Why You Should Join Automotive Glass Engineers On LinkedIn

I created Automotive Glass Engineers on LinkedIn to provide a community forum as well as a talent base for potential clients, suppliers and talent acquisition firms. As you know glass is very specific [commodity] and glass for transportation, which by the way is in the top two vehicle warranty failure modes is highly specialized with a very narrow bandwidth of talent.

You will find some of the most capable technical specialists in the transportation field. Automotive Glass Engineers specializes in product, process and bonding adhesives.

We have a best selling, award winning author that can provide you with a step by step “Design Solutions” book covering subjects like DFMEAs, PFMEAs and design tables showing the costs and ramifications of your decision making process.

I have created an open access approach. Feel free to post anything relevant as a member, remember your post reflects on you. Quality content is the goal.

Join now: https://www.linkedin.com/grp/home?gid=7491694&trk=my_groups-tile-flipgrp

Plus, here is what we talk about and the resources you’ll find:

Topic of the Week:
Each week a group member will post a new topic for discussion. I invite you to share your thoughts & expertise. My goal is to make you think and learn.

Engineering Issues:
Whether you’re an OEM, supplier or talent acquisition specialist. If you have questions, answers or concerns, voice them!

Open forum:
Let it rip! Be professional

Sound interesting? I hope so. I invite you to get engaged in discussions, ask questions, share your thoughts.

Click here to join: https://www.linkedin.com/grp/home?gid=7491694&trk=my_groups-tile-flipgrp

Best regards,
Lyn

Lyn R. Zbinden winner of the 2015 APEX Award of Excellence at the 27th Annual Awards for Publication Excellence

SAE International’s Book on Automotive Glass Engineering Wins APEX Award of Excellence

WARRENDALE, Pa., June 4, 2015 –

SAE International’s book, “Glass Engineering: Design Solutions for Automotive Applications,” is honored with a 2015 APEX Award of Excellence for Publication Excellence.

The APEX Awards are an annual competition for publishers, editors, writers and designers who create print, web, electronic and social media. The awards are based on excellence in editorial content, graphic design, and the success of the entry – in the opinion of the judges – in achieving overall communications effectiveness and excellence. The 2015 competition included 1,851 entries (120 in the Print Media category).The APEX judges saw only the most promising publications that professional communicators could enter.

Written by Lyn R. Zbinden, a mechanical engineer and glass specialist, “Glass Engineering: Design Solutions for Automotive Applications,” narrows the gap between the reader and a technical subject by using language that is easy to understand, a good variety of examples, and a series of invaluable reference design tables. The book also addresses the theme of glass from the manufacturing stage to the design, installation, and warranty aspects. It also flags, along the way, the pitfalls and the important questions to ask. More importantly, it provides the reader with practical ways to solve the not-so-obvious problems associated with the use of automotive glass.

For more information about “Glass Engineering: Design Solutions for Automotive Applications,” visit http://books.sae.org/r-433/. To request a media review copy, email pr@sae.org or call 1-724-772-8522.

SAE International is a global association committed to being the ultimate knowledge source for the engineering profession. By uniting over 137,000 engineers and technical experts, we drive knowledge and expertise across a broad spectrum of industries. We act on two priorities: encouraging a lifetime of learning for mobility engineering professionals and setting the standards for industry engineering. We strive for a better world through the work of our philanthropic SAE Foundation, including programs like A World in Motion® and the Collegiate Design Series™.        – http://www.sae.org

EAward2


“Books from SAE International” 2 week sale

                                             

Screen Shot 2015-06-16 at 9.31.34 AM

Congratulations. SAE International has won a 2015 APEX Award of Excellence at the 27th Annual Awards for Publication Excellence, sponsored by Communications Concepts, Inc. This award recognizes R-433: “Glass Engineering: Design Solutions for Automotive Applications,” by Lyn Zbinden (http://books.sae.org/r-433/).

