NAVISTAR TMS 7124-2009 Interior Structural Foam RIM.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. 2009 by Navistar, Inc. AUGUST 2009 Page 1 of 6 NAVISTAR, INC. TMS (TRUCK MATERIAL SPECIFICATION) NUMBER:

2、 TMS-7124 TITLE: Interior Structural Foam RIM CURRENT REV. No: 0908 DATE: August 2009 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: Rev B-1 - August 2001 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve haz

3、ardous 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 regulatory limits prior to use. Change Notice

4、: Replaced “International Truck and Engine Corporation” with “Navistar, Inc.” per corporate directive; added CEMS B-50 requirements; editorial changes. Reference: File 30-16B Keywords: Structural Foam, RIM 1.0 APPLICATION This specification covers rigid interior cab composite components, such as cab

5、inets, shelves, instrument panels, and dash panels. The composite consists of a reaction injection molded (RIM) foam, that may include a molded with a preformed vinyl cosmetic surface. 2.0 SCOPE This specification covers the general requirements and the property and performance requirements for the

6、finished composite. Requirements for quality, quality control and source approval are included. 2.1 Restricted Chemical Substances Effective 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

7、 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-16949 TMS-7028 ASTM D 638 NAVISTAR Manufacturing Std MS-D-13 CFR Title

8、 29, Part 1910 ASTM D 732 TMS-7021 FMVSS 302 ASTM D 790 TMS-9544 ASTM D 1621 CEMS B-50 ASTM D 1622 TMS-9543 TMS-6900 CEMS GT-31 CEMS DT-12 4.0 GENERAL REQUIREMENTS 4.1 Vinyl Facing The vinyl covering, when specified, shall meet the requirements of TMS-7121 (Type A or B, as indicated on the engineeri

9、ng print) and the color and texture requirements listed on the engineering print. Other types of facing material require qualification and shall not be used without written approval of Materials Engineering at TDTC. NUMBER: TMS-7124 TITLE: Interior Structural Foam RIM REVISION: 0908 This document is

10、 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. 2009 by Navistar, Inc. AUGUST 2009 Page 2 of 6 4.2 Rigid Foam This specification includes two (2) types of rigid foam wit

11、h two different grades available for each based on density and material properties. Type I is an unreinforced, two (2) component urethane, reaction injection molded structural foam. Type II is similar except it is glass reinforced and includes two (2) grades with different glass content and density.

12、 The selection of the Type and Grade shall be made by Materials Engineering. 4.2.1 The rigid foam shall be a two component urethane, reaction injection molded behind the vinyl facing. Any remaining mold release residue must be compatible with Navistar paint repair systems and must have prior approva

13、l of Materials Engineering. 4.3 Finished Part Colors, textures, and finishes shall be called out within the material specification on the part drawing and shall match the approved standard samples in the files of the Industrial Design Department, at TDTC. 4.3.1 Finished part weight may not vary more

14、 than 10% from the approved sample. 4.4 Property And Performance Requirements 4.4.1 Rigid Foam The material properties of the foam are dependent on the density. When foam density varies outside the nominal limits, due to part and tool design, physical properties may also vary. Areas on the part wher

15、e density varies beyond the nominal limits shall be indicated on the part drawing, and preproduction qualification testing is required. See Table 1 for the required physical properties. 4.4.2 Adhesion 4.4.2.1 Vinyl: The vinyl to rigid foam bond shall meet the requirements of TMS-7028, Bonded Interio

16、r Trim Products. Production parts shall be used for testing adhesion. 4.4.2.2 Metal Inserts: Metal inserts shall be molded or bonded in place such that any attempt to remove the insert results in foam failure. Structural components shall meet TMS-6900 for bonding appropriately modified for the appli

17、cation (Interior components would be limited 50C for hot pulls, 70C heat aging, and humidity in place of salt spray). Please contact Materials Engineering for further guidance. 4.4.3 Heat Age Heat age parts for 168 hours at 70 C (158 F). 4.4.3.1 Required Parts shall meet the physical properties, as

18、listed in Table 1, and the adhesion requirements after aging. 4.4.4 Accelerated Weathering 4.4.4.1 Method: Interior cycle per CEMS GT-31. The exposure energy for the UV requirement should be called out in a Z Note and expressed in kJ/m. 4.4.4.2 Required: There shall be no signs of color alteration g

19、reater than a E of 3, plasticizer migration, decreased pliability or tackiness after exposure. Min rating of 3.0 per AATCC Eval.-Procedure 1. NUMBER: TMS-7124 TITLE: Interior Structural Foam RIM REVISION: 0908 This document is restricted and may not be sent outside Navistar, Inc. or reproduced witho

20、ut permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. AUGUST 2009 Page 3 of 6 4.4.5 Colorfastness to Cleaning and Chemicals 4.4.5.1 Method: CEMS DT-12, Method A. 4.4.5.2 Required: A minimum rating of 4 per the AATCC color tran

21、sference scale. 4.4.6 Flammability Requirements The finished composite must conform to and be certified to meet all requirements of FMVSS-302, Flammability of Interior Materials and all requirements of TMS-9544. Components of the composite which are not 100% bonded together shall be tested separatel

22、y and each component must demonstrate required flammability resistance. Components of the composite which are 100% bonded together are not specifically required to demonstrate flammability resistance when tested as individual parts, however, the bonded (finished) composite must demonstrate required

23、flammability resistance. 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 vinyl surfaces shall be free from

24、 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 imperfections detrimenta

25、l to strength, fit, function, or service life. 5.2 Qualification Materials submitted for approval to this specification shall include the following: 5.2.1 A detailed, signed test report documenting testing to this specification per TMS-9543. 5.2.2 The complete procedure used for preparing and curing

26、 materials for test, especially surface preparation (when appropriate) and condition of the test materials. 5.2.3 A complete description, including engineering prints and pictures of any non-standard test fixtures used. 5.2.4 Adhesive, substrate and any chemicals used for bonding where appropriate.

