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SAE International Scholarly Journals

Title Two-Component Injection Molding as a Noise Countermeasure for Polycarbonate


Glazing

Author Gasworth, S., Nilajkar, V., and Terragni, M., "Two-Component Injection Molding
as a Noise Countermeasure for Polycarbonate Glazing," SAE Technical Paper
2017-01-1817, 2017.

Keyword Key value proposition of PC glazing is the opportunity for feature integration
afforded by the injection molding process generally used for forming such glazing

Abstract Polycarbonate (PC) glazing as a one-for-one glass replacement offers a 50%


weight reduction, but exhibits several dB lower sound transmission loss (STL) in
the low frequency range where tire and engine noise are dominant. In the high
frequency range where wind noise is dominant, PC glazing offers an STL at least
comparable to its glass counterpart, and an STL exceeding glass when this
frequency range encompasses the glass coincidence frequency. However, a key
value proposition of PC glazing is the opportunity for feature integration afforded
by the injection molding process generally used for forming such glazing. Two-
component (2K) molding fuses a second shot of plastic material behind, and
along the perimeter of, the transparent PC first shot. This second shot can
incorporate features and implement functions that require additional components
attached or peripheral to a glass version. In effect, a portion of the weight
reduction entitlement for PC glazing is transferred to the host vehicle, such that
the weight reduction of the glazing itself is less than 50%. Moreover, the second
shot tends to stiffen the PC glazing relative to the first shot alone. We show
experimentally that these two effects contribute to making the low frequency STL
of a 2K PC rear window intermediate between the first shot alone and the
comparable glass version. Thus, integration operates as a noise countermeasure
for glazing weight reduction. Injection molded PC glazing can also be designed
for reduced aerodynamic (high frequency) noise, further improving its noise
profile versus glass.

Finding Manufacturing processes of the product


Glass of proposition
Test of product noise

MLA Gasworth, S. M., Nilajkar, V., & Terragni, M. (2017). Two-Component Injection
style Molding as a Noise Countermeasure for Polycarbonate Glazing. SAE Technical
Paper Series. doi:10.4271/2017-01-1817