Johnson Controls is bringing the third generation of its reduced-emissions polyurethane foam to market.

Depending on the specification, Johnson Controls says the foam registers up to 90% fewer VOCs (volatile organic compounds) than ten years ago. The supplier also has significantly reduced the quantity of material impurities and their associated odours in the foam.

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“Our aim is material substitution with low-emission materials suitable for series production, without altering properties of polyurethane foams such as durability and stiffness,” said Johnson Controls Automotive Seating group vice president and general manager product group foam,” Ingo Fleischer.

“Ultimately, innovations like our latest low emission foam lead to cleaner and healthier air in the vehicle interior. We continually and systematically examine and test all new materials solutions and technologies on the market in close cooperation with our material supplier.

“Based on the results, we adapt the production process to maximise the potential of a new material for emission reduction. Foam plays an incremental part for the seat in terms of comfort and gives the seat’s cushion and back its shape.”

Cooperating with Johnson Controls’ Research and Development Centres in Plymouth, Michigan and Shanghai, Johnson Controls’ Strasbourg Technical Centre team creates solutions for the global market

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Production of the latest low-emission foam takes place at the company’s facilities in Europe and China. A third location in the US is planned.

“Over the years, we have been able to improve not only the foam material but also the production processes, testing methods and our overall expertise,” added Fleischer.

Besides the 90% reduction in VOCs, Johnson Controls maintains it has reduced odour-generating impurities and aldehydes to a minimum.