Products & Solutions

Society of Plastics Engineers (SPE) Central Europe confers two awards on Johnson Controls for innovative technologies

Weight-saving door panel and scratch-resistant surface receive SPE Automotive Award 2009

Sreenivas Paruchuri, Engineering Manager of Johnson Controls, (on the left) receiving the SPE Automotive Award 2009 for the Mini Convertible side panel.

Johnson Controls, one of the world's leading suppliers of automotive interior systems and electronics, ranks among the top award winners at the 12th Automotive Division Award of the Society of Plastics Engineers (SPE) Central Europe in the category interior systems, scooping not one, but two awards: taking 1st place for the Mercedes-Benz E-Class door panel which won over the jury with its highly perceived quality and scratch-resistant map pocket. The company also took 1st place for the rear side panel of the new MINI Convertible, which is characterized by its scratch-resistant surface.

Mercedes-Benz E-Class Door Panel
Less weight, more quality
For the Mercedes-Benz E-Class, a elementary revision of the material and production concept led to a further increase in perceived quality while offering the greatest customization options. An attractive haptic with a high-quality surface, the materials demonstrate the high quality standards both visibly and perceptibly. Significant weight and cost savings potential could also be realized in close cooperation with the automaker. The new door panels are 10 percent lighter than those in the previous model, thus reducing consumption and emissions, and making the vehicle more environmentally friendly. The supply contains the entire door panel, including map pocket, center panel, armrest and upper trim panel.

For the door panels of the new Mercedes-Benz E-Class, Johnson Controls applies several innovative production technologies. As the components were developed specifically for this process, the respective advantages of the process could be fully utilized. The targeted use of a combination of materials positively adds to this effect.

Physically foamed main substrate
A method of foam injection molding in a tandem tool is used for the door panel carrier. Also known as physical foaming, the process reduces cycle time, enables the design of thinner walls and leads to high dimensional stability of components. The resulting carrier and a deep drawn foil are subsequently foamed together. At the same time, the actual material of the foil helps form an even, constant grain. Foaming in a closed mold also eliminates the need to post-trim the component. As a result, a significant reduction in waste can be achieved during production at Johnson Controls.

Map pocket in PP Thin Film technique
For the map pocket, the interiors specialist combined physical foaming with its innovative PP Thin Film surface technology. The map pocket is characterized by its highly scratch-resistant surface, optimum degree of glossiness, and a high-quality surface finish. The foam mold-behind process chosen for the door panels of the new E-Class enables a very thin wall design – as with the door carrier. Nevertheless, the map pockets are very sturdy. Even if they are misused, e.g. to pull the door shut, an optimum component design means no damage is caused. And that’s without having to apply the expensive internal gas pressure process usually required during production.

Highly individual, multi-part panel assembly
The door center panel, map pocket and armrest come in three different materials and five different colors. Both imitation and real leather surfaces are also available. In order to be able to produce this wide variety efficiently, the door center panel is designed as a separate component, which can easily be combined with the other parts of the door panel. A special push-in system ensures the edge of the instrument panel is efficiently integrated, and also enables an optimum slot design.

High-quality interior design
Besides the technical solutions, particular attention was paid to the feel good factor when designing the door panels for the new E-Class. Ambient lighting solutions were thus installed above the door center panels and in the door handles, and sun shades were integrated in the rear door. In doing so, Johnson Controls managed to significantly improve the window cover in a minimum of space. “No matter which of the numerous design options they choose, drivers and their passengers will definitely feel at ease in this sophisticated and harmonious atmosphere,” said Matthias Berg on the latest project of Mercedes-Benz. Besides the door panel, the company also supplies the absorbent glas mat battery.
MINI Convertible Side Panel
Another award-winning product is the rear side panel for the new MINI Convertible. Once again, the PP Thin Film technology won over the jury.

Chipped paint is a thing of the past
Theoretically, numerous technologies are available for enhancing surfaces in automotive interiors. These range from painting plastic components through to various foils and RIM skin trims to elaborate natural leather covers. An alternative process used to design quality surfaces with an improved scratch-resistance and mat finish of the components is the so-called PP Thin Film.

A variable degree of glossiness enables optimum adaptation to match the finish of other components
The PP Thin Film technology consists of a composite foil made up of several, primarily polypropylene (PP) layers, manufactured in a direct mold-behind process. With this process, all types of polypropylene can be used as substrates – it even accommodates fiber glass-reinforced plastics and recycled materials. Unlike painted component surfaces, these foils are not easily scratched. As their gloss level can be varied, they can also be easily adapted to match the finish of adjacent components.

Furthermore, stability from repeated use increases, as the chipping experienced on painted surfaces is eliminated. The new foil is ideal for all interior components designed to be covered with foil. The technology can also be used for all segments. Depending on the level of design, a one or two-step production process is applied. For instance, a two-step process must be used for deep-molded products, such as the map pockets in the doors. Besides the side panels, the company designed and produced seat foam and trim covers for the new MINI Convertible.

Not the first award for Johnson Controls
SPE is a global society of engineers and scientists with over 38,000 members. A jury of acclaimed experts conferred the prestigious SPE Automotive Award in a total of four categories – Interior Systems, Exterior Applications, Applications under the Hood/Chassis, and Electronic Components. Johnson Controls was previously among the award winners in 2004, when the company earned second place in the interior category for in-mold graining, a production process for larger surface areas. Johnson Controls also ranked among the award winners in 2006, taking third place for its rear-seat entertainment system for the Mercedes-Benz S-Class and R-Class. In 2007, it took second place with a two-color door panel that could be manufactured as a single part. The company is applying this new technology for the two-color door panel of the current BMW 5 Series.

“I am delighted that we were able to win over not only our customers, but also the SPE panel with our innovations,” said Matthias Berg on accepting the awards on behalf of the entire team.
2009 SPE Award
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