Public Funding for Fusion Innovations Limited

The Eco low Rolling resistance tyre or EcoRR, project is a follow on from a successful IDP8 Proof of Concept project called EcoRR. The project focus is a tyre which can adapt it’s profile and stiffness dynamically, allowing it to operate in a very low rolling resistance mode, or in a performance grip mode when cornering or braking/accelerating. Proof of concept work showed that with better tyre design and better traction design concluded that the technology was capable of a step change 7% CO2 reduction compared to a vehicle running on conventional pneumatic tyres, and in addition had the potential to improve cornering grip, reduce tyre manufacturing costs, NVH and provide inherent run flat capability. Future development will see ECORR become a fully integrated dynamic component of the Low Carbon Vehicle. To enable this the IDP12 project has built on the existing consortium between Fusion Innovations, UOB and Randle Engineering and added OEM support from OEM's such as Jaguar Land Rover and manufacturing support from Teqniqa and Lyra Electronics.

The Eco low Rolling resistance tyre or ECORR, project is a follow on from a successful IDP6 feasibility project of the same name. The project focus is a tyre which can adapt it’s profile and stiffness dynamically, allowing it to operate in a very low rolling resistance mode, or in a performance grip mode when cornering or braking/accelerating. Analysis undertaken by the University of Birmingham (UOB) as part of the feasibility study concluded that the technology was capable of a step change 7.5% CO2 reduction compared to a vehicle running on conventional pneumatic tyres, and in addition had the potential to improve cornering grip, reduce tyre manufacturing costs, NVH and provide inherent run flat capability. Future development will see ECORR become a fully integrated dynamic component of the Low Carbon Vehicle. To enable this the IDP 8 project has built a consortium between Fusion Innovations, UOB, Potenza Technology and Randle Engineering capable of developing the concept design through to a physical demonstrator and undergoing on vehicle testing (TRL 5). The tyre concept and a supporting generator technology for inflation are both the basis of patent applications. ECORR applies to the majority of conventional wheels, and it is envisaged that full vehicle integration will further enhance operational benefits.

The project is an opportunity to complete a proof of concept on a highly innovative patent pending TOGEN tyre pressure monitoring and maintenance device. The device is unique in that it has found a way of harvesting the large amounts of energy (up to 100G) that can be produced in rolling motion and turns it into air flow and electricity. TOGEN is a spin off product from our highly successful ECORR TSB IDP6 feasibility study for disruptive technologies in low carbon vehicles with the University of Birmingham. TOGEN is a mechanically simple yet electronically complex device that sits within the tyre and is connected to the valve like todays TPMS products. The TPMS market we are expecting TOGEN to have a major competitive advantage over is being driven by legislative change that should see TPMS systems be fitted on every road tyre in the world by 2020. Legislation is already forcing automotive OEM’s to fit TPMS on new models throughout Europe and the USA. This is expected to then be applicable to all new vehicles by 2014. The Global tyre market is also expected to reach 1.72bn units by 2015. Following the same successful formula of our ECORR feasibility project this projects objective over 12 months are to: • Produce 10 work packages working concurrently to produce a risk averse development strategy. • Work with the University of Birmingham and Potenza Technology for simulation, control and physical testing to build a technical proof of concept. • Develop the algorithms required to control the harvesting. • Prove a cost effective and manufacturing solution is possible. • Prove the design can operate effectively without having an impact on vehicle NVH. • Prove the product can be reliable when operating in its hostile environment. • Develop a strategy and plan for development up to licensing. • Take the POC results and develop a partnership with UK OEM and TPMS manufacturers. • Take the business case forward and bring in external investors.

In a world where automotive manufactures are facing huge challenges legislatively and therefore financially, to reduce CO2 emissions, and of which are only going to increase, a high performance economy tyre has been until recently an oxymoron. In fact they are directly opposing requirements; however Fusion Innovations Ltd through the ECORR project is working on proving the feasibility of such a tyre. The concept was born from creating an innovative mechanism that could operate in two modes: an economic mode for normal driving conditions and a high performance high traction mode for cornering and braking. The resulting effects are akin to combining the differences of a bicycle racing tyre (fast and efficient) and a mountain bike tyre (slow but high traction). The initial designs were complex in operation and manufacture and high in cost, but enabled the concept to be protected, and attracted the interest of the TSB. Through the Low Carbon Disruptive Technologies Feasibility project the ECORR design has evolved into something ofsimplicity in operation and manufacture and at an affordable cost, as a result it has far surpassed expectations and opened up many more potential mainstream markets than was initially thought possible. The project has been a successful collaboration between The University of Birmingham and Fusion Innovations Ltd, favourable early analysis from the University is showing efficiencies in the region of 7.5 to 10% CO2 reduction, through the use of multi-compound designs and low rolling resistance mechanisms that switch between modes to provide both an economic low rolling resistant tyre and a tyre with high performance and great safety. This ground breaking British project is proving to enable a substantial competitive advantage in a market worth nearly 1.7 billion units by 2015.