1、This document is restricted and may not be sent outside Navistar, Inc. reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2018 by Navistar, Inc. JANUARY 2018 Page 1 of 7 NAVISTAR, INC. Material, Parts, and Process Specifications (
2、MPAPS) NUMBER: MPAPS D-7125 Former Designation: TMS-7125 TITLE: Composite Trim Panels CURRENT REV No.: 1801 DATE: Jan. 2018 WRITTEN/EDITED BY: J. Jamison APPROVED BY: R. Goluch SUPERSEDES: Rev. 1608 Aug 2016 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may
3、 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 to use. 1
4、.0 APPLICATION This specification covers requirements for seven types of composite trim panels used in interior applications in NAVISTAR trucks. 2.0 SCOPE This specification covers the general, durability, performance, design, quality, qualification, shipping and identification, and source approval
5、requirements for composite trim panels. 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 MPAPS B-50 specification 3.0 REFERENCE DOCUMENTS Unless otherwise specified the latest issue o
6、f 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 Supplier Packing and Shipping Std. D-13 NAVISTAR NV-2C1 CFR Title 29, Part 1910 NAVISTAR MPAPS D-7028: Bonded T
7、rim Composites, Interior NAVISTAR MPAPS D-7113: Woven or Knit Fabric, Interior Trim- Parts 1 MPAPS D-7121 for vinyls; and MPAPS D-7126 for carpets and non-woven materials. The minimum physical properties of the base supporting material are listed in Table 1. 4.1 Composition A description of the comp
8、osition of each of the types of composite panel is provided herein. 4.1.1 Type I: is a rigid cellulosic molded base. 4.1.2 Type II: is a rigid, molded wood fiber based product that uses polypropylene as a binder. This type is suitable for use as side and back panels. 4.1.3 Type III: is a semi-rigid
9、molded material that is a combination of natural fibers and thermoplastic binders mixed into needled mats. 4.1.4 Type IV: is a molded material that is a combination of urethane foam and fiberglass scrim with a backing that may be rigid if required. This type is suitable for use as a headliner. Forme
10、rly TMS-7117. The composite may consist of the following layers: 4.1.4.1 Backing Material 4.1.4.2 Fiberglass mat (in designated areas) 4.1.4.3 “Firm“ foam 4.1.4.4 Fiberglass mat (in designated areas) NUMBER: MPAPS D-7125 TITLE Composite Trim Panels REVISION: 1801 This document is restricted and may
11、not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2018 by Navistar, Inc. JANUARY 2018 Page 3 of 7 4.1.4.5 Backing material 4.1.4.6 “Soft“ foam 4.1.5 Type V: A molded laminate that is a combin
12、ation of urethane resin, fiberglass reinforcement, polyester batting, and scrim. This type is suitable for use as a headliner. Formerly TMS-7117. The composite may consist of the following layers: 4.1.5.1 Cover Material 4.1.5.2 Fiberglass Reinforcement 4.1.5.3 Resonated Polyester Batting 4.1.5.4 Fib
13、erglass Reinforcement 4.1.5.5 Scrim 4.1.6 Type VI: A rigid urethane foam molded in conjunction with a continuous strand glass mat. This type is suitable for use in door trim and B-pillars. 4.1.7 Type VII: A polyurethane elastomeric molded soft skin that consists of either an aliphatic urethane in mo
14、ld coating followed by an aromatic solid urethane skin or a solid aliphatic skin with urethane foam injected between the skin and a plastic substrate. This type is suitable for use as an instrument panel trim cover. 4.1.8 Type VIII: A thermoplastic composite of polypropylene and long glass chopped f
15、ibers. Substrate is sandwiched between outer layers of scrim and adhesive film. Composite is adhered to a foam-backed vinyl through compression molding. This type is suitable for use as headliner, back panels and B-pillars. 4.2 Performance Requirements 4.2.1 Impact Resistance Test panels mounted in
16、an appropriate fixture shall withstand a minimum impact of 3.9 J (3.0 ft/lbs) without significant damage or cracking. The sample(s) exposed in the dimensional stability test should be returned to the cold chamber at 302C (-225F) for 4 hours and tested immediately upon removal. 4.2.2 Dimensional Stab
17、ility Test panels mounted in/on an appropriate test fixture shall withstand 2 complete cycles of the environmental test indicated below, without exhibiting objectionable distortion, color or gloss change, odor, warping, sag, staining, or delamination. Dimensional changes shall not be greater than to
