FIG - Glassvar.glassonline.com/uploads/publications/section_articles/articlePDF/... · means of nano-technology and even flame-retardant coating, are now convincing design-ers to

102

n recent years, the transparent areas ofcars have been considered the exclusivekingdom of glass. As an expert on glass,

and educated in its positive and negative per-formances, the author of this investigation hasconsidered transparent plastics, mainly PC (poly-

FIG. A FIG. B

FIG. C

FIG. A - Corvette Z06

FIG. B - Toyota City modular car

FIG. C - Saab 9.5

103

This report gives us anoverview of the recentinnovations and characteristicsof the appearance of cars andtheir evolution at the FrankfurtMotor Show, where glazing wason the increase, both in sizeand in complex shape. However,a slow but partial appearanceof the use of plastic in carglazing is also taking place,similar to what took place forplastic projector lamps. Morethan ever it could be seen thatcars are exhibited to pleasemarket demand and so designis, above all, stronglycompetitive among car makers.

Giovanni Manfrè*MG CONSULT

carbonate) and PMMA (polymetilmetracrylate),alternatives only when rigidity (thickness, shapeand elastic modulus) performance is not involved.Other aspects to be considered are UV, scratch-ing, and high temperature, which negativelyinfluence the physical features of cars.

At present, the market is undergoing theadvent of the strong rigid chassis, due to theincreased weight of structures in:• hybrid cars, already in increasing numbers on

the market (normal petrol fuel plus electri-cal engines);

Glass-Technology International 2/2006w w w . g l a s s o n l i n e . c o m

Alfa Brera

Saab glazing evolution

104 • modular cars[1]; • hydrogen fuel cell electrical engines as an alter-

native to fossil fuel (in the near future).All these car types need deeper investigation

regarding the use of plastic (mainly PC) glaz-ing. UV resistance, improved anti-scratching bymeans of nano-technology and even flame-retardant coating, are now convincing design-ers to use plastic glazing, also because it givesthem more freedom with shaping. This is almostthe same situation that occurred for the plasticlenses of headlamps, where PC plastic hasalmost substituted glass and has contributedto changing positively the styling of car “eyes”.

TRANSPARENT AREA IN CARS:GLAZING AND PROJECTOR LENSES

At first glance, the feeling is that designers arestill convinced that style is a winning attractionfor car customers, and the material science is ded-icated to finding solutions for glass and plasticglazing and their relative coating, to satisfy therequested performances. The absence of theglassmakers at the Frankfurt Motor Show wasnoticed and, thus, the glazing evolution could beinvestigated only directly on the car.

The main results of this investigation arebased on the fact that theFrankfurt Motor Show,once again, points outthat cars are exhibitedto please marketdemand and so designis, above all, strongly in competition amongcar makers.

Glazing is one of thecharacteristics of the appearance ofcars and its evolution is certainlyoriented to increase in size and incomplex shape, especially in fivemain ways:1. transparent area evolution. The

windscreen flashes on the more andmore transparent roof ending witha complex backlight. In simplewords, the upper part of the car isapparently monolithic transparentglazing, with a roof that can bemoveable and split into parts as thedesign requires;

2. some plastic glazing appears to

be present where low rigidity is involved. Two different colours on the car body differentiate the rigid support from the body skin, giving new space to the glazingchoice (Lancia);

3. the contribution of transparent plastic, withno direct visibility performances, in MazdaSassou and Honda Civic;

4. the almost total absence of glassmakers,with head projector lenses in PC by injectionmoulding;

5. driver visibility has been indirectly improved,glazing apart, by projectors and backlights real-ized by LED technology and plastic lensesmanufactured by injection moulding.There is also a strong tentative to integrate

the lightning devices in the backlight and forthis reason the complex shape could be designedin plastic.

TRANSPARENT AREA EVOLUTIONStrong increase of glass -slight increase of plastic

Glazing is continuing its evolution in increas-ing the transparent area, mainly concentrated onroof transparency, coordinated with the wind-screen and backlight but, on the contrary,decreasing on the side windows.

