Closing the materials loop is a key factor in automobile sustainability initiatives. JLR and Mercedes-Benz are two automakers that have placed high priority on innovating solutions surrounding that initiative.
Today JLR announced that it has created a closed-loop polyurethane seat foam, in collaboration with Dow and Adient. This is the first time closed-loop seat foam content has been used in automotive production.
"Outside of tailpipe emissions, those from our supply chain represent the largest proportion of our emissions. Therefore, alongside the electrification of all our brands by 2030, circularity is a key part of JLR's transition towards net zero, impacting how we approach all aspects of our business - how our luxury vehicles are designed and the materials they are made of, how they are manufactured and even how they are used," Andrea Debbane, Chief Sustainability Officer at JLR told Newsweek.
Polyurethane foams are particularly challenging to recycle, unlike steel, leather, aluminum, plastics or other materials that make up a vehicle. They are designed for durability and can take decades to break down in a landfill.
JLR plans to test the material through its full production process, investigating its feasibility at scale, in pre-production vehicles early next year. It is one part of a larger "circular seat" project that JLR is working on.
The company estimates that this new style seat would cut the CO2e (carbon dioxide equivalent) emissions impact of seat creation in half, the equivalent of charging nearly 3,000 smartphones.
Mercedes too is looking to decrease its carbon footprint and create a circular supply chain for materials. Recent research into biotechnology materials focuses on the use of secondary materials and renewable raw materials in vehicles.
The materials that the company is exploring are not derived from crude oil or animals as part of a larger Mercedes-Benz Research and Development initiative to reduce the environmental impact of every component and material "as far as possible" with circularity as the ultimate goal.
During a media-only event at a workspace in Böblingen, Germany, the company showed off how it has used genetically modified bacteria to produce silk proteins. Those proteins are then refined into a silk yarn using a wet spinning process. The synthetic silk has the same properties as conventional silk.
Mercedes has already started using the silk in its vehicles. Vision EQXX and Concept CLA Class feature the silk on grab handles and door pockets.
A leather alternative made from recycled plastic and bio-based materials is also showing promise. After crafted using a multi-step process, the new, synthetic leather has "the same structure as real leather and can be crafted like real leather using re-tanning processes" the company said.
There are additional benefits to the faux leather: It is breathable, waterproof and lighter than real leather. The material also has a reduced CO2 footprint.
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