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Emission and Material Testing ofInterior Materials and Parts:
Test Methods – Chances & Benefits
Air Quality Seminar May, 2007
University of Warwick
Dr. Lutz Mayer
Car Interior Material Testing(CIMT)
2Dr. Lutz Mayer; [email protected]
AGENDA
When you need to be sure – SGS an overview1
2
3 CIMT – Car Interior Material Testing
Automotive Services
3Dr. Lutz Mayer; [email protected]
SGS in words and figures
• Founded in 1878• 48,000 employees worldwide• Global network of about 1,000
laboratories and offices around the world• Revenue 2006: 2,414 billion EUR
• Active in Germany since 1920• 1,600 employees nationwide• 30 locations in Germany
4Dr. Lutz Mayer; [email protected]
SGS – 127 years of competence
• We compare and analyze commodities, products and services, complex technical methods as well as business systems
inspection testing
certification verification
• Inspection, verification, testing and certification – SGS SA is the world‘s leading company within these fields
5Dr. Lutz Mayer; [email protected]
Business Segments of SGS and INSTITUT FRESENIUS
AgriculturalServices
AutomotiveServices
Environ-mental
Services
ConsumerTesting
Services
IndustrialServices
Oil, Gas & ChemicalsServices
TechnicalStaffingServices
Systems and Services
Certification
MineralsServices
Life ScienceServices
Trade AssuranceServices
6Dr. Lutz Mayer; [email protected]
SGS – Our Guiding Principles
SGS Code of Integrity and Professional ConductThe commitment of our employees as guarantee of absolute confidentiality concerning all information
Best in class QS/QM certificationAccreditation and certification according to highest standards
Independence and neutralityWe don‘t engange in manufacturing nor do we have trading interests
8Dr. Lutz Mayer; [email protected]
SGS Automotive Services,Germany
CTS Car Interior Material Testing (CIMT)
Lutz Mayer, PhD
CTS Failure Analysis
Olaf Günnewig, PhD
Automotive ServicesMatthias Popp
SGS OGC / Automotive services
Bernd Schwarz
SGS Automotive
Christian Naumann
SGS ICS / Automotive services
Sven Schirmer
10Dr. Lutz Mayer; [email protected]
Dresden
Sulzbach
HAMBURG
Rostock
Hannover
Berlin
Bremen
Speyer
Wilhelmshaven
München
HertenDortmund
Taunusstein
Locations
Taunusstein: Headquarter, Bioanalytics, Special Analytics, Mineral Waters, Beverages
Berlin: Pharma, WasteDresden: MicroelectronicDortmund: Business Line Automotive
Failure&Damage Analysis –Mechanical tests
Herten: Water, Waste Water, SoilCTS Automotive Car Interior Material Testing
11Dr. Lutz Mayer; [email protected]
HIGH-TECH-ANALYTIC
Central Lab: Individual logistical waysSoilDrinking waterWaste waterAutomotive
Investment:
Since 2003: 4.250.000 Euro
12Dr. Lutz Mayer; [email protected]
HIGH-TECH-ANALYTICS
Benchmarks: > 900 samples per day> 500 parametersConc. ≥ 0,001µg/kg (ppt)
Staff:
2006: 75 employees
13Dr. Lutz Mayer; [email protected]
Development ofDivision Car Interior Material Testing (CIMT)
CTS Automotive/Herten
1996 ......... Accreditation by DaimlerChrysler1997 ......... Start up of commercial testings2000 ......... Modernization & Extension of technical equipment (2nd production line)2002 ......... Recommendation by VW, VOLVO, SAAB2003 ......... Recommendation by BMW, Porsche2004 ......... Accreditation by Toyota (only two institutes in Europe)2004 ......... First IF department with flexible accreditation acc. DIN
170252004 ......... Implementation of chamber tests: weathering test,
hot light fastness, hot light ageing, Emission Test Chamber2005 ......... Reaccreditation by TOYOTA2005 ......... Implementation of sun tests/solar climatic tests
resistance test2006 ......... Reaccreditation acc. DIN 17025; flexible test fields: emission and
material tests2006 ......... Extension of technical equipment: TDS/GC/MS (3rd production line) 2007 …….. 2nd emission test chamber, 1.5 m³ weathering test chamber
14Dr. Lutz Mayer; [email protected]
Description of the market for CIMT
OEM
Automotive system
suppliersTier 1
Automotive suppliers Tier 2 – 3
(current number of clients > 450)
CIMT is accredited/ recommended byBMWDaimlerChryslerGMPorscheToyotaVolvoVW Group
Most approvals in theEuropean market.
