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 7 NAVISTAR, INC. Material, Parts, and Process Specification
2、s (MPAPS) NUMBER: MPAPS D-7028 Former Designation: TMS-7028 TITLE: Bonded Trim Composites, Interior CURRENT REV No.: 1610 DATE: Oct. 2016 WRITTEN/EDITED BY: D. Baker APPROVED BY: R. Goluch SUPERSEDES: 1608 August 2016 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specifi
3、cation 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 prior
4、 to use. 1.0 APPLICATION This specification covers interior trim composites, typically consisting of a facing fabric or material, padding, and a backing. These components are chemically, thermally, and/or dielectrically bonded or laminated parts suitable for interior uses such as wall panels, head l
5、iners, sun visors, cabinets, seat inserts, floor mats, and door trim panels. 2.0 SCOPE This specification covers the general requirements for the individual components of the composite (i.e. fabric, padding, and backing) and property and performance requirements of the bonded or molded, finished com
6、posite. Requirements for quality, qualification, shipping and identification, and source approval and quality control 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 MP
7、APS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified the latest issue of all referenced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 NAVISTAR MPAPS L-6608 NAVIS
8、TAR Supplier Packing and Shipping Std. D-13 NAVISTAR MPAPS D-7113 CFR Title 29, Part 1910 NAVISTAR MPAPS D-7121 FMVSS-302 NAVISTAR MPAPS D-7066 NAVISTAR MPAPS D-22 NAVISTAR MPAPS D-7116 NAVISTAR MPAPS D-28 NAVISTAR MPAPS D-7124 NAVISTAR MPAPS L-6505 NAVISTAR MPAPS B-50 NAVISTAR MPAPS L-6606 CFR 49,
9、Part 571.302 NAVISTAR MPAPS P-9544 SAE J1323 NAVISTAR MPAPS P-9543 ASTM D 903 NUMBER: MPAPS D-7028 TITLE: Bonded Trim Composites, Interior 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 7 4.0 GENERAL REQUIREMENTS Unless otherwise specified on the engineering drawing and/or purchase order, the manufacturing practice and bonding methods are optional. The supplier is responsible to select in
11、dividual components of the composite appropriate for the bonding method selected and so fabricate these as to insure that the finished composite is suitable for its intended use and meets all property and performance requirements specified herein. The following components of the composite may be con
12、sidered typical. Specific materials may be indicated on the engineering print. 4.1 Padding Shall be bondable urethane foam or non-woven padding (Fiberbond). The urethane foam shall meet the requirements of MPAPS L-6505. The non-woven padding (suitable for dielectric bonding only) shall meet the requ
13、irements of MPAPS D-7067. MPAPS L-6606 may be appropriate for some parts, but is not considered a bonded composite and would not be covered by this specification. Some parts may be specified without padding. 4.2 Face Materials Shall meet the requirements designated on the engineering drawing and/or
14、purchase order. Color and pattern shall match approved standards on file in the NAVISTAR Industrial Design Department. The following materials are considered suitable: Fabric: MPAPS D-7113 Carpet and carpet-like trim: MPAPS D-7126 Vinyl coated fabrics and leather: MPAPS D-7121 Rubber Mats: MPAPS L-6
15、608 4.3 Backing Fabrics Any fabric or backing which provides a composite meeting all requirements of this specification shall be acceptable but may or may not be required on different types of composites. The following backings have provided satisfactory performance in the past. Values shown are typ
16、ical values unless otherwise indicated. (Tests performed per ASTM D 751) 4.3.1 Nylon Tricot Denier: 40 Tensile Strength: 435 N (98 lbf) Tear Strength: 50 N (12 lbf) 4.3.2 Cotton Sheeting Count: 32 x 26 Weight: 73 g/m (2.16 oz/yd) Tensile: Warp/Fill: 265/265 N (60/60 lbf) Tear: Warp/Fill: 66/44 N (15
17、/10 lbf) 4.3.3 Spunbonded Nylon (Cerex) Weight: 20 g/m (0.6 oz/yd) Tensile: Machine/Transverse: 70/44 N (16/10 lbf) Tear: Machine/Transverse: 22/17 N (5/4 lbf) Burst (Mullen): 150 kPa (22 psi) NUMBER: MPAPS D-7028 TITLE: Bonded Trim Composites, Interior REVISION: 1610 This document is restricted and
18、 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 3 of 7 4.3.4 Polypropylene Sheeting Denier: 1.9 Weight: 34 g/m2 (1.0 oz/yd) Tensile: Warp/Fill:
19、 85.5/49.4 N (20/12 lbf) Elongation: Warp/Fill: 87.3/74.4 N (20/17 lbf) 4.3.5 Rigid Backing For those trim products requiring a rigid backing, such as door trim panels, the following materials are considered suitable: Pressed Wood Hardboard per SAE J1323 Laminated Fiberboard (Head Board) per MPAPS D
20、-7066 Structural RIM per MPAPS D-7124 Molded Fiberglass per TMS-7109 (withdrawn) Injection Molded Plastic per MPAPS D-7116 Molded Cellulosic per MPAPS D-7125 Fiberglass Reinforced Polyester per MPAPS D-22 Other Plastic per MPAPS D-28 4.4 Property and Performance Requirements 4.4.1 Flammability Requi
21、rements The finished composite must conform to and be certified to meet all requirements of FMVSS-302, Flammability of Interior Materials (CFR 49, Part 571.302). Components of the composite which are not 100% bonded together shall be tested separately and each component must demonstrate required fla
22、mmability 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 flammability resistance. 4.4.2 Seat Inserts - Speci
23、men Preparation for Flammability Requirement The specimen shall be completely saturated with wet steam at 77-93 C (170-200 F) followed by hand drying in a convection oven for 16 hours at 82 C (180 F) followed by conditioning as per FMVSS- 302. 4.4.3 Low Temperature Resistance (Seat Inserts Only) 4.4
