Car Interior Material Testing (CIMT) Air Quality Seminar Dr. Lutz Mayer
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Car Interior Material Testing (CIMT) Emission and Material Testing of Interior Materials and Parts: Test Methods – Chances & Benefits Air Quality Seminar May, 2007 University of Warwick Dr. Lutz Mayer 1 AGENDA 1 When you need to be sure – SGS an overview 2 Automotive Services 3 CIMT – Car Interior Material Testing Dr. Lutz Mayer; lutz.mayer@sgs.com 2 SGS in words and figures • • • Dr. Lutz Mayer; lutz.mayer@sgs.com • 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 3 SGS – 127 years of competence inspection testing • Inspection, verification, testing and certification – SGS SA is the world‘s leading company within these fields • We compare and analyze commodities, products and services, complex technical methods as well as business systems certification Dr. Lutz Mayer; lutz.mayer@sgs.com verification 4 Business Segments of SGS and INSTITUT FRESENIUS Agricultural Services Automotive Services Minerals Services Dr. Lutz Mayer; lutz.mayer@sgs.com Consumer Testing Services Oil, Gas & Chemicals Services Environmental Services Systems and Services Certification Industrial Services Technical Staffing Services Life Science Services Trade Assurance Services 5 SGS – Our Guiding Principles Independence and neutrality We don‘t engange in manufacturing nor do we have trading interests SGS Code of Integrity and Professional Conduct The commitment of our employees as guarantee of absolute confidentiality concerning all information Best in class QS/QM certification Accreditation and certification according to highest standards Dr. Lutz Mayer; lutz.mayer@sgs.com 6 2 SGS Automotive Services Dr. Lutz Mayer; lutz.mayer@sgs.com 7 SGS Automotive Services, Germany Automotive Services Matthias Popp CTS Car Interior Material Testing (CIMT) Lutz Mayer, PhD CTS Failure Analysis Olaf Günnewig, SGS Automotive SGS OGC / Automotive services SGS ICS / Automotive services Christian Naumann Bernd Schwarz Sven Schirmer PhD Dr. Lutz Mayer; lutz.mayer@sgs.com 8 3 CIMT – Car Interior Material Testing Dr. Lutz Mayer; lutz.mayer@sgs.com 9 Locations Rostock Wilhelmshaven HAMBURG Bremen Berlin Hannover Herten Dortmund Dresden Taunusstein Sulzbach Speyer Taunusstein: Headquarter, Bioanalytics, Special Analytics, Mineral Waters, Beverages Berlin: Dresden: Dortmund: Pharma, Waste Microelectronic Business Line Automotive Failure&Damage Analysis – Mechanical tests Water, Waste Water, Soil CTS Automotive Car Interior Material Testing München Herten: Dr. Lutz Mayer; lutz.mayer@sgs.com 10 HIGH-TECH-ANALYTIC Investment: Since 2003: 4.250.000 Euro Central Lab: Individual logistical ways Soil Drinking water Waste water Automotive Dr. Lutz Mayer; lutz.mayer@sgs.com 11 HIGH-TECH-ANALYTICS Staff: 2006: 75 employees Benchmarks: > 900 samples per day > 500 parameters Conc. ≥ 0,001µg/kg (ppt) Dr. Lutz Mayer; lutz.mayer@sgs.com 12 Development of Division Car Interior Material Testing (CIMT) CTS Automotive/Herten 1996 ......... Accreditation by DaimlerChrysler 1997 ......... Start up of commercial testings 2000 ......... Modernization & Extension of technical equipment (2nd production line) 2002 ......... Recommendation by VW, VOLVO, SAAB 2003 ......... Recommendation by BMW, Porsche 2004 ......... Accreditation by Toyota (only two institutes in Europe) 2004 ......... First IF department with flexible accreditation acc. DIN 17025 2004 ......... Implementation of chamber tests: weathering test, hot light fastness, hot light ageing, Emission Test Chamber 2005 ......... Reaccreditation by TOYOTA 2005 ......... Implementation of sun tests/solar climatic tests resistance test 2006 ......... Reaccreditation acc. DIN 17025; flexible test fields: emission and material tests 2006 ......... Extension of technical equipment: TDS/GC/MS (3rd production line) 2007 …….. 2nd emission test chamber, 1.5 m³ weathering test chamber Dr. Lutz Mayer; lutz.mayer@sgs.com 13 Description of the market for CIMT CIMT is accredited/ recommended by BMW DaimlerChrysler GM Porsche Toyota Volvo VW Group Most approvals in the European market. OEM Automotive system suppliers Tier 1 Automotive suppliers Tier 2 – 3 (current number of clients > 450) Dr. Lutz Mayer; lutz.mayer@sgs.com 14 Market mechanism: Top sales down approach Test Results Accepted only by recommended labs Tier 1 - 3 OEM Specifications List of test labs Test Results Recommendation/ Accreditation Dr. Lutz Mayer; lutz.mayer@sgs.com Car Interior Material Testing SGS INSTITUT FRESENIUS GmbH CTS Automotive / Herten Materials/ Parts 15 Business Relationships Locations