The bioeconomy at work: Johnson Controls introduces lightweight bio-composite headliner that improves fuel economy
Johnson Controls announces that it has unveiled a new bio-composite headliner that is lightweight and doesn't cost more than traditional headliners made from petroleum-based thermoplastics. The Ecobond headliner is in the final stages of development and is comprised of 50 percent biomaterials by mass. The green product fully meets customer requirements for strength, performance and acoustics. The headliner proves that renewable, biobased products can be competitive with and more efficient than oil based products. Its low weight improves vehicles' fuel economy.
Johnson Controls is showcasing the Ecobond headliner at the company's 2008 North American International Auto Show exhibit in room D2-15 of Detroit's Cobo Center.
Natural materials - including hemp, flax and kenaf - replace the fiberglass that is traditionally used in headliner production. Finally, a soy-based urethane is used to bond materials and create a semi-rigid product. The Ecobond headliner satisfies customers' design requirements for stiffness, toughness and acoustics. It also is lighter than standard thermoplastic headliners. Using the new Ecobond approach is not expected to add costs to the headliner production process:
energy :: sustainability ::biomass :: bioenergy :: biofuels :: bio-products :: efficiency :: renewable :: bioplastics :: biopolymers :: bio-composites :: natural fibers :: bioeconomy ::
By utilizing soy and other abundant and renewable plant-based materials, Johnson Controls is working to fulfill its sustainability goals, with initiatives that benefit its customers, the general public and future generations. Other earth-friendly products from Johnson Controls include EcoCore natural-fiber door panels, as well as soy-based seating pads, which will be featured on numerous 2008 model-year vehicles.
The new headliner joins the long list of bio-based products that are finding applications in the automotive sector. To name just a few: durable bioplastic fuel lines that can handle aggressive biodiesel (earlier post), almost-entirely-oil-free biopolymer car tires, car seat foams made from soybeans, bamboo-fibre reinforced bioplastic interior parts for car cabines, high-strength heat-resistant bioplastics similar to polypropylene for demanding car parts, and so on. Even such a key component as a methane storage tank for CNG cars doesn't escape the bioeconomy: researchers recently developed a highly efficient one from corn cobs (previous post).
Biopolymers and bioplastics made from sugarcane and maize are also used in Toyota's futuristic i-Unit; the renewable plastics are reinforced with plant fibers from the African kenaf plant, held together by lignin, a natural polymer found in wood.
Several projects are even underway to build entire 'bio-cars' that are almost fully biodegradable and that can be 'grown', so to speak: one such project was launched recently in Canada, whereas in the US a conglomerate of research organisations is working on a similar 'AgriCar', which will be made out of bio-based products for 90%. Bioplastics, biopolymers, biocomposites, biolubricants, biofuel-cells, and biofuels are coming together in the cars of the future. Or even of the present: researchers at the University of Warwick recently presented their first environmentally-friendly racing car that contains a large number of bio-components: tyres made from potatoes, a cabin from bio-composites and brake pads from cashew nut shells (more here).
Recently, researchers found that the most important bulk chemicals used to make car components and thousands of other products, can be obtained from biomass. Interestingly, they showed that in several cases it might be more efficient to use land to grow crops for such green chemicals than to keep it for biofuels. The production of such bio-products represent an opportunity to reduce global greenhouse gas emissions in a major way, they found (previous post).
Photo: blooming kenaf plantation in the US 'Cotton Belt'. The crop has been grown for decades for the different types of fibers found in its stalks. It is currently undergoing a revival because of growing interest into bio-based, renewable products. Kenaf fibers replace glass fibers in Johnson Control's new headliner.
References:
Johnson Controls: Johnson Controls Unveils 'Earth-Friendly' Automotive Headliner - Comprised of 50 Percent Plant-Based Material - at Detroit Auto Show - January 15, 2008.
