How do consumers benefit from higher voltage systems and related advanced automotive electrical/electronic (AAEE) technologies?

• Improved fuel economy and lower emissions are two key benefits as more efficient electrical/electronic systems replace traditional mechanical or hydraulic components. Increasing electrical power allows for the introduction of new systems and components, as well providing the opportunity for some existing systems and components to be driven electrically rather than putting demand on the engine.
• Safety technologies supported by higher electrically powered systems and advanced electronics may include smart airbag systems and crash avoidance features such as active suspension and advanced braking systems. The new suspension systems can enhance driver control in extreme driving conditions.
• A higher voltage system enables the broader use of vehicle communication, entertainment and navigation electronics, which may greatly increase driver convenience.

What key vehicle systems and applications will be impacted by the growth of higher voltage electrical systems?

Following is a list of key systems/components that can take advantage of the increased available electrical power and/or advanced electronic technologies and a brief summary of how DuPont is meeting requirements in each area.

Air Conditioning – New electric AC systems made possible by higher voltage systems will no longer be connected to the engine via belts and pulleys, giving designers the freedom to locate an AC system where it can deliver the best vehicle balance and function. High performance, more chemically resistant materials with improved dimensional stability, benefit key applications including: motors; compressors parts; actuators; condensers; connectors; controllers; electronic controls; evaporators; expansion valves; fan units; receivers/dryers; and, sensors.

Electrical Distribution – The electrical distribution system moves electrical power and controlling signals throughout the vehicle. Electrical distribution provides conducting paths at varying voltage levels, depending on the system design. This function will become more crucial as the voltage levels increase for vehicle systems. DuPont works across many different industries and has built a wide range of experience useful in designing electrical distribution systems. DuPont expertise and materials can help address key high-voltage issues such as arc resistance, moisture resistance, component miniaturization, electrical insulation and increased demands on connectors. Key electrical distribution applications using DuPont solutions include: connectors; electronic controls; flat flexible cables; fuses and fuse boxes; junction boxes; relays; switches; wire harnesses; and, harness mounts.

Electronic Controls (EC) – EC provides closed-loop control of many key systems. The control loop starts with sensors that detect location, movement, temperature or pressure. The information collected by sensors is then analyzed and translated into action. A microprocessor driven by software within the EC is responsible for running systems. Electromagnetic interference (EMI) and hydrolysis resistance are key concerns in this application. DuPont has developed a range of materials that can withstand extreme heat and moisture, but also provide outstanding EMI shielding for electronic controls and their microprocessors. Other EC applications using DuPont technologies include: actuators; analog sensors; analog to digital converters; digital to analog converter/switches; electric motors; gears; housings; microprocessor based controller (CPU); solenoids; and, solid state power controls.

Integrated Starter/Alternator (ISA) – The ISA will provide several essential functions. Simply stated, the ISA will incorporate an alternator to recharge the battery and an electric motor to provide initial propulsion and start the engine. The start/stop operation of the ISA increases fuel economy by electrically moving the vehicle forward before restarting the engine at a set speed. Other features such as regenerative braking, recover energy while providing power assist/boost to further increase engine efficiency during acceleration. DuPont provides advanced electrical insulation materials, as well as specialty films for this system. Other ISA applications that could use DuPont materials include: bearings; coil bobbins; connectors; encapsulated permanent magnets; flexible electrical insulation; gears; high temperature greases; housings; impregnating resins; magnet wires; rotors; slot liners and closures; springs; stators; thermal hoses; tubing; and, wire enamels.

“By-Wire” Systems – Braking, steering, suspension and throttle control are just a few of today’s mechanical or hydraulic systems that could be replaced with electric/electronic systems that are managed through innovative electrical distribution and electronic controls. The “by-wire” technologies will require much more power than the 2.5 to 3.5 kW generated by 14-volt systems. DuPont already offers a number of solutions that enable by-wire components to withstand higher voltages and exposure to extreme heat and chemicals. DuPont high-performance materials play a key role in the growing numbers of electric motors and electric controls needed for the by-wire systems. Other by-wire applications where DuPont makes a difference include: actuators; connectors; electric motors; electronic controls; housings; microprocessors; sensors; solenoids; and, wire harnesses.

Thermal Management – Many new AAEE technologies such as ISAs, may raise vehicle operating temperatures, requiring accurate and effective thermal management that does not rely on one pump mounted directly to the engine. In many cases, new thermal management systems will use several electric fans and pumps located throughout the vehicle. The pumps will need to move fluid at a higher velocity than current systems to compensate for higher system operating temperatures. Thermal management applications utilizing DuPont materials and technologies include: baffles; electric thermostats; encapsulated sensors; fans; heat exchangers; inlets/outlets; pipe fittings; radiators; reservoirs; shrouds; water pumps; valves; and, tubing.

Energy Storage Systems – To realize improved fuel economy and lower emissions, requires more electrical power. The increased electrical power will be provided and managed through increasingly complex energy storage systems. In addition to the increase battery voltages, many vehicles will require the use of ultracapacitors to work in concert with the battery to provide both the storage capacity and the power delivery necessary for the vehicles to perform. DuPont offers a wide range of films and membrane technologies, as well as housing materials that can meet the increased demands of this new energy storage environment.

Which DuPont materials and technologies will play a major role in the evolution of higher voltage vehicles?

