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Johnson Controls Engineers the First Two-Color Door Panel to a One-Piece Carrier in the new BMW 5 Series

BURSCHEID, Germany, May 8, 2007; When the BMW 5 Series was redesigned, the vehicle interior was also upgraded. For Johnson Controls , one of the world's leading suppliers of auto-motive interior systems, electronics and batteries, this meant a complete new development of the door panels. By introducing machinery and process innovations, Johnson Controls managed for the first time ever to apply a two-color foil to a single-component substrate made of natural fibers. The new process ensures both cost-effective production and a high-quality finish.

Two-color components of automotive interiors up until now have generally been produced as multiple parts before being applied to one another. As a result, seams and gaps remain visible with this method. It also makes it difficult in some cases to observe strict weight limitations - but not so with the BMW 5 Series. "Working closely with BMW, we broke new ground with this technology - being the first company to retain a single-compo-nent substrate and successfully cover it with a two-color, off-the-roll plastic foil" said Achim Hosenfeld, Vice President and General Manager of Johnson Controls.

Anyone who has ever tried to wrap an asymmetric object with striped gift wrap paper in such a way that the lines are abso-lutely parallel, even along the edges, can probably imagine the kind of challenges engineers faced. To ensure a high-quality finish and harmonious overall effect, exacting tolerances must be observed where the two colors meet on the door panels. The film is stretched when it is applied to the substrate. This distorts the color demarcation line, which then has to be brought back into proper alignment.

In the fully automated production process, machinery and tool advances ensure the color demarcation lines stay within the exacting tolerances at all times.

Kits for production in China

The BMW 5 Series currently in production at the Chinese BMW plant in Shenyang is also being fitted with these innovative door panels from Johnson Controls. The company also supplies the eight-inch display for the rear seat entertainment system for the long-wheelbase version of the BMW 5 Series being produced in China. It also provides the integrated garage door opener, HomeLink worldwide as optional equipment, too.

"We are pleased that our products and our manufacturing expertise enabled us to contribute to the high-end quality of the new model", said Achim Hosenfeld.