NAVISTAR MPAPS L-6505-2014 Urethane Foam Cut Slab.pdf

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1、This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. OCTOBER 2014 Page 1 of 6 NAVISTAR, INC. Material, Parts, and Process Specification

2、s (MPAPS) NUMBER: MPAPS L-6505 Former Designation: TMS-6505 TITLE: Urethane Foam, Cut Slab CURRENT REV. No.: 1410 DATE: Oct. 2014 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: TMS-6505 August 2007 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT

3、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 determine the applicability of re

4、gulatory limits prior to use. Change Notice: Changed to new MPAPS format; editorial changes. 1.0 APPLICATION This specification covers expanded or cellular polyurethane foams which are produced in slab and may be slit, die cut, or skived. Type I material is suitable for seat topper pads, seat pads o

5、r insulation in truck and bus applications. Type II material is suitable for acoustical applications and shall meet all the property and performance requirements of Type I and be approved by Navistar Vehicle Dynamics Department for the intended use. Type II is further divided into Grade A and B, wit

6、h medium and high sound absorptive characteristics, respectively. Rebonded foam may be used in some applications and shall be designated by an R suffix. NOTE: MPAPS L-6610 covers other thermal insulation materials used in truck applications. TMS-6612 Grade 3 covers acoustical foams used in under hoo

7、d applications. 2.0 SCOPE This specification covers the general requirements, property, performance requirements, quality, and source approval. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requiremen

8、ts of the MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified the latest issue of all referenced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 NAVISTAR TMS-95

9、44 ASTM C 384 NAVISTAR Manufacturing Std. MS-D-13 NAVISTAR MPAPS GT-31 ASTM D 3574 NAVISTAR Eng. Design Std. A-16 NAVISTAR MPAPS P-9543 ASTM E 1050 CFR 29, Part 1910 NAVISTAR MPAPS B-50 FMVSS 302 4.0 GENERAL REQUIREMENTS 4.1 Surface Condition The material shall have a homogenous cell structure, and

10、shall be free from any surface crust that will be in contact with any trim covering material. NUMBER: MPAPS L-6505 TITLE: Urethane Foam, Cut Slab REVISION: 1410 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.

11、 Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. OCTOBER 2014 Page 2 of 6 4.2 Property And Performance Requirements All tests shall be performed in accordance with ASTM D 3574, Testing Slab Flexible Urethane Foam, unless otherwise specified. 4.2.1 Indentation Force Defl

12、ection Specified Deflection (IFD, formerly ILD): Test Method B1 May be specified on the engineering drawing. 4.2.2 Indentation Force Deflection Specified Force (IFD): Test Method B2 May be specified on the engineering drawing. 4.2.3 Tensile Strength: Test Method E Shall be 69 kPa (10 psi) minimum. R

13、ebonded foam shall be 35 kPa (5.1 psi) minimum. 4.2.4 Elongation: Test Method E Shall be 150% min except for rebonded which shall be 65% minimum. 4.2.5 Tear Strength: Test Method F Shall be 2.6 N/cm (1.5 lbf/in) minimum and 1.9 N/cm (1.1 lbf/in). 4.2.6 Constant Deflection Compression: Test Method D

14、50% Deflection; shall be 40% maximum set. 4.2.7 Fatigue Test: Test Method I3 Max height loss: 5% from original after 100,000 cycles. 4.2.8 Solvent Resistance: One Hour Immersion in Petroleum Naphtha Material shall show no signs of deterioration, surface stickiness or delamination. 4.2.9 Odor Shall b

15、e inoffensive both wet and dry. 4.2.10 Staining 4.2.10.1 METHOD: Expose material contact with light colored vinyl coated fabrics to CEMS GT-31 Method F for 96 hours. 4.2.10.2 REQUIRED: Shall not stain. 4.2.11 Sound Absorption Properties (Type II Only) 4.2.11.1 METHOD: Test in accordance with ASTM C

