NAVISTAR TMS 7028-2007 Bonded Trim Composites Interior (Revision K).pdf

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1、INTERNATIONAL TRUCK AND ENGINE CORPORATION TMS (TRUCK MATERIAL SPECIFICATION) NUMBER: TMS-7028 TITLE: Bonded Trim Composites, Interior REVISION: K WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering DATE ISSUED: August 2007 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR

2、 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 determine the applicabil

3、ity of regulatory limits prior to use. Change Notice: Added Section 2.1 on Restricted Chemical Substances; Editorial Changes. Reference: File 30-6A Keywords: Trim Composites; Interior 1.0 APPLICATION This specification covers interior trim composites, typically consisting of a facing fabric or mater

4、ial, padding, and a backing. These components are chemically, thermally, and/or dielectrically bonded or laminated parts suitable for interior uses such as wall panels, head liners, sun visors, cabinets, seat inserts, floor mats, and door trim panels. 2.0 SCOPE This specification covers the general

5、requirements for the individual components of the composite (i.e. fabric, padding, and backing) and property and performance requirements of the bonded or molded, finished composite. Requirements for quality, qualification, shipping and identification, and source approval and quality control are inc

6、luded. 2.1 Restricted Chemical SubstancesEffective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the CEMS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified the latest issue of all referenced standards shall a

7、pply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 INTERNATIONAL TMS-6608 International Manufacturing Std. D-13 INTERNATIONAL TMS-7113 CFR Title 29, Part 1910 INTERNATIONAL TMS-7121 FMVSS-302 INTERNATIONAL

8、 TMS-7109 INTERNATIONAL CEMS D-22 INTERNATIONAL TMS-7116 INTERNATIONAL CEMS D-28 INTERNATIONAL TMS-7124 INTERNATIONAL, TMS-6505 INTERNATIONAL CEMS B-50 INTERNATIONAL, TMS-6606 CFR 49, Part 571.302 INTERNATIONAL TMS-9544 SAE J1323 INTERNATIONAL TMS-9543 ASTM D 903 This document is restricted and may

9、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. 2007 by International Truck and Engine Corporation. AUGUST 2007 Page 1 of 6 NUMBER: TITLE: REVISION: TMS-7028 Bon

10、ded Trim Composites, Interior K 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. 2007 by International Truck and Engine Corpor

11、ation. 4.0 GENERAL REQUIREMENTS Unless otherwise specified on the engineering drawing and/or purchase order, the manufacturing practice and bonding methods are optional. The supplier is responsible to select individual components of the composite appropriate for the bonding method selected and so fa

12、bricate these as to insure that the finished composite is suitable for its intended use and meets all property and performance requirements specified herein. The following components of the composite may be considered typical. Specific materials may be indicated on the engineering print. 4.1 Padding

13、 Shall be bondable urethane foam or non-woven padding (Fiberbond). The urethane foam shall meet the requirements of TMS-6505. The non-woven padding (suitable for dielectric bonding only) shall meet the requirements of TMS-7067. TMS-6606 may be appropriate for some parts, but is not considered a bond

14、ed composite and would not be covered by this specification. Some parts may be specified without padding. 4.2 Face Materials Shall meet the requirements designated on the engineering drawing and/or purchase order. Color and pattern shall match approved standards on file in the TDTC Industrial Design

15、 Department. The following materials are considered suitable: Fabric: TMS-7113 Carpet and carpet-like trim: TMS-7126 Vinyl coated fabrics and leather: TMS-7121 Rubber Mats: TMS-6608 4.3 Backing Fabrics Any fabric or backing which provides a composite meeting all requirements of this specification sh

16、all be acceptable but may or may not be required on different types of composites. The following backings have provided satisfactory performance in the past. Values shown are typical values unless otherwise indicated. (Tests performed per ASTM D 751) 4.3.1 Nylon Tricot Denier: 40 Tensile Strength: 4

17、35 N (98 lbf) Tear Strength: 50 N (12 lbf) 4.3.2 Cotton Sheeting Count: 32 x 26 Weight: 73 g/m (2.16 oz/yd) Tensile: Warp/Fill: 265/265 N (60/60 lbf) Tear: Warp/Fill: 66/44 N (15/10 lbf) 4.3.3 Spunbonded Nylon (Cerex) Weight: 20 g/m (0.6 oz/yd) Tensile: Machine/Transverse: 70/44 N (16/10 lbf) Tear:

