Browse Topic: Interior molding and trim

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Method of Testing Resistance to Scuffing of Trim MaterialsJ365_202009 (Current)9/18/2020
This test can be used to determine the resistance to scuffing of test specimens such as fiberboards, fabrics, vinyl-coated fabrics, leathers, and similar trim materials.
Textile and Flexible Plastics Committee
JLR tackles weight with structural electronics20AUTP03_103/1/2020
Ashutosh Tomar, electrical research technical manager at Jaguar Land Rover (JLR) said he has absolute confidence in the potential of structural electronics (SE) now being pioneered by the company. Dubbed LESA (Lightweight Electronics in Simplified Architecture), the technology is expected in upcoming JLR models, though its use in the next-generation Jaguar XJ to be launched in 2020 has not been confirmed. JLR is completing a successful R&D program into printed SE, initially to introduce curved dashboard screens. The company claims an industry first that has the potential to radically alter vehicle interiors, with other applications forthcoming. SE is not a new technology. Decades ago the aerospace industry was considering it as part of aircraft-surface morphing capability to adapt to varying flight conditions.
Birch, Stuart
Interior Decorative Clear Coating for Metal SurfacesAMS7200 (Current)2/10/2020
This specification establishes requirements for an interior decorative clear coating for wear protection of metal substrates.
AMS G8 Aerospace Organic Coatings Committee
Fast Accurate Non-Destructive Measurement of Absorber Impedance and Absorption2019-01-15846/5/2019
Cabin acoustic comfort is a major contributor to the potential sales success of new aircraft, cars, trucks, and trains. Recent design challenges have included the increased use of composites, and the switch to electrically powered vehicles, each of which change the interior noise spectral content and level. The role of acoustic absorption in cabins is key to the optimisation of cabin acoustic comfort for modern vehicles, with acoustic impedance data needed in order to assess and optimise the impact of each component of a given lay-up. Measurements of absorbing interior trim are traditionally performed using either sample holder tests in a static impedance tube (impedance and absorption), or through tests in reverberation rooms (absorption only). Both of these procedures present challenges. In-tube absorption and impedance measurements are destructive, requiring highly accurate sample cutting and sealing. Reverberation room absorption measurements are subject to the effects of varying room diffusion, along with the impact of edge diffraction, sample geometry, and location. Finally, while non-destructive methods using hand-held probes also measure absorption, they are not able to measure impedance accurately. This paper describes fast non-destructive tests using a portable flanged impedance tube, and how they be used to quantify and optimise the absorption of interior trims. Measurements are made on non-locally reacting lay-ups, with the results corrected to equivalent in-tube results using a flanged-to-sample holder correction factor. The corrected flanged tube results are then compared with baseline in-tube measurements. Discussions address data quality and how the non-destructive measurements may be used to optimise lay-ups for increased absorption.
Murray, Paul B., Alexander, Jon, Kunio, Jason, Larsen, Flemming
New design for 2020 Mitsubishi Outlander Sport as brand awaits alliance's new platforms, products19AUTP06_166/1/2019
The 2020 Mitsubishi Outlander Sport carries over with no mechanical changes compared to the 2019 model. But its new face-part of a front/rear styling redo plus new interior trims/tech for the 5-seat, 2-row SUV-signals a new start for the brand in the U.S. Having pared its product lineup to all-SUV plus the economy minded B-segment Mirage, the triple-diamond brand is saucing up its styling while it awaits a bevy of new platforms and products from its alliance with Nissan/Renault. Mitsubishi sold over 100,000 vehicles in the U.S. for the last two years running. Compared to the nearly 350,000 vehicles it sold in 2002 (or the 800K pickups Ford delivers in a year), this might not sound spectacular. But compared to the sub-54K year it had in 2009, the steady growth over the last 10 years (including a 14% jump last year in a flat-overall market) shows that life is returning to the brand.
Seredynski, Paul
Ultra-Light Weight Automotive Door: Design and Validation2018-01-01114/3/2018
An Ultra-Light Door (ULD) has been developed that is 40% lighter than a baseline 2016 mid-size vehicle’s driver side door. The ULD scope encompasses the entire door, including the door-in-white (DIW), interior trim, glazing, hardware, wiring, etc. To achieve such a substantial mass reduction while still meeting the baseline vehicle’s performance metrics (including safety, durability, NVH, appearance, etc.) at a minimal cost increase, the door design relies on a comprehensive full system approach that includes a unique architecture in addition to lightweight materials and components. This paper details the ULD design concept, simulated performance results, the current status of vehicle level validation, and comparisons between component level CAE predicted performance and physical test results.
