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Johnson Controls' unveils surface developments at IAA

Johnson Controls is announcing two new processes for producing scratch-resistant and matt finishes at the IAA Frankfurt Motor Show today.

The PP Thin Film method consists of a composite foil comprised of multiple, primarily polypropylene (PP) layers in a direct mould-behind process. All types of polypropylene and even fibre glass-reinforced plastics or recycled materials can be used as the substrate material.

Unlike enamel-painted surface parts, the films are highly scratch-resistant. As the degree of glossiness can be varied, they also can be readily adapted to match the finish of adjacent parts.

As a result, Johnson says, long-term durability of the parts is improved, since there is no paint to chip. This new thin film is suitable for all interior parts that are designed to accommodate foil coverings.

Depending on the depth of the design, a one or two-step process is used in production. Deeply moulded components, such as door map pockets, require a two-step process. First examples of parts to use PP Thin Film include floor consoles, pillar trims and seat back panels.

In a second development, RIM alpha surface technology, Johnson Controls also has introduced advances in materials processing to achieve cost-effective results. Unlike previous methods, only a one-step process is now required, reducing the processing time by about half. The all-in-one process also enables the production team to monitor wall thickness and reduce material consumption in the process. This allows strategic surface weakening to be included to accommodate airbag openings.

A processing technique also has allowed two-colour parts to be produced by the RIM method for the first time. To achieve this, Johnson Controls uses a “hidden seal” that separates the two colours from each other during the production process, and although it remains on the part once the surface has hardened, it is invisible on the final product. This process is suitable for use in all segments from lower medium to luxury class vehicles.

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