NAVISTAR TMS 7109-2001 Molded Fiberglass Headliner (Revision A-1).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. Ge32001 by International Truck and Engine Corporation. AUGUST 2001 Page 1 of

2、 4 INTERNATIONAL TRUCK AND ENGINE CORPORATION TMS (TRUCK MATERIAL SPECIFICATION) NUMBER: TMS-7109 TITLE: Molded Fiberglass Headliner REVISION: A-1 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering DATE ISSUED: August 2001 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR

3、 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

4、ity of regulatory limits prior to use. Change Notice: Reformatted and Editorial Changes Reference: File 30-14D Keywords: Fiberglass; Molded Headliner 1.0 APPLICATION This specification covers a composite headliner consisting of a molded fiberglass core with a non-woven backing material and a bonded

5、decorative fabric facing. 2.0 SCOPE This specification covers the general requirements for the molded fiberglass headliner core and performance requirements of the finished headliner. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The fo

6、llowing standards, specifications and regulations are referenced in this specification. Quality System Standard QS-9000 (ISO 9001) ASTM D 903 INTERNATIONAL IQR Quality Standard FMVSS INTERNATIONAL Manufacturing Std. D-13 INTERNATIONAL Test Procedure NV-2C1 CFR Title 29, Part 1910 ASTM C 384 4.0 GENE

7、RAL REQUIREMENTS 4.1 The molded fiberglass headliner core shall consist of: 4.1.1 Glass fibers .0043-.0061 mm (.00017-.00024 in) in diameter and up to 50 mm (2 in) in length. 4.1.2 A suitable non-toxic and non-malodorous phenolic resin binder with a total resin content of 15-19 percent and a surface

8、 resin content of 20-24 percent. 4.1.3 A suitable non-woven backing material that will protect the part until it has been installed in the vehicle. 4.1.4 The fiberglass core shall have a density of 256 25 kg/m (16 1.6 lbs/ft) for nominal 5 mm (.2 in) thick sections and 64 6 kg/m (4 .4 lbs/ft) for no

9、minal 25 mm (1 in) thick sections. 4.1.5 Reinforcement may be required as designated on the part drawing. When reinforcement is required, the method and placement of the reinforcement shall be fully detailed on the part drawing. NUMBER: TMS-7109 TITLE: Molded Fiberglass Headliner REVISION: A-1 This

10、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. Ge32001 by International Truck and Engine Corporation. AUGUST 2001 Page 2 of 4 4.2

11、 The bonded fabric facing shall consist of: 4.2.1 An adhesive that will bond securely, such that a peel test, per ASTM D-903, will result in the destruction of the glass fiber surface or a minimum peel strength of 800 N/m (4.6 lbf/in) width. No adhesive bleed-thru shall be permitted. 4.2.2 A fabric

12、covering that meets the requirements of the International specification as indicated on the part drawing. 4.3 All materials and the composite assembly must conform with Federal regulations concerning materials of this type, such as the flammability requirements of FMVSS 302 and TMS-9544. 4.4 PERFORM

13、ANCE REQUIREMENTS 4.4.1 Cyclic Aging 4.4.1.1 Sample Preparation: Seven (7) boards 200 x 300 x 5 mm (8 x 12 x 0.2 in) and seven (7) boards 200 x 300 x 25 mm (8 x 12 x 1 in) shall be prepared by cutting sections from production headliners or suitable samples representative of a production part. All bo

14、ards must include the decorative fabric facing on one of the 200 x 300 mm (8 x 12 in) faces. 4.4.1.2 Method: All fourteen (14) boards are subjected to the seven-step aging test shown in the table below. One board of each thickness 5 and 25 mm (0.2 and 1 in) is subjected to 180 peel tests per ASTM D9

15、03 after each step in the aging cycle, except as indicated below. Three peel test samples measuring 25 x 200 mm (1 x 8 in) are cut from each board for this testing. The peel test samples shall be cut immediately before the peel test and shall not be closer than 25 mm (1 in) to an edge or any other p

