Dupont’s high-performance plastics have played a significant role in the breakthrough electric vehicle (EV) motor technology of Japan-based SIM-Drive Corpn which extends the driving range 30 per cent further than current mass-produced EVs.

“Innovations that help reduce dependence on fossil fuels play a critical role in the future of the automotive industry,” said DuPont Kabushiki Kaisha (DKK) president Minoru Amoh. “The power is both in the technology and the collaborative business model used to develop the prototype.”

DuPont is one of 34 companies involved with SIM-Drive, Kawasaki City, Japan, on the prototype SIM-WIL next generation EV that features nearly 50 new technologies. It was unveiled in March.

SIM-Drive credits a unique “in-wheel” motor system and extensive use of lightweight materials for the significant increase in kilometers per charge. SIM-WIL also delivers a maximum speed of 180 km/h (110 mph), sports car acceleration from 0-100 km/h (0-60 mph) in 5.4 seconds, and offers a higher level of interior space and comfort.

Increased reliability, performance, reduced weight and an appealing interior and exterior have, in part, been achieved by the use of eight DuPont products including high-performance plastics, film, paper and paint in a collaborative development programme between the DuPont Japan Innovation Centre in Nagoya, Japan, and SIM- Drive.

The new generation SIM-Drive SIM-WIL electric vehicle features eight DuPont materials

“Especially in EV applications, these high temperature, chemically resistant products and electrical insulation materials contribute to increased EV system reliability and performance under severe conditions such as wide-ranging temperatures and high voltage,” said Tomoyuki Shinkai, operating officer, vehicle development co-ordination division general manager, SIM-Drive Corp.

DuPont high-performance plastics such as DuPont Zytel HTN PPA in the wheel motor and DuPont Kapton polyimide film in indicator lighting helped SIM-Drive keep weight lower than EVs on the road today. DuPont Zytel HTN used in key in-wheel motor bobbins is stronger, lighter and more cost effective than the PPS it replaces. Kapton, known for use in high-reliability applications from Mars Rover to mobile devices, replaces the need for a circuit board, shaving 80 per cent of the weight from the lighting component.

“This project shows how light weight, high-performance materials such as Zytel HTN PPA can take extremes, allowing designers to bring innovation to electric and hybrid electric vehicles without adding weight associated with metal,” said James Hay, regional director, DuPont Performance Polymers, Asia Pacific.

Bio-based DuPont Sorona polymer improves the environmental footprint and is used in interior applications.  Understanding the importance of aesthetics, SIM-WIL also uses DuPont coatings and DuPont Corian for refined touchpoints.

“Clearly collaboration plays a powerful role in helping showcase new and innovative ideas and in the last few years, DuPont has stepped up to the challenge with innovation centres networked around the world to connect materials-science innovation to market needs, especially in vehicle electrification, lightweighting and renewable materials,” said Hay.