Mercedes: Smart Line - steel and plastic

The Smart “forfour”, establish-es the unique “smart” body con-cept featuring two materialswith different colours that are also

manifested in the visual design.This model uses high-strengthFIG. 1A

FIG. 1B

FIG. 1D

FIG. 1C

FIG. 1E

FIGS. 1A, 1B,1C, 1D and 1E

- Theintegrationof backlightsin the rearwindow ofthe Daimler-ChryslerPremiere andthe SmartStyle“Forfour”

FIGS. 2A, 2B,2C, 2D and 2E

- PC (poly-carbonate)usedwindows onthe fixedlateral rearwindow

105

steel for all safety-related compo-nents, reassuringly visible in the trid-ion safety cell, and plastic: scratch-proof, repair-friendly and non-rustingfor all exterior parts.

These robust body panels are an inno-vation offering the utmost useful value in busycity traffic. “Brillant”, in the words of many cus-tomers - “minor dents just bounceback into shape!” The exte-rior parts come in a widerange of differentcolours, most ofwhich form a strik-ing contrast to thetridion safety cell,which is alwaysin black or silver.Anyone wishingto change the colourof their “smart for

two” can do so without the help of a paintshop. The body panels are easily replaceable with-in just an hour.

Figures 2 shows a strong orientation for cardesigners to start to seriously try and realize abacklight, a roof and part of fixed side windowsin plastic PC or PMMA (copolymer).

LamborghiniThe roof is transparent (see Figures 3) but

the glazing of the passenger cell (referred toby experts as the “greenhouse”) visibly tapersout into the rear end, accentuating the rearwheel arches in a powerful and muscular look.This, in turn, ensures optimum aerodynamicswith brake lights integrated beneath the spoil-er in the rear lid.

ToyotaThe Toyota Endo

concept car for moderncities is a good example

of modularity, which canreally change the face of inter-

nal glazing materials - glass orplastics - and of simple, no complex shapes

that are easy to realize.

FIG. 2B

FIG. 2A

FIG. 2C

FIG. 2D

FIG. 2E FIGS. 3A and 3B - The newLamborghini Gallardo SE with quite a large glazing area in themost advances solution using theconcept with an un-fixed roof

FIG. 4A - Toyota Endo with its short idealurban length forfour persons

FIG. 4B -Modularity of theToyota Endo inline with the carevolution

FIG. 3A

FIG. 3B

FIG. 4A

FIG. 4B

106 Audi Q7 4.2 QuattroThe Audi Q7 4.2 Quattro was

presented as one of the mostinnovative cars of the show(see Figure 5A) with its trans-parent roof with two glasspanels, one of which wasmoveable (Figure 5B).

The Audi Q7 4.2 Quattro has a solar controlwindshield with Southwall metallized film toreflect IR solar radiation. Note, however, the inter-nal reflection due to UV reflection higher that10 per cent, which can have a negative effect onforward visibility.

Mazda MX-CrossportThe Mazda MX-Crossport is lower in height

(Figure 6C) compared to traditional compactSUV-type vehicles and has an aggressive off-road look. Its sporty lower grille opening andpowerful front fender are similar to those of theRX-8 and achieve a unique balance between theevolutionary nature of the concept and Maz-da’s recent sports car tradition. The interior (Figures 6A, 6B) is surprisingly roomywith a “floating” seat construction, with each seat mounted on a “monorail” system inthe floor, which allows forward and backwardslide adjustment.

Mazda MX-Crossport also features anadvanced information and entertainment system. This system includes a separate screen for the front passenger that shows four different views of the driving experienceusing five cameras. However, the safety timeto be aware of through the pictures on the monitor video is 10-1 compared with thatof direct Viscon on the image of the backmirror 10-3.

FIGS. 5A, 5B

and 5C - TheAudi Q7 4.2Quattro waspresented asone of themostinnovativecars of theshow

FIG. 5A

FIG. 5B

FIG. 5C

FIGS. 6A, 6B and 6C

- Mazda MX-Crossport in linewith windscreenflashing the roof

FIG. 6A FIG. 6B

FIG. 6C

107


Renault Egeus – Luxury SUVThe suppleness of the Renault Egeus is evi-

dent in the way the bonnet flows into the round-ed windscreen (Figure 7A), which, in turn,blends seamlessly into the bubble-shaped glazedroof. The bubble shape of the rear window(Figure 7B) form a continuous, flowing line withthe windscreen in a streamlined shape worthyof any coupe. The rear window rests on broadwings that sit the car squarely on the road(Figure 7C).

