Commercial projections are currently under review for an automotive glazing technology which can impart improved performance characteristics to standard polycarbonate. Developed after a three-year development project by the Advanced Technology Centre at the Warwick Manufacturing Group (University of Warwick, GB - Coventry CV4 7AL), the dual injection moulding technique applies a selection of outer layers to the PC that will provide glazing suitable for future generations of cars. WMG is working in association with a number of auto companies and hopes to have the process in commercial production by early 2002.

By applying a single layer of woven glass reinforcement, the flexural rigidity of the PC part is increased by a factor of three, without affecting its transparency. Thermal stability is also improved. The use of other proprietary materials provides alternative benefits. Suitable control of the moulding process also produces a glazing laminate that retains the conventional strength of polycarbonate required for intruder resistance in automotive applications, but which will shatter easily if struck from the inside with a sharp implement, allowing occupants to escape if an incident leaves them trapped in a vehicle.

Project manager Kerry Kirwan considers the process to have considerable automotive potential as it is capable of providing glazing with better performance characteristics, including improved weatherability, while cutting costs. However, the polycarbonate will always require an external hard coat. “We have all the data we need,” he says, “and the costings are looking fine.”

How the technology will be commercialised has yet to be decided. Partnerships, royalties and licences are all possibilities, although the type of application and the volumes involved will be important factors. Ouside of the automotive market, bus shelters and telephone kiosks are two other potential applications.