VOC Reduction: A Pathway to Environmentally Friendly Interiors

Transcription

1 VOC Reduction: A Pathway to Environmentally Friendly Interiors Bruce Mulholland Celanese

2 VOC Reduction: A Pathway to Environmentally Friendly Interiors Component Supply Chain Eliminate Paint VOCs (and Plating) Vehicle Interior Reduce overall cabin VOCs End of Life Recycle un-painted and un-chromed parts Key is to eliminate the paint process

3 Painting/Plating Elimination Provides Green solution Eliminate VOC s from paint process Eliminate chemical handling/disposal for painting and plating operations Ability to recycle molded-in-color resins Lower part cost ( Green ) versus painting or plating Typical savings: $1/part Eliminate secondary operation Eliminate warranty claims Eliminate multiple tools/materials required for trim level differentiation Celanese Appearance Resins provide the solution for both drivers

4 Get Green Without Paint Historically, interior design features were painted to achieve: A desired color A desired level of UV performance A desired level of gloss (i.e., low gloss) A desired appearance effect (i.e., metallic)

5 VOC Reduction: A Pathway to Environmentally Friendly Interiors Component Supply Chain Eliminate Paint VOCs (and Plating) Colorability Metallics Vehicle Interior Reduce overall cabin VOCs UV Stability Low Gloss End of Life Recycle un-painted and un-chromed parts Key is to eliminate the paint process

6 VOC Reduction: A Pathway to Environmentally Friendly Interiors Component Supply Chain Eliminate Paint VOCs (and Plating) Colorability Metallics Vehicle Interior Reduce overall cabin VOCs UV Stability Low Gloss End of Life Recycle un-painted and un-chromed parts Key is to eliminate the paint process

7 OEMs moving to reduce VOC (Volatile Organic Compounds) emissions in the cabin No internationally agreed definition of VOCs World Health Organization offers a classification based on boiling point: Boiling Point Classification Examples and boiling points of VOC < 50 C Very Volatile Organic Compounds (VVOC) 50 C < 260 C Volatile Organic Compounds (VOC) 260 C < 400 C Semi-volatile Organic Compounds (SVOC) > 400 C Particulate Organic Matter Methane (-161 C), formaldehyde (-21 C), methylmercaptan (6 C), acetaldehyde (20 C), dichloromethane (40 C) Ethyl acetate (77 C), ethanol (78 C), benzene (80 C), methyl ethyl ketone (80 C), toluene (110 C), xylene (140 C) Chlorpyrifos (290 C), di-n-butyl phthalate (340 C), din-ethyl hexyl phthalate (390 C) PCB, benzopyrene OEM definitions generally overlap VVOC & VOC classifications

8 Concern began in Europe over 15 years ago Driver appears to be elimination of new car smell Evident by adoption of test method VDA 270 Qualitative Smell Test

9 Quantifying air quality in living spaces gained momentum in Japan over the last 10 years Ministry of Health, Labour and Welfare formulated indoor concentration guidelines for 13 VOCs due to sick building syndrome There have been numerous reports on residents of newly built or recently renovated houses and buildings suffering from physical disorders, due to the increased air tightness of houses and the use of building materials and interior finishing materials containing chemical substances which evaporate and contaminate the air in the rooms. While this phenomenon involves diverse symptoms, as well as the mechanisms such as the onset are largely unknown and the factors are many and complex, such symptoms are generically called sick building syndrome. Sick Building Syndrome

10 Japan Automobile Manufacturers Association (JAMA) viewed passenger compartments in cars as living spaces Voluntarily worked on defining and reducing cabin VOCs Voluntary action began with the 2007 model year Other Asian countries followed including China and Korea US OEMs are evaluating as requirements expand to vehicles exported to those regions Sources of cabin VOCs include plastic parts, carpet, seat coverings, foams, adhesives, leather, wood, insulation, etc Not just a plastics issue!

11 Many compounds being targeted by OEMs Compound Target Range (μg/m 3 ) Ethylbenzene < 4,000 Xylene < 900 Tetradecane < 350 Toluene < 270 Styrene < 250 Dibutylphthalate < 240 Diethylhexylphthalate < 130 Formaldehyde < 100 Acetaldehyde < 50 Each OEM or region may have own target compounds and levels

12 VOC Emission Limits for Total Vehicle Air Quality Compound Japan China South Korea JAMA (μg/m 3 ) SEPA (μg/m 3 ) MOCT (μg/m 3 ) Ethylbenzene 3,800 No Limit 1,600 Xylene Tetradecane 330 No Limit No Limit Toluene ,000 Styrene 220 No Limit 300 p-dichlorobenzene 240 No Limit No Limit Benzene No Limit Dibutylphthalate 220 No Limit No Limit Diethylhexylphthalate 120 No Limit No Limit Formaldehyde Acetaldehyde No Limit Each OEM or region may have own target compounds and levels

13 VOC testing is a three tiered process Test Vehicle Full vehicle testing addressed by JAMA Component Testing responsibility of Tier 1 Material Testing

14 JAMA full vehicle method Sample at ambient temperature Doors open for 30 minutes Heat vehicle to 40 C, hold for 4.5 hours, then sample Open driver door for 1 minute, set A/C to 23 C, then sample Photos courtesy of Ford Motor Company

15 Component or part level testing Asian OEMs favor bag method testing Components up to 100cm2 placed inside 10L Tedlar bag Bag with a sampling tube is sealed with tape and placed inside an oven Bag is heated at 65 C for 2 hours Headspace air sampled twice: Tenax tube (absorbent: 2,6-diphenylene oxide polymer)» Tube analyzed using GC-MS for total VOCs DNPH cartridge (dinitrophenyl hydrazine)» Cartridge analyzed using HPLC for aldehydes Blank bag must be tested to determine baseline Typical method is JASO M902

