Integrated Starter Alternator (ISA)
An integrated starter/alternator (ISA) will combine the functions of an alternator to recharge the battery and an electric motor for providing initial propulsion and starting the engine.

Energy Storage Systems (Batteries, Ultracapacitors)
The batteries of the future will need the power to start the car and also operate powerful by-wire systems, store regenerative braking energy and to operate hybrid vehicles with the demands of increasingly more powerful motor drives. Ultracapacitors also can play an important role in starting internal combustion engines of large vehicles -- especially in cold weather -- with their ability to supply very large current for short periods. With a short-term ability to store a large amount of current, ultracapacitors also can play a role in regenerative braking. They also can provide electrical backup to critical systems if battery power is lost, such as for power doors or windows.

Enable "By-Wire" Systems (Steering, Braking, etc)
"By-Wire" refers to the electric/electronic controls that ultimately will replace or assist traditional automotive mechanical or hydraulic systems such as steering, braking, suspension and throttle control.

Electric Pumps and Compressors
Advanced electrical systems make possible the use of electric water pumps for engine cooling or electric compressors in air conditioning systems. No longer connected to the engine by pulleys and belts, motors for electric compressors or pumps can be located in other locations under the hood or elsewhere in the vehicle to provide better functionality.

Traction Motors
To take full advantage of new automotive hybrid and future fuel cell systems, a new generation of electrical motors to directly power the wheels needs to be developed.

Standard Components Experiencing New Environments
This higher electrical power available in vehicles will impact standard E/E componentry as well. Common components such as electric motors and actuators, solenoids, sensors, connectors, capacitors and electronic control modules may require new materials solutions to survive their new environment.

New Challenges Require New Materials Choices
This high voltage environment will require an innovative look at materials choices because of the increasing focus on electromagnetic interference, electrical insulation and arc resistance/prevention. In addition, many components will be used where resistance to high heat, chemicals, or mechanical stresses will be required. The quest to shed weight and take advantage of the design freedom offered by miniaturization of many electronic components also presents a significant materials challenge on all fronts. At the same time, designers are mindful of the cost and performance of these materials. New materials will be required to provide equal or greater performance for the same or lower costs.

DuPont’s Offerings to Meet These Challenges

Broad offering of Crystalline Engineering Thermoplastics:

• Zytel® nylon resin

• Rynite® PET

• Crastin® PBT

• Zenite® LCP

• Delrin® acetal resin

• Thermx® PCT

  Vespel® Parts & Shapes

A family of Electronic Technologies:

• Microcircuit Materials (MCM)

• Flexible Circuit Materials (FCM)

Electrical Insulation Materials:

• Nomex® Aramid Papers

• Herberts® Electro Impregnating Resin & Wire Enamels

Wire & Cable Materials:

• Teflon® PTFE

• Tefzel® ETFE

A variety of Films:

• Mylar® polyester film

• Teonex® PEN film

DuPont - Lead Material Solutions Provider to the Advanced Auto EE market
In a recent industry survey that rated 23 materials suppliers, DuPont ranked at the very top in both its breadth of product offerings and its global auto market position. What makes this more impressive is that the study did not factor in:

• DuPont’s broad offering into electrical insulation

• DuPont’s Motors Expertise within our Nomex®, Herberts? Electro, and EP businesses

• DuPont’s expertise in Electronic Technologies (MCM, FCM, HPM)

• DuPont’s offering of Vespel® polyimide parts, Fuel Cells, and our patented Lithium Ion Battery Technology

• DuPont’s recent development of new EMI shielding polymers

• DuPont’s recent acquisition of Eastman’s LCP and PCT polymer businesses

By-Wire Systems
"By-Wire" refers to the electric/electronic controls that ultimately will replace or assist traditional automotive mechanical or hydraulic systems such as steering, braking, suspension and throttle control. By placing electronic controls (a computer) between the driver and the system, automakers can gain design flexibility, shave weight and decrease the manufacturing complexity of both system components and vehicle assembly.

The addition of many creature comforts such as heated seats, or power windows and infotainment packages including DVD players and navigation systems has pushed the electrical system in today’s vehicle to its limit. Adding new by-wire components and systems will demand even greater electrical power. Today a typical vehicle with a 14-volt system requires 3 to 3.5 kW. A full by-wire vehicle could require up to 20 kW and, thus, a higher voltage electrical architecture. DuPont high-performance materials will continue to play a key role in the growing numbers of electric motors, sensors and electronic controls needed for by-wire systems.

Electrical Distribution
Increasing demands for more electrical and electronic automotive components produces a greater challenge for designers of the electrical distribution system. The system moves electrical power and signals throughout the vehicle at a wide variety of voltage levels. With each component requiring its own set of wires – one for power, and in many cases a second to control it - the proliferation of wires is reaching a critical mass. To help ease this wiring glut, multiplexing has replaced many of the individual control wires with a common line connected to a central processing unit. That same notion can be applied to distribute the power, but it requires higher voltages. And higher voltages move over thinner wires. Higher voltage levels are the key to reducing the cost associated with moving this power. DuPont can provide materials that thrive in hot, demanding applications and the expertise to deal with arc resistance, moisture resistance, component miniaturization and electrical insulation.

Energy Storage
Electrical energy storage and management are essential to take full advantage of the capabilities of new automotive electrical systems. Though lead acid batteries are the industry standard and likely will continue to play a big role for some time, new battery technologies like Nickel Metal Hydride and Lithium Ion offer the promise of higher energy density, even though they still face a number of technical challenges before their widespread introduction in vehicles.

In addition to batteries, ultracapacitors -- used for rapid storage and discharge of electricity -- also are poised to play a significant complementary role with batteries because of their ability to capture electricity from regenerative braking and allowing for longer battery life. The advance of these new technologies requires new materials and new system designs. From films and membrane technologies to separators and cell and housing packaging, DuPont has materials for higher temperature and chemical resistance that are critical to ensure longer life and lower cost, as well as high reliability and less weight, for these storage devices.

Electrical Powertrain
Automotive designers are striving to develop low-weight, high-output and high-efficiency powertrain systems -- systems that connect all of the components -- from the powerplant or battery to the control unit, to the motors that drive the wheels. These new systems will all require higher voltages and current as high as 400 amps.

In large part the success of electrically powered vehicles will not be determined solely on their innovative technology, but equally on their environmental impact and at a price that consumers will pay. Key to that will be high-tech DuPont materials that will help shed weight and maintain high power and performance, including the electromagnetic, mechanical and electrical systems that need to be developed for the electrical powertrains of the future.

Thermal Management
No matter where you look in a vehicle, beating the heat (or the cold) is a continuous challenge for automotive engineers.

Designers and engineers are eager to reap the rewards that advanced electronics offer to boost fuel economy, reduce emissions and refine engine performance. Add in higher-voltage electrical architectures for hybrids and 42-volt systems and the challenge becomes even more demanding, while the opportunities increase. DuPont researchers are helping to develop by-wire technology and to provide durable new materials that can control the temperature of both on-engine and off-engine components – such as electric water pumps or integrated starter/alternators -- throughout all areas of the vehicle.

Climate Control
The increasing electric power capabilities of 21rst century vehicles will also make possible the use of electric compressors in air conditioning systems. No longer connected to the engine by pulleys and belts, motors for electric compressor units can be located in the trunk or in wheel wells, for example, to provide better load distribution and functionality. DuPont is involved in the switch to electric compressors, working to help provide new refrigerants, evaporator and condensor constructions and control systems.