24、.3.1 Method: Samples prepared as indicated under Cyclic Aging - Sample Prep 2 shall be exposed for four hours at a temperature of -29 C (-20 F) and then bent around a mandrel of size indicated below. Foam Thickness Mandrel Diameter mm in mm in 3.2 1/8 6.4 1/4 4.8 3/16 12.7 1/2 6.4 1/4 19.0 3/4 7.9 &
25、 Up 5/16 & Up 25.4 1 4.4.3.2 Required: Shall show no evidence of breaking, cracking, checking or loss of adhesion. After 24 hours at room temperature, shall show no evidence of shrinking, wrinkling, distortion, or discoloration. NUMBER: MPAPS D-7028 TITLE: Bonded Trim Composites, Interior REVISION:
26、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 4 of 7 4.4.4 Cyclic Aging 4.4.4.1 Sample Preparation - Opti
27、on 1 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 representative of a production part. All boards must include the decorative facing of one of the 200 x 300 mm (8 x 12 in) faces. 4.4.4.2 Sample Prepar
28、ation - Option 2 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 sections from production parts. All coupons must include the decorative fabric facing on one of the 200 x 50 mm (8 x 2 in) faces,
29、 and shall be taken from random locations. 4.4.4.3 Method: Subject all samples to the seven step aging test shown below. Three peel tests per ASTM D 903 shall be performed at the end of each step at the conditions in Table 1 below. When sample preparation 1 is used, three peel samples measuring 25 x
30、 200 mm (1 x 8 in) are scored through the first layer immediately prior to testing. For sample preparation 2, each sample is tested as is. For dielectrically bonded materials, a bond line shall be centered on each peel strip. 4.4.4.4 Required: There shall be no loss of adhesion between the bonded la
31、yers during any step of the aging cycle. All peel tests shall result in substrate destruction or meet the minimum peel values listed below or as required on the print. Table 1 Aging Test Cycle Aging Cycle Minimum Peel Strength* N/m (lbf/in) Width Fully Bonded With Padding Dielectric Linear Bond Full
32、y Bonded No Padding 1. 24 hours at 38 C (100 F) and 100% RH 400 (2.3) 175 (1) 800 (4.6) 2. 24 hours at 82 C (180 F) 400 (2.3) 175 (1) 800 (4.6) 3. Cool at room temperature (for one hour) 600 (3.4) 250 (1.4) 1200 (6.8) 4. 24 hours at -29 C (-20 F) 400 (2.3) 175 (1) 800 (4.6) 5. 24 hours at 38 C (100
33、F) and 100% RH 400 (2.3) 175 (1) 800 (4.6) 6. 7 days at 70 C (158 F) 400 (2.3) 175 (1) 800 (4.6) 7. Cool at room temperature for one hour 600 (3.4) 250 (1.4) 1200 (6.8) NUMBER: MPAPS D-7028 TITLE: Bonded Trim Composites, Interior REVISION: 1610 This document is restricted and may not be sent outside
34、 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 7 4.4.5 Thermal Shock 4.4.5.1 Method: Sections of the finished composite, as designated on the drawing, shall be s
35、ubjected to three of the cycles listed below. If no critical areas are designated, test areas shall be randomly located, although the entire part shall be capable of passing this test. There shall not be any rest between steps, and the sections shall be examined after each cycle. Thermal Shock Cycle
36、 1. 16 hours 82 C (180 F) 2. 8 hours -29 C (-20 F) 4.4.5.2 Required: There shall be no loss of adhesion. 4.4.6 Humidity 4.4.6.1 Method: Sections of the finished composite, as designated on the drawing, shall be subjected to 168 hours of condensing humidity at 38C (100F) and 100% relative humidity. I
37、f no critical areas are designated, test areas shall be randomly located, although the entire composite shall be capable of passing this test. 4.4.6.2 Required: There shall be no delamination of the fabric cover or foam core. Sections shall not warp or disintegrate. There shall be no objectionable o
38、dor. 4.4.7 Crocking, Staining, Tackiness, and Blocking Sections of the finished composite, as designated on the drawing shall meet the crocking, staining, tackiness, and blocking requirements of the specified fabric. If no critical areas are designated on the drawing, test areas shall be randomly lo
39、cated, although the entire part shall be capable of passing these requirements. 5.0 QUALITY Material shall be free from objectionable odor, have flexibility necessary for good tailoring, be uniform in quality, and match the color and finish of pre-production samples originally approved. Certificatio
40、n of compliance to this specification shall be furnished with each lot. 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 have been met. 6.1 Quality Co
41、ntrol 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, where applicable*, shall be included in the plan as features
42、 for management by statistical process control.* NUMBER: MPAPS D-7028 TITLE: Bonded Trim Composites, Interior 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 al
43、l patent liability. 2016 by Navistar, Inc. OCTOBER 2016 Page 6 of 7 * 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 7.0 SOURCE APPROVAL AND QUALITY CONTROL 7.1 Supplier Requir
44、ements 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) documentation and approval requirements. Suppliers must ma
45、intain 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 be equivalent in all respects to those samples which we
46、re 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, the supplier shall notify NAVISTAR Materials Engineer
47、ing 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 with CFR Title 29, Part 1910 shall be submitted with the
48、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 state of statistical control and with a process capable of providing all required properties. The part supplier a
