Ford Taurus to use eco-friendly bio-based seat cushions

21 Apr '10

5 min read

In support of Ford's global product development strategy, material engineers are developing standardized specifications for sustainable materials while working with parts purchasers and suppliers to use eco-friendly components in different markets.

For example, the European Ford Focus uses recycled polymer in such components as the battery tray, wheel arch liners, seat fabric and carpets. Materials engineers are in the process of determining if recycled polymer can be used for similar components in the global Focus coming to North America and Europe in 2011.

"Sustainable materials need to meet the same high standards for quality, durability and performance as virgin material; there can be no compromise on product quality," said Valentina Cerato, Ford materials engineer in Europe.

What the future holdsMaterials researchers continue to explore sustainable material applications, such as an eco-friendly replacement for the fiberglass used between the headliner and roof sheet metal that will be bio-based, lighter weight, and will deliver improved acoustics and neutralize odor.

In addition, Ford researchers are developing natural-fiber composites as a potential substitute for the glass fibers traditionally used in plastic car parts to make them stronger while reducing vehicle weight, which helps improve fuel economy and reduces emissions. Natural fiber composites also are more eco-friendly, because their production and end-of-life incineration are less energy intensive than glass fibers, which also results in lower emissions.

Ford researchers also are investigating ways to use plastics made entirely from sustainable resources such as corn, sugar beets, sweet potatoes and other vegetables. These renewable materials will help reduce dependency on petroleum, reduce CO2 emissions and allow the composting of the material at the end of a vehicle's life.

"Natural fiber-reinforced plastics and plant-based polymer resins help reduce CO2 emissions by being entirely compostable, and in some cases reduce weight, which helps improve fuel economy," said Debbie Mielewski, technical leader, Ford Plastics Research. "We have to entertain the thought of bio-replacement in baby steps, looking at every aspect of a car that could be green. One day I hope to see the world of automotive plastics go totally compostable, removing petroleum by 100 percent."

What comes outAutomobiles are among the most recycled consumer products in the world. According to the Environmental Protection Agency, more than 95 percent of all end-of-life vehicles in the U.S. are processed for recycling – compared to 52 percent of all paper and 31 percent of all plastic soft drink bottles.

In Europe, automakers are required to take back the vehicles they've produced at the end of the vehicles' useful lives. Ford has end-of-life recycling networks for its vehicles in 16 European markets and participates in industry collective systems in another 10. In 2007, Ford became one of the first automakers in Europe to be certified in compliance with end-of-life requirements, including:

"In theory, end-of-life vehicles are nearly 100 percent recoverable. In practice, however, the cost in energy and labor to recover all vehicle material often exceeds the value of the materials and offers insignificant value to the environment," Viera said. "We remain focused on achieving the highest economically viable and environmentally sound recovery percentage possible."

Ford Motor Company

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