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. 2014 by Navistar, Inc. FEBRUARY 2014 Page 1 of 8 NAVISTAR, INC. Material, Parts, and Process Specificatio
2、ns (MPAPS) NUMBER: MPAPS P-9565 Former Designation: TMS-9565 TITLE: Truck Door Trim Material, Performance, and Durability Requirements CURRENT REV No.: 1402 DATE: Feb. 2014 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: TMS-9565 October 2013 PRINTED COPIES OF
3、 THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification 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 practi
4、ces and to determine the applicability of regulatory limits prior to use. Change Notice: Major content revision and update to new MPAPS format. 1.0 APPLICATION This specification covers requirements for the complete door trim assembly including material, durability, noise, serviceability, and design
5、 criteria. 2.0 RESTRICTED CHEMICAL SUBSTANCES 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 of all referenced standards shall apply. The following
6、Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 CFR Title 29, Part 1910 NAVISTAR TMS-9516 AWS D1.1 NAVISTAR Manufacturing Std. MS-D-13 AWS D1.2 NAVISTAR TMS-6505 AWS D1.3 NAVISTAR MPAPS B-50 NAVISTAR MPAPS D-28 NAVISTAR MP
7、APS DT-19 NAVISTAR TMS-7113 NAVISTAR CEMS DT-10 NAVISTAR MPAPS L-6023 NAVISTAR TMS-7125 NAVISTAR TMS-9009 AWS G1.2M/G1.2 AWS B2.4 NAVISTAR TMS-7028 AATCC Test Method 8 VA PR 008 4.0 MATERIAL REQUIREMENTS 4.1 General Material Requirements 4.1.1 Molded Plastics The most common plastic door trim materi
8、al requirements are listed below. Plastic door trim resin should meet one of the following material specs as a minimum. Exceptions require approval from Navistar Materials and Engineering groups. Color, grain, and finish to be specified on the drawing by Navistar Design. NUMBER: MPAPS P-9565 TITLE:
9、Truck Door Trim Material, Performance, and Durability Requirements REVISION: 1402 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. 2014 by Navistar, Inc.
10、FEBRUARY 2014 Page 2 of 8 4.1.1a: Pull cup material: ASA, A2 A46 A64 C10 DF1150 K48 M24 R2150 S90 U YA1800 AC1, per NAVISTAR MPAPS D-28. 4.1.1b: Plastic door trim: PP, TEO, or TPO, A46 A64 C10 K23 M20 R240 SA120 U YA3600 AC1, per NAVISTAR MPAPS D-28. 4.1.2 Cloth Insert All woven and cloth materials
11、shall meet TMS-7113 Type P Woven or Knit Universal Fabric, Interior Trim Part. 4.1.3 Material Insert Substrate All insert and substrate material shall meet TMS-7125, Type 2. 4.1.4 Painted Metallic Parts - Unless otherwise specified, metallic components shall be painted NAV0004 Black, Class IIIA, per
12、 TMS-9009. 4.1.5 Acoustic Foam All acoustic insulation shall meet TMS-6505, TYPE II, Grade B. 4.2 Adhesion and Joining Requirements 4.2.1 Welds 4.2.1.1 Spot welds shall comply with TMS-9516. 4.2.1.2 Non-resistance welds will comply with the applicable American Welding Society (AWS) standard: AWS D1.