Reaburn, Timothy, Skszek, Timothy W.
An Exploration of Jute-Polyester Composite for Vehicle Head Impact Safety Countermeasures2018-01-08444/3/2018
Natural fiber-reinforced composites are currently gaining increasing attention as potential substitutes to pervasive synthetic fiber-reinforced composites, particularly glass fiber-reinforced plastics (GFRP). The advantages of the former category of composites include (a) being conducive to occupational health and safety during fabrication of parts as well as handling as compared to GFRP, (b) economy especially when compared to carbon fiber-reinforced composites (CFRC), (c) biodegradability of fibers, and (d) aesthetic appeal. Jute fibers are especially relevant in this context as jute fabric has a consistent supply base with reliable mechanical properties. Recent studies have shown that components such as tubes and plates made of jute-polyester (JP) composites can have competitive performance under impact loading when compared with similar GFRP-based structures. Drawing from this potential, the current study utilizes a combination of testing and CAE (computer-aided engineering) to demonstrate that trims made of jute composite can be effective countermeasures for vehicle upper interior head impact safety protection. To this end, a methodical approach is adopted according to which results obtained from tensile, compressive, and three-point bending tests for specimens extracted from a seven-ply jute laminate are initially utilized for validation of constitutive modeling of the said composite in LS-DYNA, which is then followed by CAE-based assessment of head impact performance of jute composite trim attached to an A-pillar component. A previously validated finite element model of a featureless Hybrid III headform has been used. The results obtained here indicate that HIC(d) (Head Injury Criterion (dummy)) values well below 1000 can be obtained underlining the potential of jute composite as an effective material for vehicle interior trim conforming to the extended FMVSS 201 requirement in the United States.
Shivakumar, Karthika, Deb, Anindya, Chou, Clifford C.
VW finally fills its SUV gap with 2018 Atlas17AUTP06_116/1/2017
With the market rushing headlong toward trucks, SUVs and crossovers, Volkswagen has badly needed a mid-range SUV between its $25,000 compact Tiguan and $50,000-plus premium Touareg. And now, finally, it has one. Designed and engineered in Wolfsburg, built at VW's billion-dollar Chattanooga plant and riding on the modular MQB platform, the 2018 Atlas ($31,000 base price) enters production three years after the CrossBlue concept made the autoshow rounds. Atlas was developed as “a vehicle to go straight at the heart of the mid-size SUV market,” explained Michael Lovati, Vice President of VW's mid-size/full-size product line.
Witzenburg, Gary
Volvo S90: Niche for now, but…16AUTP10_1110/1/2016
It's no secret the reconstituted Volvo, since 2010 owned by China's Zhejiang Geely, is doing interesting and innovative things-one of the most intriguing, maybe, being that it's survived and in some senses thrived (particularly if fellow Swedish auto brand Saab is used as a measure) under Geely's control. Fact is that Volvo and Geely have shut up the naysayers: in the nearly seven years Geely's been in charge, a studied and benevolent guidance (not to mention $11 billion in product-development funding announced in 2012) has delivered a Volvo that's somehow managed to evolve its brand back to a relevancy few thought it could ever recover.
Visnic, Bill
A Study on Impact Perforation Resistance of Jute-Polyester Composite Laminates2014-01-10554/1/2014
Natural fiber-based composites such as jute-polyester composites have the potential to be more cost-effective and environment-friendly substitutes for glass fiber-reinforced composites which are commonly found in many applications. In an earlier study (Mache and Deb [1]), jute-polyester composite tubes of circular and square cross-sections were shown to perform competitively under axial impact loading conditions when compared to similar components made of bidirectional E-glass fiber mats and thermo-setting polyester resin. For jute-reinforced plastic panels to be feasible solutions for automotive interior trim panels, laminates made of such materials should have adequate perforation resistance. In the current study, a systematic characterization of jute-polyester and glass-polyester composite laminates made by compression molding is at first carried out under quasi-static tensile, compressive and flexural loading conditions. Low velocity impact perforation tests at speeds of around 4 m/s are then performed in an instrumented drop-weight testing device on square plates extracted from the same laminates. The energy absorbed in each of these tests is estimated using a novel approach based on load cell data and velocity-time history measured with a high speed camera. A new parameter is identified which is used for comparing the intrinsic resistance of jute and glass composites under impact indentation conditions. In terms of gross energy absorption capacity, the current investigation shows that jute-polyester laminates which are of lower density than glass-polyester laminates can be made comparable to the latter with an increased number of plies (i.e. laminate thickness).