The APEX Awards are an annual competition for publishers, editors, writers and designers who create print, web, electronic and social media. The awards are based on excellence in editorial content, graphic design, and the success of the entry – in the opinion of the judges – in achieving overall communications effectiveness and excellence. The 2015 competition included 1,851 entries (120 in the Print Media category).The APEX judges saw only the most promising publications that professional communicators could enter.
For more about the APEX Awards you can visit: http://www.apexawards.com

Award winner background

Apex 2015_winner

SAE International – June 4 at 9:00am

        Apex 2015_winner                                         

SAE International News
June 4 at 9:00am
SAE International’s Book on Automotive Glass Engineering Wins APEX Award of Excellence
WARRENDALE, Pa. (June 4, 2015) – SAE International’s book, “Glass Engineering: Design Solutions for Automotive Applications,” is honored with a 2015 APEX Award of Excellence for Publication Excellence.
The APEX Awards are an annual competition for publishers, editors, writers and designers who create print, web, electronic and social media. The awards are based on excellence in editorial content, graphic design, and the success of the entry – in the opinion of the judges – in achieving overall communications effectiveness and excellence. The 2015 competition included 1,851 entries (120 in the Print Media category).The APEX judges saw only the most promising publications that professional communicators could enter.
Written by Lyn R. Zbinden, a mechanical engineer and glass specialist, “Glass Engineering: Design Solutions for Automotive Applications,” narrows the gap between the reader and a technical subject by using language that is easy to understand, a good variety of examples, and a series of invaluable reference design tables. The book also addresses the theme of glass from the manufacturing stage to the design, installation, and warranty aspects. It also flags, along the way, the pitfalls and the important questions to ask. More importantly, it provides the reader with practical ways to solve the not-so-obvious problems associated with the use of automotive glass.
For more information about “Glass Engineering: Design Solutions for Automotive Applications,” visit http://books.sae.org/r-433/. To request a media review copy, email pr@sae.org or call 1-724-772-8522.
SAE International is a global association committed to being the ultimate knowledge source for the engineering profession. By uniting over 137,000 engineers and technical experts, we drive knowledge and expertise across a broad spectrum of industries. We act on two priorities: encouraging a lifetime of learning for mobility engineering professionals and setting the standards for industry engineering. We strive for a better world through the work of our philanthropic SAE Foundation, including programs like A World in Motion® and the Collegiate Design Series™.
http://www.sae.org
Contact: Shawn Andreassi of SAE International, 1-724-772-8522 or pr@sae.org
SAE International News’s photo.

 

 

 

 

SAE International has won a 2015 APEX Award of Excellence at the 27th Annual Awards for Publication Excellence

        Apex 2015_winner                                         

Congratulations. SAE International has won a 2015 APEX Award of Excellence at the 27th Annual Awards for Publication Excellence, sponsored by Communications Concepts, Inc. This award recognizes R-433: “Glass Engineering: Design Solutions for Automotive Applications,” by Lyn Zbinden (http://books.sae.org/r-433/).

The APEX Awards are an annual competition for publishers, editors, writers and designers who create print, web, electronic and social media. The awards are based on excellence in editorial content, graphic design, and the success of the entry – in the opinion of the judges – in achieving overall communications effectiveness and excellence. The 2015 competition included 1,851 entries (120 in the Print Media category).The APEX judges saw only the most promising publications that professional communicators could enter.
For more about the APEX Awards you can visit: http://www.apexawards.com

Award winner background

 

 

Windshield can show acceptable optics

Windshield can show acceptable optics at 40° installation angle, whereas at 20° degrees can be completely distorted. This occurs since the light ray is required to travel longer distance in the glass as the installation angle decreases. To put it simple, the thickness of the glass that is being viewed through increases as the installation angle decreases.

The steeper the “rake’ more glass you have to look through. FMVSS 205 says 70% LT (light Transmission), ever notice that aAS1 with and arrow right below your shade band? That means 70% of the ambient light must pass through. The steeper the angles, the more glass it has to pass through. There was a time when the Federal government was going to mandate that measurement be taken from the driver’s line of sight, right now it is taken normal (perpendicular) to a point on the WS. If the government was successful in that direction, every car in the US, Canada and Europe would have to be quarantined.

Installation Angle

Designing GLASS for Style – Polycarbonates

                                                        Polycarbonates

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Glass is not the designer’s only option to glaze an opening. Lightweight materials may find exciting opportunities in the automotive industry as a means of increasing fuel efficiency. With 75% of fuel consumption relating directly to vehicle weight, potential weight reductions that result in improved price-performance ratio promote use of lightweight materials. One of the key plastics used in automotive sector is polycarbonate (PC). PC has dominated the market for vehicle headlamp covers for 15 years, and now it challenges glass in windows. Plastics are lightweight materials ideal to improve fuel efficiency and design flexibility without compromising on performance or safety. The automotive industry can expect an impressive 6-8% improvement in fuel usage with only 10% reduction in vehicle weight. This translates into a reduction of around 20 kg of CO2 per kilogram of weight reduction over the vehicle’s lifetime. With newer advances in plastics materials, the weight of these parts is bound to reduce. Lighter vehicles facilitate easier braking, reduced collision impact overall vehicle performance and superior driving experience.

 shutterstock_96668173

 

What is polycarbonate?

