1、 WORLDWIDE ENGINEERING STANDARDS Material Specification GMW15523 Door Inner Water Deflection/Barrier/Acoustic Material Copyright 2012 General Motors Company All Rights Reserved December 2012 Originating Department: North American Engineering Standards Page 1 of 5 1 Scope This specification describes
2、 the functional requirements for a sheet form material (either flexible, soft, rigid and/or combination of both) used inside the vehicle door as a means to block the intrusion of water, air, dust and/or noise into the passenger compartment. The intrusion levels of water, air, dust and/or noise will
3、be specified by the Statement of Requirements (SOR) listed for each program. The material assemblies, meeting the requirements of this specification, must function in continuous operating temperatures from -30 C to 80 C with expected intermittent exposure to automotive industry paint repair cycles.
4、These materials will not stain fabric surfaces. The three families of material constructions described herein are normally supplied with an adhesive on one side and a release surface on the opposite side so that they may be stacked for shipping. They may be flat or formed to fit the shape of door co
5、mponents as required by the Vehicle Program Component Technical Specification (CTS) and SOR. 1.1 Material Description. 1.1.1 Materials conforming to this specification may be supplied to the assembly plant and applied to the door on the assembly line as one of the types listed in 1.1.3. 1.1.2 All ty
6、pes of door sealing systems must be adhered to the door sheet metal with an adhesive which meets or surpasses the requirements outlined in 3.1.3.6. 1.1.3 Material Identification. Reference G.M. Best Practice No. 115434. (The supplier shall work with the GM Design Responsible Engineer to comprehend t
7、his requirement.) 1.1.3.1 Family 1 Materials, (For Level A and B Vehicles). Barrier material shall consist of Ethylene Vinyl Acetate, (EVA). EVA material shall have density of 1.465kg/m 0.007 kg/m. Thickness of EVA barrier must be 1.00 mm 0.02 mm. Barrier material shall be adhered to door sheet meta
8、l with non-gassed hot melt adhesive that meets requirements in Table 1. 1.1.3.2 Family 2 Materials, (For Level C, D, E and F Vehicles). Barrier material shall consist of Polypropylene or Polyethylene (PE) Film. Polypropylene or Polyethylene barrier materials shall have density of 0.120 kg/m 0.006 kg
9、/m. Thickness of polypropylene of polyethylene barrier materials to be from 0.15 mm to 0.25 mm. Barrier material shall be adhered to door sheet metal by a spray adhesive that meets requirements in Table 1. 1.1.3.3 Materials (For Level C, D, E and F Vehicles). Barrier material shall consist of a poly
10、ethylene foam sheet. Polyethylene foam material shall have a density of 0.440 kg/m 0.022 kg/m. Thickness of Polyethylene foam shall be 0.6 mm. Barrier material shall be adhered to door sheet metal with non-gassed hot melt adhesive that meets requirements in Table 1. 1.1.3.3.1 Data generated for leve
11、l A through F vehicles are acoustic performance standards generated from US Vehicle Market Segmentation Card. 1.2 Symbols. Not applicable. 1.3 Typical Applications. Door Noise Barrier Water Deflectors. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for
12、ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15523 Copyright 2012 General Motors Company All Rights Reserved December 2012 Page 2 of 5 1.4 Remarks. 1.4.1 Changes in part composition or construction must be approved by the GM Release
13、 Engineer and GM Materials Engineer. Any deviation from GM Best Practice No.115434 shall be approved by the Global Subsystem Leadership Team (GSSLT). 1.4.2 The data obtained by these methods are applicable to the material under conditions of the particular test and are not necessarily the same as th
14、ose obtained in the vehicle. Data obtained may also be used for statistical process control to measure the effectiveness of the production system. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ISO 34 ISO 8510-2
15、 SAE J1400 2.2 GM Standards/Specifications. GMW3002 GMW3182 GMW3235 GMW14093 GMW3005 GMW3205 GMW4217 GMW14124 GMW3059 GMW3221 2.3 Additional References. G.M. Best Practice No.115434 US Vehicle Segmentation Card TMC003 Material Safety Data Sheet guidance documents (available at ). 3 Requirements 3.1
16、Requirements on Delivery. 3.1.1 Chemical Requirements. Not applicable. 3.1.2 Mechanical Requirements. 3.1.2.1 Dimensional Stability (GMW4217). Maximum allowable change will be 1.5% unless approved by GM Release and Materials Engineering. 3.1.3 Physical Requirements. 3.1.3.1 Conditioning. The product
17、 shall be pre-conditioned prior to testing according to GMW3221, Code A. 3.1.3.2 Mass per Unit Area (GMW3182). Shall be specified in SOR and/or CTS and engineering drawing. Best Practice deviations shall be approved by GSSLT. 3.1.3.3 Odor (GMW3205). The odor ranking will be a 6 or higher as determin
