World's First Plastic Belt-Driven Sunroof from Aisin Combines Innovative Design, DuPont Materials to Cut Weight, Cost and Boost Performance

TROY, Mich., April 24 -- Stimulated by consumer visions of warm weather driving, industry analysts such as CSM Worldwide predict that 3.5 million vehicles with sunroofs will be produced for North America this year. An innovative sunroof system design from Aisin World Corp. of America, enabled by several DuPont materials, could make this already popular option lighter, more durable and less costly.

The plastic belt-driven sunroof system from Aisin World Corp. of America delivers 40 percent cost savings, reduces component weight 45 percent and cuts parts by 33 percent due to a unique design using DuPont(TM) Hytrel(R) polyester elastomer, Zytel(R) high-performance PPA, Rynite(R) PET, Delrin(R) acetyl and Zytel(R) PA66. This patented design, appearing on the Toyota Opa in 2003, received an achievement award in the body interior category of the SPE Automotive Division Innovation Awards program. This application is expected to be on more imported vehicles as well as on some U.S. automakers' vehicles within the next few years.

The new Aisin system uses a Hytrel(R) belt with molded-in teeth to engage a drive gear made of Delrin(R), reducing friction and noise for much smoother operation than traditional metal cable and steel gear-based systems. The older system requires plastic flocking on the cable to help reduce friction and noise, adding cost and complexity.

Hytrel(R) increases drive belt durability through exceptional wear resistance and flexibility combined with high strength and dimensional stability, even when exposed to moisture and temperatures over 120 degrees Celsius. Delrin(R) and Hytrel(R) lower friction, helping to increase the transmission efficiency of torque by 30 percent, making it possible to use a more compact, lightweight electric motor that also consumes less energy. In operation, the sunroof features an electronic stop versus a mechanical stop that further improves motor reliability.

The Aisin design significantly reduces system complexity by integrating the front shoe of Rynite(R) and the functional slider bracket of mineral and glass-reinforced Zytel(R) high-performance PPA. This eliminates several heavier metal components that require riveting for assembly. The outstanding dimensional stability and strength of Zytel(R) high-performance PPA used in this crucial bracket also help improve durability. The linkage and Zytel(R) PA66 rear shoe also are integrated, further reducing assembly complexity.

Aisin develops and manufactures a wide range of components and systems for some of the world's most demanding automobile companies. Aisin makes components for door frames, roofs, latching systems, brakes, engines, seating, trim molding, and more. Under the directive of "Quality First", Aisin is continually exploring new product lines and new ways to help customers improve the quality of their automobiles.

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.

DuPont(TM) and Hytrel(R) polyester elastomer, Zytel(R) high-performance PPA, Rynite(R) PET, Delrin(R) acetal and Zytel(R) PA66 are a trademark and registered trademarks of E.I. du Pont de Nemours and Company.