Moulded PU Foam in vehicles: Emissions testing and VOC limits An overview from Europe. Michel Baumgartner Dr. Sébastien Gentil CPI 2016, Baltimore

Transcription

1 Moulded PU Foam in vehicles: Emissions testing and VOC limits An overview from Europe Michel Baumgartner Dr. Sébastien Gentil CPI 2016, Baltimore 1

2 Contents 1 About EURO-MOULDERS 2 Emissions Influencing Parameters and Challenges 3 VOC reduction history in Europe 4 Trends expected for the coming years 5 Conclusions 2

3 About Euro-Moulders We are the European association of manufacturers of moulded polyurethane parts for the automotive industry. Our regular members operate over 30 flexible polyurethane foam (moulded for automotive seating) plants in 13 EU countries + Russia and Morocco. The collectively employ over 10,000 people. The EU s total moulded PU foam production for automotive seating is estimated to be over 150,000 tonnes for 2015, based on the number of cars produced (18,500,000 units). 3

4 Our Regular Members 4

5 Our Associated Members Air Products BorsodChem ChemTrend Covestro Evonik Industries Dow Huntsman Shell Tosoh 5

6 Emissions Influencing Parameters and Challenges Illustrating European Complexity: Physical Properties testing of PU Foam: Each line is one test item, each column one OEM, each cell one test method with one specification. If you supply all OEMs, this is your daily life. And a sheet on emissions testing would look pretty similar 6

7 Emissions Influencing Parameters and Challenges VIAQ : The OEM s Challenge in a global market 7

8 Emissions Influencing Parameters and Challenges Emissions Single Word Different Meanings Odor from materials Fogging condensation of volatile on windscreens Aldehydes and Ketones Volatile Organic Compounds + List of forbidden products for Automotive (GADSL) Different Mechanisms Different Solutions Each substance, each emission type must be carefully studied in order to be able to work on its reduction. Improvement of one type of Emission can have a bad side effect on an other type of Emissions 8

9 Emissions Influencing Parameters and Challenges Foams parts PUR material Emissions Emissions limits have been put in place by all car manufacturers but following different philosophy for emission reduction (historical reasons and geographical reasons). Reduction of global emission level from parts or materials Reduction of special substances From Car cell to Complete Seat or Complete Function Fr From Complete Seat to Foam parts and/or Foam samples Elimination of specific substances Current situation was marked by considerable ambiguity, such as a lack of global legal requirements or of an acknowledged single standard for the risk assessment of detected substances. As a result, the industry is facing a patchwork of requirements concerning emissions from materials for car production. 9

10 Heat Emissions Influencing Parameters and Challenges Heat Emissions Reduction Challenges Emission requirements can not be separated from mechanical properties requirements. Low Emission catalysts strongly impact foam mechanical properties after dry and/or humid aging. PU network Non Low Emission catalysis Emissions Low Emission catalysis Catalysts are linked Can not show up in test BUT acting as depolymerisation with aging (heat/humdity) conditions Catalysts New products for foam formulations needed to be developed with the help of our raw materials suppliers in order to overcome the ageing degradation keeping VOCs at low level. 10

11 INDUSTRY CHALLENGES NEW SPECIFICATIONS VOC Reduction History - Europe PUR material Emissions Beginning of the Story BMW GS Carb Test (FID) (VDA276) VW VW50180 Formaldehyde (VDA275) VOC (VDA277) Daimler PB VWL709 (VDA278) BMW GS List of VOC (VDA276) Volvo VCS1027,2749 VCS1027,2739 VOC (VDA277) Formaldehyde W8081 Nissan NES0402 NES0403 Toyota TSM0509G TSM0508G Daimler DBL8585 VOC targets (VDA278) Audi VW50179 (VDA276) W15635 (VDA277) Volvo VCS1027,2769 VW VW50180 Introduction of the Daimler VDA278 targets VOC 100ppm Fog 250ppm New technology New formulations needed Audi requirements Cumulative value of Amine < 2000µg/m 3 New Solutions needed

12 INDUSTRY CHALLENGES NEW SPECIFICATIONS VOC Reduction History - Europe PUR material Emissions Acceleration of the Story W15635 Formaldehyde Ford FLTMZ Formaldehyde FLTMZ (VDA277) W15635 Formaldehyde Toyota TSM0508G Renault Daimler DBL8585 VOC targets Audi VW50179 Ford WSS M99P2222 Targets Kia MS300-55E BMW GS GS Daimler DBL8585 W8081 Ford WSS M99P2222 W15635 W15853 Targets Kia MS Nissan NES0403 BMW GS Kia MS Daimler DBL5430 VW VW50180 BMW chamber test limits TVOC 1800µg/m 3 Formaldehyde 28µg/m 3 Requires New Developments New VDA278 test C 20 C 25 C 14 C 16 new new C 35 BMW chamber test limits TVOC 2500µg/m 3 /kg Formaldehyde 30µg/m 3 /kg Acetaldehyde 30µg/m 3 /kg VW chamber test Amines < 2000µg/m 3 Formaldehyde 100µg/m 3 /kg Acetaldehyde 100µg/m 3 /kg Daimler chamber test limits TVOC tbd Formaldehyde 30µg/m 3 /kg Acetaldehyde 30µg/m 3 /kg