16、384 (ASTM E 1050 is considered equivalent). 4.2.11.2 REQUIRED: Shall meet the following minimum requirements for absorption coefficients: Type II, Grade A Frequency, Hz Absorption Coefficient 500 0.20 min 1000 0.60 min 2000 0.60 min 4000 0.40 min Type II, Grade B Normal-incidence absorption shall be

17、 measured at: 500, 630, 800, 1000, 1250, 1600, 2000, 2500, 3150, and 4000 Hz. The normal incidence absorption coefficient at any one frequency shall not be less than 0.40 and the average of the normal incidence absorption coefficients shall not be less than 0.70. NUMBER: MPAPS L-6505 TITLE: Urethane

18、 Foam, Cut Slab REVISION: 1410 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. OCTOBER 2014 Page 3 of 6 4.2.12 Flammability Materi

19、al and parts must conform to and be certified by the supplier to meet all requirements of the latest issue of Federal Motor Vehicle Safety Standard No. 302 (Flammability of Interior Materials) and shall meet all requirements of Navistar Specification TMS-9544. 4.3 Property And Performance Requiremen

20、ts Rebonded Foam 4.3.1 Cyclic Aging 4.3.1.1 Sample Preparation Prepare samples for tensile testing per 4.2.3. Prepare sufficient numbers to run 5 minimum samples at each condition. 4.3.1.2 Required: There shall be no loss of adhesion between the bonded layers during any step of the aging cycle. Repo

21、rt tensile, elongation and failure mode. Table 1 Aging Test Cycle Aging Cycle Tensile Strength 1. 24 hours at 38 C (100 F) and 100% RH Report 2. 24 hours at 82 C (180 F) Report 3. Cool at room temperature (for one hour) Report 4. 24 hours at -29 C (-20 F) Report 5. 24 hours at 38 C (100 F) and 100%

22、RH Report 6. 7 days at 70 C (158 F) Report 7. Cool at room temperature for one hour Report 4.3.2 Thermal Shock 4.3.2.1 Method: Sections of seat cushions shall be subjected to three of the cycles listed below. Test areas shall be randomly located, although the entire part shall be capable of passing

23、this test. There shall not be any rest between steps, and the sections shall be examined after each cycle. Thermal Shock Cycle 1. 16 hours 82 C (180 F) 2. 8 hours -29 C (-20 F) 4.3.2.2 Required: There shall be no loss of adhesion. 4.3.3 Humidity 4.3.3.1 Method: Sections of seat cushions, shall be su

24、bjected to 168 hours of condensing humidity at 38C (100F) and 100% relative humidity. Test areas shall be randomly located, although the entire composite shall be capable of passing this test. NUMBER: MPAPS L-6505 TITLE: Urethane Foam, Cut Slab REVISION: 1410 This document is restricted and may not

25、be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. OCTOBER 2014 Page 4 of 6 4.3.3.2 Required: There shall be no loss of adhesion. There shall be no objectionable odor. 4.4 D

26、imensional Tolerances Unless otherwise specified, the dimensional tolerances shown in Table 1 of this specification shall apply, and the standard tolerances shown in the title block of the Engineering Drawing are not applicable. TABLE 1 TOLERANCES FOR FOAMS Thickness (inches) Tolerance Width and Len

27、gth (inches) .060 to .500 .030” 0.00 to 2.00 .501 to .750 .040” 2.01 to 4.00 .751 to 1.00 .050” 4.01 to 8.00 1.01 to 2.00 .060” 8.01 to 12.00 2.01 and over .120” 12.01 to 24.00 .180” 24.01 to 36.00 .250” 36.01 to 48.00 .350” 48.01 and over 5.0 QUALITY Parts supplied to this specification shall be un