Mache, Ashok, Deb, Anindya, Venkatesh, G.S.
Instrumental Color Difference Measurements for Colorfastness of Automotive Interior Trim MaterialsJ1767_201401 (Historical)1/6/2014
The practice described applies to textile and flexible plastic parts and materials used in automotive vehicles. Special care should be taken when high pile carpet samples are being evaluated.
Textile and Flexible Plastics Committee
Accelerated Exposure of Automotive Interior Trim Components Using a Controlled Irradiance Air-Cooled Xenon-Arc ApparatusJ2212_201211 (Current)11/19/2012
This SAE Recommended Practice specifies the operating procedures for a controlled irradiance, air-cooled xenon-arc apparatus used for the accelerated exposure of various automotive interior trim components. Test durations, as well as any exceptions to the sample preparation and performance evaluation procedures contained in this document, are covered in material specifications of the different automotive manufacturers.
Textile and Flexible Plastics Committee
Natural Oil Polyol (NOP) Based Polyurethane Slabstock Foam for Automotive Interior Foam-Fabric/Vinyl Laminate Construction2011-01-04594/12/2011
The drive to incorporate renewable resources continues to gain momentum within the automotive industry. FXI has developed a grade of low (1.7 pcf) density slabstock foam which uses a natural oil polyol in place of a petroleum-based polyol. This foam grade, trademarked GreenBlend\St, has been developed specifically to produce foam-fabric/vinyl laminates for automotive seating, and interior trim applications such as headrests, armrests, visors and door panels. This new foam grade satisfies all of the OEM specifications for physical properties, including fogging and flammability, and yields satisfactory bond strengths when flame-laminated to cover stock. It is also s cost competitive technology compared to conventional slabstock foam using petroleum-based polyols.
Yap, Chee, Stapleton, Ronald, Smolinski, Ronald
Test Method for Determining Stiffness of Interior Trim Materials and Substrates by a Three Point Bending TestJ949_200904 (Historical)4/20/2009
This SAE Standard presents a method of determining the stiffness of interior trim materials, substrates, and composites by a three-point bending test.
Textile and Flexible Plastics Committee
Accelerated Exposure of Automotive Interior Trim Materials Using an Outdoor Under Glass Variable Angle Controlled Temperature ApparatusJ2229_200807 (Current)7/28/2008
This SAE Standard specifies the operating procedures for the exposure of automotive interior trim materials in an outdoor behind glass apparatus in which the temperature is controlled for part of the day. Specimen preparation, test durations, and performance evaluation procedures are covered in material specifications of the different automotive manufacturers.
Textile and Flexible Plastics Committee
Global Modeling Methodology (GMM) for NVH, Static and Dynamic Performance of Interior Trim2008-01-13414/14/2008
Automotive Interiors are gaining a lot of attention as they have a great impact on car sales. The design of an automotive interior plays a pivotal role in creating a best selling car. Designing a safe and robust interior within the guidelines of the design theme is a challenge. FEA tools are used to validate the design before it goes into production. There is a suite of FEA tools used for studies on Cockpits and door trims. Time to market a product plays a key role in the profitability of the product. As the development cycle of an automobile continues to shorten, new technologies must be developed to shorten the product development time and to reduce the product development cost thereby improving profitability. This paper presents a technique developed to reduce FEA cycle time per FEA loop.
Patnala, Manoj Kumar, Eder, Bernhard
CONTROL OF WATER CARRYOVER FROM THE ENVIRONMENTAL CONTROL SYSTEM AND CONDENSATION ON THE STRUCTUREAIR1204 (Historical)12/3/2007
This publication will discuss water carryover from the environmental control system with respect to causes and indicated corrective or preventative action. In addition, condensation on structure will be reviewed with possible preventative action described.
AC-9 Aircraft Environmental Systems Committee
LED-Equipped Spectrophotometers Find Their Way to the Factory FloorTBMG-1171710/1/2007
Companies that manufacture products ultimately used by consumers — interior trim for cars, vinyl siding for homes, decorative stone for landscaping, interior wall paints, etc. — are often discovering that they need to use precise spectrophotometers to ensure first-time color quality and lotto-lot consistency.
Kia's Rio GrandeAUTOOCT05_0710/1/2005
The all-new subcompact cars from Kia aim for comfort, quality, and safety features at entry-level cost. When the Kia Rio first went on sale in August 2000, it quickly earned a reputation as reliable and affordable transportation. The subcompact sedan spent much of its first four years as the lowest-priced new vehicle in the U.S. and was the company's best-selling nameplate in 2001. But it was never praised for roominess or sporty driving characteristics.