13 VOC Reduction History - Europe PUR material Emissions Acceleration of the Story 2011 New challenge with VDA278 Foamers have been facing the following situation: VDA278 testing conditions have been changed without previous warning While OEM specifications did not change, the revision led to findings of higher TVOC and detection of new substances in both VOC and Fog. Almost all solutions in place with emission results within existing specifications (100ppm; 250ppm) were suddenly out of specifications. Example of foam results VDA 278 Before (2010) After (2011) Limits VOC (ppm) Fog (ppm)

14 VOC Reduction History - Europe PUR material Emissions Acceleration of the Story 2012 GB/T Promulgation by the Ministry of Environmental Protection of the People s Republic of China of a new guideline for the assessment of the interior air quality of passenger cars.. This guideline is filling regulatory blank spots. This guideline provides concentration limits for 8 major substances. Testing of VOC in the car cells is carried out following HJ/T Temperature: 25 C +/- 1 C Humidity: 50% +/- 10% Air flow rate: 0,3m/s Sampling: 30 minutes (at ml/min for VOC) (at ml/min for aldehydes)

15 INDUSTRY CHALLENGES NEW SPECIFICATIONS VOC Reduction History - Europe PUR material Emissions Acceleration of the Story W15635 Formaldehyde Ford FLTMZ Formaldehyde FLTMZ (VDA277) W15635 Formaldehyde Toyota TSM0508G Renault Daimler DBL8585 VOC targets Audi VW50179 Ford WSS M99P2222 Targets Kia MS300-55E BMW GS GS Daimler DBL8585 W8081 Ford WSS M99P2222 W15635 W15853 Targets Kia MS Nissan NES0403 BMW GS Kia MS Daimler DBL5430 VW VW50180 BMW chamber test limits TVOC 1800µg/m 3 Formaldehyde 28µg/m 3 Requires New Developments New VDA278 test C 20 C 25 C 14 C 16 new new C 35 BMW chamber test limits TVOC, Formaldehyde, Acetaldehyde VW chamber test Amines, Formaldehyde, Acetaldehyde Daimler chamber test limits TVOC, Formaldehyde, Acetaldehyde Volvo chamber test TVOC, Formaldehyde, Acetaldehyde

16 Europe Today Testing specifications Each automotive manufacturer has is own tests. Tests are different because of: Type of samples Size of samples conditioning Testing devices and detection possibilities Test duration Test Temperature Test Airflow Type of detected products Result calculation OEM Odor VOC tested on: Fogging Aldehydes &Ketones tested on: Daimler VDA270-16mg Part - Chamber Test 90 C C Thermodesorption VDA 278 VOC + special product list 65 C full list From Chamber Chamber Test Hyundaï Kia Kia test 4cmx9cmxthickness 65 C special list of product to look for special test 4cmx9cmxthickness simple & detailled test BMW VDA270 Part Chamber Test 65 C 5h VOC + special product list Gravimetry + Chamber Part Full list Toyota Toyota test 8cmx10cmxthickness 65 C special list of product to look for Toyota special test 8cmx10cmxthickn. Full list Renault Renault odor panel - 16mg on complete seat w/o cover 90 C type VDA278 with changes 65 C special list Reflect + gravi 2g samples Full list PSA PSA dedicated test 16mg 90 C type VDA278 with changes Reflectance Full list FORD Same as VDA C VDA277 Special test 2g samples Formaldehyde only VOLVO VDA270 on complete seat 120 C VDA C special list Gravimetry 2g samples Formaldehyde only OPEL/ VDA270 16mg 90 C C Thermodesorption VDA 278 Gravimetry 2g samples Full list VW VDA270 on parts 120 C VDA C special list Gravimetry 2g samples Full list Audi VDA270 on parts 120 C VDA C special list Gravimetry 2g samples Full list

17 Europe today Trends expected for the coming years There are timid attempts towards harmonization between OEM testing methods for emissions (chamber test). This is not the case for mechanical tests. International developments are integrated into OEM specifications (ISO ) Tests become increasingly accurate: need to work on emissions that used to be considered as non-problematic. But there also (some) OEMs seem ready to adapt targets to reality when changing testing conditions. Knowledge on chemical substances / regulatory pressure require frequent reviews of targets / lists of undesirable substances. Concretely, China GB/T27630:2011: Less stringent than initially anticipated on acetaldehyde. Focus may shift back to formaldehyde (Carc. 1B in the EU). 17

18 Conclusion Emissions is an area where Europe has little industry-wide guidelines or legislation in place. Coexistence of many different test methods and specifications is an intensive exercise for the supply chain. Small improvements on the way but still a long way to go. Common objective to reduce VOC emissions from individual products and improve VIAQ. A lot has been done already but some specifications are more challenging than others. Harmonized VIAQ test methods and test methods for individual parts can only benefit the whole supply chain. Doesn t prevent different regions of the world or individual OEMs from adopting their own limits on specific substances. There are difficulties to overcome (company culture, priorities, reference matrix ) that should not be underestimated. But we have been pushing for increased harmonization since 2009, so we re not despairing. ACEA is supportive of the work done at global level. Maybe there s light at the end of the tunnel! 18

19 THANK YOU! Disclaimer/Copyright: This presentation is aimed at serving as a basis for discussion during the CPI Polyurethanes Conference 2016 session «Moulded PU Foam in Vehicles: Emissions Testing and VOC Limits». No warranties are made with regard to its completeness, accuracy or reliability and no liability will be accepted for damages of any nature whatsoever resulting from the use of or reliance on the information it contains. It may not be copied, distributed or reproduced in any form without specific written consent from EURO-MOULDERS. 19