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Powertrain Systems

System Graphic
Problem-Solving Technology from DuPont

New hybrids and fuel cell powerplants require an equally innovative new generation of affordable electrical powertrains.  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 wheel. These new systems will all require higher voltages and current as high as 400 amps.

Concepts range from one drive per wheel to one drive per axle or a single axle drive system. These new generation motors and power control and distribution systems need to be different from existing concepts used in trains or trams, as their usage and performance profile is significantly different.  Also, existing industrial electrical motors are designed to different life cycles and do not meet the needs of the electrically driven car.

Materials Challenges

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. Getting the weight out and lowering manufacturing costs play a key role in that equation.

DuPont’s application engineers have a broad experience in traction motors for trains and trams as well with industrial motors and generators. DuPont offers expertise in materials forming systems that have proven their reliability and high performance.

DuPont is working to help you develop high-tech 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.

DuPont continues to provide a broad mix of automotive material and design solutions, along with the support you need to bring these new technologies to market. 

Related Solutions & Technology
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Arc Resistance
With the potential move to 42-volt systems, eliminating arcing is more complex, because any voltage over 15 volts can cause a sustainable arc.
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Electrical Insulation
Ensuring the integrity of advanced electric and electronic systems requires careful isolation of wires and components from other wires and components as well as protection from an often harsh vehicle operating environment.
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Electromagnetic Shielding (EMI)
When it comes to robust EMI shielding, the right material, design and astute execution deliver the shielding and mechanical properties needed in a variety of demanding applications.
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Encapsulation
Thermoplastic encapsulation of delicate electrical components and electronic devices can cut manufacturing costs and at the same time package and protect those components from harsh automotive environments.
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Miniaturization
In the advanced automotive electrical and electronic system, many formerly mechanical functions will be performed electrically and precisely controlled with advanced electronics, further driving the need for miniaturization.
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Separators/Membrane
In batteries and ultracapacitors, a permeable membrane – the separator – is central to both the function and life cycle of the devices.
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Thermal Management
Vehicles today are exposed to a wide range of operating conditions and environments from the cold of the arctic to the intense heat of the deserts to the high humidity of the tropics. Future higher voltage systems will increase the number of heat sources in the vehicle and new systems will generate heat in locations previously considered low-temperature areas.