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DuPont Automotive Safety
A Roadmap for Improving Vehicle Safety Utilizing DuPont Science and Technology
“Eliminating Fatalities in Automobiles around the World”
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DuPont Worldwide Diverse End–Use Industries
Portfolio Solutions
~ $6 Billion auto sales, more than 100 product lines, most diverse offering of any materials supplier for complete auto systems solutions
C o nstru ctio n M ateria ls
M o to r V ehic le
P las tics
C hem ica l P etro c hem ica lH ea lth P erso na l C are
P ackag ing P las tics
A g ricu ltureF o o d & N utritio n
P ap er
O ther
H o m e F urnis h ing s
E lectro nics & E lec trica lA p p lica tio n s
D uP on t W orldw ide
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Overall Auto Safety Market$ 42 B
Overall Auto Safety Market$ 42 B
Crash Avoidance (Active)$14 B
Crash Avoidance (Active)$14 B
Injury Mitigation (Passive)
$ 20 B
Injury Mitigation (Passive)
$ 20 BSecurity
$ 8 BSecurity
$ 8 B
Driver Awareness
Driver Awareness
Vehicle GuidanceVehicle
GuidanceVision
SystemsVision
SystemsOccupant RestraintOccupant Restraint
Vehicle Integrity/ Energy
Mgt.
Vehicle Integrity/ Energy
Mgt.
Theft Prevention
Theft Prevention
Response and
Recovery
Response and
Recovery
Annual Failure Costs
Expected Growth Rates (%/yr)
15 MM crashes globally $ 8.5 B theft in U.S.$ 1.7 B Canada
$ 1.0 B UK
• Occupant Restraints: 5%• Advanced glazing: 25%
• Collision Avoidance Systems: 57%• Safety Electronics: 9%• Head-up Display Electronics: 25%
• Security Electronics: 4%• Vehicle recovery system electronics: 13%
Sensors.Sensors.
Societal costs of $390 B 90,000 fatalities/yr. in Europe and N.A. -- 109,000 last year in China
4.7 million persons injured - Europe and N.A.
Auto Safety is a $42 billion industry
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Source:Harris Interactive 2004 Technology Poll
Top 10 Vehicle DifferentiatingAdvanced Automotive Technologies
Rollover Control and Protection - Side Airbags & Electronics
Pre-Crash Sensing
Fuel Cells
Electronic Stability Control
Tire Pressure Monitoring
Blind Spot Detection & Warning
Adaptive HeadlampsAdvanced Air Conditioning
Occupant Detection
Enhanced Fuel Economy
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19%
17%
16%
20%
47%
37%
34%
25%34%
28%
41%
64%
Cleaner Powertrains
EntertainmentTechnology
Greater VehiclePerformance
Enhanced SafetySystems
2003 2004 2005
Top Technology Areas Most Important to Consumers - ‘03-’05 DuPont Studies Automotive Consulting Group - Ann Arbor, MI
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2005 DuPont SAE Attendee Survey –Engineers Rate their Priority Attention to Auto Safety Systems
Top 10 Safety Technologies Respondents that believe technology will receive priority attention - % rate as high
Side and rear airbag systems 49.5%Collision avoidance systems - radar/other warnings 42.6%Occupant Detection Sensors/Vision Systems 41.6%Electronic stability control 40.6% Active seatbelt pre-tensioning systems 32.7%Tire pressure monitors and run-flat tires 25.7%Side door reinforcement and impact absorbers 23.8%Side, overhead and rear laminated safety glass 19.8%Pedestrian protection systems 15.8%Head-up display systems 7.9%
Contains multiple responses.Source: DuPont sponsored 2004 SAE attendee survey conducted by the Automotive Consulting Group, Ann Arbor, Mich.
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Side impact - door modules andcomposite beams, deployment for side curtains, configurableseats, etc.
Front/rear impact - crush cones and honeycombs,airbag fibers, airbaghousings & doors, OCS,etc.
Collision Avoidance - electronic materials for sensors, control units and OLED displays,head-up displays, windshield laminates, electroluminescent materials, etc.
Brakes and Tires - materials for regenerative braking and pads,run flat tires, etc,
Interior - crush cones and honeycombs and plasticsfor bellows, pillars,re-configurable seats,laminated sidelites, etc.
Automotive Safety - DuPont content vision
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Injury Mitigation - Vehicle Interiors Solutions
Invista™ Tough & Packable airbag fiber
EngineeringPolymers for
airbag components
housing, diffusers,
and canisters
High performance Airbag Doors/ Covers
Rigid Polymers for Seat BeltPretensionerReliability
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SentryGlas® Plus - Importance of the Innovation
• Security - $8.5 billion/yr. in vehicle/content losses
• Safety - 12,000 fatalities from occupant vehicle ejection,supplements side airbag curtain
• Sound - fundamental measure of customer satisfaction
• Solar - increasing concern about U-V exposure and loadon air-conditioning units, particularly for Hybrids
• Styling - imbedded graphics and images for differentiation, badging, etc.
