Only Exatec® 900

Transcription

Only Exatec® 900

Exatec Proprietary and Confidential Information
Exatec Company Profile
•
Exatec was founded in 1998 as 50:50 joint venture of
GE Plastics and Bayer AG
•
Market Development and European Technology
Project Management in Bergisch-Gladbach
(Germany)
•
Global Technology Development Center near Detroit,
Michigan (USA)
•
Fields of Expertise
• Technology
• Process Development
• Prototyping
• Testing & Regulations
Advantages of Polycarbonate Glazing
Styling and Design
- Shape Complexity
- Assembly Complexity and
Functional Integration
- Individualization with
Colors & Tints
Weight Saving
Safety & Security
- Passenger Retention
- Anti Smash-n-Grab
Environment
- 40-60% Mass Reduction
- Fuel Economy
- Lower Center of Gravity
- Recycling
Shape & Assembly Complexity – System Cost
Complex
Assembly
Complexity
Simple
Simple
Gentle curvature
Beyond glass
capabilities
Shape Complexity
PC
PCpart
partdesign
designbased
basedon
oninjection
injectionmolding
moldingis
iskey
keyto
tosuccess!
success!
Enabling
Enablingshape
shapecomplexity
complexityand
andcost-effective
cost-effectiveassembly
assemblysolutions
solutions
The Exatec® Process
Design
Molding
Value
Add
Printing
UV
Layer
Abrasion
Layer
Finishing
Large Optical Glazing Molding
Conventional
Molding
Stress
Reduction
Large 1K low Enhanced Large 2K low
stress Molding Stiffness stress Molding
0.6 m2
1 m2
Large 2K/IMD low
stress Molding
Integration
0.7 m2
1 m2
IMPmore®
Injection molding
®
more
1m2 IMP
• Large tonnage
• High stress
• New technology
needed for bigger
size windows
Part and
Function
window
• Large window molded
on small machine
• Low stress
• Limited integration
opportunities b/c of 1K
• Low stress Day-LightOpening
• No degating
• Multi-sequential valve
gates
• Part integration
• Function integration
• Demonstrate backlite &
roof system technologies
• Simplifies printing
The Exatec® 900 Polycarbonate Automotive Glazing System
A-SURFACE
Exatec® PECVD
Exatec® SHX
Abrasion layer
Weathering layer
R
Exatec® SHP 9X
Polycarbonate
window
Printed window
Black-out
Exatec® SHP 9X
Exatec® SHX
Exatec® PECVD
Weathering layer
Abrasion layer
B-SURFACE
®
Only
OnlyExatec
Exatec®900
900PC
PCGlazing
GlazingSystem
Systemmeets
meetsall
allperformance
performancerequirements:
requirements:
••10+
10+years
yearsweatherability
weatherability
••Glass-like
Glass-likesurface
surfacebehavior
behavior
Polycarbonate Glazing Performance Requirements
all Window Locations (except the windshield)
¾ Rigidity
¾ Mechanical Strength
¾ Crash performance
¾ Bonding System test
¾ Flexibility Test
¾ Headform Test HIC<1000
¾ Thermal expansion
¾ Noise Transmission
• ECE R43
• FMVSS 205 / CMVSS 205
• JIS R 3212
• SAE J-1976/J576C
• ASTM G154/155 and D1003
• DIN 52347/53151
