2005 NAIAS: A Johnson Controls Innovation Debuts Process to Make Multi-Colored Door and Instrument Panels

Advanced Technique Enables Supplier to Produce Interior Panels - in One Step - With Enhanced Aesthetics and Consumer Appeal

DETROIT, Jan. 9 -- Multiple colors, high levels of craftsmanship and crisp lines enhance the aesthetics and consumer appeal of vehicle door panels, instrument panels and other interior applications. And achieving such traits for interior panels has become easier for automotive designers, thanks to an all-new, advanced, injection-molding process developed by Johnson Controls .

Called CrafTec Multi-Color Injection (MCI), the process yields a two-color substrate for interior trim panels -- in one part -- without the need for extra moldings, appliques or painting. In addition, the technique simplifies and accelerates the panel design process, enhances design opportunities and reduces production scrap.

CrafTec MCI-based products already are making headway in the automotive marketplace. Five future vehicle programs planned by two major automakers will make use of interior panels supplied by Johnson Controls, and manufactured via the CrafTec MCI process.

Johnson Controls -- the largest, global supplier of automotive interior systems and batteries -- will display instrument panels, door panels and other interior applications made using the new process this week at the 2005 North American International Auto Show (NAIAS) in Detroit. They'll be shown as integrated elements in a real-world vehicle environment. The company's product and technology exhibit is being presented in room D2-15 at Cobo Center in Detroit.

The CrafTec MCI process has significant advantages compared with other types of panel-production techniques. Conventional methods necessitate the attachment of separate parts, or painting, to achieve multi-colored effects. By contrast, the Johnson Controls process is a single-substrate and single- piece method. Such an approach improves craftsmanship and quality by providing a gap-free fit and finish, and eliminates the potential for buzz, squeak and rattle problems.

"Door panels, instrument panels and other interior applications made with the CrafTec MCI process deliver what automakers want -- outstanding craftsmanship, high quality, design and timing improvements, and reduced waste," said Jeff Williams, group vice president and general manager, product planning for the Automotive Group of Johnson Controls. "In addition, automakers and vehicle-buyers get better products, thanks to the integration of different materials and colors in a single step and in one piece."

CrafTec MCI is one part of Johnson Controls' CrafTec lineup of interior processes, which also includes CrafTec Partial Mold-Behind -- a single-step, advanced injection-molding process that integrates cover materials; and CrafTec Partial Foam-in-Place -- a process in which plush softness is applied using the main substrate instead of separate, layered pieces. All CrafTec products can be designed into vehicles as separate components, or integrated together to create unique interior designs that previously would have been impossible to implement.

The entire CrafTec portfolio from Johnson Controls will be featured at the company's NAIAS exhibit.

"CrafTec MCI, and our overall lineup of CrafTec processes, reflect our ongoing commitment to deliver interior innovations to our customers," said Williams.

Johnson Controls is a global market leader in automotive systems and facility management and control. In the automotive market, it is the largest 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 , founded in 1885, has headquarters in Milwaukee, Wisconsin.