18、Machine/Transverse: 22/17 N (5/4 lbf) Burst (Mullen): 150 kPa (22 psi) AUGUST 2007 Page 2 of 6 NUMBER: TITLE: REVISION: TMS-7028 Bonded Trim Composites, Interior K This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from

19、 Corporate Technical Standards. Suppliers are required to assume all patent liability. 2007 by International Truck and Engine Corporation. AUGUST 2007 Page 3 of 6 4.3.4 Polypropylene SheetingDenier: 1.9 Weight: 34 g/m2(1.0 oz/yd) Tensile: Warp/Fill: 85.5/49.4 N (20/12 lbf) Elongation: Warp/Fill: 87.

20、3/74.4 N (20/17 lbf) 4.3.5 Rigid Backing For those trim products requiring a rigid backing, such as door trim panels, the following materials are considered suitable: Pressed Wood Hardboard per SAE J1323 Laminated Fiberboard (Head Board) per TMS-7066 Structural RIM per TMS-7124 Molded Fiberglass per

21、 TMS-7109 Injection Molded Plastic per TMS-7116 Molded Cellulosic per TMS-7125 Fiberglass Reinforced Polyester per CEMS D-22 Other Plastic per CEMS D-28 4.4 Property And Performance Requirements 4.4.1 Flammability Requirements The finished composite must conform to and be certified to meet all requi

22、rements of FMVSS-302, Flammability of Interior Materials (CFR 49, Part 571.302). Components of the composite which are not 100% bonded together shall be tested separately and each component must demonstrate required flammability resistance. Components of the composite which are 100% bonded together

23、are not specifically required to demonstrate flammability resistance when tested as individual parts, however the bonded (finished) composite must demonstrate required flammability resistance. 4.4.2 Seat Inserts - Specimen Preparation For Flammability Requirement The specimen shall be completely sat

24、urated with wet steam at 77-93 C (170-200 F) followed by hand drying in a convection oven for 16 hours at 82 C (180 F) followed by conditioning as per FMVSS- 302. 4.4.3 Low Temperature Resistance (Seat Inserts Only) 4.4.3.1 Method: Samples prepared as indicated under Cyclic Aging - Sample Prep 2 sha

25、ll be exposed for four hours at a temperature of -29 C (-20 F) and then bent around a mandrel of size indicated below. Foam Thickness Mandrel Diametermm in mm in3.2 1/8 6.4 1/4 4.8 3/16 12.7 1/2 6.4 1/4 19.0 3/4 7.9 & Up 5/16 & Up 25.4 1 4.4.3.2 Required: Shall show no evidence of breaking, cracking

26、, checking or loss of adhesion. After 24 ours at room temperature, shall show no evidence of shrinking, wrinkling, distortion, or discoloration. hNUMBER: TITLE: REVISION: TMS-7028 Bonded Trim Composites, Interior K This document is restricted and may not be sent outside International Truck and Engin

27、e Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2007 by International Truck and Engine Corporation. 4.4.4 Cyclic Aging 4.4.4.1 Sample Preparation - Option 1 Seven (7) boards 200 x 300 x 5 mm (8 x 12 x 0.2 in) a

28、nd seven (7) boards 200 x 300 x 25 mm (8 x 12 x 1 in) shall be prepared by cutting sections representative of a production part. All boards must include the decorative facing of one of the 200 x 300 mm (8 x 12 in) faces. 4.4.4.2 Sample Preparation - Option 2 Twenty-one coupons 200 x 50 x about 6 mm

29、(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 shall be taken from random locations. 4.4.4.3 Method:

30、 Subject all samples to the seven step aging test shown below. Three peel tests per ASTM D 903 shall be performed at the end of each step at the conditions in Table 1 below. When sample preparation 1 is used, three peel samples measuring 25 x 200 mm (1 x 8 in) are scored through the first layer imme

