Grammer Introduces New Surface for Auto Interiors

AMBERG, Germany, Nov. 3, 2003 -- Grammer AG-Automotive, a leading supplier of specialty automotive seating systems, has introduced a new interior surface made of polyurethane (PU) skin, which allows automakers to provide a much more pleasing feel for occupants.

Grammer, which supplies armrests and headrests for passenger cars and high-end vehicles, is providing this innovative surface technology to BMW for its 2004 5 Series models.

The PU skin has an enhanced surface feel and elegant appearance, which gives a very favorable impression to consumers. It is a relatively cost- effective, versatile solution that requires substantial technical expertise to manufacture.

Creating a PU skin involves extensive studies and tuning processes to produce a surface with the desired high level of quality. It can be exactly tuned to customer requirements, and to reflect the vehicle's image.

The selected surface structure is transferred to a mold -- in a galvanic process -- by copying the desired structure to a nickel-plated female mold. Every part requires a separate mold, which has to be duplicated for volume production. Each mold is heated, as the entire manufacturing process is based on maintaining correct temperatures.

For production, both halves of the mold are sprayed with a release agent. After it has dried, the bottom of the mold is sprayed with a special coating, a water-based acrylic polyurethane, which must meet a number of specifications. Despite the thickness of the coating, measured in micrometers, it has to cover well, resist wear and minimize emissions. It also must remain ductile and may not chip within an extreme temperature range. The coating may not change color over time, and must be anti-static.

Once the mold is closed, a narrow space (tenths of a millimeter) remains between the bottom part and the cover. The width of this space defines the final application of the skin. The mold is filled with a two-component PU elastomeric system, which is also a new development. The blocking time of the low-viscosity reactive mixture is only a few seconds until polymerization is complete. The skin is now "foamed-in" from behind.

The final step is application of a molded thermoplastic support, enabling the fastening of the skin to the specific part of the vehicle. The skin is trimmed to size and mechanically fixed to the support.

Grammer AG is a world leader in the development and manufacture of innovative components and systems for automobile interiors. Wherever people use vehicles, Grammer, based in Amberg, Germany, sets the standard for security, comfort and ergonomics. Automotive is the company's largest division and supplies headrests, armrests, center consoles and integrated child booster seats to vehicle manufacturers and their tier 1 systems suppliers. The company's second division, Seating Systems, provides driver seats for heavy trucks and off-road vehicles (tractors, construction machinery, fork-lifts) as well as passenger seats for trains and buses. Grammer Seating Systems is active both as a first-time supplier and as a retrofitter.

As a global player, the Grammer Group operates with a strong customer focus that includes location of development and production facilities close to clients and relies on an international network of partners. In fiscal 2002, Grammer Group sales were $839.7 million, with approximately $120 million in North America. Grammer and its 22 consolidated companies employ more than 7,000 people, operating in 13 different countries worldwide.

Grammer has manufacturing facilities in Piedmont, S.C.; Queretaro and Tetla, Mexico, and a sales and engineering office in Troy, Michigan. Additional information is available on the Internet at www.grammer.com .