• ANSI Z 26.1 (1996)
• OEM specific requirements
¾ Wiper Durability Test
¾ Abrasion resistance < 2%Taber
¾ Coating Adhesion
¾ Light Transmission
>70% / 75%
¾ Optical distortion limits
¾ Weathering
• Outdoor
FL & AZ
• Accelerated
ASTM G154
¾ Resistance to Humidity
¾ Resistance to Chemicals
¾ Fire Resistance
¾ Color match
Polycarbonate Glazing Performance Requirements
Roof Systems
¾ Rigidity
¾ Mechanical Strength
¾ Crash performance
¾ Bonding System test
¾ Flexibility Test
¾ Headform Test HIC<1000
¾ Thermal expansion
¾ Noise Transmission
• ECE R43
• FMVSS 205 / CMVSS 205
• JIS R 3212
• SAE J-1976/J576C
• ASTM G154/155 and D1003
• DIN 52347/53151
• ANSI Z 26.1 (1996)
• OEM specific requirements
¾ Wiper Durability Test
¾ Abrasion resistance
< 2%Taber
¾ Coating Adhesion
¾ Light Transmission
>70% / 75%
¾ Optical distortion limits
¾ Weathering
• Outdoor
FL & AZ
• Accelerated
ASTM G154
¾ Resistance to Humidity
¾ Resistance to Chemicals
¾ Fire Resistance
¾ Color match
Exatec® 900 Weatherability Testing
Method
Spectrum
Match
Speed
Control
Outdoor Florida/Arizona (5° south facing)
Very Good
Very slow
Poor
Fresnel Mirror (EMMAQUA, QTRAC, ACUVEX)
Very Good
Fast
Very Poor
QUVA
Very Poor
Fast
Good
Good
Very fast
Good
G-mod (Xe-arc, boro-boro light filter, 0.75 W/m2 @ 340 nm)
Coating
Substrate color
MJ/m2 @ 340 nm
95% CI [MJ/m2]
Eq. Years
Florida
Exatec® 900
Clear / Solar
22.2
1.3
9.3 - 9.9
Advanced Wet Coat
Clear / Solar
15.3
0.8
6.5 - 6.8
G-mod
G-modisisbest
bestaccelerated
acceleratedweathering
weatheringtest
testprotocol
protocolfor
forPC
PCglazing
glazingsystems
systems
® 900 outperforms any coating system for transparent polycarbonate
Exatec
®
Exatec 900 outperforms any coating system for transparent polycarbonate
Exatec® Predictive Weathering Model
Input
Stochastic Parameters
Predictive Model Output
Florida / Arizona solar irradiation
10,000 Trials
.053
Exatec® 900 Global
Market normalized irradiation
Garaging
G-mod weathering data
534
.040
401
.027
267
.013
134
.000
0
Shading
Frequency Chart
10.1
55
0
Lifetime Expectancy Distribution
Horizontal, privacy tint.
Orientation distributions
••Model
Modelparameters
parametersand
andoutput
outputverified
verifiedwith
withweathering
weatheringexperts
experts
••Results
Resultsin
inagreement
agreementwith
withindependent
independentliterature
literaturestudies
studies
D.R. Bauer, Service Life Prediction of Organic Coatings, ACS Symposium Series, p722;
D.R. Bauer and J.W. Martin, Eds., American Chemical Society, Washington, D.C., 1999, p378-395.
Weatherability: Coating Technology Developments
2002
2004
Outer Layer – Abrasion Resistance
Outer Layer – Abrasion Resistance
Wet coat + UV stabilizer
Wet coat + UV stabilizer
Wet coat + new UV stabilizer technology
Interface - Adhesion