15Dr. Lutz Mayer; [email protected]
Market mechanism:Top sales down approach
OEM Tier 1 - 3
Car Interior Material Testing
SGS INSTITUT FRESENIUS GmbHCTS Automotive / Herten
Specifications
List of test labs
Recommendation/ Accreditation
Test Results
Accepted only byrecommended labs
Materials/ Parts
Test Results
16Dr. Lutz Mayer; [email protected]
Business RelationshipsLocations of the CIMT clients
Revenue Germany 66% Europe/WW 33%> 450 clients in more than 30 countries
number of samples in 2006
5.912 in about 15.000 investigations
17Dr. Lutz Mayer; [email protected]
CIMT: Fields of testing (extract)test materials: all non-metallic materials, including foam, plastic, lacquer, fabrics,
leather, rubber etc.
Odour
VOC of materials, composites
FOG of materials, composites
Determination of hazardous substances
UV, Colour stability
Hot light fastness
Hot light ageing, warm ageing
Weathering, Solar simulation
Climatic stress test
Burning behaviour
Resistance tests
Emission testings Material testings
Total number of methods: 120according to OEM STD: 90
according to VDA/DIN/EU: 30
The emission test lab with thehighest amount of VOC tests in
Europe.
18Dr. Lutz Mayer; [email protected]
Emission TestingsRequirement: reduction of emission(odour, VOC, FOG)Solution: odour and emission tests
Odour characterization, VOC, FOG
Test samples: all kind of materials, composites up to parts/systems (e.g. seats, door panel, instrument panel)
Detection of hazardous substancesBenefits:
Odour rankingDetection of VOC/FOG sourcesReduction of hazardous substances –health careMore legal certainty regarding liabilityTechnical approval – entrance on restricted market (US CARB)77 accredited test methods – ISO 17025 and by OEM – high acceptance
21Dr. Lutz Mayer; [email protected]
Definitions
Emissions (under the influence of heat) are differentiated into VOC & FOGVOC: Volatile Organic CompoundsFOG: all fogging substances which condense on surfaces and form coatings primarily on windscreens and rear windows
VOC FOG
Emissions
22Dr. Lutz Mayer; [email protected]
Fogging Testings
DIN 75201 A & B
PV 3015Volvo VCS 1027, 2719Renault / PSA D45 1727 etc.
23Dr. Lutz Mayer; [email protected]
influence of fogging on windows (reflexes, etc.)quantity of fogging (T)FOG
no information about substancesadditional tests required
Resultdetermination of 60° - reflectory data against cleaned glass orweight of foil before and after the test G / mg
DIN 75201 A & Breflectometric & gravimetric fogging test
Emission Testings
Advantages Disadvantages
24Dr. Lutz Mayer; [email protected]
Emission Testings
Headspace GC/FIDVDA 277/PV 3341/Volvo VCS 1027, 2749
26Dr. Lutz Mayer; [email protected]
Quantification TVOCDetermination of individual substances is possible
No differentiation between VOC & FOGHigh temperature for a long time: pyrolysis possibleAdditional high-effort steps needed to determine individual substances
Result
Total carbon emission in µg C/g (µg carbon per g sample)
VDA 277/PV 3341/Volvo VCS 1027, 2749
Emission Testings
Advantages Disadvantages
29Dr. Lutz Mayer; [email protected]
VOC & FOG as single parameterLow temperatures (no pyrolyzing)Coupled with GC/MS: identification of single substancesQuantification
Analyzing composites only under
additional expense possible
VDA 278
Result
VOC & FOG in ppm (mg/kg) in toluene or hexadecane equivalents
Emission Testings
Advantages Disadvantage
30Dr. Lutz Mayer; [email protected]
Toyota Test Methodsprovided by CIMT
TSM 0500 GBurning behaviourTSM 0503 GFogging test according to method bTSM 0505 GOdour test with qualificationTSM 0508 GCurrently: Cooperation between Toyota Europe and SGS Institut Fresenius GmbHVOC test by using Tedlar bagsTSM 0509 GVOC test by using TDS and HPLCVDA 276
35Dr. Lutz Mayer; [email protected]
US Carb Test
PPV 4050- Circular
VDA 276 Part 1• C total: TVOC• BTXE/S• Aldehydes, ketones• Fogging
VDA 276 Part 2• Ammonia• Formaldehyde• Phenol
GS 97014 - 2/ -3• C total: TVOC• Screening (Carbotrap/TDS)• BTXE/S• Aldehydes, ketones,amines
• N-nitrosoamine• Phthalic acid esters• Fogging
Emission Test Chamber VCE 1000
37Dr. Lutz Mayer; [email protected]
Thank you for your attention!
SGS INSTITUT FRESENIUS GmbH
Am Technologiepark 10 · D-45699 HertenTelefon: +49 (0)2366 305 – 645Telefax: +49 (0)2366 305 - 611
Internet: www.sgs-auto.comE-Mail: [email protected]
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