16 Component or part level testing Asian OEMs favor bag method testing

17 Component or part level testing European and US OEMs favor chamber method Components placed inside a 1m 3 airtight stainless steel or glass-lined chamber Chamber heated at 65 C and 11% RH for 2 hours Headspace air sampled twice: Tenax tube (absorbent: 2,6-diphenylene oxide polymer)» Tube analyzed using GC-MS for total VOCs DNPH cartridge (dinitrophenyl hydrazine)» Cartridge analyzed using HPLC for aldehydes Typical method is VDA 276

18 Material level testing VDA 277 VOC by headspace GC VDA 278 VOC by thermal desorption Others specific to VOC in question VDA 275 for formaldehyde

19 Many compounds being targeted by OEMs Compound Target Range (μg/m 3 ) Ethylbenzene < 4,000 Xylene < 900 Tetradecane < 350 Toluene < 270 Styrene < 250 Dibutylphthalate < 240 Diethylhexylphthalate < 130 Formaldehyde < 100 Acetaldehyde < 50 Each OEM or region may have own target compounds and levels

20 Many compounds being targeted by OEMs Compound Target Range (μg/m 3 ) Ethylbenzene < 4,000 Xylene < 900 Tetradecane < 350 Toluene < 270 Styrene < 250 Dibutylphthalate < 240 Diethylhexylphthalate < 130 Formaldehyde < 100 Acetaldehyde < 50 Last two important for acetal

21 VOC Testing: Material Level VDA 275 to target formaldehyde 1 Qt jar with PE lid and SS hook 2 POM plaques suspended over water In oven for 3 hrs at 60 o C 80 x 50 x 1 mm 80 x 50 x 1 mm Teflon ring Water analyzed for HCHO by lutidine Teflon ring method mm 60mm Reported as mg HCHO/kg part (ppm) ml Water 50 ml Water VDA 275 reports formaldehyde emission in ppm

22 Emissions by VDA 275 (ppm) Vehicle Interior Air Quality Low VOC Materials Reaction to market trends for low emission products Emission range Manufacturing process optimized Europe Target New Target Next Gen stabilization package Nominally < 3 ppm 0

23 Typical acetal copolymer natural grades may contain: Primary antioxidant Secondary antioxidant Acid scavenger Formaldehyde scavenger Nucleant Lubricant Second generation low emission stabilization package developed to balance low emission with other performance criteria

24 Product Examples Acetal Copolymer Type Example Low VOC? VDA 275 (ppm) General Purpose Natural C 9021 or M90 No > 10 ppm C 9021 XAP2 TM Yes < 2 ppm Low VOC emission natural grades can be achieved

25 Product Examples Acetal Copolymer Type Example Low VOC? VDA 275 (ppm) General Purpose Natural C 9021 or M90 No > 10 ppm C 9021 XAP2 Yes < 2 ppm Impact Modified S 9243 No > 20 ppm S 9364 XAP2 Yes < 5 ppm Low wear, low noise C 9021 AW No > 20 ppm C 9021 AW XAP2 Yes < 5 ppm Colored grades C 9021 No > 50 ppm C 9021 XAP2 Yes < 5 ppm UV Stabilized colors UV90Z No > 50 ppm UV90Z XAP2 Yes < 5 ppm UV stabilized colors meet low emission and UV requirements

26 Type Example Low VOC? VDA 275 (ppm) General Purpose Natural C 9021 or M90 No > 10 ppm C 9021 XAP2 Yes < 2 ppm Impact Modified S 9243 No > 20 ppm S 9364 XAP2 Yes < 5 ppm Low wear, low noise C 9021 AW No > 20 ppm C 9021 AW XAP2 Yes < 5 ppm Colored grades C 9021 No > 50 ppm C 9021 XAP2 Yes < 5 ppm UV Stabilized colors UV90Z No > 50 ppm UV90Z XAP2 Yes < 5 ppm Metallic, UV colors LX90Z No > 30 ppm LX90Z XAP2 Yes < 5 ppm Metallic UV colors meet low emission and UV requirements

27 Type Example Low VOC? VDA 275 (ppm) General Purpose Natural C 9021 or M90 No > 10 ppm C 9021 XAP2 Yes < 2 ppm Impact Modified S 9243 No > 20 ppm S 9364 XAP2 Yes < 5 ppm Low wear, low noise C 9021 AW No > 20 ppm C 9021 AW XAP2 Yes < 5 ppm Colored grades C 9021 No > 50 ppm C 9021 XAP2 Yes < 5 ppm UV Stabilized colors UV90Z No > 50 ppm UV90Z XAP2 Yes < 5 ppm Metallic, UV colors LX90Z No > 30 ppm LX90Z XAP2 Yes < 5 ppm Low Gloss, UV colors UV140LG No > 30 ppm UV140LG XAP Yes < 10 ppm

28 VOC Reduction: A Pathway to Environmentally Friendly Interiors Component Supply Chain Eliminate Paint VOCs (and Plating) Colorability Metallics Vehicle Interior End of Life Reduce overall cabin VOCs UV Stability Low Gloss Recycle un-painted and un-chromed parts Colorable, UV Stabilized, Low Emission POM provides the pathway for Environmentally Friendly Interiors

29 Copyright 2014 Celanese or its affiliates. All rights reserved. This publication was presented on May 21, 2014 based on Celanese s present state of knowledge, and Celanese undertakes no obligation to update it. Because conditions of product use are outside Celanese s control, Celanese makes no warranties, express or implied, and assumes no liability in connection with any use of this information. Nothing herein is intended as a license to operate under or a recommendation to infringe any patents.