13、3 or D1.1 for steel and AWS D1.2 for aluminum. 4.2.1.3 Plastic welds including but not limited to: sonic welds, ultrasonic welds, heats staking, etc shall comply with AWS G1.2M/G1.2:1999 (R2010) or AWS B2.4:2012 4.2.2 Adhesives All adhesive bonded trim must meet TMS-7028. 4.3 Component Level Materia
14、l Requirements 4.3.1 Interior Part Performance Requirements (MPAPS DT-19): All materials in the door trim shall be tested to the procedures and requirements called out in NAVISTAR MPAPS DT-19. Navistar Engineering shall be contacted prior to testing to confirm testing locations and data requirements
15、. 4.3.2 Rubbing and Wear Test Requirements (CEMS DT-10) 4.3.2.1 Procedure Test the part following procedure outlined in CEMS-DT-10 4.3.2.2 Required The white cheesecloth shall have an AATCC rating better than class 4 on the chromatic scale (using AATCC test method #8). There shall be no surface disc
16、oloration or transfer of color to the cloth. 4.3.3 Over-Mold Adhesion Twist Retention Requirements (MPAPS L-6023) 4.3.3.1 Application Handle 4.3.3.2 Procedure MPAPS L-6023 section 4.2.8 for over mold adhesion to bar 4.3.3.3 Required The minimum applied torque required to break the material free of t
17、he insert shall be 20.4 0.3 Nm (15 0.2 ft lb). 4.3.4 Mildew Odor Requirements 4.3.4.1 Procedure Place a 50 mm X 50 mm sample of each proposed material in a container. Add enough distilled water to saturate the bottom 10 mm of sample. Close the container tightly. Expose the container to 38 +/-2 deg C
18、 for 14 days. NUMBER: MPAPS P-9565 TITLE: Truck Door Trim Material, Performance, and Durability Requirements REVISION: 1402 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
19、 patent liability. 2014 by Navistar, Inc. FEBRUARY 2014 Page 3 of 8 4.3.4.2 Required The specimen shall be inspected for mildew growth and related odor. No mildew growth or related odor is permitted. 5.0 DURABILITY AND PERFORMANCE REQUIREMENTS 5.1 Road Load Durability 5.1.1 Procedure The door trim a
20、ssembly shall be subjected to road input accelerations by a shaker test simulating the life of the vehicle. The procedure shall be defined by Navistar Engineering and tested at Navistar. 5.1.2 Required The door trim must withstand the shaker test without exhibiting loss of retention, damage, or loos
21、ened parts. The maximum allowed effect of any part of the door trim is 1mm offset from the start position at specified points to be determined by test and product engineer. Components must remain mounted upon completion of test. Threaded fasteners must not exhibit any backing out. Door trim BSR gene
22、rated sound must be less than 60dB at beginning of test and less than 65dB at conclusion of test. 5.2 Door Slam Load Durability 5.2.1 Procedure Slam the door at 1.5 m/s (4.9 ft/ sec) with the complete door assembly and cab interface present. Cycle the following four phases for three full cycles, for
23、 a total number of slam cycles of 260,000. Phase Environment Cycles 1 -40 C 13,000 2 Ambient 34,667 3 85 C 13,000 4 40 C, 95% RH 26,000 5.2.2 Required While mounted on a door, the door trim panel must withstand the following cycle without exhibiting loss of retention, visible damage, cracking on A o
24、r B side surfaces, or loosened parts. The maximum allowed effect of any part of the door trim is 1mm offset from the start position at specified points to be determined by Navistar Engineering. Components must remain mounted upon completion of test. Threaded fasteners must be marked before the test
25、and not exhibit any backing out. 5.3 Pull Handle Durability 5.3.1 Procedure While mounted on a door, apply a 40 lbf horizontal load to the inboard face of the pull cup or pull handle using a cushioned right angle bracket that is 90mm (3.5 inches) wide. This test can be completed as part of the door
26、slam test cycle. Use a cycle rate of 10-cycles/ minute unless testing is done concurrently with the slam test cycle. Discuss and clarify exact procedure with Navistar Engineering prior to testing if two tests are to be combined. NUMBER: MPAPS P-9565 TITLE: Truck Door Trim Material, Performance, and
27、Durability Requirements REVISION: 1402 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. 2014 by Navistar, Inc. FEBRUARY 2014 Page 4 of 8 5.3.2 Required Th
28、e door trim panel must withstand the test without exhibiting loss of retention, visible damage, cracking on A or B side surfaces, or loosened parts. The maximum allowed effect for any part of the door trim is 1mm offset from the start position. Threaded fasteners must be marked before the test and n
29、ot exhibit any backing out. 5.4 Grab Handle Ingress Egress Durability 5.4.1 Procedure Apply a 108 lbforce load away from the grab handle at an angle of 15 degrees down from horizontal that is parallel to the door plane. Cycle the load a total of 260,000 times. Grab handles, map pockets and pull hand
30、les can be considered handholds for ingress and egress. 5.4.2 Required The door trim shall not exhibit loss of retention, visible damage, cracking on A or B side surfaces, or loosened parts. Threaded fasteners must be marked before the test and not exhibit any backing out. 5.5 Pull Handle Ingress Eg
31、ress Handle Durability 5.5.1 Procedure Apply a 108 lbf load away from the pull cup at an angle of 45 degrees down from horizontal. Cycle the load a total of 260,000 times. 5.5.2 Required Deflection Displacement (elastic): 15.2 mm Permanent Set Displacement for duration of test: 1.6 mm Permanent Set
