FRANKFURT, Germany, Sept. 17 /PRNewswire-Asia/ -- Comprehensive system capability is the basis for innovative contributions to lightweight vehicle construction by Johnson Controls, one of the world's leading suppliers of automotive interior systems, electronics and batteries. To achieve this, the company uses the full range of possible materials and construction methods to produce cockpit systems and door panels that satisfy consumer requirements for both look and feel, and simultaneously support automakers in reducing vehicle weight.
(Photo: http://www.prnasia.com/sa/2009/09/17/20090917669750.jpg )
Lightweight construction has been a must in the conceptual design of new vehicles for many years. Automakers and their suppliers are thereby equally challenged. The goal is to reduce overall vehicle weight by using the lightest possible individual components and therefore reduce both fuel consumption and emissions. Also, public discussion about CO2 emissions produced by individual transport means that lightweight vehicle construction is currently highly topical. Through a comprehensive range of interior components and systems with optimized weights, Johnson Controls is helping to keep the weight of current and future automobiles as low as possible, despite increasing demand for safety and comfort features. Material substitution, process innovations and the integration of functions into existing components make this possible.
Vehicle interiors with potential for lightweight construction
In addition to lightweight seats, Johnson Controls also is committed to applying lightweight construction designs to its instrument and door panels. Modifications to surface layout, airbag integration and the component structure itself are the starting point for lightweight instrument panel construction. Depending on how these individual opportunities are combined, instrument panels can be made up to one third lighter than comparable units manufactured by conventional means. EcoSpace, a reduced cross-car beam for vehicle cockpits that may be seen in the current re3 concept car, for example, does more than merely save considerable space on the passenger side of the vehicle.
Thanks to hybrid plastic and steel construction the EcoSpace cockpit structure saves up to 26% of mass compared to conventional cross-beams. As a result, the free space opens up new design perspectives on the passenger side. Alternatively, EcoSpace can also be used to make the instrument panel smaller, thereby saving even more weight.
Visible natural materials for class A surfaces
A concept development involving visible natural fibers in the vehicle interior called "Exposed Natural Material" has a different purpose. In this context, Johnson Controls has succeeded in applying a new surface technology for the first time to structure materials already used in series production that are based on natural fibers so that their surface appeal satisfies the stringent demands in automotive interiors. A weight savings of up to 30% can be achieved by using a substrate element protected with transparent film, with no further surface material lamination. At the same time, this innovative concept also helps achieve authentic and natural aesthetics for the interior. This also appears in the re3 concept car, which contains both door panels and parts of the instrument panel made using this new material. For Han Hendriks, Vice President Global Product Centers Cockpit Systems at Johnson Controls, it would not have been possible to develop the new Exposed Natural Materials without profound production skills using natural fiber matting: "Our many years of experience in the field of natural fibers and our own production line enable us to modify materials and processes for new applications."
Specialized material substitutions
Even the traditional method of substituting conventional materials with alternative materials enables further weight savings to be achieved in the vehicle interior. Simply by replacing conventional injection molding techniques with foam injection molding on the main door panel carriers can save up to 300 g per door. The reason is that this procedure, also known as physically foamed injection molding, achieves particularly low wall thicknesses for components while still retaining a high level of dimensional stability. Besides the main carriers, these structural advantages can also be used in the manufacture of map pockets, for instance.
Using natural fiber materials to reduce weight
The same applies to the use of natural fibers as substrate materials for door panels or instrument panels. Depending on component geometry, two different material concepts are used, besides other natural fiber alternatives: Fibrowood, a wood fiber mat with an acrylic resin binder, or EcoCor, a moldable mat made of polypropylene and natural fibers that can be formed and covered in a one-step process. Both materials encourage the use of sustainable resources, have good crash performance and great potential for lightweight construction because the weight per unit area of natural fiber materials is much lower than normal thermoplastics, simply switching materials can achieve a weight saving of up to 25 percent.
The potentials for lightweight construction offered by Fibrowood can be used to still greater effect if the components are designed with thinner walls, or if functional elements are pressed directly into the components, therefore saving the weight of the adhesive that would otherwise be required.
In Han Hendriks' opinion, the availability of options for lightweight construction and materials means that still other opportunities for use are possible: "Our extensive systems and integration skills enables us to work with our customers in a targeted approach to further improve components," he said, revealing a focus for future development.
Digital photos are available at http://www.johnsoncontrols.co.uk/press .
Johnson Controls (NYSE: JCI) is the global leader that brings ingenuity to the places where people live, work and travel. By integrating technologies, products and services, we create smart environments that redefine the relationships between people and their surroundings. Our team of 140,000 employees creates a more comfortable, safe and sustainable world through our products and services for more than 200 million vehicles, 12 million homes and one million commercial buildings. For additional information, please visit http://www.johnsoncontrols.com .
