Auto industry experts predict that by 2010, 40 percent of all new cars will feature sunroofs in response to consumer demands for brighter, more open vehicle interiors. In addition, the use of panoramic sunroofs, which provide even greater exposure to the exterior environment, is increasing rapidly. As sunroofs grow in size, so do vehicle weight and concerns about safety in the event of impact. As a solution to both the safety and weight concerns, DuPont has introduced its Spallshield composite interlayer technology, which can enable use of laminated glass with improved protective capabilities and reduced weight.

"This is an excellent example of DuPont materials science enabling improved protection,” said Craig Binetti, vice-president and general manager – DuPont Packaging & Industrial Polymers. “As we continue to see the need for increasing safety in automobiles, we have a number of exciting research developments in light control, lightweighting and new structural materials that can improve passenger comfort and safety.”

The first-generation Spallshield is a plastic composite (of PolyVinyl Butyral film and Polyethylene Terepthalate (PET) and that provides up to eight times the impact performance of standard laminated glass. Two layers of plastic are laminated to a single layer of glass with the plastic on the inside, protecting passengers from glass shards from exterior impact and from the potential of ejection in the event of a roll-over accident. By essentially eliminating one layer of glass from a standard glass laminate and replacing it with an abrasion-resistant polyester film, weight reductions of up to 30 percent can be achieved. The technology has already been adopted by DaimlerChrysler for its Mercedes S and R-Class vehicles.