of the CIMT clients Revenue Germany 66% Europe/WW 33% > 450 clients in more than 30 countries Dr. Lutz Mayer; lutz.mayer@sgs.com number of samples in 2006 5.912 in about 15.000 investigations 16 CIMT: Fields of testing (extract) test materials: all non-metallic materials, including foam, plastic, lacquer, fabrics, leather, rubber etc. Emission testings Material testings Odour UV, Colour stability VOC of materials, composites Hot light fastness FOG of materials, composites Determination of hazardous substances The emission test lab with the highest amount of VOC tests in Europe. Hot light ageing, warm ageing Weathering, Solar simulation Climatic stress test Burning behaviour Resistance tests Total number of methods: 120 according to OEM STD: 90 according to VDA/DIN/EU: 30 Dr. Lutz Mayer; lutz.mayer@sgs.com 17 Emission Testings Requirement: 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 substances Benefits: Odour ranking Detection of VOC/FOG sources Reduction of hazardous substances – health care More legal certainty regarding liability Technical approval – entrance on restricted market (US CARB) 77 accredited test methods – ISO 17025 and by OEM – high acceptance Dr. Lutz Mayer; lutz.mayer@sgs.com 18 Odour Testings TSM 0505 G VDA 270 Dr. Lutz Mayer; lutz.mayer@sgs.com 19 Odour Testings TSM 0505 G Dr. Lutz Mayer; lutz.mayer@sgs.com 20 Definitions Emissions VOC FOG Emissions (under the influence of heat) are differentiated into VOC & FOG VOC: Volatile Organic Compounds FOG: all fogging substances which condense on surfaces and form coatings primarily on windscreens and rear windows Dr. Lutz Mayer; lutz.mayer@sgs.com 21 Fogging Testings DIN 75201 A & B PV 3015 Volvo VCS 1027, 2719 Renault / PSA D45 1727 etc. Dr. Lutz Mayer; lutz.mayer@sgs.com 22 Emission Testings DIN 75201 A & B reflectometric & gravimetric fogging test Result determination of 60° - reflectory data against cleaned glass or weight of foil before and after the test G / mg Advantages influence of fogging on windows (reflexes, etc.) quantity of fogging (T)FOG Dr. Lutz Mayer; lutz.mayer@sgs.com Disadvantages no information about substances additional tests required 23 Emission Testings Headspace GC/FID VDA 277/PV 3341/Volvo VCS 1027, 2749 Dr. Lutz Mayer; lutz.mayer@sgs.com 24 Emission Testings VDA 277/PV 3341/Volvo VCS 1027, 2749 Dr. Lutz Mayer; lutz.mayer@sgs.com 25 Emission Testings VDA 277/PV 3341/Volvo VCS 1027, 2749 Result Total carbon emission in µg C/g (µg carbon per g sample) Advantages Quantification TVOC Determination of individual substances is possible Disadvantages No differentiation between VOC & FOG High temperature for a long time: pyrolysis possible Additional high-effort steps needed to determine individual substances Dr. Lutz Mayer; lutz.mayer@sgs.com 26 TDS/GC/MS VDA 278 Dr. Lutz Mayer; lutz.mayer@sgs.com 27 TDS/GC/MS VDA 278 Desorption conditions VOC 90 °C FOG 120 °C Dr. Lutz Mayer; lutz.mayer@sgs.com 28 Emission Testings VDA 278 Result VOC & FOG in ppm (mg/kg) in toluene or hexadecane equivalents Advantages VOC & FOG as single parameter Coupled with GC/MS: identification of single substances Quantification Low temperatures (no pyrolyzing) Dr. Lutz Mayer; lutz.mayer@sgs.com Disadvantage Analyzing composites only under additional expense possible 29 Toyota Test Methods provided by CIMT TSM 0500 G Burning behaviour TSM 0503 G Fogging test according to method b TSM 0505 G Odour test with qualification TSM 0508 G Currently: Cooperation between Toyota Europe and SGS Institut Fresenius GmbH VOC test by using Tedlar bags TSM 0509 G VOC test by using TDS and HPLC VDA 276 Dr. Lutz Mayer; lutz.mayer@sgs.com 30 TDS (Toyota): Volatile Hydrocarbons Dr. Lutz Mayer; lutz.mayer@sgs.com 31 TDS (Toyota) : Volatile Hydrocarbons Dr. Lutz Mayer; lutz.mayer@sgs.com 32 DNPH (Toyota): Aldehydes and Ketones Dr. Lutz Mayer; lutz.mayer@sgs.com 33 TOYOTA TSM 0509G Dr. Lutz Mayer; lutz.mayer@sgs.com 34 Emission Test Chamber VCE 1000 GS 97014 - 2/ -3 • C total: TVOC • Screening (Carbotrap/TDS) • BTXE/S • Aldehydes, ketones, amines • N-nitrosoamine • Phthalic acid esters • Fogging US Carb Test PPV 4050 - Circular VDA 276 Part 1 • C total: TVOC • BTXE/S • Aldehydes, ketones • Fogging Dr. Lutz Mayer; lutz.mayer@sgs.com VDA 276 Part 2 • Ammonia • Formaldehyde • Phenol 35 Emission Test Chamber VCE 1000 Range of Specimens Dr. Lutz Mayer; lutz.mayer@sgs.com 36 Thank you for your attention! SGS INSTITUT FRESENIUS GmbH Am Technologiepark 10 · D-45699 Herten Telefon: +49 (0)2366 305 – 645 Telefax: +49 (0)2366 305 - 611 Internet: www.sgs-auto.com E-Mail: lutz.mayer@sgs.com Dr. Lutz Mayer; lutz.mayer@sgs.com 37
