DuPont Performance Materials

AUTOMOTIVE

Applications & Development

Martin Pilař

Polymercoach 2016

Value Proposition and Business Model

Enhance customers’ product performance, improve sustainability and reduce total downstream system cost

Design: Work Materials: Create new together with our formulations when customers to enlarge new properties possibilities Inclusive are required Innovation

Processing: Work together with customers to optimize process efficiency with our products

Expert Applications Development TrendsKey Automotive DuPont impacting

Economics Consumer Environment Regulation Cost competitivenessCost wh andsource networking Global design in and modularity Standardization efficiency Fuel length warranty Increased brand / image perceivedand Comfort compartment Engine in conditionssevere More improvementsefficiency and downsizing Engine Renewably adoption H&EV powertrain (68dB Noise Safety and A) Tailpipesystemscontrol emission vehiclethe of weighting Light sourced

materials and sustainable design and sustainable materials

ere is thegrowth

2

DuPont Market-Back Innovation for Automotive CO2 Emission is the Most Significant CHALLENGE Faced by Car Manufacturers

Lightweighting

Sustainability

Efficiency Electrification Engine Downsizing

3L V6 Non Turbo

2.4L 4 Cylinder OEMs are removing cylinders (6 to 4, 4 to 3, even 2) Turbo and reducing engine displacements

Turbo charging has reduced weight of  200 HP  AIM by ~50%

4 Air Induction and Turbo-charging Increased Engine Temperatures

Electrification / Hybrid Vehicles Lightweighting Innovation

5 Thermoplastics Composites solutions Vizilon®

6 Automotive - Powertrain

•Air ducts and resonators High Temperature Air •Turbo Charger Hoses Metal Replacement •Throttle bodies High Performance Acid Resistance •Air intake manifolds Oil exposure •Oil pans Durability •Oil modules •Rocker covers • •Engine Sealing •EGR Systems •Front covers •Transmission

Hytrel® Vamac® Zytel® HTN Zytel® PLUS Zytel® PA66 + PA6 Zytel® RS Automotive - Powertrain Lightweighting with Plastics, Weight savings in Engine Applications … Material Science advances

Rear camshaft retainer: 0.2 kg Manifold: 1.0 kg Charge air cooler: 1.0 kg Turbo duct, hose: 0.5 kg Oil pan: 1.0 kg Cooling system: 0.8 kg Rocker cover: 0.5 kg Engine cover: 1.0 kg Cylinder head cover: 4.5 kg Pumps, throttle body, small components: 0.5 kg

Eliminating just 11 kg on 70 million light-vehicle engines could save more than 900 million liters of fuel

Data: DuPont Powertrain Rocker Covers Chrysler BMW

1977 1990 1995 NOW

First RC Porsche Boxer BMW M52 -First high New generation 2K prototype First EU RC mass, high complex gasket for radial already in 2k Fastest SOP ever system : 30% weight sealing ? 30% weight saving saving (and attractive Cost saving cost saving) Moving to the lower part of the engine  Oil Pans

1980 2000 2008 2010 NOW

First prototype Functional First commercial Functional Integration of oil in the US protos in EU part (Bruss for integration pick-up pipe, oil Daimler) (ElringKlinger) level switch, oil filter and other oil return Components or even oil pumps.

Air Intake Manifolds are one of the highest volume applications for engineering plastics

1987 1990 1995 NOW

DuPont Troy GM introduces World’s largest Air intake manifolds to Machines 3800 Manifold AIM for Ford integrate more functions in DuPont Zytel® prototypes Mustang In  PPA for thinner walls, with 2 –piece DuPont Zytel® welded design. higher temperature

The charge-air cooler is incorporated into the intake manifold (VW)

Integrated AIM/CAC

Source: Source:

Mahle

Magazine

No D duct (CAC to AIM) / shorter C duct (TC to CAC) with higher temperature exposure… Automotive Development Application Profile

Application: • Air ducts BMW

Engineering polymer: • Hytrel® HTR4275

Benefits: • Easy processing with blow molding • Pressure pulsation performance at high temperatures • Excellent weldability • Blow by gas resistance

Turbo Hoses - Hot Side Air Duct • Commercial Application

Zytel® 70G35HSLX - Injection moulded

Zytel® BM70G20HSLX - Blow moulded

Zytel® 70G35HSLX Injection moulded + welded shells

Vamac® / ® / Vamac®

HP welding

FKM/ VMQ / ® / VMQ

Copyright © 2015 DuPont. Hytrel®, Crastin®, Zytel®, Vamac®, Kevlar® and Nomex® are trademarks or 15 15 registered trademarks of E.I. du Pont de Nemours and Company or its affiliates. All rights reserved. Lightweighting with High Temperature Plastics, in Transmissions

