Dave, at least one of the specs were on their presentations and they were also given in the interview. I find it tough to believe that anyone at Dow would mistake units of measurement. I've sent an email asking them to verify the spec.
Dave, the spec Dow provided was 1.45 gm/cc. Note that that's 25 percent less dense than the previous product at 2.0 gm/cc. James did not provide price details, or mention sheet forms of this product or any other future plans regarding it.
@Ann: Calling soybean oil a "byproduct of food production" rather than a food product is a little disingenuous. Soybean oil is one of the most widely-consumed cooking oils.
It's true that the soy flakes, which remain after the oil is extracted, are used as animal feed (and for soy protein for human consumption). Using the oil as an industrial feedstock wouldn't affect this use.
Of course, soybean oil is already widely used in industry -- for instance, it's used to make ink -- and it seems unlikely that the (relatively) small amount of additional soybean oil which would be used to make these foams would have any impact on the price or supply of cooking oil.
I also think it's cool that this cavity foam using a non-food renewable material that's a byproduct of food production. Many materials companies are getting on the bandwagon to ensure that their feedstocks are really green: both renewable and non-competitive with the human food supply.
@Ann: Are you sure that the density is 1.45 g/cm³? This is equivalent to 90 pounds per cubic foot. At this density, the foam would sink in water. The density of a typical polyurethane sound-absorbing foam is around 2 pounds per cubic foot (about 0.03 g/cm³). Are you sure the density wasn't given in U.S. units, rather than metric units?
Generally, the sound absorption of foams depends on the frequency of the sound. Any indication of what frequency range this foam is best suited for?
Also, any word on whether Dow has any plans to market this material in sheet form? Or will it be sold only as an injectable cavity foam?
Finally, how does the cost of the soy-based polyurethane compare to petroleum-based polyurethanes? This will definitely be a big factor in its acceptance.
Love to see these efforts around creating renewable versions of proven materials and carrying over many of the same characteristics so they have high utility for materials engineers. Makes it very easy to go the sustainability route when the choices are just part of good, everyday design practices.
Wal-Mart will hold its second Made in the USA Open Call July 7-8, at its headquarters in Bentonville, Ark. The event will be a repeat effort by the world’s biggest seller of consumer goods to increase the amount of US-made products it sells in Wal-Mart stores, in Sam’s Club members-only wholesale outlets, and on walmart.com.
From design feasibility, to development, to production, having the right information to make good decisions can ultimately keep a product from failing validation. The key is highly focused information that doesn’t come from conventional, statistics-based tests but from accelerated stress testing.
There’s a good chance that a few of the things mentioned here won't fully come to fruition in 2015 but rather much later down the line. However, as Malcolm X once said, "The future belongs to those who prepare for it today."
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