Biopact: Researchers find bio-based bulk chemicals could save up to 1 billion tonnes of CO2 - December 17, 2007
Johnson Controls is showcasing the Ecobond headliner at the company's 2008 North American International Auto Show exhibit in room D2-15 of Detroit's Cobo Center.
The Ecobond headliner is made from natural fibers instead of glass, making the final product a lightweight, bio-based product, which can help increase fuel economy and reduce carbon emissions, and is easier to recycle at the end of the vehicle's useful life. - Byron Foster, North American interiors business director of Johnson ControlsThe production process for the Ecobond headliner relies on soy-based adhesives, a soy-based urethane core foam, and natural fibers - reducing the need for non-renewable resources. The headliner is made via the use of an existing technology that Johnson Controls established for its Polybond process. Soy-based polyols are blended with petroleum polyols to create a foam core.
Natural materials - including hemp, flax and kenaf - replace the fiberglass that is traditionally used in headliner production. Finally, a soy-based urethane is used to bond materials and create a semi-rigid product. The Ecobond headliner satisfies customers' design requirements for stiffness, toughness and acoustics. It also is lighter than standard thermoplastic headliners. Using the new Ecobond approach is not expected to add costs to the headliner production process:
energy :: sustainability ::biomass :: bioenergy :: biofuels :: bio-products :: efficiency :: renewable :: bioplastics :: biopolymers :: bio-composites :: natural fibers :: bioeconomy ::
By utilizing soy and other abundant and renewable plant-based materials, Johnson Controls is working to fulfill its sustainability goals, with initiatives that benefit its customers, the general public and future generations. Other earth-friendly products from Johnson Controls include EcoCore natural-fiber door panels, as well as soy-based seating pads, which will be featured on numerous 2008 model-year vehicles.
The new headliner joins the long list of bio-based products that are finding applications in the automotive sector. To name just a few: durable bioplastic fuel lines that can handle aggressive biodiesel (earlier post), almost-entirely-oil-free biopolymer car tires, car seat foams made from soybeans, bamboo-fibre reinforced bioplastic interior parts for car cabines, high-strength heat-resistant bioplastics similar to polypropylene for demanding car parts, and so on. Even such a key component as a methane storage tank for CNG cars doesn't escape the bioeconomy: researchers recently developed a highly efficient one from corn cobs (previous post).
Biopolymers and bioplastics made from sugarcane and maize are also used in Toyota's futuristic i-Unit; the renewable plastics are reinforced with plant fibers from the African kenaf plant, held together by lignin, a natural polymer found in wood.
Several projects are even underway to build entire 'bio-cars' that are almost fully biodegradable and that can be 'grown', so to speak: one such project was launched recently in Canada, whereas in the US a conglomerate of research organisations is working on a similar 'AgriCar', which will be made out of bio-based products for 90%. Bioplastics, biopolymers, biocomposites, biolubricants, biofuel-cells, and biofuels are coming together in the cars of the future. Or even of the present: researchers at the University of Warwick recently presented their first environmentally-friendly racing car that contains a large number of bio-components: tyres made from potatoes, a cabin from bio-composites and brake pads from cashew nut shells (more here).
Recently, researchers found that the most important bulk chemicals used to make car components and thousands of other products, can be obtained from biomass. Interestingly, they showed that in several cases it might be more efficient to use land to grow crops for such green chemicals than to keep it for biofuels. The production of such bio-products represent an opportunity to reduce global greenhouse gas emissions in a major way, they found (previous post).
Photo: blooming kenaf plantation in the US 'Cotton Belt'. The crop has been grown for decades for the different types of fibers found in its stalks. It is currently undergoing a revival because of growing interest into bio-based, renewable products. Kenaf fibers replace glass fibers in Johnson Control's new headliner.
References:
Johnson Controls: Johnson Controls Unveils 'Earth-Friendly' Automotive Headliner - Comprised of 50 Percent Plant-Based Material - at Detroit Auto Show - January 15, 2008.
Biopact: Researchers find bio-based bulk chemicals could save up to 1 billion tonnes of CO2 - December 17, 2007
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