Valve body cover: 2.50 lb Transmission control module: 1.00 lb Gasket: 0.50 lb Automatic transmission fluid level valve: 0.25 lb Automatic transmission fluid filter body: 0.50 lb Range sensor: 0.25 lb Valve body: 4.00 lb Hydraulic Accumulator: 1.20 lb Case baffle: 0.50 lb Differential baffle: 0.50 lb Additional, proprietary development programs: 5.00 lb

DRIVELINE IS ANOTHER 15 lb and those ARE IN DEVELOPMENT

Eliminating just 5 to 7 kgs on the 40 million automatic transmissions globally would save 340 million litres of fuel Transmissions- real need for weight saving

Electronic transmission control system & modules Zytel 70G35 HSLX

Transmission oil pan Zytel 70G35

GM 6-Speed transmissions use Seals in Hytrel® for ATF baffle and seal – to reduce fluid aeration and allow fluid-fill for life. Next switch from metal to plastics ?

Engine Front Covers ?

Transmission Front Housing ? Exhaust Mufflers ?

Dual mass fly wheel ? Manual transmission Forks ? Converter wheel ? High Temperature

230°C

220°C

210°C

200°C

Performance 190°C Zytel® Zytel® 70G35HSRX 180°C Zytel® 70G35HSLX 70G35HSLRA4 160°C Zytel® New product development 73G30HSL

Price Automotive – Thermal Management

Downsizing •Thermostat & Heater Housings Durability • •Outlets/Inlets, Lightweight •Coolant tubes High Efficiency •Valves, Cross overs •Coolant Pumps •Water Jacket Spacers •Charge Air Cooler •Radiator end tanks •Fan shrouds •HVAC

Zytel® HTN Zytel® PA66 + PA6 Zytel® RS Automotive – Thermal Management Thermostat Housings / Water Outlets: ZYTEL® HTN (PPA) Benefits/Features:  Excellent Resistance to Hot Long Life Coolant.  Minimal creep to maintain sealing surface  Dimensional Stability for strength around bolt inserts  Cost and Weight $avings vs. Aluminum, and PPS 12000

Lower Aromatic HTN51 Content than HTN 9000

PA6T/6I/66

6000

PA66

3000 Tensile Modulus Aged, MPa Aged, Modulus Tensile 50% G05 LLC, 130 oC,3000 hr

0 0 10 20 30 40 50 60 Stress at Break after Aging, MPa ZYTEL® HTN51G35HSLR or HTN51G45HSLR General pres Water Pump Housings and Impellers

Zytel® 70G30 HSLR

PP GF45

Citroen C3 Bergstrom Zytel® PLS90G30

PA66GF30

Zytel® HTN51G35HSLR Toyota Electric pump David CRAIG PTY Automotive – Interior

Noise Air Quality • Door Systems Lightweight • Safety Restraint Systems Safety • Seating Systems Comfort • Airbag Systems • Dashboard Systems • Storage and Trim • Gear shift • Turn signals

Crastin® Delrin® Delrin® LE Hytrel® Hytrel® RS ® EP Zytel® PA66 + PA6 Zytel® RS Automotive – Interior Polyacetal parts used in the interior

Sunroof Safety System - Sliding Guide - Seat Belt Button Door Panel - Window Motor - Retentioner - Door Lock System - Window Regulator - Child Seat Seats - Clip, Fastener - Seat Adjuster - Headrest Tubes

Front Panel - Heater Fan / AC - Speedometer - Switches - Audio/GPS - Airbag System Car manufacturer interior emission requirements VDA 275*

HCHO Emission Many Delrin® standard OEM (mg/kg) grades meet the VDA 275 Audi < 2 requirement of <10mg/kg while Delrin® E grades BMW < 2 meet the <2mg/kg limit Daimler < 2 Ford < 5 GM/Opel < 5 PSA < 10 Renault < 10 Volkswagen < 2 * or equivalent Delrin® Acetal Homopolymer – Grades with Low (<8 ppm) and Very-Low (<2 ppm) VOC Emissions