18、ed by a panel of non-production personnel. 3.1.3.4 Barrier Performance (SAE J1400). For initial qualification only; the sound transmission loss (STL) shall be at least as great as the values calculated for production thickness stock by the equation: STL (dB) = 20 log 10 W + 20 log 10 F - 47.2 Where:
19、 W = mass per unit area kg/m F = sound frequency Note: This test is for information only. Results of this test shall be retained by supplier for reference. 3.1.3.5 Water Leak Test. A bead of material 6 mm in diameter or a film of pressure sensitive adhesive 25 mm wide and 275 mm long shall be applie
20、d (using production equivalent equipment and process) in a “U” configuration to a 100 mm x 100 mm painted panel (representing the door inner) and rolled with a 2000 g roller once in one direction to insure contact. Fill the “U” with colored water and place over white paper towels. Examine after 24 h
21、 at room temperature for any signs of water leakage. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15523 Copyright 2012 General Motors
22、Company All Rights Reserved December 2012 Page 3 of 5 3.1.3.5.1 Repeat assembly of test fixture as in 3.1.3.5. Submit this test fixture to 1 cycle of GMW14124, Cycle W. After cycle test, allow test fixture to set for 1 h per GMW3221, Code A. Fill the “U” with colored water and place over white paper
23、 towels. Examine after 24 h at room temperature for any signs of water leakage. 3.1.3.6 Adhesion. The specified pressure sensitive adhesives (PSA) must be tinted with a pigment so the outline is visible on clear sheeting. Adhesive film thickness must be sufficient on production applications to meet
24、these specification requirements. Table 1: Adhesive Requirements Environment Non-gassed Hot Melt Family 1 and 3 Spray Adhesive Family 2 5 minutes at 25 C 2500 Nm 150 Nm 15 minutes at 25 C 2500 Nm 200 Nm 24 h at 25 C 2500 Nm 300 Nm 72 h immersion in water at 25 C followed by 2 h in air at 25 C 3300 N
25、m 150 Nm 14 days at 80 C in vertical position, then recover at 25 C for 4 h 3500 Nm 400 Nm 3.1.3.6.1 Test Preparation and Procedure. Cut three strips from the adhesive zone of the deflector sheet 225 mm long and 25 mm wide. Apply the strips side by side across the narrow direction of a 100 mm x 254
26、mm x 0.85 mm painted steel panel coated with the current and applicable topcoat paint systems. The ends of the strips should extend more than 100 mm off one edge of the panel. Roll down the strips using a 2000 g roller once in one direction only. The above prepared test, once exposed to the conditio
27、ns in 3.1.3.7.1, shall show no signs of lifting, tunneling, peeling or any signs of adhesion loss. Perform adhesion tests per ISO 8510-2. 3.1.3.6.2 Test Temperatures. Room temperature test shall be conducted at 23 C. All temperature tests must be within 2 C of the specified temperature unless otherw
28、ise specified. 3.1.3.6.3 The values of some properties and performance parameters may depend upon direction along the material sample. It may be necessary to perform both parallel and perpendicular to machine direction to determine the true minimum and maximum values for conformance to requirements
29、of this specification. 3.1.3.6.4 Cold Impact (GMW14093). Apply water deflector material with adhesive to steel panel painted with approved paint per each region. Primer system per GMW3002 and topcoat system per GMW3005. 3.1.3.6.4.1 Steel panel must be impacted on side opposite the side barrier mater
30、ial is adhered to. Adhesive material must not crack or lose adhesion to the substrate prior to or after two 1.7 J impacts at -30 C at a drop height of 0.5 m. Use Method B. 3.1.3.6.4.2 This test is to be used for adhesive development only. 3.1.3.7 Fog Resistance (GMW3235 Method B). 3.1.3.7.1 Gravimet
31、ric Procedure: Bath temperature to be set at T2, cooling temperature of 21 C, 18 h test time, 24 h post-conditioning time. The amount of fog, when weighed, shall be 2.0 mg. Samples that result in a residue that forms a transparent film, discernible droplets (0.05 mm in diameter), or any visual signs
32、 of crystallinity, when viewed at 40x magnification shall be judged to have not passed this requirement. Provide a 40x magnified picture of each fog plate with the results. 3.1.3.8 Blocking Resistance. A stack of ten patches (80 mm diameter circles or 80 mm x 80 mm squares) with liners (if applicabl
33、e) at production thickness are heated in an air circulating oven for 72 h at 60 C while under a uniformly applied load of 7 kPa. The samples should be stacked so the material of one patch faces the other in five facing pairs. Remove the weight only after the samples have cooled to room temperature.