16、eel test sample. After cutting the peel test samples, the test chamber and all samples shall be returned to the conditions of the particular step before performing the peel test. 4.1.1.3 Required: There shall be no loss of adhesion between the fabric facing and the fiberglass core or delamination of

17、 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 fiberglass surface, or must meet the minimum peel strength specified for the particular step of the aging test. The fiberglass board shall not lose shape

18、or integrity during any step of the aging test. Aging Cycle Minimum Peel Strength* N/m (lbf/in) Width 1. 24 hours at 38 C (l00 F.) and 100% RH 400 (2.3) 2. 24 hours at 82 C (180 F.) 400 (2.3) 3. Cool at room temperature for one hour 800 (4.6) 4. 24 hours at -29 C (-20 F.) 400 (2.3) 5. 24 hours at 38

19、 C (100 F.) and 100 % RH 400 (2.3) 6. 7 days at 70 C (158 F.) 400 (2.3) 7. Cool at room temperature for one hour 800 (4.6) * Only required if substrate remains intact NUMBER: TMS-7109 TITLE: Molded Fiberglass Headliner REVISION: A-1 This document is restricted and may not be sent outside Internation

20、al Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. Ge32001 by International Truck and Engine Corporation. AUGUST 2001 Page 3 of 4 4.4.2 Thermal Shock 4.4.2.1 Method: Sections of the finished head

21、liner, as designated* on the drawing, shall be subjected to three of the cycles 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 shal

22、l be capable of passing this test. 4.4.2.2 Required: There shall be no loss of adhesion of the fabric facing. 4.4.2.3 Thermal Shock Cycle 1. 16 hours 82 C (180 F.) 2. 8 hours -29 C (-20 F.) 4.4.3 Humidity - ASTM G53 4.4.3.1 Method: A 100 x 200 mm (4 x 8 in) cloth-covered section shall be exposed to

23、168 hours of condensing humidity at 38 C (100 F.) and 100 percent relative humidity. 4.4.3.2 Required There shall be no delamination of the fabric cover or the fiberglass bats. The sections shall not warp or disintegrate. There shall be no objectionable odor. 4.4.4 Sound Absorption Properties 4.4.4.

24、1 Method: Test in accordance with Test Procedure NV-2C1 ASTM C384. 4.4.4.2 Required: Production representative assemblies shall meet the following requirements based on the nominal density of the finished part: 4.4.4.3 Low Density (25 mm thick and 64 kg/m) The normal incidence absorption coefficient

25、s shall be measured at: 500, 600, 700, 800, 900, 1000, 1200, 1400, 1600, 1800, 2000, 2500, 3000, 3500, 4000 Hz. The normal incidence absorption coefficient at any one frequency shall not be less than .40 and the average of the normal incidence absorption coefficients shall, for all frequencies teste

26、d, not be less than 0.70. 4.4.4.4 High Density (5mm thick and 256 kg/m) Shall satisfy Noise and Vibration Laboratory at TDTC as to its suitability for use. 5.0 QUALIFICATION Samples representative of production parts shall be submitted to Materials Engineering at TDTC for testing, accompanied by a d

27、etailed test report showing conformance to the requirements of this specification. A sufficient number of samples for each type of fabric facing shall be submitted for complete testing by both the Materials Engineering Laboratory and the Noise and Vibration Laboratory. NUMBER: TMS-7109 TITLE: Molded

28、 Fiberglass Headliner REVISION: A-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. Ge32001 by International Truck and Engine

29、 Corporation. AUGUST 2001 Page 4 of 4 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements Suppliers must conform to the requirements of the International IQR Quality Standard which includes conformance to the QS-9000 (ISO 9001) Quality System Standard. A mutually acceptable Quality Con

30、trol Plan as described therein is required for source approval to the requirements of this specification. 6.2 Approval Parts 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 i

31、n 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

32、 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) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 6.3 Process Control The

33、 supplier shall either perform and report results of tests on specific lots of parts produced 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 plant metallurgist and/or the quality control manager of the using International plant may determine testing and reporting requirements on specific products.