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Technical Paper

Transmission-Mounted Power Control Unit Including 12-Volt DC-DC Converter for Two-Motor Hybrid System

This research proposes a third-generation power control unit (PCU) for a two-motor hybrid system. To make a more compact intelligent power unit (IPU) to be located under the second seat, a PCU with a 12-volt DC-DC converter (DCDC) that mounts directly on the transmission was developed, whereas the DCDC was previously mounted within the IPU. Since this has a considerable impact on the engine room layout, the technology described below was used to make the PCU even more compact than the second-generation unit. The power module, a key component of the PCU, now uses Ag nanoparticles sintering bonding rather than conventional solder bonding. This helps lower thermal resistance and enables smaller power semiconductors. The voltage control unit (VCU) has a new circuit that uses a multi-stage switching circuit and electric power transfer capacitor instead of the conventional chopper circuit.
Technical Paper

Lead Free Cationic Electro-Deposition for Automobile Body in White

Organic tin compounds were examined as replacements for the hardening catalyst function of lead in order to produce a lead-free cationic E-coat. The mechanism of the decline in adhesion, at the interface between the anti-chip primer and the primer surfacer, when an organic tin compound migrated to the anti-chip primer layer, was determined. Monobutyl tin compounds were found to have the lowest mobility within the film of organic tin compounds capable of functioning as hardening catalysts. A lead-free E-coat, employing a monobutyl tin compound, demonstrated no decline in adhesion, and the performance of the film was equivalent to that of conventional E-coat.
Technical Paper

Development of a High-Strength Aluminum Cylinder Block for Diesel Engine Employing a New Production Process

A high-strength aluminum cylinder block manufactured using a new production process, ASCT (Advanced Semisolid Casting Technology) has been adopted for the newly developed 2.2L 4-cylinder i-CTDi (Intelligent Common rail Turbo Diesel Injection) diesel engine fitted in the new Accord to be marketed in Europe. In the production process, a semisolid aluminum is used during high-pressure die-casting. In addition, newly developed pressure resistant sand cores are used to mold the closed deck. Heat treatment is conducted to ensure a high level of materials strength. To respond to the high load on the crankshaft journal, die-cast aluminum lower block with cast iron bearing caps inserts are employed. Adopting the dummy head honing to reduce bore deformation and offset cylinders have enabled the achievement a lightweight and compact cylinder configuration matched to the high combustion pressure of the latest diesel engines, while maintaining a high level of quietness.