GE Helps Volvo Reduce Carbon Emissions Inside the S40 Sedan for a Cleaner, More Pleasant Cabin Climate

That traditional new-car smell – a signature aspect of a vehicle purchase – may not be such a good thing after all. Interior odors, caused by off-gassing of volatile organic compounds (VOC) from plastics and other materials – can irritate some individuals. In addition, off-gassing of carbon can result in a film build-up of on the inside of the windshield. As part of its ongoing program to reduce interior emissions, Volvo Car Corporation sought new materials that could minimize odors in its S40 sedan.

GE Plastics and Volvo Car Corporation

The Challenge: Improving the Consumer Experience with Reduced Cabin Emissions

Volvo Car Corporation has been proactive in reducing chemicals, including polybrominated diphenyl ethers (PDBEs) (flame retardants) and phthalates (plasticizers), given off in the interiors of its vehicles. In fact, the Ecology Group ranked Volvo as the industry leader in terms of indoor air quality. Volvo is focusing on reducing these off-gassing emissions because they can irritate some vehicle occupants. From an aesthetic standpoint, off-gassing of chemicals can lead to an unattractive, hazy film on interior window surfaces.

When the company was designing its 2004 S40 sedan, which is manufactured in Belgium and exported worldwide, a decision was made to find a material for molding interior trim, pillars, and panels that could offer reduced carbon emissions. Specifically, the automaker lowered the acceptable level from 100 to 40 micrograms/gram of resin. In addition to lower emissions, Volvo required good impact and low-temperature resistance, and the ability to custom-color the resin.

Volvo tested a number of general-purpose materials including many acrylonitrile-butadiene-styrene (ABS) resins but could not identify anything that met its emission specifications. Based on a long-standing relationship with GE Plastics, Volvo asked GE for a specialty resin that could meet its stringent requirements.

The Solution: GE’s Cycolac* DL100 Resin for Low Emissions

GE Plastics recommended its Cycolac DL100 ABS resin, a high-heat specialty grade, engineered to deliver exceptionally low emissions. GE Plastics had developed the Cycolac resin in anticipation of requirements for lower emissions.

GE’s high-heat Cycolac grades excel in automotive interiors, where they provide superb materials solutions for dashboards, door trim, pillars, and other interior elements. Cycolac DL100 resin also met Volvo’s other requirements: it provides good impact resistance, good low-temperature ductility, excellent processability, and high gloss. It can be color-matched.

GE Plastics’ Customer Innovation Center in Bergen op Zoom, the Netherlands, handled the color-matching process, which utilized a three-point blending technique for exceptional accuracy.

GE also worked closely with Volvo’s Tier 1 suppliers of the more than 30 interior parts that were injection molded from Cycolac resin. Volvo also used GE’s Cycoloy* in the upper compartment due to its high processability and good cold and head impact behavior.

The Benefits: Emissions Cut from 100 to 40 Micrograms/Gram

Through the extensive use of GE Cycolac DL100 resin in the S40 sedan’s interior, Volvo was able to meet its target: reducing carbon emissions from about 100 micrograms/gram of resin to less than 40 micrograms/gram. This represented a reduction of 60 percent. Lower emissions help improve the cabin climate, making it more pleasant due to reduced odor, and cleaner due to reduced carbon deposits.

We tested many types of ABS resin but GE’s Cycolac resin met our stringent emissions standard,” said Anders Löfvendahl, Attribute Leader Environment, Volvo Car Corporation. “With our conversion to Cycolac resin, we are able to offer our customers an interior environment that is cleaner and virtually odor-free for an improved driving experience.”

Details at: www.volvocars.com