Wards Auto Interiors Conference

Panel 7: Fuel Efficient Interiors

22 May 2013

Bryan NyeholtVice President, Innovation - InteriorsJohnson Controls

Johnson Controls2

Panel 7: Fuel Efficient InteriorsKey ideas

Industry Statistics:

The role of the interior in the vehicle mass breakdown

Current status of vehicle weight and achieving CAFÉ targets

Comfort and convenience feature growth

Interior Solutions that are not visible:

Instrument Panel: Long Fiber PP and wall stock reduction

Door Panel: Fiber carriers with back injection

Interior Solutions that are visible:

Precision torque hinge

Access Floor console

Seating Functional integration

CAMISMA Seat back

The role of the interior in the vehicle mass breakdownThe interior is 10-15% of vehicle mass

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The interior is the area that has added comfort, convenience, and safety features. It has also added the most weight

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Vehicles have gotten heavier, faster, and more fuel efficient (mass adjusted).This has resulted in stagnant overall fuel mpg improvement

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Interior Solutions that are not visible

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Instrument Panels: Using long-glass fiber polypropylene allows thinner cross-sections for IP carriers. Evolution has occurred from 3.0 mm to 2.0 to 1.8 mm thickness and weight (40% reduction)

Door Panels: Fiber carriers with back injection (production BMW 3 Series shown) have resulted in a stronger carrier, elimination of glue and other fasteners (39% weight reduction from an ABS carrier)

Interior Solutions that are visible

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Access Floor console: rethink, improve and save. Significant increase in storage volume with easy access. The armrest accommodates multiple occupant sizes, eliminates hinging mechanisms and reduces weight.

Precision Torque Hinge: A mechanism that replaces a steel, stamped hinge for storage armrest with better performance (35% weight reduction for the hinging mechanism)

Visible Interior Solutions

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Seat Function Integration: A focus on seat to vehicle integration eliminates redundant components. Advancements in thin seating can lead to smaller cabins and elimination of a portion of the body. New seat attachments can help lower the roof line.

Interior Graphic reference: Mazda show car

Visible Interior Solutions

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Seat back redefinition: A focus on cutting the mass of the seat back in half using reinforced carbon fiber with an over molded seat back and molded rib inner structure (50% targeted reduction in seat back mass)

Johnson Controls10

Panel 7: Fuel Efficient Interiors

Summary:

20-50% mass reductions are occurring in interior components without compromising feature and function, often enhancing them

Ideas that may have been “shelved” before may have renewed merit as mass savings become more important for OEM’s to meet increasing CAFÉ and CO2 requirements

“Value” for mass reduction improvements needs to be discussed more so projects can be prioritized appropriately

There are features that need to be optimized: ie: door locks/barrels, and switches

Key areas are being redefined: Electronic shifter and park brake

Interiors components are reducing weight and helping drive fuel efficient interiors