31、diately prior to testing. For sample preparation 2, each sample is tested as is. For dielectrically bonded materials, a bond line shall be centered on each peel strip. 4.4.4.4 Required: There shall be no loss of adhesion between the bonded layers during any step of the aging cycle. All peel tests sh

32、all result in substrate destruction or meet the minimum peel values listed below or as required on the print. Table 1 Aging Test Cycle Aging CycleMinimum Peel Strength* N/m (lbf/in) Width Fully BondedWith Padding Dielectric Linear BondFully Bonded No Padding1. 24 hours at 38 C (100 F) and 100% RH 40

33、0 (2.3) 175 (1) 800 (4.6) 2. 24 hours at 82 C (180 F) 400 (2.3) 175 (1) 800 (4.6) 3. Cool at room temperature (for one hour) 600 (3.4) 250 (1.4) 1200 (6.8) 4. 24 hours at -29 C (-20 F) 400 (2.3) 175 (1) 800 (4.6) 5. 24 hours at 38 C (100 F) and 100% RH 400 (2.3) 175 (1) 800 (4.6) 6. 7 days at 70 C (

34、158 F) 400 (2.3) 175 (1) 800 (4.6) 7. Cool at room temperature for one hour 600 (3.4) 250 (1.4) 1200 (6.8) 4.4.5 Thermal Shock 4.4.5.1 Method: Sections of the finished composite, as designated on the drawing, shall be subjected to three of the cycles listed below. If no critical areas are designated

35、, test areas shall be randomly located, although the entire part shall be capable of passing this test. There shall not be any rest between steps, and the sections shall be examined after each cycle. AUGUST 2007 Page 4 of 6 NUMBER: TITLE: REVISION: TMS-7028 Bonded Trim Composites, Interior K This do

36、cument 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. 2007 by International Truck and Engine Corporation. Thermal Shock Cycle 1. 16 hours

37、82 C (180 F) 2. 8 hours -29 C (-20 F) 4.4.5.2 Required: There shall be no loss of adhesion. 4.4.6 Humidity 4.4.6.1 Method: Sections of the finished composite, as designated on the drawing, shall be subjected to 168 hours of condensing humidity at 38C (100F) and 100% relative humidity. If no critical

38、 areas are designated, test areas shall be randomly located, although the entire composite shall be capable of passing this test. 4.4.6.2 Required: There shall be no delamination of the fabric cover or foam core. Sections shall not warp or disintegrate. There shall be no objectionable odor. 4.4.7 Cr

39、ocking, Staining, Tackiness, and Blocking Sections of the finished composite, as designated on the drawing shall meet the crocking, staining, tackiness, and blocking requirements of the specified fabric. If no critical areas are designated on the drawing, test areas shall be randomly located, althou

40、gh the entire part shall be capable of passing these requirements. 5.0 QUALITY Material shall be free from objectionable odor, have flexibility necessary for good tailoring, be uniform in quality, and match the color and finish of pre-production samples originally approved. Certification of complian

41、ce to this specification shall be furnished with each lot. 5.1 QualificationMaterials submitted for approval to this specification shall include the following: 5.1.1 A detailed, signed test report documenting testing to this specification per TMS-9543. 5.1.2 The complete procedure used for preparing

42、 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 bonding where ap

43、propriate. 5.2 Submission The material test report shall be submitted to: Manager of Non-Metallic Materials Materials Engineering and Technology International Truck and Engine Corporation PO Box 1109 Fort Wayne, IN 46801 5.3 Approval A report from International will be issued approving new materials

44、 to this 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. AUGUST 2007

45、 Page 5 of 6 NUMBER: TITLE: REVISION: TMS-7028 Bonded Trim Composites, Interior K 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 liabil

46、ity. 2007 by International Truck and Engine Corporation. 6.0 SOURCE APPROVAL AND QUALITY CONTROL6.1 Supplier RequirementsAll suppliers to International Truck and Engine are required to be registered to ISO 9001 Quality System Requirements. International will also accept TS-16949 registration as long

47、 as the supplier 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 International Corporate Buyer upon reques

48、t. 6.2 ApprovalParts supplied against contracts or purchase orders citing this 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 product are required, the supplier shall notify Materials Engineering at TDTC and Purchasing and Supplier Development of the proposed change(s