34、The Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15523 Copyright 2012 General Motors Company All Rights Reserved December 2012 Page 4
35、of 5 samples should separate cleanly and not stretch or lose shape. Parts may not be dusted with talc or other coating in order to meet this requirement. 3.1.3.9 Tear Strength (ISO 34, Method A). Tear strength per ISO 34, Method A must be 5 kN/m. 3.1.3.10 Release Liner Removal (if Applicable). The r
36、elease liner must be easily removed in one whole piece without tearing or delaminating the barrier material or adhesive. The whole bond surface of the adhesive must be in contact with the release liner, and there must not be any contamination of the bond interface between the time release liner is r
37、emoved and contact with the painted surface. 3.1.4 Sampling Requirements. 3.1.4.1 For initial qualification, unless otherwise indicated, each released production thickness must be tested on a minimum of five samples from each of six production batches by a GM approved laboratory. Tentative approval
38、will be granted on a minimum of five samples from two laboratory batches and one production batch. Data will be reported to a six sigma limit. 3.1.4.2 Unless otherwise indicated for quality control, sources need only test the finishes and sizes they sold to GM that model year. The sampling shall rep
39、resent 0.1% of the total production part volume. All tests will be run unless otherwise specified. 3.1.4.3 Test values may depend upon the method of sample preparation and the directions to flow the samples are cut. The reported values will be in the weakest direction. 3.2 Processing Requirements. N
40、ot applicable. 3.2.1 Chemical Requirements. Not applicable. 4 Manufacturing Process Not applicable. 5 Rules and Regulations 5.1 Legal Regulations. All materials must satisfy applicable laws, rules, regulations and recommendations valid in the country of usage. 5.2 Language. In the event of conflict
41、between the English and domestic language, the English language shall take precedence. 5.3 Inspection and Rejection. Samples of components or materials released to a GM material specification shall be tested for conformity with the requirements of this material specification and approved by the resp
42、onsible Engineering department prior to commencement of delivery of bulk supplies. A new approval must be received for any changes, e.g., properties, manufacturing process, location of manufacture, etc. If not otherwise agreed, all testing and documentation normally required for initial release must
43、 be completed. It is the responsibility of the supplier to inform the customer in a timely manner, without solicitation, and to include documentation of all modifications of materials and/or processes and to apply for a new release. If not otherwise agreed, all release tests shall be repeated and do
44、cumented by the supplier prior to commencement of delivery of non-conforming bulk supplies. In individual cases, a shorter test can be agreed to between the responsible Engineering department and the supplier. 5.4 Material Safety Data Sheets/Safety Data Sheets (MSDS/SDS). For new product submissions
45、, or when a change in chemical composition of an existing product has occurred, a complete copy of the Material Safety Data Sheet/Safety Data Sheet must be submitted in compliance with the Globally Harmonized System of Classification and Labeling of Chemicals (GHS) requirements or other country-spec
46、ific MSDS/SDS requirements. In addition, product MSDS/SDS submissions must be in compliance with specific country General Motors TMC003 Material Safety Data Sheet/Safety Data Sheet guidance documents where available. 5.5 All materials supplied to this standard must comply with the requirements of GM
47、W3059, Restricted and Reportable Substances for Parts. 6 Approved Sources Materials supplied to this specification must be approved by General Motors. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted witho
48、ut license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15523 Copyright 2012 General Motors Company All Rights Reserved December 2012 Page 5 of 5 The appropriate GM Materials Engineering department(s) must confirm material as meeting the requirements of this specification. Any test data sheets
49、 of material submitted to General Motors for such confirmation (e.g., during Production Part Approval Process (PPAP) under this material specification must list all properties and must apply corresponding test methods of this material specification. 7 Notes 7.1 Glossary. MATSPC: Global repository of GM approved materials for corresponding GM Engineering Standards. 7.2 Acronyms, Abb
