专注发泡胶整体解决方案
专注发泡胶整体解决方案
For automotive headlights, taillights, and fog lamps, the clear lens is the most fragile part: it is easily scratched on the surface and cracked at the edges, while the rear housing, mounting feet, and connector are sensitive to vibration and pressure. Headlights often transfer through several legs of transit, so the pack must protect the lens surface while holding the whole lamp firmly in the carton.
Risk Points for Headlight Packs
First, the lens can be scratched if it rubs against any other material inside the box, which affects appearance and light output. Second, the lens edge and housing seam can crack on impact. Third, mounting feet and connector ports are delicate and can break if pressed by foam or the carton. Fourth, long-term vibration can loosen the internal reflector and lens assembly.
How Foam-in-Place Wraps the Lamp
CosMolar first wraps the lens in PE film to keep foam and carton material from rubbing against the lens surface. The lamp is secured at a suitable angle inside the carton, then AB polyurethane foam is dispensed into the gaps around it. The foam expands in seconds, fills the outline of the lamp, and cures to hold the lamp centered and still. An even cushion layer is left over the lens face, while the rear mounting feet and connector are kept clear of direct foam pressure to prevent broken feet.
Density and Carton Matching
Regular shipments use the 6kg/m3 general-purpose foam grade. For higher-value lamps, frequent transfers, or larger lenses, 17kg/m3 high-density foam adds impact resistance. The outer carton is a reinforced carton matched to the weight; heavy or multi-transfer lamps add corner protectors, and a wooden crate can be used where needed.
Validation and Rollout Service
The pack is validated through free sample testing and a drop test before bulk rollout, confirming no lens scratch, no housing crack, and no mounting-foot damage. In bulk production, equipment carries a one-year warranty, with 4-hour phone response and 24-hour on-site service in the Pearl River Delta and 48-hour response nationwide. For headlights or other auto parts needing export packaging, call 400-812-0328 or visit https://www.cosmolar.com/.