The extended bubble shaped glazed roof ofthe Renault Egeus – Luxury SUV allows a veryoriginal rounded internal compartment.

Alfa BreraDeep flashing

and tapering of thewindshield andbacklight with theroof give this inno-vative Alfa Breramodel the feeling

of strong compactness without reducing frontand rear aerodynamic streaming elegance,where the bumpers are integrated into theoptical systems with a convergent profile as awedge shape. This model is almost a histori-

cal selection of the Alfa style solutions,which started from the Giulietta Sprint

with a stronger impact for improveddriver visibility.

FIG. 7C

FIG. 7C

FIGS. 7A, 7B and 7C - RenaultEgeus – Luxury SUV with itsbubble-shaped roof

FIG. 7B

FIG. 7A

FIG. 8 – Alfa Brera: new frontglazing and backlight stronglyflashing aerodynamically withthe roof

Fiat Idea and Fiat Panda 4x4The two innovative Fiat cars, Idea and Pan-

da 4x4, the latter with a turbo-diesel enginerespecting the limits of the present normatives,are defined “Don’t stop me, baby”. Both havethe front flashing and tapering with the roof, whilethe Panda also has a transparent roof, giving atouch of elegance in line with the present trend(Figure 9) even if it is an “off road”.

INCREASING TRANSPARENT AREAS FOR ROOFS - FIXED OR MOVINGTransparent fixed roof

With the Mitsubishi Sport back, Citroen CSport and Multicolor, we can, once again,point out that glazed roofs in an almost single fixed monolithic appearance (threeparts in realty) are no longer a design hope.

FIGS. 9A and 9B -Fiat Idea and FIGS.

9C and 9D - FiatPanda 4x4:

two Fiat city (Idea)and “off road”

(Panda 4x4) cars

108


FIG. 9A

FIG. 9B

FIG. 9C

FIG. 9D

FIG. 10A

FIG. 10B

FIGS. 10A and 10B -Mitsubishi Sportback

109


They are, in fact, now a real design concept to be realized by glass (or plastic) manufac-turers, following the strategic evolution ofall-around visibility as was conceived by theauthor 10 years ago.

Moving transparent roof: WebastoWebasto certainly represents the moving

transparent roof evolution and it is worthgoing into detail regarding its new design.Webasto has created a concept vehicle based

on the Volkswagen Touareg for the IAA.Named Hat-trick, this concept is the base forseveral technologies. An external shade onthe roof limits heat build-up. The panoramicsunroof is thinner, creating more headroominside the vehicle. Moreover, the sun visors inthe windshield have been replaced by films thatcan be darkened electronically.

Webasto will also introduce a new generationof auxiliary heating remote controls, and a newplastic film for roof modules that helps make glasspanels more resistant to braking.

FUTURE DESIGNCadillac SRX

Thanks to the large area of the harmoniouslyintegrated panorama roof of the Cadillac SRX,which stretches from the windscreen to the rear

window, this sunroofgives passengers in theback plenty of lightand air. This productbrings the latest trendin panoramic roofs tothe United States.

Mercedes A-ClassTransparent lamellas let lots

of light into the passenger compartment ofthe Mercedes A-Class, even when the roof isclosed. Made of high-quality, non-shatteringpolycarbonate, the roof has variable open-ing configurations, giv-ing optimum air andlight conditions.

Mercedes E-ClassOn the outside, the panoramic roof inte-

grates harmoniously into the vehicle design,while on the inside, the large, “out-built” sun-roof and electricallyoperated headliningoffer individually selectable light condi-tions and fresh air sup-ply as well as a pleas-ant in-car atmosphere.

MiniThe Mini gives more light, more air, greater

feeling of space. Thetransparent panoramicroof with its large open-ing area makes the inte-rior so bright andfriendly, even in com-pact cars.

Audi A6The Audi A6 has a

glass roof for greaterfeeling of space, evenwhen the roof is closed,giving a feeling of lux-ury, comfort and free-dom of choice.

Opel ZafiraThe multifunctional roof of the Opel Zaffira

provides a feeling of space and extra storagecapacity for every day,day trips and holidays.Electrically operatedroller sun-blinds guar-antee perfect light con-ditions and vision.