Polycarbonates are a particular group of thermoplastics. They are easily worked, molded, and thermoformed; as such, these plastics are very widely used in modern manufacturing. They are called polycarbonates because they are polymers having functional groups linked together by carbonate groups in a long molecular chain.

Polycarbonate is a very durable material, and can be laminated to make bullet-resistant “glass”. This polymer is highly transparent to visible light and has better light transmission characteristics than many kinds of glass. The primary advantages of polycarbonates in automotive glazing are lowered weight and associated CO2 emissions reductions along with greater styling freedom and simpler functional integration. The wide choice of styling options with polycarbonates is testing conventional assumptions of automotive window design and creating whole new opportunities for advanced vehicle styling.

Polycarbonate is becoming more common in industry. It is often used to create protective features, for example in banks as well as vandal-proof windows and lighting lenses for many buildings. Other products made from polycarbonate include sunglass/eyeglass lenses, compact discs, DVDs, and automotive headlamp lenses.

PC auto glazing permits parts integration previously not possible. Features such as colored glazing for tinted sunroofs and windows aft of the “B” pillar are now possible along with gaps in the window, sharp corners, smooth corner radii or complex three dimensional shapes. These features are undesirable, unmoldable or cost-prohibitive with laminated or tempered glass. PC auto glazing permits parts integration previously not possible. It is possible to create a roof-module frame and optical panel in one piece.

fisker-karma-atlantic-7

Fiskar Karma Atlantic 7

Molding heating/defrosting elements and fractal antennas into a PC window panel is also possible using in-mold films with preprinted circuitry. This is a versatile material to use, but advances in this application have been slowed by UV sensitivity of the material and its tendency to scratch easily, which makes it less weatherable than glass. If your production run is niche and well-funded, and you are looking to distinguish yourself from your competition, by all means, look at it. This is one material that is position specific. Legally it cannot be used everywhere, it is very expensive once it has been made fully coated for the durability cycle demanded of commercial use, usually 10 years.

The designer must now ask him or herself “What is my total cost versus what can be gained in mass reduction and design freedom?” The main drawback to a PC is weathering, resistance to scratch and scuffing. By the time you apply a hard coat, any potential savings derived from weight is now lost due increased piece price cost which can be as much as 4:1. There are infinite number ways that Design (Styling/Industrial Design) and engineering can and should work together upfront in the process. This can be used in the fixed vent window of, let’s say a Ferrari or framed sidelites for the XL1.

fixed vent

It saves weight, becomes a unique feature, like carbon fibre, but is unrealistic in normal production due to cost vs. value. Value still must be derived.

VW-XL1-door-open

The Volkswagen XL1 uses polycarbonate windows to help save weight, just one of many distinguishing features

The Volkswagen hybrid concept, XL1 plug-in is one such vehicle that makes use of the innovative automotive lightweight solutions mentioned. The Volkswagen XL1 becomes the first vehicle to feature advanced plasma coating technology on two-component (2K) injection molded PC windows. Using polycarbonate resin, which is an amorphous engineering thermoplastic, characterized by outstanding mechanical, optical, electrical and thermal properties, Volkswagen reportedly estimates a reduction in weight in previous all glass applications at 33%, while delivering a high-quality optical appearance and scratch-resistant surface.

volkswagen-xl1-plug-in-diesel-hybrid_100419660_m

 

The ability to create an aggressive curvature of the upper portion of the sidelite adds to form and function. Since the upper lite is polycarbonate and stationary there are no additional abrasion issues due to traveling between a door moldings or packaging issues with getting the glass in a confined opening like the door inner and outer envelope. The occupant will generally not depend on that area for general viewing.

VW_front_side_lo_resLooking at the XL1’s fixed and roll-down side windows pictured above, notice that the sidelite is two separate glass lites. The smaller of the two lites is glass and dynamic. The larger stationary lite is framed polycarbonate on its periphery to provide its structural integrity. This is because a polycarbonate side window will billow like a sail once the vehicle is mobile if not supported. The frame around the window adds rigidity, but also adds weight.

