NAVISTAR MPAPS D-7117-2016 Foam Composite Trim Panel.pdf

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1、This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by International Truck and Engine Corporation. OCTOBER 2016 Page 1 of 6

2、NAVISTAR, INC. Material, Parts, and Process Specifications (MPAPS) NUMBER: MPAPS D-7117 Former Designation: TMS-7117 TITLE: Foam Composite Trim Panel CURRENT REV No.: 1610 DATE: Oct. 2016 WRITTEN/EDITED BY: D. Baker APPROVED BY: R. Goluch SUPERSEDES: Rev. 0108 August 2001 PRINTED COPIES OF THIS DOCU

3、MENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to

4、 determine the applicability of regulatory limits prior to use. 1.0 APPLICATION This specification covers a chemically bonded composite trim panel consisting of a foam composite core with a woven backing material and decorative fabric facing suitable for headliners and back panels over a temperature

5、 range of -30 to + 180F. 2.0 SCOPE This specification covers the general requirements for the foam composite core and performance requirements of the finished panel. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comp

6、ly with the requirements of the MPAPS B-50 specification 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-

7、16949 CFR Title 29, Part 1910 NAVISTAR Supplier Packing and Shipping Std. D-13 ASTM D 903 ASTM D D3574 NAVISTAR Engineering Design Std. A-16 NAVISTAR MPAPS B-50 NAVISTAR MPAPS P-9544 4.0 GENERAL REQUIREMENTS 4.1 Construction 4.1.1 Headliners The composite shall consist of the following layers: 4.1.1

8、.1 Backing Material 4.1.1.2 Fiberglass mat (in designated areas) 4.1.1.3 “Firm“ foam NUMBER: MPAPS-7117 TITLE: Foam Composite Trim Panel REVISION: 1610 This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate T

9、echnical Standards. Suppliers are required to assume all patent liability. 2016 by International Truck and Engine Corporation. OCTOBER 2016 Page 2 of 6 4.1.1.4 Fiberglass mat (in designated areas) 4.1.1.5 Backing material 4.1.1.6 “Soft“ foam 4.1.1.7 Outer fabric 4.1.2 Back Panels The composite shall

10、 be the same as for headliners except the fiberglass mats may be omitted. 4.1.3 Core The foam composite core shall consist of: 4.1.3.1 A firm inner layer of resin impregnated polyurethane foam as described in Table 1. 4.1.3.2 A soft outer layer of resin impregnated polyurethane foam as described in

11、Table 1. 4.1.3.3 These resins shall be non-toxic, non-malodorous resin binders suitable for chemical bonding. See Table 1 for resin content. 4.1.3.4 A 25 x 14 woven polyester backing material to provide flexible support and protection prior to installation in the vehicle. 4.1.3.5 When reinforcement

12、is required, such as for headliners, a 20 mil non-woven, random pattern, glass fiber filament mat shall be utilized in areas designated on the part drawing. 4.1.4 Outer Layer The decorative outer layer shall consist of a fabric covering meeting the requirements of the International specification as

13、indicated on the part drawing. TABLE 1 Foam Properties (Prior to Fabrication) Inner Layer Outer Layer Density, lbm/ft3 1.8 1.5 Thickness, in + 1/16 1/4 1/4 ILD on 4 in thickness 25% 80 - 65% 120 60 Support Factor 65/25 1.5 1.5 Resilience (% Rebound) 50 50 Tear Resistance, lbf/in per ASTM D3574 2.0 -

14、 2.5 1.5 - 1.8 Static Fatigue per ASTM D3574, Procedure 1 (75% deflection, 17 hrs) % Loss in 25% ILD 30 30 % Loss in Thickness 5 5 Resin Content, % 150 + 20 100 + 20 NUMBER: MPAPS-7117 TITLE: Foam Composite Trim Panel REVISION: 1610 This document is restricted and may not be sent outside Internation

15、al Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by International Truck and Engine Corporation. OCTOBER 2016 Page 3 of 6 4.2 Performance Requirements 4.3.1 Cyclic Aging 4.3.1.1 Sample Prep

16、aration Twenty-one coupons 200 x 50 x about 6 mm (8 x 2 x about 1/4 in) and 21 coupons 200 x 50 x about 13 mm (8 x 2 x about 1/2 in) shall be prepared by cutting sections from production parts. All coupons must include the decorative fabric facing on one of the 200 x 50 mm (8 x 2 in) faces, and shal

17、l be taken from representative locations. 4.3.1.1.1 Method All 42 coupons are subjected to the seven-step aging test shown in the table below. Three coupons of each thickness are subjected to 180 peel tests after each step in the aging cycle, per ASTM D903, except as indicated below. 4.3.1.2 Require

18、d There shall be no loss of adhesion between the fabric facing and the foam core or delamination of the headliner during any steps of the aging cycle, or after the test is completed. All peel tests shall result in 100 percent destruction of the foam substrate and must meet the minimum average peel s

19、trengths specified below. The foam composite shall not lose shape or integrity during any step of the aging test. Average Min. Peel Str. lbf/in Aging Cycle 1/4“ Thick 1/2“ Thick 1 24 hours at 38C (100F) and 100% RH 2.0 1.0 2 24 hours at 82C (180F) 2.0 1.0 3 Cool at room temperature for one hour 2.0

