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Nanotechnology for Automotive

Carlo Vittorio FolonariExecutive Vice President, Technologies Division

Centro Ricerche Fiat, Torino

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Sensors• Navigation-control, MOEMS-NEMS• Nanomagnetics films - Spintronics• High transmittance polymer IR lenses• High sensitivity IR sensors

Micro Power-Energy• High efficiency solar cells• Hydrogen storage• Innovative fuels• Energy accumulators• Electrochemical conversion, fuel cells• Microreators - microcombustors

Lighting and on-board information• New lighting sources• Thin film and wearable display• Optical switches, Electro-optical films

Coatings• High resistance coatings • Antiadehesion coatings• Iridescent coatings ....new colors• Low friction, nanocatalitic (eng.)• Nanotubes based vernices

Structural and functional Materials• Shape memory alloys• Nanocomposites….• Self extinguishing materials• Explosives for welding/sealing• New cooling fluids and MR-fluids• Air filters• Active Interior tissues

INTEGRATION OF MICRO AND NANOTECHNOLOGY IN AUTOMOTIVE, …(ROBOTIC, AERO-SPACE…)

Nanofabrication of 3D structures• High aspect ratio 3-D structures• Nanostereolitography

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OPTICS AND PHOTONICS FOR LIGHTING

Taillights,parking lights

Side lightsHeadlamps

Courtesy and interior lights

Door light

Interior luggagelight

High mounted stop light

Considerable Improvment of theOverall electrical to optical efficiency

Currently ~ 1%

By the development of diffractive and microoptics, new light sources and

their integration with Power Supply

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CONFORMABLE LIGHTING by the integration of microoptics and microsources

Chip on glass/plastic bonding

Example of reflector designCRF patents

Embedded packaging

Reflecting coating Epoxy

Chip on glass/plastic

Nanophosphors

ADVANTAGES• Uniformity through nano-phosphors• Cost and weight reduction• Compactness• High freedom design• Flexible and conformal devices

Final lighting system

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Microlamp US Patent 5,884,995 - sett. 1995US Patent 5,841,596 - sett. 1995

Microlamp

Reflective surface or TIR

MICROLAMPS AND MICROTELESCOPES FOR LIGHTING

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CHARACTERISTICS:• Matrix of point like sources• large area Thin film devices• Comparable performance with state fo the art white LEDs• Low cost fabrication process

NANOSTRUCTURED METALLIC SOURCES

2001: First prototype of a point source matrix

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V

LIGHT

Low resolution 16x16( pixel 0.850x0.4mm2)

Mid resolution 32x32( pixel 0.46x0.22mm2)

High resolution 32x32( pixel 0.32x0.23mm2)

DISPLAY DEVICESWorkingWorking principleprinciple

RSiO

Rigid electrode Glass substrate

Flexible layer

V=0V=0 betweenbetween rrigid electrodeigid electrodeandand flexible layerflexible layer

SiO

Glass substrate

Flexible layer

V= VV= V00 between rbetween rigid electrodeigid electrodeandand flexible layerflexible layer

ELECTROSTATIC SHUTTER DISPLAYS

CRF patents applied for light control and already licenced for high accuracy infrared spectrometry.

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THE DISAPPEARING COCKPIT

Under Development in partnership with LUXOTTICA

versatile, interactive, adaptive to the environment, high visual confort, wide field of view

Speakers

IMU

Brightness sensor

Micro-optical light guide

(CRF patent)

Battery

RF Tx/Rxmodule

Microcamera

Microphone

Primary display unit (s)

CPU

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APPLICATIONS OF SMAS IN VEHICLES

Climate controlTechnology: SMA

Direct InjectionTechnology : Piezo

Smart bumpertecnology: Piezoelectric

Active damperstecnology: MR fluids

Active noise and vibration controltecnology: Piezoelectric, SMA, MR fluids

Door Latchestecnology: SMA,

Rear view mirrorstecnology: SMA

Valves controltecnology: SMA

Battery cut-offtecnology: SMA

Active Front-endtecnology: SMA

Active aerodynamicstecnologia: SMA

Seats latchestecnology: SMA,

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SHAPE MEMORY INTEGRATED LOCKWITH ELECTRICAL ACTUATION

The agreement with Oxford automotive

Main advantages:

• Electrical and mechanical operation in one• Direct linear movement and force without any external moving parts• Flexible and scalable • High reliability • Low Weight and Low Cost• Noiseless operation Low EMI

Mechanical Backup

SMA Actuator

Through the collaboration with:

CNR (Lecco), the Saes Group, The Sila Group, Oxford Automotive,…

We aim to be the largest European manufacturers of SMA materials and products by 2004.

