Johnson Controls Supplies Many Interior Products for New Mercedes-Benz C-Class

Technology Drives Quality

BURSCHEID, Germany, April 19 -- Quality was the focus of particular attention when the Mercedes-Benz C-Class went into series production. The same principle was applied by Johnson Controls, one of the world's leading suppliers of automotive interior systems, electronics and batteries. Intensive collaboration between automaker and supplier prevailed for the duration of the project, and resulted in a number of innovations. Components supplied by Johnson Controls include the headliner, together with sun visors and grab handles, the rear seat structure, the instrument panel and seating components, plus the integrated HomeLink garage door opener and park distance warning display, both of which aids are optional extras.

"When buyers of the new Mercedes-Benz C-Class first familiarize themselves with the interior of their new sedan, they will initially be impressed by the high quality finish and attention to detail", said Matthias Berg, Vice President and General Manager DaimlerChrysler Customer Business Unit at Johnson Controls. At best, they will only be able to guess at the many process innovations that have contributed to these developments. Johnson Controls broke new ground in manufacturing components like the headliner: With a new round table system, the company not only increased production efficiency but also improved the quality of the product at the same time.

Laser-welded, rear-seat backrests

As a pioneer in laser remote technology, Johnson Controls also came up with a unique method of producing sandwich structures for the rear-seat backrests. This process has already shown its value in other components, when used in conjunction with traditional welding methods. After experts came up with a rear-seat backrest design suitable for laser processing, it was possible to use laser remote technology alone for the first time ever in the production of a large-scale series component.

This process involves directing the high-energy laser beam into an optical system and then using mirrors to redirect it at a high speed to the individual welding points on the component. Because only the mirrors - and no heavy electrode holders - have to be moved mechanically, the welding process is up to six times faster than traditional methods. Other advantages of this still new technology include the fact that the weld seam is up to 25% stronger.

Johnson Controls utilized a practical approach when it came to the instrument panel. Tried and tested processes define production in this area. Injection-molded substrate materials with a sprayed polyurethane skin are used to meet stringent quality standards. A knee airbag has been incorporated for the first time in large-scale series production, including a laser weakened, predetermined breaking point below the steering column to permit its release.

Commenting on these groundbreaking developments, Matthias Berg noted, "Close collaboration between the project teams has shown that it is possible to continually identify and implement new enhancements, even for well established products."

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