Plastic Challenges Glass in Auto Glazing
05 December 2001 Despite its success in headlamps, polycarbonate has so far been unable to penetrate the automotive glazing market. It may not however be too long before car window systems are made from plastic. David Platt, Senior Plastics Industry Analyst with Frost & Sullivan explores the details in this article from chemicals.frost.com. In March 1998, Exatec GmbH was established to develop automotive window systems. The company is a 50-50 joint venture between the world's largest polycarbonate suppliers, Bayer AG and General Electric Plastics. The company, which claims that the joint effort will cut development time and minimise entrepreneurial risks, plans to spend around $40m on the polycarbonate windows project. Advantages of plastic Exatec claims hat polycarbonate windows have a number of advantages, including:  Weight saving of around 50.0 percent and hence better fuel economy.  Better design innovation and styling freedom  Glass-like abrasion resistance and an inherent UV screen  Better noise performance at high frequencies than glass  Minimum potential for breakage  Superior toughness versus glass and acrylics  100% recyclable materials The Development Plan The development project will proceed in three stages. The first product is likely to be a small fixed side window. The use of polycarbonate in larger windows with integrated functions such as mounting mechanisms, believed to offer considerable cost advantages over glass, will follow. A third phase will focus on integrated modules such as door and roof elements, as well as side panels and coating technology aimed at making polycarbonate more weatherproof and abrasion resistant. Front windscreens at present are regarded as too tough a challenge. According to Exatec, the moulding process still needs "significant" work. While glazing for the test vehicles was made from extruded sheets by thermoforming, this quite complex process is regarded as unsuitable for large volume production lines. Converters will be included in the process when the windows are ready for series production, but Exatec will work in advance with machinery manufacturers to perfect the moulding technology. Market testing Exatec is currently holding intensive discussions with a number of international car manufacturers to develop cooperation agreements for testing and market development. A technical centre currently exists at Wixom, USA, and a pilot plant is planned on the same site, for completion by end 2002. Exatec is optimistic about the future prospects for their automotive glazing system, claiming that demand could be at least 200,000 tpa by 2008.