Johnson Controls recently unveiled its new Ecobond headliner at the 2008 North American International Auto Show. Made from 50 percent biomaterials by mass, the headliner is touted as a lightweight solution that fully meets customer requirements for strength, performance and acoustics, while at the same time reducing its own carbon footprint. "With our existing processes and resources, we have created and manufactured an ingenious, earth-friendly headliner from sustainable materials — an outstanding product that meets the performance and cost expectations of our customers," says Byron Foster, who leads the North American interiors business of Johnson Controls. "Additionally, 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." The 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 knaf — 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. By using 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. "Given the auto industry's strong focus on green initiatives, we have an excellent opportunity to use sustainable resources, while creating appealing products that meet our customers' needs," Foster said. "Leveraging the momentum of the Johnson Controls seating team, we have extended the use of soy-based materials to other, high-quality interior products." For more information about Johnson Controls, visit the company's Web site. |
