| The new Mercedes-Benz A-Class that was premiered
in September is said by DaimlerChrysler to be setting new standards in
terms of environmental protection with more than 40,000 individual processes
being analysed and optimised as part of the company’s integrated
environment analysis for the new A-Class. The overall assessment covers
a total of more than 200 “input” factors (resources) and some
300 “output” parameters (emissions).
Around 21 per cent of all
plastic components in the new A-Class can be produced from
high-quality recycled plastics – three times higher
than the outgoing model |
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A combination of technological innovations in the body, chassis and engine
design and advances in manufacturing processes allowed for the reduction
in the emissions generated through the production and use of the new A-Class.
Examples of these successful developments include the solvent-free powder
clearcoat, which protects the body, and the new or modified petrol engines.
The result is that nitrogen oxides are down 17 per cent, sulphur dioxide
is down by six per cent, volatile hydrocarbons are down by eight per cent
and special waste materials are down by 10 per cent. Primary energy consumption
also drops by around eight per cent, falling around 50 gigajoules below
the value of the outgoing A-Class which equates to the energy stored in
some 1,300 litres of petrol.
Environment-friendly product development has also led to the increased
use of recycling-friendly plastics and natural materials. Around 21 per
cent of all plastic components are produced from high-quality recycled
plastics – three times higher than for the outgoing A-Class. 26
components of the latest Mercedes model are made from renewable raw materials.
The Mercedes “Design for Environment” philosophy begins with
the selection of materials. Only materials boasting low consumption of
resources, outstanding recycling properties, a minimal energy requirement
and low emissions in their manufacturing, processing and use are permitted
in the construction of the Stuttgart-based brand’s passenger cars.
On this basis, the new A-Class already satisfies the recycling rate of
85 per cent stipulated Europe-wide from 2006 and is also set to meet the
recycling target of 95 per cent – with a maximum of 10 per cent
of the car parts being allowed to be utilised for incineration to produce
energy – planned for implementation in 2015.
The A-Class consists largely of materials for which recycling processes
have already been developed and tested – steel and iron-based materials
account for 65 per cent, plastics for 17 per cent and non-ferrous metals
and light alloys by seven per cent.
When it comes to preserving resources, Mercedes-Benz gives high-quality
secondary raw materials priority wherever possible. Mercedes experts have
had some positive experiences with the use of recycled plastics and are
committed to channelling plastics from end-of-life vehicles and scrapped
car parts back into the production of new vehicles. A total of 54 components
with a combined weight of 34 kg are made from high-quality recycled plastics
– equating to 21 per cent of all the plastic parts used. The number
of approved recycled components for the new car is therefore more than
three times higher than was the case for the outgoing model.
The development and production of car parts made from renewable raw materials
is another important part of preserving resources and of the Mercedes
“Design for Environment” philosophy. Mercedes-Benz sees the
use of natural materials as an important contribution to reducing carbon
dioxide emissions. After all, using renewable raw materials helps to put
the brakes on the consumption of traditional energy resources such as
coal, natural gas and petroleum.
In the new A-Class, 26 components with a combined weight of 23 kg have
been manufactured using natural materials. The combined weight of components
made from renewable raw materials has therefore risen by around 98 per
cent from the levels in the outgoing model. One example of the use of
natural materials in automotive construction is the covers for the front
seat backrests in the new A-Class, which consist of a combination of plastic
and flax fibres.
Mercedes engineers have also opted for a natural raw material to ensure
fuel tank venting, with olive wood used in the production of an activated
charcoal filter. This microporous material absorbs the hydrocarbon emissions
and is self-regenerating.
The latest tests carried out as part of DaimlerChrysler’s materials
research show that natural fibres are also extremely effective in material
composites. Indeed, they could even replace glass fibre as a strengthening
agent in plastic parts for car bodies due to their exceptional bending
and tensile strength. Natural fibres also stand out from glass fibres
with their lower weight, superior ease of use and suitability for recycling.
Another source of natural materials is the abaca plant which grows in
the Philippines. Its fibres, which are extremely elastic and boast impressive
tensile strength, are currently being tested for use in the manufacture
of part of the underfloor panelling of the new A-Class. Abaca fibres are
considered to be the strongest and longest natural fibres on the planet.
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