Johnson Controls simplifies production of soft touch surfaces * Faster way to produce high-end, sandwich parts

Burscheid (Germany) 31 October (PROTEXT/ots) - Johnson Controls, one of theworld’s leading suppliers of automotive interior systems, electronics andbatteries, is the leading engineering partner behind the plasticsindustry's "Dolphin" consortium, and the driving force behind aninnovative, dual component injection-molding process for automotiveinterior parts. The aim is to produce a high-performance component fromsubstrates and soft foam surfaces in a single processing step.

The "Dolphin" consortium comprises the following companies: BASF AG, EngelAustria 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, economicalproduction of sandwich-molded components such as central consoles, armrestsand glove compartments. At the same time, it will help secure thecompetitiveness of even high-wage manufacturing locations."

Far fewer processing steps

However, one of the main benefits is the reduced number of processing stepsrequired, compared to the classic process that typically involves multiplestages. At the same time, the number of tools required is also reduced fromfour to just one and a half. The advantage of this is that significant costsavings can be made in producing practically identical components. JohnsonControls has already verified this with an armrest of a current vehiclemodel of the lower middle segment. Initial testing of the parts accordingto 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 (toolblank) or painted surfaces. At the same time, soft touch surfaces in thesesegments 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 willreplace the previously required steps - of injection-molding a substrate,producing a surface and then connecting the two components together to formone part - with a single processing step. A substrate is initially formedon one machine with dual injection-molding units by the classicinjection-molding process. Then the tool turns over into the secondinjection-molding unit, where it is sprayed with special polyester blownwith nitrogen gas. As the gas expands within the tool, the polyester beginsto 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 relatedpolyester plastics, good adhesion occurs between the two layers. What'smore - unlike the conventional combination of completely different types ofplastic - it is also easier to recycle.

The new process is expected to be available in vehicles from model year2010. Only recently, at the IAA 2007, Johnson Controls presented an armrestthat was manufactured using the new process. At the upcoming K-Messe,anyone interested in this innovation can also get a general idea of theDolphin process by visiting the booth of Engel Austria GmbH and BASF.

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

Johnson Controls (NYSE: JCI) is the global leader that brings ingenuity tothe places where people live, work and travel. By integrating technologies,products and services, we create smart environments that redefine therelationships between people and their surroundings.

Our team of 140,000 employees creates a more comfortable, safe andsustainable world through our products and services for more than 200million vehicles, 12 million homes and one million commercial buildings.Our commitment to sustainability drives our environmental stewardship, goodcorporate citizenship in our workplaces and communities, and the productsand services we provide to customers. For additional information, pleasevisit http://www.johnsoncontrols.com.

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