Johnson Controls Simplifies Production of Soft Touch Surfaces
30/10/2007 18:37
PR Newswire
BURSCHEID, Germany, October 30 /PRNewswire/ --
- Faster Way to Produce High-End, Sandwich Parts
Johnson Controls, one of the world's leading suppliers of automotive
interior systems, electronics and batteries, is the leading engineering
partner behind the plastics industry's "Dolphin" consortium, and the driving
force behind an innovative, dual component injection-molding process for
automotive interior parts. The aim is to produce a high-performance component
from substrates and soft foam surfaces in a single processing step.
The "Dolphin" consortium comprises the following companies: BASF AG,
Engel Austria GmbH, Georg Kaufmann AG and P-Group GmbH. As Dr. Oliver Becker,
Director of Advanced Manufacturing Engineering for Johnson Controls, says,
"The Dolphin process has the potential for fast, high-quality, economical
production of sandwich-molded components such as central consoles, armrests
and glove compartments. At the same time, it will help secure the
competitiveness of even high-wage manufacturing locations."
Far Fewer Processing Steps
However, one of the main benefits is the reduced number of processing
steps required, compared to the classic process that typically involves
multiple stages. At the same time, the number of tools required is also
reduced from four to just one and a half. The advantage of this is that
significant cost savings can be made in producing practically identical
components. Johnson Controls has already verified this with an armrest of a
current vehicle model of the lower middle segment. Initial testing of the
parts according to the specifications of individual automakers has been very
promising.
This new development is primarily aimed at vehicles in the lower
segments, which, for cost reasons, are built using components with untreated
(tool blank) or painted surfaces. At the same time, soft touch surfaces in
these segments could also greatly enhance the perceived value of the cars.
Innovative production process replaces conventional process
This new production technology for soft touch interior components will
replace the previously required steps - of injection-molding a substrate,
producing a surface and then connecting the two components together to form
one part - with a single processing step. A substrate is initially formed on
one machine with dual injection-molding units by the classic
injection-molding process. Then the tool turns over into the second
injection-molding unit, where it is sprayed with special polyester blown with
nitrogen gas. As the gas expands within the tool, the polyester begins to
foam. At the same time, a compact skin forms on the surface of the tool.
Since the substrate material and the outer surface are chemically related
polyester plastics, good adhesion occurs between the two layers. What's more
- unlike the conventional combination of completely different types of
plastic - it is also easier to recycle.
The new process is expected to be available in vehicles from model year
2010. Only recently, at the IAA 2007, Johnson Controls presented an armrest
that was manufactured using the new process. At the upcoming K-Messe, anyone
interested in this innovation can also get a general idea of the Dolphin
process by visiting the booth of Engel Austria GmbH and BASF.
Johnson Controls (NYSE: JCI) is the global leader that brings ingenuity
to the places where people live, work and travel. By integrating
technologies, products and services, we create smart environments that
redefine the relationships between people and their surroundings. Our team of
140,000 employees creates a more comfortable, safe and sustainable world
through our products and services for more than 200 million vehicles, 12
million homes and one million commercial buildings. Our commitment to
sustainability drives our environmental stewardship, good corporate
citizenship in our workplaces and communities, and the products and services
we provide to customers. For additional information, please visit
http://www.johnsoncontrols.com
Further information is available from:
Johnson Controls GmbH
Automotive Experience
Industriestr. 20-30
51399 Burscheid
Germany
Astrid Schafmeister
Tel: +49-2174-65-3189
Fax: +49-2174-65-3219
E-mail: astrid.schafmeister@jci.com
Ina Longwitz
Tel: +49-2174-65-4343
E-mail: ina.longwitz@jci.com
Further information is available from: Astrid Schafmeister, Tel.: +49-2174-65-3189, Fax: +49-2174-65-3219, E-mail: astrid.schafmeister@jci.com; Ina Longwitz, Tel.: +49-2174-65-4343, E-mail: ina.longwitz@jci.com