Alexander, David
Accelerated Exposure of Automotive Interior Trim Components Using a Controlled Irradiance Water Cooled Xenon-Arc ApparatusJ1885_200503 (Historical)3/9/2005
This test method specifies the operating procedures for a controlled irradiance, water cooled xenon arc apparatus used for the accelerated exposure of various automotive interior trim components. Test durations, as well as any exceptions to the sample preparation and performance evaluation procedures contained in this document, are covered in material specifications of the different automotive manufacturers.
Textile and Flexible Plastics Committee
Repairable System Reliability Prediction2004-01-04573/8/2004
For a vehicle or repairable system, incidents (conditions) are neither necessarily independent nor identically distributed. Therefore, traditional statistical distributions like Weibull, Normal, etc, are no longer valid to estimate reliability. The Non-homogeneous Poisson process (NHPP) model can be used to predict reliability and warranty of the field product. It can also measure the reliability improvement during the development cycle. The NHPP model is discussed in this paper. In applying a NHHP model to reliability data on a repairable system, one may have few or no failures. This paper presents the I/100 and reliability derivations when the parameter β in the ROCOF function is assumed to have a known value.
Lu, Ming-Wei, Rudy, Richard J.
Light Weight Polypropylene Bonded Long Glass Fiber Technology - For Niche Vehicle Interior Trim2004-01-12583/8/2004
The Ford GT is a niche vehicle with a very limited production volume. A solution was needed that would minimize cost, particularly up-front investment, and produce a lightweight, high-class vehicle interior, while maintaining the standard quality, material and design requirements.
Benninger, E.J., Hipwell, J.G., Ewing, Kip
Accelerated Exposure of Automotive Interior Trim Components Using a Controlled Irradiance Xenon-Arc ApparatusJ2412_200311 (Historical)11/17/2003
1.1 This test method specifies the operating procedures for a controlled irradiance, xenon arc apparatus used for the accelerated exposure of various automotive interior trim components. 1.2 This is a performance standard based on the test parameters of SAE J1885. 1.3 Test duration as well as any exceptions to the sample preparation and performance evaluation procedures contained in this document, are covered in material specifications of the different automotive manufacturers. 1.4 Equipment qualified to perform this test is determined by material test comparison between instruments approved for SAE J1885 and those intending to perform SAE J2412. A specific test protocol to compare new test equipment to those previously approved must be done by material test comparison by the contractual parties. The interested contractual companies shall identify details of the test protocol and the materials to be tested. At the time of publication of this test method, the committee is developing a `Protocol To Verify New Test Apparatus' identified as SAE J2413. 1.5 Any deviations to this test method, such as filter combinations, is to be agreed upon by contractual parties.
Textile and Flexible Plastics Committee
Test Method for Determining Stiffness (Modulus of Bending) of Interior Trim Materials and SubstratesJ949_200304 (Historical)4/11/2003
This SAE Standard presents a method of determining the stiffness of interior trim materials, substrates, and composites by a three-point bending test.
Textile and Flexible Plastics Committee
Distributive Lighting Systems for Interior Applications2002-01-09793/4/2002
With the development of cars towards mobile offices and homes, people are spending more time inside their vehicle than ever before. Consequently, humanization of car interiors is becoming increasingly important to enhance the drivers' comfort and thereby his performance and safety. This is acknowledged by the car industry and has led to an increasing number of light outlets in the car interior over the last decade. Lighting plays a valuable role in the way the car's interior environment is perceived and this in turn determines the drivers' and passengers' comfort and safety. While up to now functional lighting applications (e.g. switch indicators and reading lamps) have dominated the car interior, these do not contribute significantly to its humanization. Ambient, orientation and contour lighting applications reveal the real value of a car's interior environment. Large-area plastic light guide devices enable us to combine several of the above mentioned interior lighting applications, e.g. ambient lighting and a reading spotlight, utilizing a build-in depth of only 6-8 mm. In this set-up, the ambient lighting function is served at luminance levels complying with the low glare requirements set for not disturbing the drivers' view. In another solution, an 80 – 150 lux reading spot illuminating an area of about an A3 size paper can be generated from the same device, using a single 16W bulb with integrated reflector. In this presentation we will elaborate on several examples of such distributive lighting systems.
‘Kim’ Jalink, C. J.