FIG. 11 - Citroen C Sport

FIG. 12 - Webasto’s roof shadelimits heat build-up in the car

FIGS. 13A,13B, 13C, 13D

and 13E -Webasto’smoving sunroof, alsomulti-functional inthe Zafira(FIG. 13E)

FIG. 13A

FIG. 13B

FIG. 13C

FIG. 13D

FIG. 13E

110

Ferrari-Webasto-Saint-Gobain with EC GlassThe Ferrari America was on show for the first

time at the Geneva Show (March 2005)[2]. Thedifference of the EC roof (Saint-Gobain tech-nology) does not show efficient switchingbetween transparency (off) and coloured (on)and again (see the light of the lampthrough the EC roof off andon) with manual elec-

trical switching by the driver. It isthe first time that EC glass technol-ogy used for a car light switchingon/off had a very slight differencein transparency, and was not used

automatically in function of solar control.

TWO COLOURS: RIGID SUPPORT AND LOW RIGID BODY

Innovation with improved visibility, andstrong innovative design with two colours,splits the external body in two parts: rigid sup-port and lack of rigidity, which gives less con-tribution to the total rigidity of the car.

LanciaLancia Ypsilon MonoDesign and its two

colours: rigid parts, skin body and glazing. Style,in symbiosis with advanced technology of bothItalian Lancia and MonoDesign, have been

FIGS. 14A, 14B, 14C, 14D and14E - Ferrari Americaelectrochromic glass on thecoupe’s moving roof

FIG. 14A FIG. 14B

FIG. 14D FIG. 14E

FIG. 14C

FIG. 15A

FIG. 15B

FIGS. 16A, 16B and 16C - LanciaMusa Platino and the twin

Phedra Unique Edition in linewith the new Lanciastrategy

111

achieved on the Ypsilon innovative modelwith an innovative design, the use of avail-able new materials and more attention todetails. Aesthetics at industrial level, bychromatic personalization (Orange) onthe external body, even matching theextremely flashing glazing also (finally)on the black roof frame, give positive model-ling for a small sportive and elegant car with glaz-ing contribution. Lancia Musa Platino and

and Phedra Unique EditionIn the same orientation of the Ypsilon, Lan-

cia has, once again, chosen an elegant andsophisticated two-colour body. “Visone Stradi-vari” is used for the lower part and an exclusive

“Brown Caravaggio” in the upper part,where two transparent panels give

better luminosity of the internalcompartments as can be seen in

Figure 16 for a twin car: MusaPlatino and Phedra Unique Edi-tion can be considered the Lan-cia-Fiat answer to the marketrequest for a family car.

Citroen C3 PlurielIn line with the choice of Lan-

cia with Ypsilon, the Citroen C3Pluriel has also been conceived with

the innovative design of two coloursfor the body. This can be achieved with

a distinction of body support and with trans-parency on the upper part with hidden supportunderneath the lower part of the body, underlinethe distinction of the three-body compartment.

FIG. 15C

FIG. 15D


FIGS. 15A, 15B, 15C and 15D - Theinnovative Lancia Ypsilon: sportive and elegant

The support is in one colour (grey), withtransparency on the upper part, which can be lessimplied in car rigidity (leaving a possibilityfor the use of plastic, at least in certain areas),and the lower body, where rigidity is less andso plastic can be used, as shown in the HondaCivic of Figure 19.

THE CONTRIBUTION OF TRANSPARENT PLASTIC WITH NODIRECT VISIBILITY PERFORMANCESMazda Sassou

Mazda Sassou was one of the best cars at theFrankfurt Motor Show with the use of plastic PCin a very innovative way. The exterior designevolves Zoom-Zoom design language to com-municate the dynamic potential Mazda designis known for, and mixes this with lightness andsurprising hidden features never seen on a Maz-da concept before.

