Johnson Controls has shown off a new environment-friendly Ecobond headliner that is in the final stages of development.
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The headliner is lightweight and comprised of 50% biomaterials by mass yet fully meets automaker requirements for strength, performance and acoustics, the company claimed.
The headliner is made from natural fibres instead of glass, making the final product easier to recycle.
The production process relies on soy-based adhesives, a soy-based urethane core foam and natural fibres. The headliner is made using existing technology that Johnson Controls developed for its Polybond process. Soy-based polyols are blended with petroleum polyols to create a foam core.
Natural materials – including hemp, flax and kenaf – replace the fibreglass that is traditionally used in headliner production. Finally, a soy-based urethane is used to bond materials and create a semi-rigid product. The headliner satisfies customers’ design requirements for stiffness, toughness and acoustics and is lighter than standard thermoplastic headliners. Using the new approach is not expected to add costs to the production process.
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