Plastics Industry 'Oscar' for Innovative Covering Process

BURSCHEID, Germany, October 20 --

- Johnson Controls Receives Award for 'In-Mold Graining' from the International Association of the 'Society of Plastics Engineers'

Johnson Controls, one of the world's leading suppliers of automotive interior systems, interior electronics and batteries, was honoured with the 2nd prize of the 'Automotive Division Award 2004' of the Society of Plastics Engineers (SPE) - Central Europe. This award is considered to be the 'Oscar' of the plastics processing industry. Johnson Controls received the prize in the Interiors category for 'In-Mold Graining' a manufacturing process for larger surfaces the company developed to series maturity. The technique is being used for the first time on a large surface in the production of the door panels for the new Opel Astra.

'In-Mold Graining' is a covering process in which an ungrained Thermoplastic Polyolefin (TPO) foam foil is wrapped onto a carrier and grained in a single process stage. The new process offers a greater design freedom than the conventional methods using pre-grained foils. These tend to lose their texture during the covering process. Because the grain is not formed until the compression stage in the 'In-Mold Graining' process, the pattern is retained even on sharp edges and radii. It is also possible to apply different grains in a single process stage. "The process can be used with all conventional carrier materials. It is also possible to combine it with conventional foam processes" explains Wim Jacobs, Director of Material and Process Engineering at Johnson Controls.

A further advantage of 'In-Mold Graining' is its environmental sustainability. The TPO foil used in the process can be separated from the carrier material with relative ease to enable the materials to be recycled. The natural fibre carrier, as used in the Astra, is made of ninety per cent raw materials from sustainable sources and can be disposed of cleanly.

As an alternative to the long-standing conventional covering technologies, 'In-Mold Graining' is also ideal for use in instrument panels. The company is using this technique for the first time on a large surface in the series production of the door panels of the Opel Astra. Johnson Controls is also using the process in the production of the cockpit of the new Mitsubishi Colt. The surface is attractive and has two different graining effects.

'Automotive Division Award' for the ninth time

This is the ninth time that the company has received the SPE Central Europe's Automotive Division Award. The categories entered are: Body Interior, Body Exterior and Chassis. A jury composed of 25 members from all branches of plastics development and processing evaluates the quality of the materials, their processing and the innovative potential of the new developments. The SPE is a worldwide association of engineers and scientists with over 38,000 members.

Along with the Opel Astra, ten other vehicle models received awards in Dusseldorf including a Rolls-Royce, a Maybach and a Smart Forfour.

Further information is available from:

    
    Johnson Controls GmbH                  Johnson Controls GmbH
    Automotive Group                       Automotive Group
    Astrid Schafmeister                    Ina Longwitz
    Industriestrasse 20-30                 Industriestrasse 20-30
    51399 Burscheid                        51399 Burscheid
      
    Tel.: +49-2174-65-3189                 Tel.: +49-2174-65-4343
    Fax: +49-2174-65-3219                  Fax: +49-2174-65-3219
    E-Mail: astrid.schafmeister@jci.com    E-Mail: ina.longwitz@jci.com

Johnson Controls, Inc. is a global market leader in automotive systems and facility management and control. In the automotive market, it is a major supplier of integrated seating and interior systems, and batteries. For non-residential facilities, Johnson Controls provides control systems and services including comfort, energy and security management.

Johnson Controls (New York Stock Exchange: JCI), founded in 1885, has its headquarters in Milwaukee, Wisconsin, USA. The company's sales for 2003 totalled US$22.6 billion, the Automotive Group worldwide generating US$17 billion of this figure and Europe accounting for US$5.9 billion. The European headquarters is in Burscheid, Germany. The company's product portfolio also includes instrument panels/cockpits, door systems, overhead systems, interior electronics, electrical energy management and engine electronics.

Johnson Controls GmbH, Automotive Group, Astrid Schafmeister, Tel: +49-2174-65-3189, E-Mail: astrid.schafmeister@jci.com or Johnson Controls GmbH, Automotive Group, Ina Longwitz, Tel: +49-2174-65-4343, Fax: +49-2174-65-3219, E-Mail: ina.longwitz@jci.com