An added bonus of using Paxon SP5504, which is undergoing further research, is that post-consumer recyclate (PCR) content can be increased with minimal impact on its properties.

Dr. James Stern, HDPE Business Development Manager, North America, at ExxonMobil, commented: “This new product will be an ‘enabler’ for the value chain to create truly innovative solutions for blow-molded HDPE bottles and containers. Ongoing commercial tests and trials with converters and brand owners are proving highly successful, so we are confident about the interest this new solution will generate across the value chain.”

Paxon SP5504 reportedly boosts environmental stress cracking resistance without compromising stiffness, impact, top load performance, or processability.

“We are proud to have supported Toyota and its Tier suppliers with this first-to-market, plasma-coated rear quarter window on a very special car,” said Scott Fallon, SABIC’s automotive business leader. “No other technology is available today with the same level of durability for PC-glazed windows than this plasma solution. It is a good example of the superior value that we can deliver to today’s automakers as they strive to build light, stylish and well-finished vehicles.”

ExxonMobil has introduced a new Paxon HDPE grade that creates what the company calls a “paradigm shift” in properties normally associated with unimodal HDPE resins. Offering a “step change in environmental stress cracking resistance (ESCR) performance without compromising stiffness, impact, top load performance, or processability,” Paxon SP5504 is suited for household and industrial chemical (HIC) bottles and containers for bleach, wipes, agricultural chemicals, and similar products.

Paxon SP5504 enables the production of multiple applications from standard blow molding to more-demanding HIC-type applications. The material also enables the fabrication of complex molded designs. Brand owners can now be more creative with their packaging designs, while converters can reduce polymer inventories, said ExxonMobil’s announcement.

The car’s rear quarter window is injection molded with Lexan polycarbonate (PC) resin from SABIC. The optically clear window is about 50 percent lighter compared to a conventional glass solution.

Until she retired in September 2021, Clare Goldsberry reported on the plastics industry for more than 30 years. In addition to the 10,000+ articles she has written, by her own estimation, she is the author of several books, including The Business of Injection Molding: How to succeed as a custom molder and Purchasing Injection Molds: A buyers guide. Goldsberry is a member of the Plastics Pioneers Association. She reflected on her long career in "Time to Say Good-Bye."

Because Toyota wished to achieve regulatory requirements at a global level, the Japan-based OEM turned to Exatec plasma technology from SABIC. This flexible glass-like coating is deposited on top of a base wet coat to enhance performance. Applying this advanced coating made it possible to meet Toyota’s high quality requirements.

Until now, manufacturers have produced rear quarter windows in PC using wet-coat only solutions. Depending on vehicle type and passenger position, wet-coat solutions can meet industry requirements for weatherability and abrasion resistance at that window location. In some cases though, a higher level of performance is required to meet driver visibility needs.

“Blow-molded HDPE parts typically contain PCR in the core of multi-layer bottles and containers,” said Mark Canright, Global Polyolefin Product Technology, ExxonMobil. “In California, for example, the current mandate for PCR content in blow-molded HDPE parts is 25%, and this is expected to rise in the next year. But adding PCR can impact the properties of virgin material, such as ESCR and top load. Paxon SP5504 enables converters to add even more PCR without significantly compromising the properties of the finished parts.”

Exatec plasma coating technology from SABIC can make it possible for PC-glazed windows, where regulations allow for their use, to meet legislated driver visibility requirements. For larger PC-glazed surfaces like backlights and sunroofs, weight savings of up to 50 percent can be possible, helping automakers to improve fuel efficiency and lower emissions.

Toyota’s special edition 86 GRMN sports car is the first production vehicle to feature a rear quarter window in polycarbonate (PC) material with a plasma-coat solution designed to deliver the highest level of durability performance. The vehicle, exclusive to Japan, was exhibited earlier this year at Tokyo Auto Salon 2016.

With the industry driving toward increased recycling of post-consumer plastic waste, ExxonMobil has demonstrated value-in-use at PCR levels at and above 25%, which may help brand owners and converters to meet changing sustainability targets.

In addition, compared to other material solutions for windows, new combinations of style and function are possible with PC glazing. For example, rear quarter windows can smoothly integrate an aerodynamic spoiler, roof pillar, airflow separators, door handle scallops and even rear lamps.