#Japan #Shinagawa #Koito Manufacturing #Headlamp Lens #Lightweight Technology

Innovating in Automotive Lighting: Koito's Exquisite Achievement

Koito Manufacturing, based in Shinagawa, Tokyo, has recently been awarded the Kanto Bureau of Economy Prize at the 10th Monozukuri Japan Awards for its groundbreaking development of the world's thinnest and lightest headlamp lens made from Light Green Polycarbonate (PC). This prestigious award highlights the significant contributions of skilled professionals and emerging talent in Japan's manufacturing sector, recognizing their exemplary work in advancing fabrication technologies. This marks Koito's third time receiving this award, which is supported by various ministries including the Ministry of Economy, Trade and Industry and the Ministry of Education, Culture, Sports, Science and Technology.

Commitment to Sustainability

In its pursuit of a decarbonized society, Koito is dedicated to reducing environmental impact throughout the product lifecycle. Recent trends show that automotive headlamps are increasingly multifunctional and larger, resulting in greater weight. To address this challenge, Koito took significant steps to lighten the headlamp lens, which comprises a major portion of the headlamp's weight.

The development process involved the creation of a new material, Light Green® PC, that withstands high-temperature molding. By enhancing the moldability of the resin and improving cooling performance, Koito has successfully developed a new manufacturing technique. This method ensures quick shaping without compromising the integrity of the lens, ultimately achieving the world's thinnest and lightest headlamp lens.

Importantly, the new lens can be integrated with existing molding machines, allowing it to be deployed across the globe. Since 2022, this innovative lens has been adopted in all vehicle models produced, showcasing Koito's strong commitment to innovation in automotive lighting technology.

Profound Impact on CO2 Emissions

The introduction of Light Green® PC headlamp lenses significantly impacts automotive efficiency. Compared to traditional lenses, the new design reduces mass by 20%, leading to a decrease in CO2 emissions by approximately 3.0 kg per vehicle over ten years of use with a mileage of 120,000 km. This translates to a remarkable 48,000 tons of CO2 reduction projected for vehicles adopting this technology in 2023.

Enhanced Safety Features

In addition to the environmental benefits, the new lightweight lens design also enhances vehicle safety. Studies show that in the event of a vehicle-pedestrian collision, the damage to a pedestrian's thigh could be reduced by 40%. Such advancements clearly indicate Koito's dedication not only to manufacturing excellence but also to enhancing public safety.

The Teams Behind the Success

This award celebrates the collaborative efforts of a dedicated team at Koito, including:

• - Kenta Sugiyama (Production Management)
• - Takashi Furui (Research Institute)
• - Seiji Katayama (Production Technology)
• - Yuichi Iketani (Sagara Factory Components Manufacturing)
• - Hiroya Ito (Fujikawa Machining)
• - Hideaki Yamamoto (Research Institute)
• - Eiji Matsubara (Production Technology)

These professionals have exemplified the spirit of innovation that drives Koito Manufacturing towards a sustainable future.

Conclusion

As Koito Manufacturing continues to pursue advancements in environmentally friendly technologies, it aims to contribute actively to a sustainable society while demonstrating resilience and innovation in the automotive industry. With ongoing efforts to reduce environmental loads throughout its product lifecycle, Koito sets a powerful example for the future of manufacturing. This latest recognition not only highlights their achievements but also marks a significant milestone in the journey towards responsible and intelligent automotive lighting solutions.