The Mazda Sassou design concept by Giugiarois based in part on the “Shoji” principle. Sho-

ji screens are thin Japanese doorsthat partially hide what is behindthem. Opening them for the first time

can reveal something surprising, whichis also true of the first encounter with

FIGS. 17A-D - Citroen C3 Pluriel

FIG. 17A

FIG. 18A

FIG. 17B

FIG. 17C

FIG. 17D

FIGS. 18A,18B, 18C,18D, 18E, 18F and 18G - MazdaSassoudesignconcept byGiugiaro

FIG. 18B

FIG. 18C

FIG. 18D

113


Mazda Sassou. For instance, aningenious use of translucent plas-tic partially hides the front (Figure18C, Figure 18D) and rear lampgraphics (Figure 18A and 18B),which become fully visible once thecar is unlocked, with light pulsing inthe exterior light graphics in a way thatmake the car seem to come alive – Maz-da Alive. The transparency of this model, main-ly increased by the transparent roof (Figure18G), is now realized in glass by Italian transformerHard Glass (Padua).

The Mazda Sassou, designed by a Europeanarchitect, can be considered a prototype carmatching the glass in the rigid part of the vehi-cle system and the transparent plastic compo-nent where the rigidity of the vehicle does not(quite neglectingly) vary with or without themount of the component.

New Honda CivicThe Frankfurt new Honda Civic had already

been exhibited at the Geneva Motor Show, withthe purpose of achieving new standards in the com-

petitive segment C withmore emotion, sporti-ness and driving pleasureat the same time. The newHonda Civic is especial-

ly for the European marketwhich, in addition to the three val-

ues mentioned above, also has to be verypractical and multifunctional. In short, it has to be a car without any com-

promises for the client’s choice: long front andshort ground level in order to consider it ascompetitive.

The solution, considered revolutionary, basedon the Japanese “kimono” - the suit (the exter-nal body) - wraps up the internal bones of thebody by tidy and determined lines. The resultis that the new Civic (after seven previous mod-els), and following the logical “Honda” and“Magic Honda” technologies, offers an internalspace that is practical and efficient, really futur-istic, including a dashboard with dual link in threedimensions (see Figure 19E).

The external body, the main topic of thisreport, in Figures 19A, 19B, 19C and 19D, showsin detail the contribution of plastic in the back-light. In fact, there is a PC window underneaththe glass backlight, below the spoiler, giving trans-

parency to the baggage area and giv-ing the Honda Magic internal space.The PC window is realized by ItalianIncos Srl (Treviso).

FIG. 18E

FIG. 18F

FIG. 18G

FIG. 19A FIG. 19B

FIG. 19C FIG. 19D FIG. 19E

FIGS. 19A, 19B, 19C, 19D and19E - Honda Civic: practicalinternal design and sportiveelegance

114


Information regarding the inno-vation of the new Honda Civic,even at the Frankfurt Motor Show,was very limited in the Honda pressbook. Therefore, the author’s defin-itive information has been post-poned until the comparison betweenthe innovations of Frankfurt andthose of the Tokyo Motor Show.

A foreseen innovation by Hon-da, in collaboration with Densocorporation, is that of the new concept ofsophisticated antenna navigation and recep-tion system which can be placed underneath thespoiler, of which a preliminary example isshown in Figure 20.

LAMINATE SHAPING BY PARALLELSTAMPING (PRESS MOULDING)

The lamella roof of Mercedes A-Class was real-ized in polycarbonate by thermoforming in aclean room as shown in Figure 21A, and for

Zafira in Figure 21B. Pressinjection moulding has beenimproved considerably, evenin two colours.

THE (ALMOST TOTAL) ABSENCE OFGLASSMAKERS

Before concluding thispart, it is worth mentioningthat with the strong increaseof transparent glass areas

and the first realindustrial presenceof transparent plas-tic (PC), even innon-rigid parts,glassmakers were

completely absent forthe first time at a big

motor show.In fact, only Rio Glass

(Spain), as a transformer,had its own stand, wheresome glazing samples real-ized by the company’s engi-neering centre were exhibited.These complex shapes, shownin Figure 22, can be consid-ered the extreme possibilityto be obtained with glass,but only for special niches ofthe market.

HEAD PROJECTORSLENSES IN PC

Different types of headprojector lenses and back-lights with the use of LEDtechnology were an exampleof the trend of integration in plastic panels.