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NANO MR-FLUIDS

Nano-magnets “Embedded” on micro-particles

Substrate

Nanomagnets

Withoutmagnetic field

N S

Withmagnetic field

1000 nm

APPLICATIONS

•High speed mechanical components•Active Dampers •Brakes•Clutches( success depends on the mechanical design )

ADVANTAGES OF WORKING WITH NANOMAGNETS OVER MICRO PARTICLES

- Reduced wear- Reduced aggregation- Reduced power consumption- Faster response time

Solutions of active rotative dampers patented by CRF are under advanced experimentation

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CATALYSED DIESEL PARTICULATE FILTERS• optimised contact between diesel soot and catalyst

due to the nano-scaled morphology similar to the particulates size

• lower filter regeneration temperature (below to 450°C)

50 nm

Ceramic support

Nano-structured catalyst layer (Pt-CeOX)

Exhaust gas

Diesel Particulate agglomerates

ADVANCED NANO-STRUCTURED CATALYSTS

Goal: to meet EURO IV and EURO V emissions

standardStart of production in 2004 for passenger cars – CRF Patents

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Steering angle sensorFluid-level

sensor

Climatic controlsensor, central locking, mirror positioning, etc.

On-Board electronics self-testing

Air-Bagsensor

Tires: pressure, temperature.Sensors

Engine control sensors (injection

flux sensor, actuators)

Seat occupancy

Shafts torque sensing for

combustion quality

Suspension positioning systems

Rotation/accelerationsensor for ABSdifferential gear

Many applications for positioning systemsgyroscopes and accelerometers

SPINTRONICS: APPLICATIONS

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Possible applicationsPossible applications::• Linear /Angular acceleration sensor• Relative/Absolute linear/angular position

measurements• Linear/Angular speed measurements• Linear /Angular acceleration measurements

AdvantagesAdvantages::

High precision• Cost effective • Digital output

•• NonNon--contact measurementscontact measurements•• Programmable outputProgrammable output•• Low weightLow weight

POSITIONING SENSING

S N SN

NSNS

H H H H

S N SN

NSNS

H H H H

Voltage output change

Ferromagnetic – Spacer – Ferromagnetic Sandwich Structure

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Advantages:• Smaller size and weight• Faster response• No hydraulic connections• Fully programmable• LIN compatible

GMR BASED BRAKING BY WIRE SYSTEM

Actual architecture, entirely hydraulic

Current solution

µP Compressor/actuator

Electronicdriver

CRF solution

System Architecture

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0

500

1000

1500

2000

2500

3000

3500

NiMH Zn/Air Li-Ion Li-polymer Methanol FC

Cell Type

Sp

ec

ific

En

erg

y (

W h

/Kg

) nominal

high

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POWER DENSITY FOR DIFFERENT TECHNOLOGIES

Device Power Density (MW/m3)

Micro-lithium 0.4

Micro solar cells 1

Micro electric motors (need power supply)

1.7

DMFC 2

PEM-FC 8

Micro reactors on Silicon 20

Large scale combustors (cars..) 40

Micro channel reactors (metal) 150

Micro-magnetic motors 200

Aircraft engines 1500

MIT Silicon micro turbine 2300

Pulsed micro combustors CRF 2000-10000

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PROTOTYPES AND CRF PATENTS ON MATRICES OFMICROFUEL CELLS ON FILM

IC

Micropump Supercapacitor

Processor

DMFC

Fuel Inlet

Fuel OutletICIC

Micropump Supercapacitor

Processor

DMFC

Fuel Inlet

Fuel Outlet

Power Output

ICIC

Micropump Supercapacitor

Processor

DMFC

Fuel Inlet

Fuel OutletICIC

Micropump Supercapacitor

Processor

DMFC

Fuel Inlet

Fuel Outlet

Power Output

FCFCFCFCMPMP

20A 20B25 2331

3030A

30B21

24 26

20

22 26A

Fig. 2

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Fuel tank (nanoparticle fuel)

Fuel injection driver

Catalytic combustor

Micro injectionsystem

MICRO COMBUSTOR(IN COLLABORATION WITH OLIVETTI I-JET)

CRF has patented solutions having a movable element (figure) and others where chemical energy is directly converted into electrical energy.

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TECHNOLOGICAL PLATFORM: PATENTED CONFIGURATION OF A MICRO FLYING AUTONOMOUS

ROBOT BASED ON TWO DUCTED FANS

Inertial navigation, motors control, stabilisation system

Microcameras for vision, optical flow and Obstacle avoidance

m. fuel cell power supply forElectronic component

Strutural nanocompositedensity ~0.12

WLan and bluetooth communication system