28、iform throughout in texture, finish, and properties. Finished parts shall not exhibit solid spots, cracks or craters larger than 6.4 mm (1/4 in) in diameter by 6.4 mm (1/4 in) deep. No surface shredding or crumbling shall be evident, during or after assembly. Defects, which affect the appearance or

29、performance of the finished product, shall be cause for rejection. 5.1 Qualification Materials submitted for approval to this specification shall include the following: 5.1.1 A detailed, signed test report documenting testing to this specification per MPAPS P-9543. 5.1.2 The complete procedure used

30、for preparing and curing materials for test, especially surface preparation (when appropriate) and condition of the test materials. 5.1.3 A complete description, including engineering prints and pictures of any non-standard test fixtures used. 5.1.4 Adhesive, substrate and any chemicals used for bon

31、ding where appropriate. 5.2 Submission The material test report shall be submitted to: Manager of Non-Metallic Materials Materials Engineering and Technology Navistar, Inc. 2601 Navistar Dr. Lisle, IL 60532 NUMBER: MPAPS L-6505 TITLE: Urethane Foam, Cut Slab REVISION: 1410 This document is restricte

32、d and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. OCTOBER 2014 Page 5 of 6 5.3 Approval A report from Navistar will be issued approving new materials to this

33、specification. Formal approval is not granted until this report has been published and the new material is listed in this specification. However, the approval report may be used as authorization for usage of that approved material/process prior to a change to this specification. 5.4 Quality Control

34、Plan A Quality Control Plan for this product will be established by mutual agreement between Navistar and the supplier. Unless specific exception is noted, the following characteristics, where applicable*, shall be included in the plan as features for management by statistical process control. * Typ

35、e I - Density and Thickness Type I Seat cushions IFD and Thickness Type II - Density and Thickness * Other characteristics for inclusion in the control plan may be specified on the engineering drawing and/or purchase order. * See Engineering Design Standard A-16. 5.4.1 The Quality Control Plan shoul

36、d include periodic evaluation of the sound absorption properties. 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 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

37、 can also fulfill all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies of registration certificates to their Navistar Corporate Buyer upon request. 6.2 Approval Parts

38、 supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples that were approved by the purchaser. No changes in formulation or processing practices are permitted without approval. In the event that changes in material, properties, proc

39、essing practices, construction, color, or labeling of the 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 ne

40、w or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 6.3 Process Control The supplier shall either perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 gui

41、delines, or provide statistical evidence of the lot having 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 o

42、n specific products. NUMBER: MPAPS L-6505 TITLE: Urethane Foam, Cut Slab REVISION: 1410 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar,

43、 Inc. OCTOBER 2014 Page 6 of 6 7.0 SHIPPING, PACKING AND IDENTIFICATION Loading, packing and identification shall be in accordance with Manufacturing Std. MS-D-13. 8.0 DESIGNATION ON DRAWINGS The type and compression load deflection (IFD) or density shall be specified on the engineering drawing. Exa

44、mples: 1) Urethane Foam, Type I, MPAPS L-6505; Load Deflection (IFD) = 222 N (50 lbf) or 2) Urethane Foam, Type I-R, MPAPS L-6505; Load Deflection (IFD) = 222 N (50 lbf) or 3) Urethane Foam, Type II, MPAPS L-6505; Density = 32 1.6 kg/m (2 0.1 lbm/ft) or 4) Urethane Foam, Type II, Grade A, MPAPS L-65

45、05; Density = 321.6 kg/m (20.1 lbm/ft). NOTE: Drawings referring to Type II (with no grade indicated) shall meet Grade A requirements. Drawings specifying MPAPS L-6505 without indicating any type shall meet Type I requirements. Drawings for under hood acoustical applications referencing MPAPS L-6505

46、, Type II must now meet the requirements of TMS-6612, Grade 3. 9.0 APPROVED SOURCES Type II - See individual part drawings for approved sources. 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. Navistar, Inc. 2601 Navistar Dr. Lisle, Il. 60532 E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/