Ergonomic Evaluation of an Aircraft Cockpit with RAMSIS 3D Human Modeling Software2001-01-21156/26/2001
The 3D digital human model RAMSIS, which is primarily used in the automotive industry, has been used to predict probable pilot behavior in a proposed cockpit design for the Eclipse 500 jet. The results were used to detect potential accommodation problems as early as possible, as well as to establish guidelines and requirements for further design of the cockpit and interior components. Defining interactions between a digital human model and a CAD environment, such that it reflects interaction between real pilots and cockpits as realistically as possible, is often an arbitrary process. Nevertheless, 3D human models prove to be powerful design tools for aircraft cockpit designers to ensure functional and comfortable accommodation of the target pilot population.
van der Meulen, Peter A., DiClemente, Perry
Advanced material technologies meeting the challenges of automotive engineering2000-05-00496/12/2000
Advanced material technologies play a key role in automotive engineering. The main objective of the development of advanced material technologies for automotive applications is to promote the desired properties of a vehicle. It is characteristic of most materials in modern cars that they have been developed especially for automotive requirements. Requirements are not only set by the customer who expects the maximum in performance, comfort, reliability, and safety from a modern car. Existing legal regulations also have to be met, e.g., in the areas of environmental compatibility, resource preservation, and minimization of emissions. To achieve goals like weight reduction or increased engine performance permanent material developments are essential. In this paper, numerous examples chosen from body, suspension, and powertrain components show clearly how low weight technologies, better comfort, and high level of recyclability can be achieved by advanced material solutions. General trends in material development for automotive applications are pointed out. Examples shown are high strength steels for body-in-white, aluminum for suspension, and modern plastics for interior trim and engine components. In addition, an outlook is given on potential future material technologies. Performance and economy of future cars, as well as customer acceptance, will become increasingly dependent on the use of advanced material technologies. As a result, technological advances in improving material properties especially for automotive applications are not only intended to fulfill the automotive demands of today and the future, but are necessary to secure automotive competitiveness in the years to come.
Stauber, Rudolf, Baur, Markus
Instrumental Color Difference Measurements for Colorfastness of Automotive Interior Trim MaterialsJ1767_199501 (Historical)1/1/1995
The practice described applies to textile and flexible plastic parts and materials used in automotive vehicles. Special care should be taken when high pile carpet samples are being evaluated. The intent of this SAE Recommended Practice is to specify procedures for the instrumental measurement of color differences brought about by the exposure of textile and flexible plastic automotive parts to various colorfastness tests. It may be used for the specification of limits of color differences which may be tolerated in a specific test.
Textile and Flexible Plastics Committee
Interior Automotive Plastic Part TestingJ1717_199406 (Historical)6/10/1994
SAE J1717 is an advisory document suggesting minimum recommended testing, appearance evaluation, and protocol for specifying the recommendations with regard to Singular Unassembled Automotive interior trim Parts. The purpose of this SAE Recommended Practice is to: a. standardize the testing and appearance evaluation requirements for interior unassembled plastic parts for the automotive industry; b. standardize the associated test and appearance evaluation methods; and c. Provide a method for specifying these requirements by the use of a simple line call-out designation.
Plastics Committee
Intrinsically Foamed SMA in Interior Trim Applications9407083/1/1994
Co-Polymers of styrene and maleic anhydride have been around since the '40's. The addition of maleic anhydride to the polymer backbone has a two fold effect; firstly, it increases chain stiffness and secondly chain-chain interactions are increased. Both of these effects increase the glass transition temperature of the co-polymer. A production technology has been developed which enables to generate co-polymers containing a relatively high maleic anhydride content (typically up to 35 wt %) resulting in materials with glass transition temperatures up to 170 °C. A technology has been discovered and patented whereby these high maleic anhydride containing co-polymers can, under the influence of the right chemistry and temperatures (between 230 - 260 °C), release carbon dioxide which is then used as the blowing agent to generate low density (intrinsically blown) foams. In general these foams are produced on tandem foaming lines and typically have the following property profile: The advantages of SMA-foam produced by the intrinsic foaming technology are obvious: High temperature resistance. Environmental friendly (no CFC or hydrocarbon emission). Low cost. Based on this intrinsically blown SMA foam, a new generation of headliners has been developed. The thermomechanical properties of these headliners are comparable to those of structures based on thermosetting polyurethane. The SMA used in the headliners can be recycled using a “solvent recycling” process. Due to the large segmental repulsion between the polar/a-polar monomer units SMA forms miscible or compatible blends with a large range of polymers or co-polymers, which effectively reduces this internal repulsion. Examples of polymers which are compatible with SMA are PMMA, SAN, PVC, PCL, ABS, PA and PET. This broad miscibility/compatibility range enhances options for recycling.
