High-Tech GE Plastics Pave the Way to a Greener Chevrolet Volt
GE Plastics understands the tremendous pressures its automotive customers face with respect to developing fuel-efficient vehicles. GE’s resins and newest composite technologies are some of the key lightweight materials that helped GM to reduce mass on the Volt. These materials also allow for less fuel consumption, fewer carbon dioxide emissions, and improved overall performance.
Composites are typically used in the aerospace industry and on racecars due to their super lightweight structure and performance. GE Plastics, in partnership with Azdel*, Inc., premieres its own version of composites made with Xenoy iQ* resins on the Volt doors and hood. The composite addresses three critical environmental concerns: conserving energy, lowering greenhouse gas emissions, and up-cycling or regenerating post-consumer waste such as PET plastic bottles.
Amanda Roble, executive director for GE Plastics’ Automotive business stated, “On the Volt, the fender, window glazings, instrument panel and steering wheel can each offer from 30 to 50 percent weight reduction per part. Wire running throughout the Volt is made from non-halogenated GE plastics and reaches an approximate 25 percent weight reduction compared to traditional wire in automobiles.�' said Roble.
GreenOrder, an environmental strategy firm based in New York, N.Y. that audited the Volt claims, validated that if 3.2 million vehicles of 3,500 pounds were manufactured making use of GE Plastics’ weight reducing components, greenhouse gas emissions would be reduced by more than 194,000 tons each year - that is equivalent to the amount of carbon dioxide absorbed by over 48,000 acres of forest. It also is equal to more than 20 million gallons of oil that would have been conserved each year or over 30 Olympic size swimming pools or more than 470,000 barrels of oil.
Design Signature Surfaces
When it comes to improving fuel economy, even the most discreet design features can add up to significant fuel savings and improved safety. GE’s plastics enabled GM Design custom styling cues to differentiate the Volt from any other vehicle concept in the world.
"The overall solid shape, open-air roof, high beltline and powerful, crisp fender forms of the Volt are made possible only with GE design-enabling materials," said Bob Boniface, director of GM’s Warren Advanced Design Studio.
The transparent plastic window glazings instill a sense of openness, while allowing drivers 360 degrees of clear vision and improved safety. A scalloped hood, high shoulders, sinewy, and tight lines are made possible through select GE Plastics resins, allowing the GM designers to create exciting shapes and forms.
“The distinctive styling of the Volt was the result of allowing the GM design team to explore unique and elegant new possibilities made possible by GE's alternative materials,�' states Robert Butterfield, global market director for Design Innovation at GE Plastics’ Automotive business.
Leading-Edge Preventative Occupant and Pedestrian Safety Systems
GM’s challenge in designing the Volt was to make safety an aspirational aspect of the vehicle’s design and accordingly two key GE technologies have been employed. The first key occupant protection instrument panel system first premiered in the US in 2005 with GM, and its proven reliability is what makes it an integral part of the Volt cockpit. With active occupant protection to brace the front passenger, the automatically extending fragment free airbag deployment is designed to keep the passenger safe prior to an impending accident, to prepare both occupants and vehicle for a collision.
The second technology from GE is a global energy absorber designed to meet pedestrian safety regulations worldwide. GE Plastics energy absorbers allow the Volt to maintain aggressive vehicle styling architecture, and meet both North American (FMVSS/CMVSS) and European Union (Pedestrian Phase 2 of the Pedestrian Protection Directive) bumper impact legislations.
Chevrolet Volt Concept Sedan Specifications
Overview
| Model: | Chevrolet Volt Concept |
| Body style / driveline: | 4-5-passenger sedan, unitized frame, electric propulsion, front wheel drive |
| Construction: | body-frame-integral structure with composite exterior panels and roof |
| EPA vehicle class | compact car (four doors with rear liftgate) |
Drive system
| Description: | electrically driven system with onboard range extender, plug-in recharge capability |
| Battery system: | |
| Type: | lithium-ion |
| Energy: | 16 kWh (minimum) |
| Peak power: | 130 to 140 kW |
| Voltage: | 320 to 350 |
| 100% recharge time: | |
| 110-volt outlet: | 6 to 6.5 hours |
| Electric traction system: | |
| Max. electrical power: | 130 to 140 kW |
| Max. mechanical power: | 120 kW |
| Continuous electrical power: | 45 kW |
| Continuous mechanical power: | 40 kW |
| Generator: | |
| Power: | 53 kW peak power |
| Drive: | direct |
| Range extender: | |
| Type: | 3-cylinder, turbocharged engine |
| Size: | 1L |
| Fuel: | gas or E85 |
| Nominal speed: | 1500 to 1800 rpm |
| Max speed: | 3200 rpm |
| Fuel tank (gal / L): | 12 / 54.5 |
| Charger: | |
| Type: | plug-in |
| Voltage / amp: | 110 / 15 |
| Horsepower (hp / kW): | 160 / 120 |
| Torque (lb-ft / Nm): | 236 / 320 |
| Electric mode range: | 40 miles – full electric vehicle (EV) range |
| Estimated fuel economy @ constant state of charge: | 50 mpg during charge sustaining operation |
| Daily usage equivalent mpg: | |
| @ 40 miles or less: | not applicable – no fuel used |
| @ 60 miles: | 150 mpg |
| @ 80 miles: | 100 mpg |
| 0 to 60 mph: | 8 to 8.5 seconds |
| Top speed (mph) | 120 (limited duration) |
Chassis/Suspension
| Front: | independent, strut-type |
| Rear: | semi-independent torsion beam |
| Steering type: | electric, speed-sensitive, variable assist rack-and-pinion |
| Turning circle, curb-to-curb (ft / m): | 37 to 38 / 11.2 to 11.5 |
Brakes
| Type: | electro-hydraulic power assisted; front disc, rear drum |
Wheels/Tires
| Wheel size (in): | 21 x 6.5 |
| Tires: | 195/55R21, low-rolling resistance |
Dimensions
Exterior
| Overall length (in / mm): | 170 / 4318 |
| Height (in / mm): | 52.6 / 1336 |
| Width (in / mm): | 70.5 / 1791 |
Interior
| Seating capacity (front / rear): | 2 / 2 |
| Headroom (in / mm): | front: 37.3 / 947 rear: 35.9 / 912 |
| Legroom (in / mm): | 31.5 / 802 |
| Shoulder room (in / mm): | 50.6 / 1285 |
| Hip room (in / mm): | 53.1 / 1349 |
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