18、lerances indicated on the part/assembly drawings. Test panels shall be examined after completion of the environmental test and again after a two-hour recovery period. 4.2.3 Environmental Test Cycle: 4.2.3.1 16 hours at 95 5% R.H. at 38 2 C (100 5 F) 4.2.3.2 2 hours at ambient condition 4.2.3.3 16 ho
19、urs at 85 2 C (185 5 F) 4.2.3.4 2 hours at ambient condition 4.2.3.5 4 hours at 30 2 C (-22 5 F) 4.2.3.6 2 hours at ambient condition 4.2.4 Flammability The finished composite must conform to and be certified to meet all requirements of FMVSS-302 and all requirements of MPAPS P-9544. Components of t
20、he assembly/composite which are not 100% bonded together shall be tested separately and each component must demonstrate required flammability resistance. Components of the composite which are 100% bonded together are not specifically required to NUMBER: MPAPS D-7125 TITLE Composite Trim Panels REVIS
21、ION: 1801 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. 2018 by Navistar, Inc. JANUARY 2018 Page 4 of 7 demonstrate flammability resistance when tested
22、 separately as individual parts, however; the bonded composite must demonstrate the required flammability resistance. 4.2.5 Adhesion Parts shall meet the requirements of MPAPS D-7028. 4.2.6 Fastening and Handling The finished composite/assembly shall have sufficient strength/rigidity to permit handl
23、ing in installation and service procedures without damage. Punched holes for mounting or retention purposes shall be free of loose fibers and/or frayed material. To prevent fraying in the hole-punched area, a heat process may be used to melt the frayed material and hold it in place. Any process used
24、 to accomplish this operation will not cause an objectionable appearance problem/defect. 4.2.7 Accelerated Weathering per MPAPS GT-31, Zone A, Zone B or Zone C All materials shall qualify to one of the two following tests: 4.2.7.1 Xenon Arc: 4.2.7.1.1 Interior parts, per Method A 4.2.7.1.2 Interior
25、parts, per Method F 4.2.7.2 Required (Either Method): There will be no sign of color alteration greater than a E of 3, decreased pliability or fiber degradation after exposure. A minimum rating of 3.0 per AATCC Evaluation Procedure 1. 4.2.8 Mildew Resistance: AATCC Method 30 Shall not exhibit any ob
26、jectionable odor or growth of mildew. 4.2.9 Sound Absorption Headliners Only*: ASTM C 384 (NAVISTAR NV-2C1) The normal incidence sound absorption coefficients shall be measured at: 500, 630, 800, 1K, 1.25K, 1.6K, 2K, 2.5K, 3.1K, min normal abs coeff 0.40. The test method shall be ASTM C 384 (NAVISTA
27、R NV-2C1). The headliner test sample shall be mounted in the sample holder in the same orientation and part relationship as in the truck, with the back-plate of the sample holder representing the roof sheet metal. If there is more than one typical air gap between the headliner and roof, test each fr
28、equency with each air gap and generate an average for each frequency based on the relative area of each air gap. * Note: This fully applies to Day Cab headliners only. Sleeper headliners shall be tested to this and the results reviewed and approved by NAVISTAR Global Engineering Noise, Vibration and
29、 Harshness Group. 5.0 QUALITY Material supplied shall be free from objectionable odor, be of uniform quality, and match the pattern, color, finish, and texture of pre-production approved samples on file in the TDTC Industrial Design Department. Pre-production samples of material sufficient for compl
30、ete test and evaluation should be submitted to TDTC Materials Engineering for approval. All samples shall be accompanied by a laboratory report per MPAPS P-9543 showing conformance to all items denoted in the specification(s). 5.1 Qualification Materials submitted for approval to this specification
31、shall include the following: 5.1.1. A detailed, signed test report documenting testing to this specification per MPAPS P-9543. NUMBER: MPAPS D-7125 TITLE Composite Trim Panels REVISION: 1801 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from
32、Corporate Technical Standards. Suppliers are required to assume all patent liability. 2018 by Navistar, Inc. JANUARY 2018 Page 5 of 7 5.1.2. The complete procedure used for preparing and curing materials for test, especially surface preparation (when appropriate) and condition of the test materials.
