NAVISTAR MPAPS D-7124-2016 Interior Structural Foam RIM.pdf

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. 2016 by Navistar, Inc. OCTOBER 2016 Page 1 of 6 NAVISTAR, INC. Material, Parts, and Process Specificatio

2、ns (MPAPS) NUMBER: MPAPS D-7124 Former Designation: TMS-7124 TITLE: Interior Structural Foam RIM CURRENT REV No.: 1610 DATE: Oct. 2016 WRITTEN/EDITED BY: D. Baker APPROVED BY: R. Goluch SUPERSEDES: Rev. 0908 August 2009 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This speci

3、fication 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 regulatory limits pri

4、or to use. 1.0 APPLICATION This specification covers rigid interior cab composite components, such as cabinets, 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

5、This specification covers the general requirements and the property and performance requirements for the 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 requireme

6、nts of this specification must comply with the requirements of the MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Qua

7、lity System Standard ISO 9001 or TS-16949 ASTM D 638 MPAPS B-50 CFR Title 29, Part 1910 ASTM D 732 MPAPS D-7121 FMVSS 302 ASTM D 790 MPAPS P-9544 MPAPS DT-12 ASTM D 1622 MPAPS K-6900 MPAPS P-9543 ASTM D 1621 MPAPS GT-31 MPAPS D-7028 AATCC proc. 1 NAVISTAR Supplier Packing and Shipping Standard D-13

8、4.0 GENERAL REQUIREMENTS 4.1 Vinyl Facing The vinyl covering, when specified, shall meet the requirements of MPAPS D-7121 (Type A or B, as indicated on the engineering print) and the color and texture requirements listed on the engineering print. Other types of facing material require qualification

9、and shall not be used without written approval of Navistar Materials Engineering. NUMBER: MPAPS D-7124 TITLE: Interior Structural Foam RIM REVISION: 1610 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppli

10、ers are required to assume all patent liability. 2016 by Navistar, Inc. OCTOBER 2016 Page 2 of 6 4.2 Rigid Foam This specification includes two (2) types of rigid foam with two different grades available for each based on density and material properties. Type I is an unreinforced, two (2) component

11、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. The selection of the Type and Grade shall be made by Materials Engineering. 4.2.1 The rigid foam shall be a two component uretha

12、ne, reaction injection molded behind the vinyl facing. Any remaining mold release residue must be compatible with Navistar paint repair systems and must have prior approval of Materials Engineering. 4.3 Finished Part Colors, textures, and finishes shall be called out within the material specificatio

13、n on the part drawing and shall match the approved standard samples in the files of the Navistar Industrial Design Department. 4.3.1 Finished part weight may not vary more than 10% from the approved sample. 4.4 Property And Performance Requirements 4.4.1 Rigid Foam The material properties of the foa

14、m 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 where density varies beyond the nominal limits shall be indicated on the part drawing, and preproduction qualification testing is req

15、uired. 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 MPAPS D-7028, Bonded Interior Trim Products. Production parts shall be used for testing adhesion. 4.4.2.2 Metal Inserts: Metal inserts shall be molded or

16、 bonded in place such that any attempt to remove the insert results in foam failure. Structural components shall meet MPAPS K-6900 for bonding appropriately modified for the application (Interior components would be limited 50C for hot pulls, 70C heat aging, and humidity in place of salt spray). Ple

17、ase 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 listed in Table 1, and the adhesion requirements after aging. 4.4.4 Accelerated Weathering 4.4.4.1 Method: Interior cycle

18、 per MPAPS 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 greater than a E of 3, plasticizer migration, decreased pliability or tackiness after exposure. Min rating of 3.0 per A

19、ATCC Eval.-Procedure 1. 4.4.5 Colorfastness to Cleaning and Chemicals 4.4.5.1 Method: MPAPS DT-12, Method A. 4.4.5.2 Required: A minimum rating of 4 per the AATCC color transference scale. NUMBER: MPAPS D-7124 TITLE: Interior Structural Foam RIM REVISION: 1610 This document is restricted and may not