20、1.0 4 24 hours at -29C (-20F) 2.0 1.0 5 24 hours at 38C (100F) and 100% RH 2.0 1.0 6 7 days at 70C (158F) 2.0 1.0 7 Cool at room temperature for one hour 2.0 1.0 4.4 Thermal Shock 4.4.1 Method Sections of the finished headliner, as designated* on the drawing, shall be subjected to three of the cycle

21、s listed below. There shall not be any rest between steps, and the sections shall be examined after each cycle. * If no critical areas are designated, test areas shall be randomly located, although the entire headliner shall be capable of passing this test. 4.4.2 Required There shall be no loss of a

22、dhesion of the fabric facing. 4.4.2.1 Thermal Shock Cycle 1. 16 hours 82C (180F) 2. 8 hours -29C (-20F) NUMBER: MPAPS-7117 TITLE: Foam Composite Trim Panel REVISION: 1610 This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permissi

23、on from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by International Truck and Engine Corporation. OCTOBER 2016 Page 4 of 6 4.5 Humidity 4.5.1 Method Sections of the finished headliner, as designated * on the drawing, shall be subjected to 168 hours of

24、condensing humidity at 38C (100F) and 100 percent relative humidity. * If no critical areas are designated, test areas shall be randomly located, although the entire headliner shall be capable of passing this test. 4.5.2 Required There shall be no delamination of the fabric cover or the foam core. T

25、he sections shall not warp or disintegrate. There shall be no objectionable odor. 4.6 Flammability Resistance Parts supplied to this specification shall conform to and be certified by the supplier to meet the requirements of Federal Motor Vehicle Safety Standard No. 302 - Flammability of Interior Ma

26、terials and the requirements of MPAPS P-9544. 5.0 QUALITY Parts supplied shall be; free of objectionable odor, free of foreign material and mold release, and uniform in quality. Parts shall match the color, finish, and performance of pre-production approved samples. 5.1 Primary cosmetic fabric surfa

27、ces shall be free from voids, bumps, dimples, cuts, wrinkles, and bubbles. Surfaces that are not normally visible shall be indicated on the print and shall meet a mutually agreed level of surface quality and be so stated in the part control plan. The exposed foam surface shall be free of voids or im

28、perfections detrimental to strength, fit, function, or service life. 6.0 QUALIFICATION Engineering qualification of sources is required in advance of production shipments. Samples shall be accompanied by test data certifying that all requirements of the specification have been met. Suppliers shall s

29、ubmit samples for approval of finish, luster, color and appearance to the Navistar Industrial Design Group. Upon approval, styling master samples denoting the minimum level of acceptable appearance quality shall be developed and retained by the supplier and the quality department of each using NAVIS

30、TAR facility. NUMBER: MPAPS-7117 TITLE: Foam Composite Trim Panel REVISION: 1610 This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liabili

31、ty. 2016 by International Truck and Engine Corporation. OCTOBER 2016 Page 5 of 6 6.1 Quality Control Plan A Quality Control Plan for products supplied to the requirements of this specification will be established by mutual agreement between NAVISTAR and the supplier. Unless specific exception is not

32、ed, the following characteristics, where applicable*, shall be included in the plan as features for management by statistical process control.* * Other characteristics for inclusion in the control plan may be specified on the engineering drawing and/or purchase order. * See NAVISTAR Engineering Desi

33、gn Standard A-16 7.0 SOURCE APPROVAL AND QUALITY CONTROL 7.1 Supplier Requirements All suppliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements. NAVISTAR will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Production Part

34、Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies of registration certificates to their Corporate Buyer upon request. 7.2 Approval Parts supplied against contracts or purchase orders citing this

35、 specification shall be equivalent in all respects to those samples which were approved by the purchaser. No changes in formulation or processing practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the

36、 product are required, the supplier shall notify NAVISTAR Materials Engineering and Purchasing and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MS

37、DS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 7.3 Process Control The supplier shall either, perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide statistical evidence of the lot havi

38、ng been produced in a state of statistical control and with a process capable of providing all required properties. The part supplier and the quality control manager of the using NAVISTAR plant may determine testing and reporting requirements on specific products. 8.0 SHIPPING AND HANDLING Shipping

39、and identification shall be in accordance with NAVISTAR Supplier Packing and Shipping Standard D-13. Parts shall be packaged so as to avoid any damage in shipment detrimental to the appearance of the part. NUMBER: MPAPS-7117 TITLE: Foam Composite Trim Panel REVISION: 1610 This document is restricted

40、 and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by International Truck and Engine Corporation. OCTOBER 2016 Page 6 of 6 9.0 DESIGNATION ON DRAWINGS

41、 Example of note to use on drawings: MPAPS D-7117 10.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Suppliers may purchase controlled copies of this specification by contacting: Materials Engineering and Technology Dept. 10400 W. Nort

42、h Avenue Melrose Park, IL 60160 E-mail: MaterialsEngineeringN IHS Markit 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/ A.0 GENERAL INFORMATION Approved Source Colamco, Inc. REVISION HISTORY Revision Level Change Approved by Date Approved 1610 Converted to MPAPS R. Goluch 10/6/2016