Small changes can make huge difference. Consider a plastic storage bin. By using wheat straw-reinforced plastic rather than 100-percent traditional petroleum products, it is estimated that petroleum use will be reduced by approximately 20,000 and CO2 emissions will be reduced by approximately 30,000 pounds per year.

The first application of the natural fiber-based plastic that contains 20-percent wheat straw bio-filler is on the 2010 Ford Flex’s third-row interior storage bins. Ford is already considering using the environmentally-friendly technology in the construction of center-console bins and trays, interior air registers, door trim panel components and armrest liners.

Ford’s sustainable materials portfolio also includes soy-based polyurethane seat cushions, seatbacks and headliners; post-industrial recycled yarns for seat fabrics; and post-consumer recycled resins for underbody systems, such as the new engine cam cover on the 2010 Ford Escape’s 3.0-liter V-6 engine

“Ford continues to explore and open doors for greener materials that positively impact the environment and work well for customers,” said Patrick Berryman, a Ford engineering manager who develops interior trim. “We seized the opportunity to add wheat straw-reinforced plastic as our next sustainable material on the production line, and the storage bin for the Flex was the ideal first application.”

Collaborative effort

Ford researchers were approached with the wheat straw-based plastics formulation by the University of Waterloo in Ontario, Canada, as part of the Ontario BioCar Initiative – a multi-university effort between Waterloo, the University of Guelph, University of Toronto and University of Windsor. Ford works closely with the Ontario government-funded project, which is seeking to advance the use of more plant-based materials in the auto and agricultural industries.

The University of Waterloo already had been working with plastics supplier A. Schulman of Akron, Ohio, to perfect the lab formula for use in auto parts, ensuring the material is not only odorless, but also meets industry standards for thermal expansion and degradation, rigidity, moisture absorption and fogging. Less than 18 months after the initial presentation was made to Ford’s Biomaterials Group, the wheat straw-reinforced plastic was refined and approved for Flex, which is produced at Ford’s Oakville (Ontario) Assembly Complex.

The wheat straw-reinforced resin is the BioCar Initiative’s first production-ready application. It demonstrates better dimensional integrity than a non-reinforced plastic and weighs up to 10 percent less than a plastic reinforced with talc or glass.

“Without Ford’s driving force and contribution, we would have never been able to move from academia to industry in such lightning speed,” said Leonardo Simon, associate professor of chemical engineering at the University of Waterloo. “Seeing this go into production on the Ford Flex is a major accomplishment for the University of Waterloo and the BioCar Initiative.”

An interior storage bin may seem like a small start, but it opens the door for more applications, said Dr. Ellen Lee, technical expert, Ford’s Plastics Research.

“We see a great deal of potential for other applications since wheat straw has good mechanical properties, can meet our performance and durability specifications, and can further reduce our carbon footprint – all without compromise to the customer.”

Abundant waste material put to good use

The case for using wheat straw to reinforce plastics in higher-volume, higher-content applications is strong across many industries. In Ontario alone, where Flex is built, more than 28,000 farmers grow wheat, along with corn and soybeans. Typically, wheat straw, the byproduct of growing and processing wheat, is discarded. Ontario, for example, has some 30 million metric tons of available wheat straw waste at any given time.

“Wheat is everywhere and the straw is in excess,” said Lee. “We have found a practical automotive usage for a renewable resource that helps reduce our dependence on petroleum, uses less energy to manufacture, and reduces our carbon footprint. More importantly, it doesn’t jeopardize an essential food source.”

To date, Ford and its suppliers are working with four southern Ontario farmers for the wheat straw needed to mold the Flex’s two interior storage bins.

History in the making

Ford’s interest in wheat dates back to the 1920s, when company founder Henry Ford developed a product called Fordite – a mixture of wheat straw, rubber, sulphur, silica and other ingredients – that was used to make steering wheels for Ford cars and trucks. Much of the straw used to produce Fordite came from Henry Ford’s Dearborn-area farm.

The company’s new-age application for wheat straw joins other bio-based, reclaimed and recycled materials that are in Ford, Lincoln and Mercury vehicles today, including:

• Soy-based polyurethane foams on the seat cushions and seatbacks, now in production on the Ford Mustang, Expedition, F-150, Focus, Escape, Escape Hybrid, Mercury Mariner and Lincoln Navigator and Lincoln MKS. More than 1.5 million Ford, Lincoln and Mercury vehicles on the road today have soy-foam seats, which equates to a reduction in petroleum oil usage of approximately 1.5 million pounds. This year, Ford has expanded its soy-foam portfolio to include the industry’s first application of a soy-foam headliner on the 2010 Ford Escape and Mercury Mariner for a 25 percent weight savings over a traditional glass-mat headliner.
• Underbody systems, such as aerodynamic shields, splash shields and radiator air deflector shields, made from post-consumer recycled resins such as detergent bottles, tires and battery casings, diverting between 25 and 30 million pounds of plastic from landfills. The newest addition is the engine cam cover on the 3.0-liter V-6 2010 Ford Escape.
• 100 percent post-industrial recycled yarns in seat fabrics on vehicles such as the Ford Escape. The 2010 Ford Fusion and Mercury Milan Hybrids feature 85 percent post-industrial yarns and 15 percent solution-dyed yarns. The 100 percent usage represents a 64 percent reduction in energy consumption and a 60 percent reduction in CO2 emissions.
• Repurposed nylon carpeting made into nylon resin and molded into cylinder head covers for Ford’s 3.0L Duratec engine. The industry’s first eco-friendly cylinder head cover is currently found in the 2010 Ford Fusion and Escape vehicles.