Polycarbonate (3-6 mm)
Impact and Optical Performance
Wet coat
EXATEC® 500
EXATEC® 900
Mid 1990’s
16
16
12
12
12
10
10
10
R
6
4
Benzophenone
2
Microcracking
8
6
OH
HO OH
4
Tethered benzophenone
2
Microcracking
Si
Delta YI
14
8
-2
-2
-4
6
8
10
FL years equiv.
HO SI OH
HO
Tethered oligomeric keto-resorcinol
-4
0
2
4
6
FL years equiv.
8
10
0
2
4
6
Years FL equiv.
®
EXATEC
EXATEC®Polycarbonate
PolycarbonateGlazing
GlazingSystems
Systemsdemonstrate
demonstrate
significantly
improved
weathering
performance
significantly improved weathering performance
R
HO
HO
2
-4
4
n
4
-2
2
Delamination
6
0
0
R'
O
OH
O
8
0
0
OH
16
OH
14
OH
O
Delta YI
Delta YI
14
O
8
10
Glass-like Surface: Abrasion Resistance
Typical Exatec Glazing
Abrasion Layer Properties:
• Thickness: 2-3um
• Hardness (Vickers): 70-100
TEST
Wet Coat
EXATEC® PC
Glazing Systems
TEMPERED
GLASS
Taber 500
cycle
<10%
∆ Haze
<1%
∆ Haze
<1%
∆ Haze
Taber 1000
cycle
>15%
∆ Haze
<2%
∆ Haze
<1%
∆ Haze
Car Wash
(GM TEST)
10%
∆ Haze
0.50%
∆ Haze
0.75%
∆ Haze
Sand blast
11.8%
Gloss loss
5.7%
Gloss loss
10.1%
Gloss loss
Sand blast
3.2%
∆ Haze
1.6%
∆ Haze
3.2%
∆ Haze
Oscillating
Sand
27.2%
∆ Haze
5.5%
∆ Haze
2.1%
∆ Haze
…
…Sometimes
Sometimeseven
evenoutperforming
outperformingglass!
glass!
Glass-like Surface: Abrasion Resistance
Amtec Kistler
Sand Blast
Delta%Haze
Gloss loss
0.60
12
0.50
10
%Gloss loss
%Haze
144 km/h @ 45° impact
0.40
0.30
0.20
0.10
8
6
4
2
0.00
0
Wet Coats
Exatec® 900
Coating System
Wet Coats
Exatec® 900
Coating System
®
Superior
Superiorperformance
performanceof
ofExatec
Exatec®900
900in
intests
testsmost
mostrelevant
relevantfor
forroof
roofarea
area
NHTSA
otor
M
l
a
r
Fede sk us
f
o
n
ou a
tatio
e
Y
r
.
in
p
s
r
l
d
e
a
t
i
e
r
n
s
i
e
t
u
or an lazing Ma ” may be
f
t
s
e
use
G
qu
ial
r
r
,
e
o
r
e
5
f
t
r
l
0
a
u
a
2
m
ri
ups
yo
o.
e
o
g
t
r
o
N
n
a
t
i
g
)
z
m
s
d
S
VS
ond
ic gla y glazing prescribe
p
t
M
s
s
F
e
(
a
r
l
d
p
This
afet
ted
the
ndar
s
a
(
a
s
o
t
t
c
g
e
S
“
n
e
i
fety
0, a
it m
glaz
a
0
f
i
S
9
2
)
e
c
s
l
m
e
d
Vehic r the Exat fied for Ite windshiel
e
ci
pt
wheth areas spe hicle exce
e
le
vehic re in the v ard.
he
nd
anyw in the sta
ts
of tes
o
t
r
e
w
s
n
a
The
.
s
e
y
s
i
n
o
i
t
s
e
u
q
r
u
o
y
NHTSA
ated
r
o
p
r
inco
y
g
o
l
no
ction
h
e
t
c
o
e
r
t
ced
ce p
n
n
a
a
t
v
s
i
d
res
ea
h
g
t
n
t
i
r
a
e
h
eath
tes t
a
w
t
t
s
n
c
a
Exate es signific ears.
0y
vid
1
o
r
t
of
s
p
l
a
e
a
e
c
i
l
r
n
t
e
a
t
a
t
0 ma e span of
resis
0
g
9
n
i
c
r
of
xate
athe
ful lif
s
E
e
e
e
i
s
w
s
t
r
i
u
e
o
Th
into
in a
orat
b
s
t
a
l
its
L
u
r
s
e
l
o
e
l
f
r
e
t
t
n
a
a
th
spa
yB
b
e
f
i
l
d
e
d
t
valua ’s predicte
e
y
l
t
den
atec
n
x
e
E
p
e
h
n ind urred wit
e
e
b
has
conc
0
e
0
l
l
9
e
t
EC
Ba
EXAT us, Ohio.
b
Colum material.
g
glazin
Defroster for Polycarbonate

