Cynthia M. Flanigan, Christine Perry, and Deborah M. Mielewski. Materials & Nanotechnology Department, Ford Motor Company, Ford Research and Advanced Engineering Laboratory, Dearborn, MI 48121
Renewable resources are becoming a promising alternative for petroleum products for automotive applications. These materials can offer a reduced environmental footprint as well as advantages in cost savings and performance for select applications. Our work focuses on using functionalized soybean oil to produce flexible polyurethane foams. Flexible, polyurethane foams are used extensively in the automotive industry for applications such as seating, instrument panels and headliners. Formulations and processing methods for soy-based foams were optimized for mechanical properties and odor. One of the main objectives was to maximize the amount of soy content within the foam formulation while maintaining performance properties. Molded soy foams were compared to key properties required for interior automotive applications and showed promising results. This presentation will discuss methods to eliminate odor within the foam including the use of a novel, synthetic method to produce soy polyol. In addition, the benefits of soy products, technical and commercialization challenges, and methods for evaluating automotive foams are discussed.