"The Jay Leno Show" Ford Focus BEV

Background: A battery-electric Ford Focus will appear, Friday, Sept. 18 on “The Jay Leno Show” (NBC, Monday through Friday, 10-11 p.m. ET) in a segment they call “Green Car Challenge.” The battery-electric Ford Focus will be used throughout the first season of the show, driven by celebrity guests who accept the challenge.

VIDEO: Focus BEV for the Jay Leno Show

SUMMARY / PHOTO CAPTIONS:

• An electric-powered Ford Focus is ready to race tonight on “The Jay Leno Show” (NBC, Monday through Friday, 10-11 p.m. ET) in a segment called “Green Car Challenge.” Tuned to perform on a racetrack that was specifically designed for “The Jay Leno Show,” the battery-electric Ford Focus will be the car used throughout the first season. Actress Drew Barrymore is the first celebrity guest to accept the show’s “Green Car Challenge.”

• A one-of-a-kind battery-electric Focus will make its television debut tonight on “The Jay Leno Show’s” “Green Car Challenge.” Celebrities who accept the challenge will be at the wheel, driving quickly to establish a fast lap time thatfuture guests will try to beat. The “Green Car Challenge” will be a regular segment on “The Jay Leno Show.”

• The electric Focus to be driven by celebrity guests on “The Jay Leno Show” is one-of-a-kind vehicle, based on the European five-door production Focus ST, modified into a battery electric vehicle (BEV) as part of Ford’s BEV test fleet. The Focus BEV foreshadows many of the same systems that Ford will begin selling to consumers in an all-new electric Ford Focus, scheduled to go on sale in North America in 2011. The new Focus BEV is one of four electrified vehicles Ford is introducing now through 2012 as part of the company’s commitment to deliver best-in-class fuel efficiency with every new vehicle it introduces.

• “The unique Focus BEV for “The Jay Leno Show” started life as a European production Focus ST, built in Germany in July. The car was delivered to Ford’s world headquarters in Dearborn, Mich., where engineers went to work, removing the traditional engine and gas tank and installing an entire electric powertrain – all in six weeks. With Recaro racing seats, a full roll cage, a five-point racing harness and wearing a unique (and fitting) “Electric Orange” paint scheme, the battery-electric Focus ST is ready for racing.

• With a sophisticated electric powertrain, the zero-emissions Ford Focus BEV delivers nearly as much torque at the wheels as a 2010 Ford Mustang V-6. It also stores enough energy to power an average household for 24 hours.

• Thanks in part to the battery placement, the race-ready Ford Focus BEV has a nearly ideal 50/50 weight distribution for improved racetrack handling. The front springs and dampers come from the performance-minded Ford Focus RS, a popular, high-performance European production model. The rear dampers and springs are unique to Leno’s Focus BEV.

• The car is specifically tuned to perform on the track built alongside “The Jay Leno Show” studio at NBC. To help improve performance, Ford created a similar track at its proving ground in Michigan so the vehicle would be ready to handle the tight turns.

• Besides an ability to perform on the track, the Ford Focus BEV boasts the impressive statistics of a conventional battery electric vehicle, with a range of nearly 80 miles on a charge and peak power of 141 horsepower (105 kilowatts).

VEHICLE SPECS:
Powertrain: Permanent magnetic electric motor
Power: 141 hp / 105 kw
Torque: 236 lb.-ft. / 320 Nm
Redline: 7500 rpm
Batteries: 98 air-cooled, 60 A-h Lithium-ion batteries
Capacity: 23 kilowatt hours
Transmission: Single-speed gearbox

Steering: Electric power-assisted rack-and-pinion
Front suspension: MacPherson-type struts
Rear suspension: Independent short-long arm (SLA), control blade multi-link system
Brakes: Front: 12.6 in / 320 mm ventilated discs
Rear: 11.0 in / 280 mm solid disc
Anti-lock system

Wheelbase: 104 in / 2640 mm
Overall length: 171.7 in / 4362 mm
Overall height: 58.9 in / 1497 mm
Overall width: 72.4 in / 1840 mm
Curb weight: 3,421 lbs

Source: http://www.ford.com/about-ford/news-announcements/press-releases/press-releases-detail/pr-electric-ford-focus-ready-to-race-31034