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01-27-2014

Foil Technology

Two-Color Surfaces on Door Panels

Foil Technology

Johnson Controls, one of the world's leading companies in automotive electronics and interiors, presented a new manufacturing concept for two-colour door panels at the 65th International Motor Show (IAA) in Frankfurt/Main, Germany. The process permits high-quality, cost-effective application of two different surfaces onto a one-piece carrier. Precision positioning of the visible color-split line within a groove eliminates the need for an appliqué covering, leading to a high-quality appearance previously only available in the premium segment, and at a lower cost. Dispensing with the assembly of two parts of different-colored cover stocks, the new foil process yields a multi-color door solution with a contoured design line that can be installed as a complete door panel.

In the past, two-color door panels were typically made by assembling two different-colored panels and welding them together. The poor quality of the line between the two colors often necessitated the use of costly coverings. The two-color innovation from the automotive supplier provides a high-quality joint line, with precision positioning into a groove in the door panel carrier. Simulation and novel tooling technology employed during development ensure a consistently high-quality product at a lower cost than current two-color solutions.

Foil Technology

“We believe this is a highly efficient production technology and that there is significant market potential for the new two-color foil process. This simple, cost-saving technology enables two-color solutions with a high-quality appearance in lower vehicle segments,” says Han Hendriks, vice president, Advanced Product Development for Johnson Controls Automotive Electronics & Interiors.

Future applications using foil made of thermoplastic polyolefin (TPO) are also possible. According to the manufacturer, the optimized process for producing two-color door panels not only offers the benefits of reduced weight, costs, and logistics outlay, but also considerably improved noise-vibration-harshness (NVH) and crash performance. The patented two-color foil process from Johnson Controls will be available for model year 2016 vehicles.

Company profile

Johnson Controls GmbH Europa-Zentrale

Industriestr. 20-30
DE 51399 Burscheid
Tel.: 02174 65-0
Fax: 02174 65-3100

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