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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: [email protected]
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.
