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GENEVA, Switzerland, 3 March 2009 — The automotive industry needs materials and technologies that enable improved fuel efficiency and reduction of CO2 without compromising performance and at reasonable cost. DuPont is firmly committed to put science to work to support this concept of “sustainable mobility”.

Today, automotive original equipment manufacturers (OEMs) are increasingly committed to sustainable mobility in response to rising fuel costs, regulatory requirements and the need to reduce CO2 emissions. This drive includes improving vehicle efficiency by reducing overall vehicle weight, reducing energy loss through friction, using new technologies to boost the output of smaller internal combustion engines as well as reducing energy used at vehicle manufacturing facilities.  At the same time, OEMs are introducing advanced propulsion systems – from hybrids to fuel cells – that run on various alternative energy sources.

DuPont -- Contributing to Energy Savings Today
This all-consuming challenge has OEMs rethinking multiple components and systems, especially in the engine, driveline and fuel systems.  The stakes for reducing vehicles’ carbon footprint and improving fuel economy are high.  Several studies show a 25-kilogram weight reduction can yield a 1 percent increase in fuel economy, depending on the vehicle.  A 100-kilogram weight reduction can reduce CO2 emissions by 8.5 grams per kilometre. 

Vehicle Light-weighting
High performance DuPont engineering resins enable replacement of metal parts and components, contributing to weight reduction, fuel savings and CO2 emission reduction.

• One of the latest innovations developed in the technical centre in Meyrin (ETC - Geneva, Switzerland) is the first thermoplastic polymer oil pan used for serial-production of the Daimler Mercedes-Benz C Class model. More than 1 kg weight reduction is achieved thanks to DuPont™ Zytel® Nylon, versus a 100% aluminium design. A specific high-speed (more than 200 km/h) impact testing procedure has been developed at the ETC to verify the performance of the new oil pan.

• Airducts in DuPont™ Hytrel® allow 20 to 50% weight and overall cost reduction by replacing metal ducts with single-piece fully integrated thermoplastic solutions made by 3D blow moulding techniques. This application was also developed and tested in close collaboration with customers and partners at the DuPont ETC in Switzerland.

• DuPont™ Kevlar® can be found also in car and truck tires, offering puncture, abrasion and tear resistance, but also a reduction in rotational weight, which can decrease strain on the engine and consequently improve fuel efficiency. At the Geneva International Motor Show, Dunlop is launching its new ultra-high performance concept tire with DuPont™ Kevlar® technology. See related Press Release on www.europeanmediacenter.dupont.com and on www.dunlop.eu

More Power to the Wheel: The Friction Story
The stake for reducing energy loss through friction is also high. Studies have shown that only some 15 percent of the energy available in gasoline actually gets used to move a vehicle down the road.  The remaining 85 percent of the energy is lost to engine and driveline inefficiencies, accessories and idling.

• DuPont™ Vespel® parts and shapes help the industry improve efficiency and get more power to the wheel by reducing friction and weight, especially in driveline systems. Eight thrust washers made from DuPont™ Vespel® polyimide are used in Magna’s transfer case installed in premium Sport Utility Vehicles (SUVs) from Daimler and Land Rover. Not only do these durable, maintenance free thrust washers help reduce friction, they also reduce weight and require less space than the alternative of needle bearings - again allowing more energy to get to the wheels.

Energy Efficient Auto Manufacturing
DuPont also is contributing to energy efficient systems for the actual automotive manufacturing process.  The DuPont EcoConcept system streamlines the OEM painting process by eliminating one complete coating layer, the so-called primer-surfacer, and combining it into a single environmentally-compliant water-based basecoat.  This allows the automobile manufacturer to eliminate an entire spray booth and its associated drying equipment.  The benefits include reduced emissions of greenhouse gases due to reduced solvent use, lower energy consumption and higher productivity. DuPont has recently begun to license the technology, providing an opportunity for more OEMs to adopt it. The DuPont EcoConcept technology is currently used at two Volkswagen plants in Mexico and Spain. Some 200,000 cars have already been produced using this process.

Energy Savings for the Future
With its unique expertise in material science and biofuels, DuPont is well positioned to offer alternative fuel system solutions that best meet the industry’s growing performance needs.

• A key step toward electrification is better, lighter and safer batteries. DuPont is leading development of energy efficient storage options for electric and hybrid vehicles, which deliver up to 50% more energy at high discharge rates (DuPont Hybrid Membrane Technology). It results in increased power density and less wasted energy.

• DuPont™ Teflon® wire insulation contributes to fuel efficiency as well as to comply with the latest environment legislations by collecting vital engine information from the hottest areas, for example oxygen sensors installed on the exhaust system of each commercial car.

• Under the hood and in fuel systems, Viton® fluoroelastomers and Vamac® offer unique properties that helped establish new standards for high performance automotive sealing applications, like turbo charger hoses, fuel hoses, boots, etc. They help keep evaporative emissions low, offer high temperature resistance and excellent compatibility with biodiesel and biofuels.

Car manufacturers around the world extensively use DuPont materials and coatings for a variety of vehicle interiors, exteriors and engine parts . The company’s offering for the automotive industry includes more than 100 products, which contribute to innovative applications to move toward the next generation of automobiles.

Visit www.automotive.dupont.com and www.drivenbyscience.dupont.com for detailed information.

DuPont is a science-based products and services company. Founded in 1802, DuPont puts science to work by creating sustainable solutions essential to a better, safer, healthier life for people everywhere. Operating in more than 70 countries, DuPont offers a wide range of innovative products and services for markets including agriculture and food; building and construction; communications; and transportation.