Backlites represent ~ 30% of market potential
80% of backlites have defroster
PC thermal conductivity is 20% of glass
Highest conductivity paste 20% of frit material
Jun ’03
May ’04
Aug ’04
Mar ’05
Exatec® PECVD
Exatec® SHX
Exatec® SHP 9X
Defroster
OEM s
irm
f
n
Co
Black-out
Polycarbonate
Window
European
EuropeanTier:
Tier:“Performance
“Performanceis
isbetter
betterthan
thanglass.”
glass.”
Glass-like Surface: Accelerated Wiper Testing
1,022,230 cycles with Bosch premium wiper blade at 33 g/cm pressure
Cycles with water and mud (2.5% fine dust, 5% salt) [SAE J942]
A
Wet coat
A
B
B
Exatec® 900
Glass
®
Exatec
Exatec®PC
PCGlazing
GlazingSystem:
System:compatible
compatiblewith
withcommercial
commercialwiper
wipersystems
systems
Exatec®
Manufacturability
Backlite Technology with Defroster
• Working Defroster System
• Wiper System Compatibility
• 3D Printing Process
• Abrasion Resistance
• Weathering Performance
• Innovative Part Designs
• Lighting Integration
• Lightweight Rear Door Modules
Exatec
Exatecprovides
providesaacomplete
completetechnology
technologypackage
packageto
tothe
theautomotive
automotiveindustry
industry
Summary – Exatec® 900
Only Exatec® 900 …
• Is allowed in US Item AS-2 window locations
• Meets global weatherability requirements for all window locations for
polycarbonate automotive glazing
• Provides glass-like abrasion resistance
• Compatible with commercial wiper systems
• Compatible with established system components used for glass
(adhesives, encapsulation, sealing etc.)
• Provides additional functionality (defroster, antenna)
Exatec® 900vt
Polycarbonate Glazing System
for Advanced Roof Applications
®
Introducing: Exatec® 900vt
Exatec® PECVD
®
Exatec
SHX
A-SURFACE
Exatec® SHP 9X
Abrasion
Layer
R
Weathering
Layer
Polycarbonate
Window
Black-out
PRINTED
WINDOW
Exatec® SHP 9X
Exatec® SHX
Exatec® PECVD
Abrasion
Layer
B-SURFACE
®
Exatec
Exatec®900vt
900vtis
isespecially
especiallydesigned
designedfor
forvehicle
vehicletop
topapplications:
applications:
Functionality
Functionalitywhere
whereneeded,
needed,cost
costout
outwhere
wherepossible
possible
Exatec® 900vt
The Ideal Choice for Polycarbonate Roof Glazing Applications
Optimized for Vehicle Top applications
• Targets roof glazing opportunities
• Significant cost reduction
– Reduced material cost
– Improved yields
• Improved optical appearance
– No ‘picture framing’
•
•
•
•
•
•
•
•
•
Abrasion resistance (Taber) – exterior
Abrasion resistance (Taber) – interior
Weatherability – exterior
Weatherability - interior
Water immersion + X-hatch adhesion
Adhesive bonding test
Thermal cycling (-20 - +85°C)
Elongation (flexibility)
Chemical resistance (ECE R43, ANSI Z26.1)
9 Pass (<2.0% Δhaze)
9 Pass (similar to wet coats)
9 Pass (10+ yrs)*
9 Pass (Vehicle interior specs)
9 Pass (10 days @ 65°C)
9 Pass
9 Pass
9 Pass (>1.1%)
9 Pass
®
Exatec
Exatec®900vt
900vtis
isespecially
especiallydesigned
designedfor
forvehicle
vehicletop
topapplications:
applications:
Functionality
Functionalitywhere
whereneeded,
needed,cost
costout
outwhere
wherepossible
possible
*based on Exatec accelerated weathering data and predictive modeling
Advantages of Exatec® 900vt for Advanced Roof Systems
Polycarbonate offers these advantages:
• Freedom for Styling and Design
• Weight Savings (Center of Gravity)
• Safety & Security
• Environmental
Exatec®900 adds these advantages:
• Long-term Weatherability
• Glass-like Abrasion Resistance
Exatec®900vt adds these advantages:
• Reduced Material Cost
• Higher Production Yield
• Improved Optical Quality
®
Exatec
Exatec®900vt
900vtand
andPolycarbonate
Polycarbonate
The
TheIdeal
IdealChoice
Choicefor
forVehicle
VehicleTops
Tops
Exatec® 900vt : Opportunities
®
Exciting
Excitingopportunities
opportunitiesfor
forExatec
Exatec®900vt
900vt and
and
polycarbonate
polycarbonatein
inyour
yourfuture
futureroof
roofsystems!
systems!
®

Only Exatec® 900

Transcription

Similar documents