Kariya City, Japan - DENSO, teaming with Daihatsu Motor, Co., Ltd., is using its expertise in radiator and air-conditioning products to develop a light, high-performance front-end module that is more efficient and 30 percent lighter than conventional components. The new module contains the carrier, radiator, electric fan and condenser for the car’s air conditioner, an intercooler (for turbocharged vehicles), and air cleaner. Daihatsu will use this new module in the Copen, its small, sporty roadster.

The front-end carrier usually is made of iron for strength and impact resistance. DENSO’s carrier is made of a light, cost-efficient polypropylene material reinforced with long-fiber glass, which reduces weight and cost over conventional carrier designs.This new carrier design weighs 8 pounds (4 kg) less than a traditional steel carrier. The resin material used to build the carrier also is recyclable. These improvements help reduce environmental impact and improve fuel efficiency, allowing DENSO to remain a leading company in environmental protection and helping to fulfill DENSO EcoVision 2005.

Traditionally, radiator and air-conditioner condenser products are attached separately to the front of the vehicle,where they are exposed to air while in operation for heat exchange efficiency. By optimizing the entire front-end thermal component zone, DENSO achieved improved heat exchange efficiency not possible through improvements on individual components. For example, by shielding the air conditioning condenser from radiator heat, energy needed for air-conditioner compressor operation is reduced by approximately 13 percent. This translates into better fuel efficiency and improved air conditioner performance.

“DENSO takes a wide range of thermal components, electric systems and electronics for automobiles that are conventionally designed separately, and integrates their functions, thereby promoting the modularization of auto parts to create better performance,” said Koichi Fukaya, senior managing director, DENSO Corporation.

DENSO began producing cooling modules in August 2000 and air/fuel modules in September 2001 and, since then, has completed development of cockpit modules. DENSO intends to expand this business field by supplying function-intensive modules to create superior value automobiles.