Gill, J. S., Härtel, V., Schoot, H. G.
New Developments in Low Density RIM Composites for Interior Trim9407033/1/1994
The use of low density reinforced Reaction Injection Molded (RIM) substrates for covered interior automotive articles continues to increase globally. Reduced party mass, consolidation of manufacturing steps (labor), and the use of aluminum tooling, instead of steel, are cited advantages that LD-RIM offers when compared to traditional wood based and thermoplastic materials. Two RIM processes are successfully being used to produce covered interior door panels. Low density structural RIM (LD-SRIM), utilizing conventional RIM equipment, involves the placement of a pre-cut fiberglass mat in the tool cavity prior to open-pour injection of the 2-stream liquid urethane components. Low density reinforced RIM (LD-RRIM), utilizing lance cylinder RIM equipment, incorporates reinforcing fibers, such as milled fiberglass or wollastonite, in the liquid resin component. The liquid resin containing reinforcing filler is injected with the isocyanate component into a closed mold. Both LD-SRIM and LD-RRIM covered door panels meet OEM performance specifications. Little difference exists between LD-SRIM and LD-RRIM substrates, aside from tool design considerations and processing with either glass mat or reinforcing filler. In-mold polymer cure times and pressure/temperature profiles are essentially the same for both processes, and are dependent on the polyurethane components (i.e. polyol, catalysts etc.) employed, polyurethane wall thickness, and polyurethane density (1). Aluminum production tools are preferred because: 1) the polyurethane substrates are “class B surfaces” and do not have the distinctness of image requirements which “class A” parts obtain from steel surfaces, 2) the low level of reinforcement (< 20 percent by weight of the substrate) is non-abrasive to the tool surface, and 3) the low tonnage (<100 ton) RIM clamps which are used. Advancements have been made in LD-RIM substrates to reduce weight further, to proliferate the LD-RIM substrate to other automotive applications, to demonstrate the recyclability of both PVC covered LD-SRIM and LD-RRIM substrates, and to impart “self-release” properties of the LD-RIM substrate from aluminum production tools.
Weaver, Laura B., Ference, Donald M., Laux, Joseph J.
The Active Control of Sound in Aircraft9320597/1/1993
Active Sound Control is an effective means of reducing low frequency sound in the cabins of passenger aircraft. This paper reviews and provides some guidelines on the issues of implementing an active sound control system in an aircraft cabin. I start by explaining the principles of active sound control, the advantages of its application to aircraft cabins and the expected sound reduction. There are two important implementational aspects of an effective system; it must match both the acoustics of the cabin sound field and track the changes in the unwanted sound. The acoustic matching is achieved by careful design and location of the loudspeakers. These have to be both lightweight and efficient at low frequencies and also must fit acceptably into the aircraft trim. To track the changing sound requires a powerful digital controller designed for the aircraft environment and a sophisticated control algorithm.
Curtis, Alan
Accelerated Exposure of Automotive Interior Trim Components Using a Controlled Irradiance Air-Cooled Xenon-Arc ApparatusJ2212_199303 (Historical)3/1/1993
This SAE Recommended Practice specifies the operating procedures for a controlled irradiance, air-cooled xenon-arc apparatus used for the accelerated exposure of various automotive interior trim components. Test durations, as well as any exceptions to the sample preparation and performance evaluation procedures contained in this document, are covered in material specifications of the different automotive manufacturers.
Textile and Flexible Plastics Committee
Interactions of Flexible Urethane Foam and Slush Molded PVC Powder for Instrument Panel Applications9300373/1/1993
Slush molded PVC instrument panel skins interact with the flexible urethane foam backing. This interaction is accelerated by the light and heat present in the automobile interior, and may result in discoloration, shrinkage and general hardening of the instrument panel. New low stain urethanes have been introduced, which reduce the severity of these problems. These foams, when coupled with recent developments in PVC skin compounds, may produce significant improvements in long term durability of instrument panels.
Shrewsburg, James E., McDougal, Guy C.
Accelerated Exposure of Automotive Interior Trim Materials Using An Outdoor Under Glass Variable Angled Controlled Temperature ApparatusJ2229_199302 (Historical)2/1/1993
This SAE Standard specifies the operating procedures for the exposure of automotive interior trim materials in an outdoor behind glass apparatus in which the temperature is controlled for part of the day. Specimen preparation, test durations, and performance evaluation procedures are covered in material specifications of the different automotive manufacturers.
