Delphi Builds Extensive 'Green' Product Portfolio
19 April 1999
Delphi Builds Extensive 'Green' Product Portfolio
New Application for TPO Skin, Continued Leadership in Catalytic Converters
Highlight Delphi's Portfolio of Environmentally Friendly Products
TROY, Mich., April 19 -- Delphi Automotive Systems
, the manufacturer of the first vertically integrated thermoplastic
olefin (TPO) skin vehicle instrument panel, announced today that it will
extend the usage of TPO, a 100-percent recyclable plastic material, to other
interior products in its portfolio.
The new application expands Delphi's extensive portfolio of "green"
products designed to reduce emissions and increase recyclability.
Last fall, Delphi became the first North American manufacturer to use TPO
skin in an instrument panel application, when its Matamoras manufacturing
facility in Mexico began production of the material for the modular cockpit
Delphi supplies to the Mercedes-Benz M-Class program in Alabama, USA.
Delphi's scientists developed the material in conjunction with Mercedes-Benz
and Mytex Polymers.
Delphi's TPO is the first in the industry with a water-based primer and
topcoat system; this means reduced volatile organic compound (VOC) emissions.
According to Norm Kakarala, advanced development research scientist at the
Delphi Interior Systems Engineering Center in Troy, Mich., "Delphi has also
validated closed loop recycling for its TPO usage, which helps us approach
100-percent material utilization."
At the same time that Delphi is expanding the usage of TPO skin, the
company is aggressively reducing scrap at each of its facilities and
concentrating effort to regrind scrap material and reuse them in its products.
There also is a large market from reclaimers for polypropylene-based products
from end-of-life vehicle recycling.
"Delphi's development of recyclable TPO skin for instrument panels and
current efforts to expand its usage in other products are excellent examples
of Delphi's commitment to provide simplified solutions for our customers,"
said Rodney O'Neal, vice president of Delphi Automotive Systems and president
of Delphi Interior Systems. "I am proud that these efforts will help improve
the environment for everyone."
CATALYTIC CONVERTERS LEAD DELPHI'S "GREEN" PRODUCT PORTFOLIO
Delphi has a long history of introducing environmentally friendly
products. One of Delphi's most successful "green" products ever is its
catalytic converters, which are designed to remove the great majority of
pollutants from engine exhaust streams.
Delphi has manufactured 130 million catalytic converters since introducing
the product on 1975-model passenger cars and trucks. During that time, Delphi
engineers estimate that Delphi emissions control technology has cleaned
automotive exhaust streams in the United States of nearly 42 million tons of
hydrocarbons, about 195 million tons of carbon monoxide, and at least 37
million tons of oxides of nitrogen.
Delphi further makes clean air through a complete emissions control
system, including: early fuel evaporation systems, which heat intake
manifolds to help vaporize fuel and lower hydrocarbon and carbon monoxide
emissions during a cold start; exhaust gas recirculation systems, which lower
temperatures in the combustion chamber and reduce formation of oxides of
nitrogen; exhaust oxygen sensors which measure and control the air fuel
mixture of the engine to minimize exhaust emissions; air meters, which
precisely measure air flowing into an engine; positive crankcase ventilation
valves, which control hydrocarbon emissions from the crankcase; and
evaporative canisters to capture fuel vapors.
These products offer lower emissions, better fuel economy, improved
vehicle performance and smooth driveability -- all at the same time.
OTHER "GREEN" PRODUCT HIGHLIGHTS
Other highlights of Delphi's "green" product portfolio include:
E(TM) Steer(TM) Electric Power Steering. While recyclability of products
is important, Delphi also believes that the reduction or elimination of
materials goes even farther in helping the environment. With no fluid, no
hoses, no pump and fewer seals, Delphi's E-Steer Electric Power Steering means
a significant reduction in raw material -- which means less material to
recycle, dispose or landfill after the life of the product.
The significance of this can be seen through a study of 1995 vehicle
production, when traditional power steering was on 75 percent of all cars sold
globally. "Those 37 million cars carried an estimated 10 million gallons (or
40 million liters) of hydraulic fluid in their steering systems," said Dan
Crishon, director, Delphi E-Steer global manager.
The fluid was enough to fill 500 average swimming pools, Crishon said.
E-Steer, which is a fully electric power steering system, eliminates the
fluid. E-Steer also eliminates the extensive seals found on the traditional
gear and pump, replacing them with an environmental seal that uses less
material.
Non-Azide/Hybrid Airbag Inflators. Due to environmental concerns, Delphi
no longer sources inflators using the traditional sodium azide. While
effective in producing the inert nitrogen gas necessary to fill the airbag,
sodium azide is a toxic substance and cannot be recycled. Delphi now sources
all new programs with nonazide or hybrid inflators, which use organic gas
generants. Organic propellants and residues from deployment are non-toxic.
Once deployed, the steel-constructed inflator is recycled.
Airbag Cushion Materials. Delphi recycled 1.2 million pounds of nylon
fabric last year from cutting offal and scraps. Traditional airbag fabrics
are coated with neoprene or silicone. While these materials decrease the
cushion's gas permeability, they're not recyclable with nylon. Uncoated
airbag cushions can be recycled because both the cushion fabric and the thread
used to sew the cushions are nylon. Last year, 74 percent of Delphi's airbag
fabric (by yardage) used was uncoated nylon fabric.
Urethane Steering Wheel Manufacture. Since 1992, Delphi has reduced the
number of VOCs (Volatile Organic Compounds) associated with the manufacture of
urethane steering wheels by more than 90 percent. Delphi accomplished this by
reducing the amount of foam blowing agent, eliminating solvent for cleaning
inserts and molds, and by converting to water based paint. Further reductions
in VOC's are being investigated through the conversion to waterbase mold
release and waterblown foam.
Three significant Delphi "green" technologies under development include:
Advanced Energy Systems, Energen(TM). Delphi's Energen technology
provides optimized generation, conversion, storage and distribution of
electrical energy for individual vehicle requirements. Energen combines
electrical power with engine-based power to improve performance and lower fuel
consumption. It also provides higher electrical power to meet the increased
demands needed for electrical valve trains, satellite communications, multi-
zone climate control, heated seats, on-board computers, and even electric
propulsion.
Advanced Engine Management Systems. Greater fuel economy, reduced
dependency on fossil fuels and reduced emissions are issues challenging
vehicle manufacturers around the world. To simplify the solution, Delphi has
developed comprehensive system solutions which address these challenges for
vehicle platform needs globally. Delphi's advanced engine management system
features a "building block" approach that uses modular systems architecture,
rapid algorithm development tools, and model-based controlled algorithms.
Then, depending on the OEM requirements, Delphi will be able to add off-the-
shelf interchangable hardware and "plug-and-play" software modules so that
recalibration work will be kept to a minimum.
Alternative Fuel-Handling Systems. To meet the demand for wider use of
alternative fuels, Delphi has been producing methanol- and ethanol-tolerant
fuel handling systems for racing cars, for test fleets in California and other
states, and for the Brazilian market.
Delphi Automotive Systems, with headquarters in Troy, Mich., USA, is a
world leader in automotive component and systems technology. Delphi's three
business sectors -- Dynamics & Propulsion; Safety, Thermal & Electrical
Architecture; and Electronics & Mobile Communications -- provide comprehensive
product solutions to complex customer needs. Delphi has more than 200,000
employees and operates 168 wholly owned manufacturing sites, 40 joint ventures
and 27 technical centers in 36 countries. Regional headquarters are located
in Paris, Tokyo and Sao Paulo. Delphi can be found on the Internet at
http://www.delphiauto.com.