The Ford Motor Company has strived for many years to make its vehicles more eco-friendly, fuel-efficient and generally more in tune with the environment. From its hybrid offerings that reduce fuel consumption, to its EcoBoost engines that reduce carbon dioxide emissions by some 20 percent, to electric vehicles that would eliminate gas consumption altogether, Ford has sought to make a minimal impact on the planet.
Researchers at Ford are developing alternatives for car components that would reduce or replace many of the parts made from plastics, rubber, foam, film, fabric and fiberglass with those derived from biomaterials to decrease our dependence on foreign oil. Ford’s team is developing all-new composites made from natural ingredients such as soy, hemp, cellulose and the sugars in corn, sugarcane and sugar beets.
About 10 percent of an automobile is made up of plastics – from doors, interior cabin parts and instrument panels to those out-of-sight sections such as impact shields, engine covers and insulating materials. Tests have shown that natural-fiber reinforced plastics reduce weight by up to 30 percent, depending on the part. Ford is now working with a biodegradable plastic called polylactic plastic (PLA) made from the sugars in sugarcane, corn, switch grass and other plants. Parts made of this can biodegrade after their lifecycle in from 90 to 120 days compared to up to 1,000 years in a landfill for traditional petroleum-based plastic.
There is a downside. Natural fiber replacements are more likely to absorb moisture, retain odors and are designed to biodegrade quickly. Researchers want to make sure that they last the lifetime of the vehicle before that happens. That’s why Ford started the BioCar Initiative, an Ontario government-funded project designed to advance the use of more plant-based materials in both the automotive and agricultural industries.
Working with several universities and organizations such as the University of Ontario and the University of Toronto, scientists are looking toward nano fillers that have the potential to reduce weight, yet maintain or even surpass the strength of materials made with glass fibers. Debbie Mielewski, Technical Leader, Ford Plastics Research, says, “We have to entertain the thought of bio-replacement in baby steps, looking at every aspect of a car that could be green.”
Ford is already the industry leader in soy-based polyurethane foam seat cushions and seatbacks, which are in more than 1.5 million Ford, Lincoln and Mercury vehicles. That represents a petroleum usage reduction of approximately 1.5 million pounds. The 2010 Ford Fusion and Mercury Milan feature 85 percent post-industrial yarns in seat fabrics.
Ford has also worked with other industries to capitalize on its greener materials technology and leads the way in innovative research to develop leaner and greener vehicles and reduce petroleum-based product consumption to ensure a cleaner environment for all.
Source: IMN
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