NAVISTAR TMS 7117-2001 Foam Composite Trim Panel (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-7117 TITLE: Foam Composite Trim Panel 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 C

3、URRENT 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 applicabilit

4、y of regulatory limits prior to use. Change Notice: Reformatted and Editorial Changes Reference: File 30-16B Keywords: Foam Composite; Trim Panel 1.0 APPLICATION This specification covers a chemically bonded composite trim panel consisting of a foam composite core with a woven backing material and d

5、ecorative fabric facing suitable for headliners and back panels over a temperature 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. 3.0 REFERENCE DOCUMENTS Unless otherwise specified,

6、the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Quality System Standard QS-9000 (ISO 9001) INTERNATIONAL TMS ASTM D 903 INTERNATIONAL IQR Quality Standard INTERNATIONAL TMS ASTM D 1564 INTERNATION

7、AL Manufacturing Standard D-13 INTERNATIONAL TMS ASTM D 156 CFR Title 29, Part 1910 4.0 GENERAL REQUIREMENTS 4.1 Construction 4.1.1 Headliners The composite shall consist of the following layers: 4.1.1.1 Backing Material 4.1.1.2 Fiberglass mat (in designated areas) 4.1.1.3 “Firm“ foam 4.1.1.4 Fiberg

8、lass 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 be the same as for headliners except the fiberglass mats may be omitted. NUMBER: TMS-7117 TITLE: Foam Composite Trim Panel REVISION: A-1 This document is restricted

9、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 4.1.3 Core The foam compos

10、ite 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 Table 1. 4.1.3.3 These resins shall be non-toxic, non-malodorous resin binders suitable for chemical

11、 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 is required, such as for headliners, a 20 mil non-woven, random pattern, glass fiber filament mat sh

12、all 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 indicated on the part drawing. TABLE 1 Foam Properties (Prior to Fabrication) Inner Layer Outer Laye

13、r 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 D1564 2.0 - 2.5 1.5 - 1.8 Static Fatigue per ASTM D-156, Procedure A (75% deflection, 17 hrs) % Loss in 25% ILD

14、 30 30 % Loss in Thickness 5 5 Resin Content, % 150 + 20 100 + 20 4.2 Performance Requirements 4.3.1 Cyclic Aging 4.3.1.1 Sample Preparation 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 secti

15、ons 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 representative locations. NUMBER: TMS-7117 TITLE: Foam Composite Trim Panel REVISION: A-1 This document is restricted and may not be sent outside Inter

16、national 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 4.3.1.1.1 Method All 42 coupons are subjected to the seven-

17、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 Required There shall be no loss of adhesion between the fabric facing and the foam core or delamination of t

18、he 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 strengths specified below. The foam composite shall not lose shape or integrity during any step of the

19、 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 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 (1

20、58F) 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 cycles listed below. There shall not be any rest between steps, and the sections shall be examined after e

21、ach 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 adhesion of the fabric facing. 4.4.2.1 Thermal Shock Cycle 1. 16 hours 82C (180F) 2. 8 hours -29C (-20

22、F) 4.5 Humidity 4.5.1 Method Sections of the finished headliner, as designated * on the drawing, shall be subjected to 168 hours of 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 he

23、adliner shall be capable of passing this test. NUMBER: TMS-7117 TITLE: Foam Composite Trim Panel 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 require

24、d to assume all patent liability. Ge32001 by International Truck and Engine Corporation. AUGUST 2001 Page 4 of 4 4.5.2 Required There shall be no delamination of the fabric cover or the foam core. The sections shall not warp or disintegrate. There shall be no objectionable odor. 4.6 Flammability Res

25、istance 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 Materials and the requirements of TMS-9544. 5.0 QUALIFICATION Samples representative of production parts

26、 shall be submitted to International Technical Center for testing, accompanied by a detailed 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 the Materials Engineering L

27、aboratory. 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 Control Plan as described ther

28、ein 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 in formulation or processing

29、 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).

30、 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 supplier shall either perf

31、orm 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 contro

32、l manager of the using International plant may determine testing and reporting requirements on specific products. 7.0 SHIPPING, PACKING, AND IDENTIFICATION Loading, packing, and identification shall be in accordance with Manufacturing Std. D-13. 8.0 DESIGNATION ON DRAWINGS TMS-7117 9.0 APPROVED SOURCE Colamco, Inc.