20、 be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. OCTOBER 2016 Page 3 of 6 4.4.6 Flammability Requirements The finished composite must conform to and be certified to meet

21、all requirements of FMVSS-302, Flammability of Interior Materials and all requirements of MPAPS P-9544. 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 ar

22、e 100% bonded together are not specifically required to demonstrate flammability resistance when tested as individual parts, however, the bonded (finished) composite must demonstrate required flammability resistance. TABLE 1 PHYSICAL PROPERTY REQUIREMENTS PROPERTY min or max value unless shown as a

23、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% % MPAPS DT-8 0 0 15 10 Density Test2 Limits, max lb/ft kg/m ASTM D 1

24、622 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

25、112 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

26、- 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 -

27、1450 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 -

28、1450 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 NUMBER: MPAPS D-7124 TITLE: Interior Structural Foam RIM REVISION: 1610 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permissi

29、on from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. OCTOBER 2016 Page 4 of 6 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 per

30、formed with material not exceeding the specified limit. Density requirement is the primary factor affecting the other material properties. * Values have yet to be determined. Note: Examples of Material Grades are as follows: Type 1 Unreinforced - Grade A - Grade B IVCR: Improved Vinyl Clad Rigid Ure

31、thane Type 2 Reinforced - Grade A T-RIM: Tempress Reaction Injection Molding 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.

32、1 Primary cosmetic vinyl surfaces shall be free from 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 surfac

33、e shall be free of voids or imperfections detrimental to strength, fit, function, or service life. 6.0 QUALIFICATION Engineering qualification of sources is required in advance of production shipments. Samples shall be accompanied by test data certifying that all requirements of the specification ha

34、ve been met. Suppliers shall submit samples for approval of finish, luster, color and appearance to the Navistar Industrial Design Group. Upon approval, styling master samples denoting the minimum level of acceptable appearance quality shall be developed and retained by the supplier and the quality

35、department of each using NAVISTAR facility. 6.1 Quality Control Plan A Quality Control Plan for products supplied to the requirements of this specification will be established by mutual agreement between NAVISTAR and the supplier. Unless specific exception is noted, the following characteristics, wh

36、ere applicable*, shall be included in the plan as features for management by statistical process control.* * Other characteristics for inclusion in the control plan may be specified on the engineering drawing and/or purchase order. * See NAVISTAR Engineering Design Standard A-16 NUMBER: MPAPS D-7124

37、 TITLE: Interior Structural Foam RIM REVISION: 1610 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. 2016 by Navistar, Inc. OCTOBER 2016 Page 5 of 6 7.0 S

38、OURCE APPROVAL AND QUALITY CONTROL 7.1 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 can also fulfill all AIAG PPAP (Production Part Approval Process) docu

39、mentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies of registration certificates to their Corporate Buyer upon request. 7.2 Approval Parts supplied against contracts or purchase orders citing this specification shall b

40、e 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,

41、 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 new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance wit

42、h CFR Title 29, Part 1910 shall be submitted with the request for change. 7.3 Process Control The supplier shall either, perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide statistical evidence of the lot having been produced in a

43、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 on specific products. 8.0 SHIPPING AND HANDLING Shipping and identification sha

44、ll be in accordance with NAVISTAR Supplier Packing and Shipping Standard D-13. Parts shall be packaged so as to avoid any damage in shipment detrimental to the appearance of the part. 9.0 DESIGNATION ON DRAWINGS Example: Material: Interior Structural Foam RIM per MPAPS D-7124 with vinyl surface Type

45、 A per MPAPS D-7121 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. 10400 W. North Avenue Melrose Park, IL 6016

46、0 E-mail: MaterialsEngineeringN IHS Markit 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/ NUMBER: MPAPS D-7124 TITLE: Interior Structural Foam RIM REVISION: 1610 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. 2016 by Navistar, Inc. OCTOBER 2016 Page 6 of 6 REVISION HISTORY Revision Level Change Approved by Date Approved 1610 Converted to MPAPS R. Goluch