The requirements for plastic glazing are met by depositing plasma coating on the parts after molding. This glass-like plasma coating, applied over a hard coat, delivers enhanced weathering, durability, and abrasion performance and enables compliance with global requirements and regulations for plastic glazing applications.

wet_coat

Wet coating

Federal regulations prohibit the use of polycarbonate in an AS1 position (windshield). Federal regulations further state, for these positions must demonstrate the ability to meet ≥ 70% Light transmission (LT) for AS1 (Windshield) and AS2 (Sidelites) applications. In 2005, the U.S. Dept. of Transportation’s National Highway Traffic Safety Administration (NHTSA) confirmed that polycarbonate may be used in vehicle areas specified for Item 2 (AS2, AS3) glazing (safety glazing material for use anywhere in a motor vehicle except windshields), provided that the product satisfies the existing performance standards for Item 2 glazing. Questions persist regarding retention of the necessary transparency over the useful lifetime of the vehicle. A test has been developed for coated polycarbonate automotive glazing to measure their resistance to windshield wipers. This test enables simulation of the actual stress exerted on the wiped glazing far more realistically, accurately, and with a higher reproducible quality than is possible with the Taber abrasion test stipulated in the regulations. Initial tests have shown that, when dirty panes with a polysiloxane coating are wiped under primarily wet conditions, they exhibit virtually no clouding that is visible to the naked eye – even after 30,000 double-wiper cycles.

 

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Wiper performance is critical in the design, engineering, and testing acceptance of a windshield for a saleable vehicle.

PC glazing technology continues to enable the development of advanced, lightweight window designs for the automotive industry. Polycarbonate glazing may enable weight reductions up to 50% versus comparable glass materials, depending on the complexity and design of the window part, but as you saw with the XL1 33% will probably be the realistic range.

prius-v-five-moonroof

Toyota’s two-panel Prius V moonroof made of polycarbonate plastic.

In conclusion; Polycarbonate is sneaking into the western auto industry as glass replacements in non-strategic areas. Hyundai has used it on concept cars and Bugatti on a new lightweight targa top for the Veyron (saving 13 pounds).

Bugatti Targa top

Bugatti Targa top

 The most prominent mainstream users of polycarbonate right now are Mercedes (which puts it into fixed Smart side windows, as well as those roof panels) and Toyota, which is introducing it on the V, the new station wagon version of the Prius.

GM Volt

General Motors also introduced it in the concept Chevy Volt roof panel.

New legislations in Western countries have been introduced to limit pollution caused by vehicles. European legislations such as EC 715/2007 (Euro 5, 6 standards) and U.S. regulations such as EPA 2010 are applying stricter rules to reduce CO2 emissions from new cars. The United States government announced a plan to increase fuel efficiency by more than 5% pa starting in 2012. These requirements necessitate lighter vehicles and improved fuel efficiency. European regulation currently permits polycarbonate (PC) use in all automotive glazing applications except the windshield. In the United States, the US Department of Transportation’s National Highway Traffic Safety Administration (NHTSA) has approved the use of PC for all non-windshield glazing applications provided that it meets all existing auto glazing specifications for laminated glass as prescribed in the Federal Motor Vehicle Safety Standard (FMVSS) No. 205. This includes < 2% delta haze in the all-important Taber 1000 abrasion test. However, uncertainty over long term weathering and compliance with the ANSI regulation has held back adoption of PC glazing in the US.

 

Technical data on polycarbonates

Polycarbonate has:

Density = 1.20 g/cm3

Use range from -100°C to +135°C

Melting point around 250°C

Refractive index equal to 1.585 ± 0.001

Light transmission index equal to 90% ± 1%

Poor weathering in an ultraviolet (UV) light environment

Developing a seminar, webinar and lecture series based on my book

Front Cover newhttp://books.sae.org/r-433/

SAE 2014 Thermal Management Systems Symposium

SAE Thermal

 

http://www.sae.org/events/tmss/

With the advent of new vehicle powertrains such as hybrid, electric and fuel cell, how to handle vehicle heating and cooling has become a paramount issue in the mobility industry. All thermal management systems, including mobile air conditioning systems, require new concepts to provide passenger compartment heating and cooling as well as heating and cooling of batteries and cooling of vehicle fuel systems.

SAE 2014 Thermal Management System Symposium will be expanding its programming content to focus on environmental regulatory requirements and the technologies to meet them. Leading experts from the United States, Europe, and Asia will speak about cutting-edge thermal management technology and regulation compliance strategies.