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Innovative production method for versatile interior solutions in all vehicle segments
Johnson Controls high-frequency welding process offersgreater scope in the design of seat covers
Bursc heid, Germany 09 September 2010. Johnson Controls provides new
capabilities for adding variety to the design of vehicle interiors with an innovative
technology for attractive seat covers. The global leader in automotive interiors and
electronics has adapted a high-frequency welding process to address quality
concerns of the automotive industry regarding easy processing, appearance and
durability. HF welding enables designs and three-dimensional imprints to be
applied to trim covers of different quality in just a few process steps. This makes
HF welding the ideal technology for the automotive industry, where there is a
strong demand from car purchasers for more individual and personalized interiors.
The exterior design of a vehicle is what attracts car buyers and makes certain
models desirable, said Marc van Soolingen, senior design manager at Johnson
Controls Automotive Experience. The interior design, on the other hand, tends toengender a sense of loyalty toward the vehicle model and the car brand, growing
every time the consumer uses the car. Whether it is sporty, robust or elegant
colors, applications or the type of seams give the interior its distinctive look and
special seat covers are often reserved solely for certain engine specs or trim
levels. Thus the interior design plays a key role in purchasing decisions. This is
the reason why automakers not only pay a great deal of attention to the style and
functionality of all interior components, but also to the quality and design of the
seat covers.
Permanent bond of different materials
Depending on the design involved, the cover of a car seat may comprise 12 to 50
pieces. Generally, designs are only found in the central panels of the seating
surface and on the backrests. The classic method is to weave these patterns into
the material panels by a flat-bed or round-knit process, before they are filled with a
layer of foam and backed with facing material into a complete seat cover a
complex process, since yarns of different colors and qualities have to be used to
achieve the end result. HF welding simplifies the manufacturing process
significantly, as the covers can be created in a single color, since all of the design
elements are applied at a later stage. As Marc van Soolingen said: The desired
designs in each case serve as the template for molds made out of copper or
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aluminum that are produced by a three-dimensional CAD process. The ready-cutpieces of the seating panels and a thin plastic foil are then placed between this
mold and an equally electro-conductive carrier plate. When the HF welding
process is applied, a high-frequency, electromagnetic, alternating field develops
between the mold and the carrier plate. Hence the dipoles of both materials are
heated and consequently welded together. The part is then taken out of the mold
and any non-welded remnants of the plastic foil discarded.
If designs of many colors or several different materials are desired, separate molds
are constructed for each of these steps. That sounds like a lot of effort, conceded
Peter-Gerd Mller, product business manager for foam and trim at Johnson
Controls Automotive Experience, but in actual fact, it is faster and more efficient
than having to include the colors and designs in the weave of the fabric and then
apply further design elements or three-dimensional structures at a later stage.
Moreover, the fact that HF welding of individual cover panels is such a high-
precision process means that when the various panels are sewn together, they are
guaranteed to fit perfectly: Each design element ends up exactly where it is
supposed to be, cited Marc van Soolingen as a further benefit that adds to the
appealing cost-effectiveness of this process.
Host of designs and fabrics plus long-lasting quality
Johnson Controls is already producing car seat covers for several automakers
using the high-frequency welding method, after rigorous testing verified their
durability. The process has really proved itself in every way, as it is possible to
achieve a whole range of variations simply by selecting different materials for both
the cover and the foam that lies beneath it. Furthermore, we are able to
incorporate patterns, structures and three-dimensional shapes in the door panels
by applying the HF welding method. This means the automaker can address
current design trends and tailor various interior lines to the exact demands of each
vehicle segment and market, recapitulated Peter-Gerd Mller.
Digital images are available online from www.johnsoncontrols.co.uk/press.
Please do not hesitate to contact us if you would like more information:
Johnson Controls GmbH
Automotive Experience
Industriestrasse 2030
51399 Burscheid
Germany
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Ulrich Andree
Tel.: +49 (0)2174 65-4343
Fax: +49 (0)2174 65-3219
Email: ulrich.andree@jci.com
Johnson Controls is a global diversified technology and industrial leader serving customers
in over 150 countries. Our 130,000 employees create quality products, services and
solutions to optimize energy and operational efficiencies of buildings; lead-acid automotive
batteries and advanced batteries for hybrid and electric vehicles; and interior systems for
automobiles. Our commitment to sustainability dates back to our roots in 1885, with the
invention of the first electric room thermostat. Through our growth strategies and byincreasing market share we are committed to delivering value to shareholders and making
our customers successful.
Johnson Controls Automotive Experience is a global leader in automotive seating,
overhead systems, door and instrument panels, and interior electronics. We support all
major automakers in the differentiation of their vehicles through our products, technologies
and advanced manufacturing capabilities. With more than 200 plants worldwide, we are
where our customers need us to be. Consumers have enjoyed the comfort and style of our
products, from single components to complete interiors, in over 200 million vehicles.
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