27、5.3 Submission The material test report shall be submitted to: Manager of Materials Engineering NAVISTAR, Inc. PO Box 1109 Fort Wayne, IN 46801 5.4 Approval A report from Navistar will be issued approving new materials to this specification. Formal approval is not granted until this report has been

28、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. NUMBER: TMS-7124 TITLE: Interior Structural Foam RIM REVISION: 0908 This document is restrict

29、ed and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. AUGUST 2009 Page 4 of 6 TABLE 1 PHYSICAL PROPERTY REQUIREMENTS PROPERTY min or max value unless shown as a

30、range UNITS TEST METHOD TYPE I (Unreinforced) TYPE II (Reinforced) GRADE A GRADE B GRADE A GRADE B Nominal Foam Density, 10% lb/ft kg/m ASTM D 1622 21 336 24.5 35 561 35 560 Glass Plies, min 0 0 (1) (1) Glass/Filler Content, min 5% % CEMS DT-8 0 0 15 10 Density Test2 Limits, max lb/ft kg/m ASTM D 16

31、22 18 - 24 288 - 384 39 625 Compressive Strength, min avg value psi MPa ASTM D 1621 700 - 1000 4.8 - 7.6 1840 12.7 800 5.5 Tensile Strength, min avg value psi MPa ASTM D 638 500 - 700 3.4 - 4.8 1210 8.34 2,000 13.8 3000 20.7 Tensile Modulus of Elasticity, min avg value psi MPa ASTM D 1632 * 16,200 1

32、12 35,000 241 150000 1,000 Shear Strength, min avg value psi MPa ASTM D 732 300 - 300 2.1 - 2.1 140 0.965 * * Flexural Strength 72F/22C, min avg value psi MPa ASTM D 790 950 - 1450 6.6 - 10.0 2210 15.2 3,500 24.1 3000 20.7 Flexural Strength 158F/70C, min avg value psi MPa ASTM D 790 950 - 1450 6.6 -

33、 10.0 1,400 9.7 3000 20.7 Flexural Modulus 72F/22C, min avg value psi MPa ASTM D 790 950 - 1450 6.6 - 10.0 38,400 265 150,000 1,034 3000 20.7 Flexural Modulus 158F/70C, min avg value psi MPa ASTM D 790 950 - 1450 6.6 - 10.0 80,000 551 3000 20.7 Tensile Elongation, min avg value % ASTM D 1632 950 - 1

34、450 6.6 - 10.0 9.7 10% 10% 3000 20.7 Gardner Impact, 72F/22C, min avg value in-lbs J ASTM D 5420 950 - 1450 6.6 - 10.0 18 2.0 3000 20.7 HDT 66 psi / 0.455 MPa, min avg value F C ASTM D 648 950 - 1450 6.6 - 10.0 175 79.4 165 74 3000 20.7 HDT 264 psi / 1.820 MPa, min avg value F C ASTM D 648 950 - 145

35、0 6.6 - 10.0 135 57 3000 20.7 CLTE x 10-5, min avg value in/in/F cm/cm/C ASTM D 696 950 - 1450 6.6 - 10.0 3.0 5.4 3000 20.7 1 - Density may vary due to part configuration. Parts exhibiting this tendency must be approved by TDTC prior to production. 2 - Material testing shall be performed with materi

36、al not exceeding the specified limit. Density requirement is the primary factor affecting the other material properties. * Values have yet to be determined. NUMBER: TMS-7124 TITLE: Interior Structural Foam RIM REVISION: 0908 This document is restricted and may not be sent outside Navistar, Inc. or r

37、eproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. AUGUST 2009 Page 5 of 6 Note: Examples of Material Grades are as follows: Type 1 Unreinforced - Grade A - Grade B IVCR: Improved Vinyl Clad Rigid Urethane Ty

38、pe 2 Reinforced - Grade A T-RIM: Tempress Reaction Injection Molding 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 suppl

39、ier 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 Pa

40、rts 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,

41、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). Test data indicating conformance to all requirements of this specification, test samples, and

42、 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 perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949

43、guidelines, 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 Navistar plant may determine tes

44、ting and reporting requirements on specific products. 7.0 SHIPPING, PACKING AND IDENTIFICATION Loading, packing, and identification shall be in accordance with Manufacturing Standard MS-D-13. 8.0 DESIGNATION ON DRAWINGS Material: Interior Structural Foam RIM per TMS-7124 with vinyl surface Type A pe

45、r TMS-7121 NUMBER: TMS-7124 TITLE: Interior Structural Foam RIM REVISION: 0908 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. 2009 by Navistar, Inc. AUG

46、UST 2009 Page 6 of 6 9.0 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. Truck Development and Technology Center 2911 Meyer Road Fort Wayne, IN 46803 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:/