FIG. 20A

FIG. 20B

FIG. 20C

FIGS. 20A, 20B and 20C -The advanced car navigatorand information system ofthe Honda Civic

FIGS. 22A, 22B, 22C,22D, 22E, 22F and22G - Complex glassshapes by Rio Glass(Spain) trying to avoidplastic glazing

FIGS. 21A,21B, 21C and 21D -Laminateshaping byparallelstamping

FIG. 21A FIG. 21B

FIG. 22A

FIG. 22B

FIG. 22C

FIG. 22D

FIG. 22E

FIG. 22F

FIG. 22G

FIG. 21C FIG. 21D

FIG. 25C FIG. 25C

115


LED head projectors orother illumination technol-ogy can be considered one ofthe evolving components thathave changed the style ofthe front and back of theinnovative cars, where plas-tics such as PC and PMMAhave found strong applica-tions in lenses for the auto-motive industry. Potentiallightning from LED’s canbe summarized as follow-ing with the contribution ofthe main three worldwideproducers of projectors andbacklights.

Even if the forecast is thatit is not certain that LED pro-duction can lower its priceenough to reach the massmarket, it has the expectedadvantages:• more styling flexibility for

cornering lights;

FIGS. 23A and 23B -Smart Style Concept,backlights andprojectors integrated in the rear windows

FIGS. 23C and 23D -Mercedes Concepts,Projector: Roundish onVision R63 AMY A cars

FIGS. 25A, 25B, 25C

and 25D - Citroen C6,projector andbacklights

FIGS. 26A, 26B and 26C -The potential for LED’s isshown in these prototypesby Visteon (A), Valeo (B)and Hella (C)

FIG. 27 - A Visteonprototype for Mercedes

FIGS. 28A, 28B and 28C -The possibility of colourmatching by LED’s whichcan be realized in threefundamental colours

FIGS. 29A and 29B -Denso Project for aMercedes backlight

FIG. 23A

FIG. 23B

FIG. 23C

FIG. 23D

FIG. 25A

FIG. 25B

FIG. 26A

FIG. 26B

FIG. 26C

FIG. 27 FIG. 28A

FIG. 28B

FIG. 28C

FIG. 29A

FIG. 29B

FIG. 24 - GM Corvette, narrow and almost all frontintegrated underneath the

bonnet with PC plastic panels

FIGS. 30A and 30B - Mazda Sassou back-lights and projectors

FIG. 31 - Porsche, backlights that can beintegrated in the rear window, at least

partially, especially with PC glazing

FIGS. 32A and 32B - Micra by Nissan

FIG. 33 - Renault Egeus concept

FIG. 34 - SUV vehicle

FIGS. 35A, 35B, 35C and 35D - Ford sedan cars

116

• xenon-like performance at lower cost; and• vehicle life time durability.

In simple words, LED lights must becomemore powerful, less expensive (cheaper by a fac-tor of 2 or 2.5) and simply handle the four pro-jectors (Figure 27) in competition with xenonand halogen units.

A series of pictures (Figures 28) show the potential contribution of colours with LEDtechnology using the International Take of yellow, blue, red, with electronic back-lights and projectors.

LED lighting was also seen even in small, SUVand Sedan cars, such as the Chrysler Premiereand the Smart “forfour”, where their integrationcould be tentatively realized by transparentplastics (PC).

REFERENCES[1] G.Manfrè “Strong consumer demand for

modular designs brings new challenges inautomotive glazing”. Intelligent Glass Solu-tions, Issue 1, 2005, at GPD 2005 -Tam-pere (Finland).

[2] G.Manfrè “Geneva 2005: innovative tech-nology and increased complex glazing” Glass-Technology International, 5/2005, for Vit-rum 2005 (Milan 5-8 October 2005). ■

*Consultant

MG Consult SrlVia Vicenza, 11 - 37042 Caldiero (VR)

ItalyTel: +39 - 045 - 6151022Fax: +39 - 045 - 6151303

E-mail: [email protected]

www.mgcomputer.it

FIG. 30A

FIG. 31

FIG. 30B

FIG. 32A FIG. 32B

FIG. 33A FIG. 33B

FIG. 34 FIG. 35A

FIG. 35B FIG. 35C

FIG. 35D


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FIG - Glassvar.glassonline.com/uploads/publications/section_articles/articlePDF/... · means of nano-technology and even flame-retardant coating, are now convincing design-ers to