32、Displacement maximum at completion of test: 1.9mm Must not exceed the maximum allowable strain of the material based on the yield stress (all components). While mounted on a door, the door trim panel must withstand the cycle without exhibiting loss of retention, visible damage, cracking on A or B si
33、de surfaces, or loosened parts. Components must remain mounted upon completion of test. Threaded fasteners must be marked before the test and not exhibit any backing out. 5.6 Grab Handle Strength 5.6.1 Procedure Apply a vectored load along the Anticipated Direction of Handhold Use of 300lbs. Spread
34、the load over 5in. Apply the load at the center and both ends of the handhold starting with new parts for each load condition. Grab handles, map pockets and pull handles can be considered handholds for ingress and egress. 5.6.2 Required All components must remain below the maximum allowable strain o
35、f the material based on the yield stress. The grab handle shall maintain its functionality during and after the application of this load. Maximum allowable deflections: Deflection Displacement (elastic): 25.4mm; Permanent Set Displacement (inelastic): 6.4mm. 5.7 Touch Deflection 5.7.1 Procedure Defl
36、ection zones will be tested in the normal direction with a 22N (5 lb) load applied normal to the surface over a 10mm diameter disc. NUMBER: MPAPS P-9565 TITLE: Truck Door Trim Material, Performance, and Durability Requirements REVISION: 1402 This document is restricted and may not be sent outside Na
37、vistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. FEBRUARY 2014 Page 5 of 8 5.7.2 Required The maximum deflections measured using a force gage at the locations specified by Navistar design a
38、nd test engineers. High Touch Zone: 1.0 mm Medium Touch Zone: 1.5 mm Low Touch Zone: 3.0 mm 5.8 Switch Durability 5.8.1 Procedure Apply the maximum allowable effort to activate the switch at each location and activation load vector. The door trim mounting interface must withstand 100,000 switch acti
39、vation cycles in each switch activation direction. 5.8.2 Required While mounted on a door, the door trim panel must withstand cycling without exhibiting loss of retention, cracking, or loosened parts. The maximum allowed effect of any part of the door trim is 1mm offset from the start position at sp
40、ecified points to be determined by test and product engineer. Components must remain mounted upon completion of test. 5.9 Switch Mounting Strength 5.9.1 Procedure Apply a 270N load at the center of the switch module perpendicular to the surface. 5.9.2 Required Maximum Deflection Displacement (elasti
41、c): 10mm Permanent Set (inelastic): 2mm No loss of retention, visible damage, cracking on A or B surface, or loosened parts. 5.10 Armrest Durability Testing 5.10.1 Procedure Elbow Test 89N (20 lb) load applied vertically with 38mm diameter disc. Test three armrests, one each at: 8,000 cycles at ambi
42、ent, 1,000 cycles at -40 deg C, and 1,000 cycles at 82 deg C. Arm Test 334N (75 lb) load applied vertically with 100mm x 50mm block. Test three armrests, one each at: 1,000 cycles at ambient, 50 cycles at -40 deg C, and 50 cycles at +82 deg C. 5.10.2 Required While mounted on a door, the assemblies
43、must withstand both cycles with no visible damage, cracks in the A or B side surface, or separations greater than 1mm. (Six armrests shall be tested in all, one armrest for each testing cycle and condition). Deflection Displacement (elastic): 15.2mm Permanent Set Displacement (inelastic): 1.9mm 5.11
44、 Armrest Ultimate Load Testing 5.11.1 Procedure Apply a 150 lbf load normal to the top center of the armrest using a 100mm x 50mm block. 5.11.2 Required While mounted on a door, the assembly must withstand the load applied with no visible damage, structural cracks, or separations greater than 1mm. D
45、eflection criteria Deflection Displacement (elastic): 25.4mm Permanent Set Displacement (inelastic): 6.4mm. NUMBER: MPAPS P-9565 TITLE: Truck Door Trim Material, Performance, and Durability Requirements REVISION: 1402 This document is restricted and may not be sent outside Navistar, Inc. or reproduc
46、ed without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. FEBRUARY 2014 Page 6 of 8 5.12 Door Component Retention 5.12.1 Procedure Mount the door component in the installed position. Apply a 50N force at the center of the
47、component. If the component has an activation force the load shall be 50N + activation force. 5.12.2 Required No visible damage, structural cracks, or separations greater than 1mm when the component is pulled at center with a force of 50N applied perpendicular to the mounting surface. 6.0 INTERIOR N
48、OISE REQUIREMENTS 6.1 Natural Frequency Test 6.1.1 Procedure A sine sweep shall be performed to identify resonant frequencies. Samples shall be functional during testing and mounted in vehicle position. 6.1.2 Required The resonance frequencies determined from this test shall not have first vibration
49、 resonant modes below 18 Hz nor between 25 to 40 Hz. 6.2 Subjective Evaluation of Full-Vehicle Acoustic Attributes (BSR) 6.2.1 Procedure Test according to procedure outlined in VA-PR-008. 6.2.2 Required Passing requires a subjective rating of 8 or higher according to the scale outlined in VA-PR-008. 6.3 Noise System Level 6.3.1 Procedure: The door trim must be excited with representative road load data and a sine sweep of expected input freque
