TROY, Mich., March 3 /PRNewswire/ -- After the perennial top concern over cost reduction, safety is rated as the number one challenge among automotive engineers to stay competitive in the design of the next generation of motor vehicles, according to the 10th annual DuPont sponsored survey of those planning to attend the 2004 SAE World Congress and Exposition, March 8 - 11. The DuPont SAE survey results also ranked advanced safety and entertainment systems as virtually tied among the top two technologies consumers would be willing to pay for in their next vehicle.

"The SAE survey results support double-digit growth projections for safety systems development and validates our experiences around the world with first tier and OEM customers," said Michael L. Sanders, global business director for DuPont and INVISTA(TM) Automotive Safety Systems. "Our primary focus is to contribute materials technology and the expertise to apply it in priority development programs for side impact and rollover protection as well as collision avoidance and pedestrian protection systems that are on the near- term horizon."

DuPont and INVISTA, the DuPont textiles unit that maintains a safety systems marketing alliance with DuPont, will participate in the 2004 SAE Exposition at booth 1643 with a focused display of automotive safety materials technologies. Technical experts from both companies will be available to consult with attendees on ways they can achieve their engineering design goals at lower cost, space and weight.

The 2004 SAE study report indicates that the top 10 safety systems to receive priority attention among first tier suppliers and OEMs over the next five years will include the following:

Collision avoidance systems - 62 percent "high" attention
DuPont is developing applications for its electronic and communications technologies including ceramic and precious metal paste microcircuit materials for weight- and space-savings and greater durability in "bluetooth" wireless communications, radar, infrared and other warning systems. DuPont engineering polymers, such as DuPont(TM) Crastin® PBT and DuPont(TM) Zytel® nylon, will be used to house and encapsulate sensors and control modules. New display materials and methods are available, including the DuPont(TM) SentryGlas® Wedge(TM) that enables sharper head-up display images in windshields.

Side and rear air bag systems - 56.5 percent "high" attention
Redesign of side air curtains, knee and rear air bag systems will be undertaken to integrate deployment components, and as a result, save weight and cost through the use of a variety of DuPont plastics technologies. System deployment and occupant sensors rely on DuPont electronic materials such as DuPont(TM) Pyralux® flexible circuitry and DuPont(TM) Kapton® polyimide film, DuPont microcircuit materials and engineering plastics. DuPont(TM) Hytrel® TEEE and new DuPont(TM) Advantech(TM) TPO resins are used for air bag deployment doors. INVISTA, a leading supplier of air bag nylon fiber, is a DuPont marketing partner in pursuing the development of air bag systems.

Active seatbelt pre-tensioning systems - 43.5 percent "high" attention
DuPont is a current leader in supplying engineering plastics such as Crastin® PBT and DuPont(TM) Rynite® PET thermoplastic polyester, DuPont(TM) Delrin® acetal, Zytel® nylon and other resins for seatbelt retractor mechanisms, buckles and electric motor components.

Pedestrian protection systems - 41 percent "high" attention
The first phase of the European Union Directive for vehicle and pedestrian safety standards will be implemented in 2005. In addition to frontal air bags, auto engineers are testing crush cones and honeycomb structures of DuPont engineering plastics for improved bumper and interior compartment impact absorption. The technology is aimed at providing tunable impact absorption in ways that foam technology cannot.

Electronic stability control - 39 percent "high" attention
Harnessing control of multiple vehicle systems to increase driver control and reduce rollovers through electronic stability systems will require a range of DuPont electronics and polymer technologies for optimum reliability and cost-benefit.

Side door reinforcement and impact absorbers - 36 percent "high" attention
A critical need for side impact protection and for matching smaller and larger vehicle crash compatibility is the potential to increase intrusion beam performance, combined with interior and door panel impact protection -- all within a limited space. Composite structures of DuPont(TM) Kevlar® aramid fiber and a variety of crush cone, honeycomb and bladder concepts in DuPont engineering plastics offer potential.

Tire pressure monitors and run-flat tires - 36 percent "high" attention
Wheel rim sensors and wireless communication electronics are being employed to meet the mandate for measuring and alerting drivers to tire pressure levels. DuPont microcircuit materials can be used in the sensors and to facilitate the "bluetooth" wireless communication. DuPont(TM) Zytel® nylon is used to house a commercial tire pressure sensor.

Side, overhead and rear laminated safety glass - 22 percent "high" attention
NHTSA studies indicate that laminated glass could be a major factor in reducing the toll of 10,000 occupant ejection fatalities each year in the United States alone. DuPont(TM) SentryGlas® Plus safety glass interlayer offers added rigidity and tear strength for side windows to keep side windows in place and to deter thieves of vehicle contents. It is commercially used as an option on both the BMW 5 and 7 Series models. New SentryGlas® technology will be debuted at SAE for its additional benefits in providing acoustic, solar and styling benefits in addition to safety and security.

Head-up display systems - 18 percent "high" attention
DuPont is the leader in supplying a partial wedge-shaped interlayer for windshield laminated safety glass that allows head-up display (HUD) systems to present a cleaner, sharper image for increasingly critical driver information such as turn-by-turn navigation and collision avoidance warnings. Future HUD systems will save space and weight by employing a variety of DuPont electronics and plastics technologies as they place critical information in the driver's view of the road ahead.

Inflatable seat belt systems - 16 percent "high" attention
Another opportunity, especially for rear passenger protection, is seen in "belt-in-bag" systems. These systems would rely upon the extensive DuPont materials technology offering that enables seatbelt mechanism and air bag deployment and electronic sensor performance.

DuPont is a science company. Founded in 1802, DuPont puts science to work by solving problems and creating solutions that make people's lives better, safer and easier. Operating in more than 70 countries, the company offers a wide range of products and services to markets including agriculture, nutrition, electronics, communications, safety and protection, home and construction, transportation and apparel.

Source: DuPont Automotive

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