Textile and Flexible Plastics Committee
Accelerated Exposure of Automotive Interior Trim Components Using a Controlled Irradiance Water Cooled Xenon-Arc ApparatusJ1885_199203 (Historical)3/1/1992
This test method specifies the operating procedures for a controlled irradiance, water cooled xenon arc apparatus used for the accelerated exposure of various automotive interior trim components. Test durations, as well as any exceptions to the sample preparation and performance evaluation procedures contained in this document, are covered in material specifications of the different automotive manufacturers.
Textile and Flexible Plastics Committee
Low Density Structural RIM: Glass Mat Reinforced Structural Foam for Interior Trim Applications9204972/1/1992
ICI Polyurethanes has developed a series of structural reaction injection molding resins for automotive interior trim applications. These new resin systems are CFC-free polyurethane foams specifically designed for glass mat reinforcement. These light weight composites can be described as low density structural RIM, LD-SRIM. LD-SRIM can offer a weight reduction of 50% over competitive materials with similar physical properties in applications such as door panels. A LD-SRIM composite with 20% glass reinforcement and a specific gravity of 0.55 g/cm3 has a flexural modulus of 2370 MPa. The LD-SRIM process has several benefits such as the consolidation of manufacturing steps achieved through molding in fasteners or decorative materials and the design flexibility inherent to liquid molding technology.
Makey, Paul W., Schroeder, Jeffrey M., Covins, Kenneth G.
Advances in Urethane Foam Composites for Interior Trim9105202/1/1991
The use of low density urethane foam composites in automotive interior trim is an established technology. In existing applications such as door trim panels, increasing production volumes are providing the impetus for process modifications and improved formulations. In emerging applications such as instrument panel covers new performance requirements must be met. The development of new Baydur STR/F formulations to address these needs are discussed.
Dempsey, Michael P., Hurley, Michael F.
Thermoplastic Polyurethane Headliners: Properties, Processing, and European Market9107872/1/1991
Prefabricated headliners are now completely accepted in Europe and have almost fully substituted conventional suspension headliners. This success in the European marked did however take some time. The headliner versions developed in the USA and Japan provided guidelines for the European development. The initial reason for using prefabricated headliners came from the assembly line. It was necessary to make it easier for workers to fit the headliner into the car. But there was a second important argument which still applies: cost reduction. The cost reduction argument became the pet of all who had developed a prefabricated headliner. This is ultimately the reason why in the early days of the changeover to the new system only very cheap solutions were ever discussed. This demand has since remained the most important challenge for all innovative steps.
Wagner, Werner
UV Stabilized Acetal for Automotive Interior Applications9000972/1/1990
UV stability is an extremely important design property of colored performance plastics for the automotive industry. Moreover, US automakers have been demanding improvements in polymer UV stability over the last several years. This has culminated in the development of test method SAE J1885, which uses a Xenon arc weather-ometer to test the UV stability of interior trim components. This more stringent test method required all suppliers to re-evaluate their position in this market and most likely develop new grades to meet the requirements of this J1885. Acetal is one such polymer which Hoechst Celanese embarked upon a major product development effort to meet the demanding requirements of J1885 for molded-in-color. This development work focused on the total stabilizer/additive system, whereby each component was assumed to be either beneficial or detrimental to UV stability. Results of this work emphasized the importance of reducing a total system approach to practice, as an improved UV stabilized grade of acetal copolymer was developed. This paper focuses on the conclusion of this product development effort.
Mulholland, Bruce M.
Thermoplastic Olefins for Automotive Soft Interior Trim9004762/1/1990
Recent technological advances have made thermoplastic olefins a viable material for automotive soft interior trim. Targeted at replacing PVC skins, polyurethane foams, and substrates made from traditional styrenics, these new polypropylenes can be used in such applications as instrument panels, door panels, consoles, and seating. They offer many advantages over current materials in these stringent applications. This paper describes the olefinic materials that are suitable for soft interior skins, polyolefin extruded foam sheets that can be used in a laminate with the skin, rigid olefin compounds that are used for substrates, and the process to use these materials in manufacturing soft interior trim components.
Haylock, J. C., Addeo, Antonio, Hogan, A. J.
