

In the late 1800s when automobiles started driving on the streets (or lack there of) of America, it revolutionized the way things were done in more ways than one. As you can imagine, driving during night time back then proved to be difficult and highly dangerous.

Still today, so many automotive accidents occur at night. It didn't take long before automobile manufacturers realized that headlights were necessity if cars were going to stay on the road after the sun went down.

The first headlights, also referred to as headlamps, were unveiled in 1898. Invented by the Electric Vehicle Company, these electric headlamps were first installed as an option for the Columbia Electric Car. However, the short service life of the light filaments, coupled with the harsh conditions environmental conditions of the outdoors, prevented the widespread use of electric headlamps on cars. In addition, there were technological hurdles that prevented the creation of a dynamo small enough to be installed on cars, yet powerful enough to provide sufficient lighting for night driving purposes.

By 1904 the technology had advanced, and acetylene headlights became the norm, with "Prest-O-Lite" becoming the brand of choice by many car manufacturers. Four years later, in 1908, Peerless started to delve into electric-powered headlamps. But it was the Cadillac Company that introduced the blueprint to modern headlight system. In 1912, Cadillac first installed a lightning system that was fully integrated with the car’s ignition mechanism.

This became the trend for the most part of the automotive history until in 1940, when technology allowed car manufacturers to produce sealed beam headlights. This system was incorporated by major car makers in North America, Japan, and Europe throughout the 1960s.

Modifications to the system were introduced, such as control and dips, but the technology wouldn't evolve much for another 50 years, until halogen bulbs came to the scene and reinvented automotive headlights.  However, most cars in the United States did not use halogen bulbs until 1978.

In 1991, the BMW 7-Series became the first roadster to debut xenon headlights. Xenon bulbs were not only brighter than halogen headlights, but also had a longer lifespan, lasting up to 2,000 hours compared to the 1,000 hours of service provided by halogen bulbs.

LED (short for light-emitting diode) technology debuted on the 2008 Lexus LS 600h hybrid for low-beam and side-marker lighting. LED is now the norm for all cars manufactured in this ear up until today. That said, LED lights are not yet fully used as primary headlights for most cars. Many car manufacturers install LED lights for use with turn signals, daytime running lights or brake lights.

While it is costlier than most forms of automotive lighting, it has lower power requirements, making it an ideal option for electric and hybrid vehicles.

There is still an on-going debate between the National Highway Traffic Safety Administration and several car makers on whether LED technology can be utilized as primary source of lighting for headlights. For now, NHTSA maintains that LED technology does not fit the requirements provided by the Federal Motor Vehicle Safety Standard 108, which disallows the use of headlights that which “shine in such a dynamic way.”

Regardless of their technology, headlights today start to fade and show signs of wear because of the harsh outdoor elements. At D&I Body Shop & Glass, we offer professional restoration services for headlights that will revitalize the look of your car, and restore their brightness.

For more information on headlight restoration, call us at (404) 885-9575 or visit our shop at 1779 Marietta Blvd NW Atlanta, GA 30318.

How Windshields Are Made

The windshield has a lone and very rich history, which stems from 1905 when it was discovered that glass can be heat tempered. Heat tempering is a treatment widely used back then to make glass resistant to shattering. Heat tempered glass became the windshield material of choice up until the middle of the 20th century, when lamination proved to be a better alternative to heat tempering.

Laminated glass consists of one plastic layer bounded by two sheets of glass. Laminated glass can bend upon impact, instead of shattering and breaking. This feature made laminated glass the dominant trend in most countries. In fact, many states in the United States requires auto manufacturers to install windshields made of laminated glass because they pose less risks to passengers compared to heat tempered windshields.

Windshields have very complex material structure. Raw materials needed to make windshield glass include silica, sodium oxide, and calcium oxide. These chemicals are often derived from sand, soda ash and lime. Other materials needed for auto glass and windshield manufacturing are magnesium oxide, feldspar, and potassium oxide. In some instances, cullet (broken waste glass) is included in the mix.

 

How are Windshields Made?: The Manufacturing Process

1. The raw materials mentioned above are weighed carefully and are prepared in appropriate amounts. Once this is done, the materials are mixed together with a small amount of water to prevent segregation.
2. After the batch is made, it is then placed in a large tank where it is melted. This is called the float process. In this phase, the glass material is melted at 1,835 degrees Fahrenheit (1,000 degrees Celsius). After which, it is placed onto a bath of melted tin. Once the glass floats, it then rolls out from the flat chamber to the oven. Otherwise known as the annealing lehr.
3. In the lehr or furnace, the glass is significantly cooled to about 395 degrees Fahrenheit (200 degrees Celsius). Once the glass comes out of the furnace, it is significantly stronger and clean of impurities. At this point, the glass is ready to be polished into an auto windshield.
4. Once the design and dimensions are finalized using a diamond scribe, the glass is then cut. Modern glass cutting technologies have made this process faster and easier. Once the glass is cut, it is then bent and fitted into a mold. The mold is heated, which makes the glass to sag according to the shape of the mold.
5. After the shaping phase, the glass material will be tempered in a furnace to about 1,565 degrees Fahrenheit (850 degrees Celsius). After which, the glass is cooled with blasts of cool air. This cooling process, also known as quenching, toughens the glass and makes it durable even during collisions and impacts.
6. Once the glass is tempered and cleaned, it is then laminated. The lamination process involves bonding two sheet of glass with a layer of plastic and takes place in a furnace where the materials are heated and pressed to form a single unit that is highly resistant to shattering.
7. Plastic moldings are then attached to the glass, which makes it ready for car installation. Any other modifications, such as glazing, are usually done by the automobile manufacturer.

About D&I Body Shop

1779 Marietta Blvd NW
Atlanta, GA 30318
(404) 885-9575
www.dandibodyshopandglass.com