SAE International Novel Lightweight Laminate Concept with Ultrathin Chemically Strengthened Glass for Automotive Windshields 2015-01-1376

This paper proposes a novel concept for lightweight vehicle design, offering a step change in weight reduction for automotive glazing. Reducing window weight can be achieved by decreasing the thickness of the glass plies used to form vehicle windows. However, reducing the thickness of conventional automotive windows also decreases its effective strength; therefore, concerns about glass breakage become a limiting factor for weight reduction. Chemically strengthened ultrathin Corning 2x Gorilla 2x Glass offers the potential to go beyond existing thickness limitations. Its higher strength compared to standard soda lime window glass allows the design of thin, low weight window constructions. In addition, its unique manufacturing process delivers pristine glass surfaces and precise thickness control for high quality window optics. While this concept can be applied to all vehicle openings, this study focuses on automotive windshield design. By replacing the thick inner ply of a windshield laminate with an ultrathin Gorilla Glass ply, a significant weight reduction can be achieved. An overall reduction in windshield weight of more than 30% can be achieved with the proposed constructions in comparison to conventional designs. Test results will be discussed to demonstrate concept feasibility under consideration of regulatory and OEM vehicle design criteria. Benefits, as well as trade-offs, will be reviewed.