33、 5.1.3. A complete description, including engineering prints and/or pictures, of any non-standard test fixtures used. 5.1.4. Adhesive, substrate and any chemicals used for bonding where appropriate. 5.2 Submission The material and test report shall be submitted to: Materials Engineering and Technolo
34、gy Dept. 10400 W. North Avenue Melrose Park, IL 60160 E-mail: MaterialsEngineeringN 5.3 Approval A report from NAVISTAR will be issued approving material to this specification. Approval is not granted until this report has been published. Specification changes listing the approval may be delayed fro
35、m the date of the original approval; this report is authorization of that approval prior to this change. 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-169
36、49 registration as long as the supplier 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
37、 Buyer upon request. 6.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples that were approved by the purchaser. No changes in formulation or processing practices are permitted without approval. In the event tha
38、t changes in material, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify NAVISTAR Materials Engineering, Purchasing, and Integrated Supplier Quality of the proposed change(s). Test data indicating conformance to all requirements
39、 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 perform and report results of tests on specific lots of p
40、arts 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 and the plant metallurgist and/or the quality control manager of t
41、he using NAVISTAR plant may determine testing and reporting requirements on specific products. NUMBER: MPAPS D-7125 TITLE Composite Trim Panels REVISION: 1801 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. S
42、uppliers are required to assume all patent liability. 2018 by Navistar, Inc. JANUARY 2018 Page 6 of 7 7.0 SHIPPING, PACKING AND IDENTIFICATION Shipping, packing and identification shall be in accordance with NAVISTAR Supplier Packing and Shipping Standard D-13. 8.0 DESIGNATION ON DRAWINGS Composite
43、Trim Panel per MPAPS D-7125 Type I, II, III, IV, V, VI, VII, or VIII (as applicable) 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
44、and Technology Dept. 10400 W. North Avenue Melrose Park, IL 60160 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:/ Table 1 Material Physical Properties Property Test Method Type I Type II Type
45、III Type IV Type V Type VI Type VII (Skin) Type VII (Foam) Type VIII Nominal Thickness, mm 2.5 3.0 2.5 Specific Gravity ASTM D1037 0.95 1.07 0.50 1.01 Hardness - Shore D ASTM D2240 65 70 Shore A 71 Moisture Content, max % ASTM D1037 1.0 1.5 8.0 Water Absorption 2.5 hours max % 24 hours max % SAE J31
46、5 2.0 2.0 1.5 2.5 0.5 1.0 Tensile Strength, min MPa ASTM D638 15 MD- 17.4 AMD- 12.8 MD- 21.0 AMD- 13.0 19/15 15 8.7 6 Tensile Modulus, min GPa ASTM D638 1.7 MD- 2.5 AMD- 2.0 MD- 4.1 AMD- 1.0 2.2/1.5 650 Tensile Elongation, % ASTM D638 1.5 1.5 1 1.9 1 2.4/2.2 212 NUMBER: MPAPS D-7125 TITLE Composite
47、Trim Panels REVISION: 1801 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. 2018 by Navistar, Inc. JANUARY 2018 Page 7 of 7 Flexural Strength min MPa ASTM
48、 D790 35 MD- 35.0 AMD- 29.0 40/31 30 3 Flexural Modulus min GPa ASTM D790 2 MD- 3.1 AMD- 2.1 2.6/1.8 1.1 430 Burst Strength, min, kPa SAE J315 3000 2250 3400 3500 Impact Strength, min, -30C, Joules ASTM D3029 Geometry GB 10 0.9 10 Bond Strength min ASTM D751 30 N/25mm Tear Strength min ASTM D5587 29 kN/m Values indicated are for raw material flat stock; values from molded components may be different. Report values and test methods to NAVISTAR Materials Engineering and Technology. Revision Level Change Approve