With the industry’s largest thermoplastic portfolio and expertise, DuPont is in a unique position to support both the move to higher voltage automotive electrical systems as well as the increasing advancements in electronic control systems in the global market. The expanding range of DuPont E/E materials include:

• DuPont™ Nomex® aramid paper provides excellent thermal and electrical insulation.
• DuPont™ Teflon® fluoropolymer is a versatile material for wire insulation.
• DuPont™ Mylar® polyester films from DuPont-Teijin, fit a range of wire insulation, membrane and capacitance applications.
• DuPont™ Kapton® polyimide films are used in advanced circuitry.
• DuPont Displays and DuPont Microcircuit Materials, part of DuPont Electronic Technologies, are utilized in a number of advanced vehicle circuits.
• DuPont Performance Coatings offer Herberts“ Electro wire enamels and impregnation resins in a variety of motor applications.
• DuPont Engineering Polymers offers the industry the broadest portfolio of semi-crystalline engineering polymers such as; DuPont™ Crastin® PBT thermoplastic polyester resins, DuPont™ Zytel® nylon resins, DuPont™ Rynite® PET thermoplastic polyester resins and DuPont™ Zenite® LCP liquid crystal polymer resins.
• DuPont™ Zytel® DMX was developed as a high-performance connector resin in direct response to more demanding requirements from the automotive industry.
• New versions of Zytel® nylon resins including high-temperature resins, flame retardant materials and electromagnetic shielding resins, will become vital in the harsher higher voltage environment.

Why should OEMs and their suppliers partner with DuPont?

As the sole material supplier participating in MIT’s Industry Consortium on Advanced Automotive Electrical/Electronic Systems and Components, DuPont, working with other consortium members, is becoming directly involved in developing materials solutions that can help overcome the complex technical and cost challenges the industry faces in order to successfully enable the benefits that can be realized through the use of higher electrical power and advanced electronics.

DuPont also is the only material supplier with a business venture group and technology development team focused directly on this automotive transition, drawing on expertise around the globe to support advances in AAEE applications and higher voltage systems. In this way, DuPont is able to integrate a wide range of knowledge and materials to provide “whole system solutions” that are focused on increasing system functionality while improving overall system cost.

What are the greatest challenges for OEM’s and their suppliers as the industry shifts to higher voltage systems? How is DuPont helping to meet these challenges?

For the first time in nearly 50 years, traditional automotive systems are undergoing wholesale change raising a whole range of systemic challenges. Nearly every major component will be reviewed and potentially redesigned, demanding that OEMs and suppliers work together to ensure these sophisticated new systems help reliably improve vehicle performance at a cost acceptable to the consumer. OEMs will need solutions to complex technical issues, and suppliers must step up to these challenges without delaying product launches or significantly increasing costs.

Material suppliers must clearly understand the challenges the OEMs and Tier I suppliers face as they develop more robust, yet highly sophisticated components. As the world’s leading science company with over 200 years experience in delivering technology based solutions, DuPont understands what OEMs and their suppliers need to turn innovative concepts into reliable systems able to thrive in the demanding higher voltage environment. Materials will need to perform in more intensive electrical, physical and chemical environments.

For example, in the early 1990s most vehicles had one central engine control unit. Today, an average vehicle has about 30 electronic control modules, and as more advanced safety, performance, efficiency and convenience features require more “intelligence,” this number in some of the current luxury vehicles is climbing to as many as 70. As these control modules are located around the vehicle, they need to perform in a variety of new environments. DuPont has developed several materials for intricate, yet durable electronic controls essential for higher voltage technologies.

When will higher voltage systems be available on commercial applications?

More than 100,000 hybrids and mild hybrids have already been sold globally and industry observers are forecasting unit builds in the 11-13 million range by 2010. Government incentives around the world are helping to encourage consumer interest in HEV vehicles and automotive manufacturers are responding.

• Toyota’s current HEV line up includes the Prius, Estima and Crown.
• Lexus plans to roll out a hybrid RX330 SUV.
• Honda launched a HEV version of the Civic.
• General Motors plans to introduce a HEV GMC Sierra and Chevrolet Silverado full-size truck in 2003/04.
• Ford has announced the Escape SUV will be available with a HEV powertrain in 2003/04.
• The Saturn Vue crossover-SUV will get a hybrid version in 2005.
• HEV systems will be available in the Chevrolet Malibu and Equinox crossover by 2007.
• Also due in 2007, is a full-size HEV Dodge Ram truck.

What is the future of the higher voltage systems?

Higher voltage (42-volt and higher) vehicles have arrived. As mentioned, Toyota and Honda have launched five (5) vehicles to date, and have announced their intention to continually add to this number. GM has recently announced their intention to begin launching a series of Hybrid Electric Vehicles starting this year, stating they will have the capacity to manufacture 1 million units. Ford and Chrysler also have announced vehicle platforms that will take advantage of higher electrical power to deliver a range of benefits to the consumer and society.

DuPont believes that over the next 10-15 years, the introduction of higher electrically powered vehicles will continue. We believe we can uniquely enable this transition by providing the material solutions that assist automakers in meeting the technical challenges at an affordable cost to consumers. We believe our involvement in this work is supportive of the concept of sustainability, and directly aligned with our ultimate corporate goal of creating sustainable growth.

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