GE Helps the SEAT Leon Project a Winning Attitude with an Unconventional Quarter Window Design

The Leon, manufactured in Spain by SEAT, a division of Volkswagen, is a young model that emphasizes unconventional styling. Although the car is a five-door hatchback, the aim was to make it appear sporty and more like a two-door coupe. To help achieve this effect, SEAT wanted to create a unique quarter window incorporating a recessed hand grip, instead of using a traditional rear door handle. However, this complex glazing application could not be fabricated in glass. A material offering design flexibility coupled with high impact resistance and crystal clarity was needed. To find the optimal solution, SEAT’s Tier 1 supplier, Freeglass, recommended GE Plastics.

GE Plastics and SEAT

The Challenge: Moving Beyond Glass to Achieve New Glazing Designs

The SEAT Leon is a compact car with a big attitude. SEAT, a division of Volkswagen, designed it to project the aggressive sportiness and speed of a two-door coupe, even though the vehicle is actually a five-door hatchback. To streamline the Leon with a “dynamic line,” SEAT decided to add a rear quarter window with a built-in recessed hand grip that provides access to a hidden door handle. This design would eliminate the traditional, obtrusive rear door handle. The integration would also provide part consolidation.

However, the quarter window’s recessed hand grip and curved shape exceeded the limitations of glass. This application required a material with exceptional design freedom to create the unique window shape. The search for a better material also offered the chance to find a lighter-weight replacement for the glass to promote better fuel economy.

“We needed a material that could enable both form and function,” said Francisco Galan, Body Development Director for SEAT. “It had to provide design flexibility, as well as high performance and ease of use in day-to-day operation of the vehicle. Based on our excellent ongoing relationship with GE Plastics, we were confident they could provide the right plastic for this part.”

The Solution: GE’s Lexan* Resin for a Sleek, Sporty Design

SEAT selected tough, crystal-clear Lexan LS2 polycarbonate (PC) resin, matching the glass color of the vehicle, plus a silicone topcoat for weathering and abrasion resistance. Lexan resin is widely used in the automotive industry for complex glazing and lighting applications that do not lend themselves to glass. In addition, Lexan resin is significantly lighter in weight than glass, helping to improve fuel efficiency.

“GE worked closely with Freeglass to enable the success of this challenging application,” said Volker Kessler, Automotive Industry Manager for Body Panels and Glazing, GE Plastics. “We added value to the design and manufacturing process with predictive tools such as part fill simulations, and color-matching services. Our Center of Excellence for Glazing in the Netherlands played a key role in this collaboration.”

The quarter window is injection molded and coated by Freeglass.

The Benefits: Up to 40 Percent Weight Savings and Significant Part Consolidation

The use of lightweight, versatile Lexan resin instead of glass reduced the weight of the quarter window by about half and enabled seven parts to be consolidated into one. These factors contribute to improved fuel economy for the Leon, and help to reduce system costs for this component.

The unique design offers both practicality and flair. The quarter window provides extra light and visibility for rear passengers, as well as the safety and security of tough Lexan resin. The clever design hides the door handle to provide a smooth, sleek line to the car’s exterior.

“GE’s Lexan resin made this design a reality,” said Galan. “Because the quarter window could not be made with glass, we were concerned that our vision for the Leon would be compromised. Thanks to GE Plastics, we achieved exactly the look and functionality we desired – and our customers are delighted.”

Details at: www.seat.com