BMW 7 Series
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Pedestrian Protection Europe EC Regulation and Euro NCAP
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Pedestrian ProtectionBumper Lower Leg Energy Absorber
REQUIREMENTS:
• Energy absorption in pedestrian low leg test ( EEVC WG17 )
• Recovery to the original shape and properties, must be better than EPP (1st Tiers, OEMs)
• Uniform energy absorption over temperatures - 20° C + 60° C (1stTiers )
• Light weight
• Limited space available
• Low cost
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Pedestrian Sensor - PSA, Jaguar
E Box
Optical Fiber , PMMA
Hytrel® sandwich structure
foam
Bumper Beam
Pedestrian Impact
Bumper Shell
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ACTIVE HOOD - Reversible or IrreversibleHood Lifters (actuators) = opportunity for metal
replacement
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HEAD IMPACT ENERGY ABSORBERCRASH BOX PSA
Zytel® 70G30HSL
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Engineering Polymers Technical Support and Application Development
Mold Flow Analysis: … to reduce cycle time for mold optimizationWarpage Analysis: …. for improved dimensional stability of complex partsFEM simulation: … for shorter developtime cycles for complex partsInjection Molding Facilities: … to check molding performance of new gradesBlow Molding Lab: …to develop new processing technology eg. to reduce system costMolding Analysis (Cavan, Ejectan...): … for optimized and controlled processingAssembly Technologies: … to ensure functionallity of assembled systemsFriction and Wear Lab: … for components with longer life time and reduced squeakingPart Testing: … to reduce qualification and development time, e.g. shaker testingNoise Vibration and Harshness (NVH): … to optimize noise emission from partsNEW: Software for Crash Simulations NEW: High Speed Testing Machine up to 60 km/h
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Thick FilmTechnologyYaw RateSensor
DuPont™ 942 Low LossGreen Tape™RF Performance forShort Range Radar
DuPont™ Green Tape™for Collision Mitigation
The Wedge™windshield interlayerfor sharper images
DuPont™ CeramicSystems
for dependable airbag,ABS/Traction control sensors
DuPont™ Pyralux®Flexible laminates
DuPont Automotive Safety & Electronic Technologies Overview
AC
C
Engineering PolymersEngineering Polymersto encapsulate, house &house &integrate
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Occupant Classification SystemResistive mat technology:
Electronic Technologies:• Polyimide films as mat substrates• Silver and Carbon pastes for conductive / resistive integrated circuitry
Enabling Technologies:• Engineered polymers for ECU housings, cabling, connectors, seat pad
frame/springs• Polyester films as mat substrates for capacitive systems• Microcircuit materials
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Automotive Seat SensorsAutomotive seat sensors are a major application area
• Airbag on/off, Seat Belt Reminder, Occupant Classification• Multiple printing steps using MTS technology
– Silver, carbon and dielectric inks• Requirement for excellent registration and flatness• Stabilized polyester is the substrate of choice for many sensors
– Good mechanical and thermal properties– Acceptable balance of cost versus performance
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Head-Up Display Equipment
Market Drivers: NHTSA - Driver Distraction, Additional info systems to driver - Collision Avoidance, Navigation, Traffic Jam DuPont Advantages - Multi-SBU products enabling next generation technology. HUD Wedge market leadership, potential fit with “BigD” Displays strategy
The Wedge™Laminated safety glass interlayer
for Head-Up Display systems
DuPont DisplaysChanging the way you see things™
C
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DuPont Microcircuit Materials in the Auto IndustryIntegrated Electronics and Safety with miniaturization, reliability and high frequency
capabilities at a lower systems cost
Antilock Brake SystemsTraction Control
Engine Control Modules
VoltageRegulator
Air-Mass Sensor
Mirror and SeatHeating
Pressure Sensors
Fuel Sender
Gear Shift -PRNDLIlumination
Rear Window Defroster
Electro-luminescentLighting
Airbag sensors
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•• Collision mitigation systems will seek to provide 360° range of protection.
• OEM adaptation of automotive radar is being accelerated through the first system usage of 24 Ghz (SRR) short range radar applications for lane departure, parking assist and blind spot radar detection systems.
• Competing offerings are vision image systems, ultrasonic, and infrared.
• SRR offers wide field of view, better resolution and response of multiple objects moving or stationary, and operates in all weather conditions
• But, costs are high and will slow adoption and growth
SRR For Automotive Safety: Application Profile
Courtesy: Bosch
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DuPont GreenTape™Courtesy of IMST Gmbh
Complete Material System for Automotive Radar- Blind Spot Detection - Collision Avoidance- Parking Assist - Lane Departure
• Embedded Passive Components• Materials Tested to 77 Ghz• Economical technology choice • Superior robustness in Harsh Environments• Demonstrated reliability in field testing• Operates in all weather conditions• Object Detection up to 30 meters
LTCC GreenTape™ for Active Safety
• Integrate Designs in Agilent ADS• 28-38 GHz Frequency Range• Commercial, Automotive & Military Applications• Popular Component Types• Create Schematics & 3-D Layouts• Review Simulation Results
CouplersResonatorsFilters
Green Tape™ Design Library
Design Resources at Your Fingertips
TransitionsCapacitorsInductorsBalun
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Continental ESC Sensor Cluster Housing
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All passenger vehicles will have tire pressure monitoring systems (TPMS)beginning with the 2006 model year according to MVSS 138 by NHTSA.The regulation requires that manufacturers install a system that can detectwhen one or more of the vehicle’s tires are 25 percent or more below therecommended inflation pressure.
Phase-in of the new regulation will begin Oct 5, 2005. All new 4-wheeled vehicles weighing 10,000 pounds or less must be equipped with the monitoringsystem by the 2008 model year.
Zytel® HTN54G15HSL -- PPA material for sensor support cradle and housing body.
Zytel® 71G13HS1L nylon housing body cover
SmarTire™ Sensor-- uses lightweight, high temperature resistantand dimensionally stable materials
New TPMS Standard
