The sound-deadening headliner in the 2010 Buick LaCrosse uses padding made from discarded cardboard packaging containers. It is the first General Motors application of Federal-Mogul's QuietShield GRN.
"This product represents an example of GM's green efforts by way of working with our suppliers to develop materials that contain GM manufacturing by-products that meet or exceed product performance specifications and reduce our environmental footprint," said John Bradburn, GM Staff Environmental Engineer.
In April 2006, Federal-Mogul began development work on QuietShield GRN, a "green" product that can be made from a variety of materials, such as domestic cardboard, carpet fibers, recycled yarns and fabrics, as well as certain Asian-produced short-fiber-length cardboards.
"Federal-Mogul has the capability to blend multiple materials and tailor the performance of the product to meet critical performance specifications, [which] are achieved by controlling mix percentages of the various materials fed into the process," explained Ritesh Mehbubani, Product Development Team Leader for Systems Protection at Federal-Mogul Corp.
In addition, "our technique enables us to meet customer specifications by…controlling material distribution throughout the webbing process, varying web thickness and weight, and choosing the right bonding technique," according to Mehbubani.
Cardboard packaging from GM's Marion, IN, plant (which stamps and assembles sheet metal for doors, hoods, roofs, and other panels for GM trucks and SUVs) is transported to a Federal-Mogul facility in Pennsylvania for processing into the patent-pending QuietShield GRN.
"We are using QuietShield GRN on the top side of the headliner of the 2010 Buick LaCrosse to reduce noise in the interior cabin, which is the objective of Buick's exclusive 'QuietTuning' engineering," according to Jeff Luke, Chief Engineer of the 2010 Buick LaCrosse.
QuietShield GRN is appropriate for a variety of vehicle applications. For instance, the product can be used "to fabricate linings and sound-deadening padding in headrests, headliners, door and kick panels, as well as trunk liners. QuietShield is comparable in acoustical performance to most standard shoddy, polyester, or polypropylene materials," noted Chris Foy, North American Director of Sales for Systems Protection at Federal-Mogul.
Applications for QuietShield GRN are also appropriate for other industries, including aerospace, according to Foy.