GE Plastics Helps Nissan Sculpt Unique, Asymmetrical Glazing Shapes to Create the Bevel Concept Car

When Nissan Design America began designing its Bevel Concept car, the team recognized that traditional glass could not deliver the unusual glazing components they envisioned. The Bevel Concept, a utility vehicle that targets middle-age men with many hobbies and activities, features asymmetrical styling, a roof cargo system, and other unique glazing designs that were not possible to achieve with glass. In addition, because the car is designed to be environmentally responsible – for example, it features roof-mounted solar panels – Nissan wanted to find ways to reduce overall vehicle weight for fuel savings. As a longstanding GE Plastics customer, Nissan approached the plastics supplier to help identify a glazing solution.

GE Plastics and Nissan Design America

The Challenge: Creating One-of-a-Kind Glazing Shapes

Conceived at Nissan Design America, Inc. (NDA) in La Jolla, Calif., in collaboration with Nissan advanced product planning groups in the United States, the Bevel Concept car aims to meet the needs of a specific demographic: male “empty-nesters” who are actively involved in hobbies, recreation, and volunteer work. The utility vehicle was envisioned as highly practical, with large doors for easy cargo loading, a tall hatch with a tailgate platform to be used as a protected workbench, electrical outlets powered by solar cells, and even special accommodations for pets.

To achieve its design goals, NDA required special glazing shapes. Specifically, the roof panel, an asymmetrical shape, was designed to cover the photovoltaic cells and also incorporate six round, raised areas with integrated pop-up hooks to tie down cargo. The roof had to appear glazed on the exterior but function as a normal, opaque roof from the interior.

Another glazing challenge was the recessed back window, also an asymmetrical part. This complex shape had to incorporate rear lighting that would appear invisible until illuminated. And the large windscreen with its highly curved profile also presented potential difficulties.

“It was clear early in the process that glass simply was not up to the challenge of creating these large and complicated shapes,” said John Cupit, Chief Designer, Nissan Design America. “Having worked on many successful projects with

GE Plastics, we asked them to help identify a material solution that could provide a new level of creativity and innovation. GE Plastics not only presented the material option of Lexan* GLX resin that could be used with Exatec® 900 coating, but gave us new options for exciting design features we hadn’t even considered with glass.”

The Solution: GE’s Lexan GLX Resin with Exatec 900 Coating to Combine Art and Practicality

Nissan ultimately chose tough, crystal-clear Lexan GLX polycarbonate (PC) resin protected with Exatec 900 coating system from Exatec LLC for abrasion resistance and weatherability. This solution offers automakers expanded design options for large, three-dimensional glazing panels used in rear and roof applications. The combination of these technologies has opened the door to GE’s Signature Surfaces* program designed to enhance curb appeal through deeper surface geometries, unique lighting effects, changed vehicle proportions, and novel daylight openings.

Roof panels and rear windows are typically among the largest and heaviest glass on a vehicle. The use of GE’s Lexan GLX resin technology may potentially reduce weight by up to 50 percent vs. comparably sized glass windows. In addition, reducing the weight of glazing translates into a lower center of gravity for the vehicle, improving handling and safety.

Exatec coating systems include an optimized siloxane coating tailored to the specific weathering requirements of the automotive glazing environment. This advanced siloxane coating improves adhesion to the final protective layer (plasma coating), and offers a wider processing window than competitive materials for higher yields at potentially lower costs.

“Our Lexan GLX resin is changing the look of glazing across the automotive industry,” said Derek Buckmaster,

GE Plastics’ Global Market Director for Exterior Body and Glazing, Automotive. “Combined with Exatec coating, Lexan GLX resin outperforms traditional glass in design freedom, weight savings, aesthetics, and safety. We’re delighted that NDA chose our material for the stunning new Bevel Concept car, which showcases many unique glazing designs made possible by our technology.”

The Benefits: Delivering Optimal Utility without Sacrificing Great Design

The use of GE’s Lexan GLX resin allowed NDA to design and produce three major glazing components for the Bevel Concept car. First, the GE material allowed six “pucks,” or round raised areas, to be integrated into the surface of the roof panel. The pucks, which serve as the anchors for pop-up metal hooks used to tie down cargo, are an integral part of the roof for greater strength – in fact, the roof glazing system can carry up to 250 pounds. Further, GE’s Lexan resin made it possible to design the Bevel Concept’s very large roof panel without excessive weight that could destabilize the vehicle. Finally, the ability to injection mold the panel allowed NDA to create a unique, free-form shape with curved areas.

Second, Lexan GLX resin made it possible to recess the back window and incorporate all rear lighting for a clean, uncluttered look. The large window, which is oversized due to the height of the hatch door, is also asymmetrical to match the design theme of the car. The window edge curves inward to create a 3D shape – which was impossible to create using glass.

The GE material also enabled the curved shape of the Bevel’s raked windscreen. Completing the glazing applications are the large side windows. All of the glazing features molded-in tinting provided by the Lexan GLX resin.

In addition to design freedom, GE Lexan resin offers the practicality of lighter weight for improved fuel efficiency and handling, as well as durability for harsh driving conditions. The Exatec 900 coating helps to prevent abrasion, UV degradation, and other weathering impacts.

“With the help of GE Plastics, we’ve designed a truly innovative concept that meets the particular vehicle needs of the ‘Everyday Hero,’ a middle-age man involved with personal and community projects,” said Cupit. “As always,

GE Plastics found the right material solution for our demanding requirements, and the results speak for themselves – unique glazing designs, gorgeous aesthetics, and everyday utility.”

Details at: www.nissan-global.com

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