High Molecular Weight Medium-High Viscosity Medium Viscosity Flow Series High Performance Balance of Features Good Flow General Use, High Performance, General Use, High Performance, General Use, High Performance, Low Emissions Very Low Emissions Low Emissions Very Low Emissions Low Emissions Very Low Emissions Characteristics (<8 ppm) (<2 ppm) (<8 ppm) (<2 ppm) (<8 ppm) (<2 ppm) Very Low Emissions Grades (Automotive) 100P 300CP 500P Standard, Unmodified Grades 111DP 100PE 311DP 300PE 511DP 500PE UV Stabilized 127UV 127UVE 327UVE 527UV 527UVE 100T 100TE Toughened 100ST 100STE 300TE 500T 500TE Low Wear and Friction 100AL

Coming next: Delrin® 111PE – creep resistant high viscosity Delrin® 511PE – creep resistant medium viscosity Delrin® 911PE – creep resistant low viscosity Delrin® 100ALE – improved wear and friction high viscosity

Automotive Development Application Profile

Application: • Interior Door Handle

Engineering polymer: • Minlon® 73M40

Benefits: • Excellent surface aspect for chrome plating • Dimensional stability • Stiffness and impact performance

Automotive - Exterior Recyclability Durability • Light weighting Styling versatility Safety

• Lighting • Fascias and Panels • Roof Accessories • Wiper Systems • Exterior Trim • Wheels & wheel covers

Crastin® Delrin® Hytrel® Sorona® EP Zytel® Zytel® HTN Automotive - Exterior Successful CRASTIN® projects

Application: VW Sharan VW Touran • Head lamp bezels Audi A4 Engineering polymer: • Crastin® Benefits: • Low outgassing • Excellent surface quality • High flow PBT, ease of processing • Temperature performance and durability

Successful CRASTIN® projects

OEM - model: AUDI Q3

Application: Headlamp Bezel

Product: CRASTIN® CE2055

SOP: 2014

Successful CRASTIN® projects

VW Sharan VW Touran

OEM - model: ŠKODA Octavia

Application: Headlamp Bezel

Product: CRASTIN® CE2055

ŠKODA Octavia - Headlamp Bezels

VW Sharan VW Touran ŠKODA Yeti - Headlamp Bezel

VW Sharan VW Touran

OEM - model: ŠKODA Yeti

Application: Headlamp Bezel

Product: CRASTIN® CE2055

SOP: Q1 2014

Mercedes GLA - Headlamp Bezel

VW Sharan VW Touran

OEM - model: Mercedes GLA

Application: Headlamp Bezel

Product: CRASTIN® CE2055

SOP: Q1 2014

Mercedes CLS - Full LED Module

VW Sharan VW Touran

OEM - model: Mercedes CLS

Application: Full LED Module

Product: CRASTIN® LW9330 BK851

SOP: 2011

Automotive - Electrical & Electronics

• Sensors & Solenoids Safety Regulation • • Connectors Fuel Efficiency • HEV & EV System High Performance Down Sizing • Ignition Systems Cost Reduction • Motors & Actuators Comfort • Control Modules • Relays & Switches • Steering Wheel Module • Wire & Cable

Crastin® Delrin ® Hytrel® Sorona® EP Rynite® Vamac ® Zytel® HTN Zytel® PA610+ PA612 Automotive - Electrical & Electronics Automotive - Chassis

• CVJ boots • Jounce Bumper Emission Reduction Durability • Fuel Systems • Fuel Efficiency • Engine Mounts • Brake & Suspension Driving Performance Comfort • Fluid hoses and tubing • Fasteners • Exhaust Muffler • Pedals & Gearshift • Steering Systems

Delrin® Hytrel® Vamac® Zytel® Zytel® RS Zytel® HTN Automotive - Chassis Hytrel® solution to replace Foam PU Jounce Bumper

Hytrel® Jounce Bumper Current injected Foam PUR By specific thickness solution Thermoplastic profile, Hytrel® Jounce Elastomer Bumper design can Hytrel® absorb maxim energy

Blow Bellows molding design process First commercialization: Replacement of PUR on Fiat Punto

Polyurethane foam

Hytrel® Hytrel® vs. PUR foam: Significant cost reduction

Polyurethane foam : 4 parts Hytrel® : 1 part

Base cup No Base cup

POM/Rubber Ring No Ring

Jounce Bumper Jounce Bumper integrated with Dust Cover dust protection

• Less assembly cost (integration, less parts) • Low tool investment (blow molding tool) • Low machine investment (Ossberger machine) • Less part reference (1 instead of 4) • Fast cycle time (from 20s to 30s) • Recycle resin (regrind about 30%) • …

6/21/2016 We Continue To Fuel The Automotive Industry With Innovative Solutions

+100 yrs Automotive Industry is a strategic market