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Johnson Controls develops revolutionary soy-based seat foam

The Bean Goes Green

In what is being billed as a significant environmental advance for the auto industry, engineers at Johnson Controls have created a new type of foam pad used in the creation of vehicle seats—it’s a combination of soy-based foam (derived from soy oil) and conventional polyurethane. And it heralds a new environmental era in the automotive industry, one that will have significant implications for sustainability and the use of renewable materials.
Soy foam
What’s New?
Most foam pads used in automotive seats are made from petroleum-based polyurethane, but Johnson Controls engineers successfully replaced 5 percent of the composition with the soy product, decreasing an overall dependence on petroleum products. As a result, there is less environmental impact. Best yet, since soy is a renewable resource, it’s in abundant supply, unlike petroleum. Likewise, this renewability means less market fluctuation, providing more pricing stability.
“We are strongly committed to developing and using eco-friendly materials that come from renewable sources,” says Charlie Baker, group vice president of engineering-worldwide, for Johnson Controls’ Automotive Experience business. “Using greater quantities of bio-materials … can help cut the industry’s reliance on petroleum-based products.” Soy-based seat systems from Johnson Controls will be introduced in a number of model-year 2008 production vehicles.
To the consumer, there’s no difference between a soy-based seat and the old kind. That’s because Johnson Controls engineers put the soy product through rigorous comparison testing to evaluate durability, shape and comfort levels. They found no difference—except for soy’s environmental benefits.

What’s Next?
Ultimately, Johnson Controls is looking to create a product with even more soy composition, replacing more petroleum-based products in the manufacturing process. “We have the processes already in place to move toward this goal,” says Baker. “[We’ll] apply lessons learned today with environmentally friendly materials to create earth-friendly products of the future.”
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