Techniques and Equipment for Processing Headliner Materials9008282/1/1990
A process known as High Caloric Transfer Medium (HCTM*) has been developed and patented by Astechnologies that involves the use of superheated vapor introduced to a perforated tool or three (3) dimensional mold for forming and/or laminating. This process offers very unique possiblilites for cost reductions in the manufacture of most soft interior trim parts including headliners. This process utilizes the super-heated vapor combined with vacuum to cure thermosets, heat thermoplastics, shape fabrics and cool a variety of materials. This provides for reduced cycle times and in some cases eliminates processing steps in the manufacture of headliners. Comparisons are made between conventional and HCTM* forming and laminating methods in order to fully describe the advantages of the latter process.
Simmons, Art, Elliott, George, Elliott, Chris
New Developments in Materials and Fabrication Processes for Automotive Interior Trim Skin Materials8905882/1/1989
Automotive interiors consist of sandwich type components (e.g., instrument panel, door trim, headliner); hard trim (e.g., pillar trim) and functional solid components (e.g., load floor, seat backs, etc.) The intermaterials competition among new processes for fabricating these 3 types of components were described previously (1)*. This paper examines new developments specifically in the area of skin materials used for the sandwich type interior trim components.
O'Malley, Mitra, Eller, Robert
Statistical Decision Making in FMVSS Testing8907712/1/1989
This paper presents a method of accounting for sample variability and sample size in establishing the acceptable bogey levels. The technique makes use of the statistical tolerance theory which accounts for the variability of the sample mean and standard deviation by determining a K-factor adjusted for sample size. The result is a tolerance that is reasonably assumed to cover a specified fraction of the population of parts. The technique, although not as simple as a fixed bogey, does discriminate between designs with different levels of energy management robustness.
Tilly, Lynn K., Rudy, Richard J.
Instrument Panel Weatherability8805062/1/1988
The purpose of this paper is to review current laboratory test methods for conducting artificial weathering of vinyl/foam composites as specified by major automotive manufacturers for instrument panel components. Critical test parameters for each method, including spectral irradiation (ultraviolet, visible, and infrared components), light/dark cycles, ambient temperatures, black panel temperatures, and moisture levels are reviewed. The mechanisms by which these test conditions are controlled are discussed. The subjectivity of criteria used to judge whether test results are considered passes or failures are discussed and alternative quantitative methods suggested. The need for uniform weatherability test standards throughout the automotive industry is considered in terms of the implications on automotive supplier material development efforts. The technical validity of commonly chosen test parameters used to accelerate weatherability studies is revisited for the purpose of understanding how the test results correlate to actual instrument panel weatherability in the field.
Lord, Ellen M., Kishbaugh, Levi, Russel, John, Arthur, Jeff
Effect of Thermal Stabilization on Short and Long Term Polymer Properties8805022/1/1988
This paper discusses the effect of various individual and combinations of thermal Stabilizers and their effect on polymer properties. We will show the effect on initial molded properties with various stabilizers, and how the proper balance of stabilization can enhance the long term heat aged properties on both ASTM test specimens and also on actual large molded part performance. Physical Properties investigated are those of Izod, multi-axial impact, tensile and flexural properties over a range of aging times and temperatures.
Sierodzinski, Mitchell J., Roberts, Otis J., Hall, William J.
Accelerated Exposure of Automotive Interior Trim Components Using a Controlled Irradiance Water Cooled Xenon-Arc ApparatusJ1885_198708 (Historical)8/1/1987
This test method specifies the operating procedures for a controlled irradiance, water cooled xenon arc apparatus used for the accelerated exposure of various automotive interior trim components. Test durations, as well as any exceptions to the sample preparation and performance evaluation procedures contained in this document, are covered in material specifications of the different automotive manufacturers.
Textile and Flexible Plastics Committee
Plasticizers for Automotive Interior Trim8703182/1/1987
This paper discusses several important parameters of flexible vinyl that automotive interior trim suppliers have to meet. One of the most important properties which the North American car manufacturers require is low volatility and a corresponding low fogging. Besides this, other properties such as low temperature flexibility, light and thermal stability and processability play a key role in the selection of a plasticizer by the trim supplier. This work demonstrates the plasticizer effect on these parameters and provides a technique for selecting a plasticizer with the best balance of properties. Two plasticizers satisfy these requirements - a di-7,9,11-alkyl phthalate and a 100% di-iso-nonyl phthalate (N) that is based on a less branched nonanol.
Wadey, Brian L., Holzmann, Jürgen
A New Weather Stable Polymer for Automotive interior Trim Applications8705592/1/1987
In response to Automotive OEM's need for higher quality in plastics used in interior trim applications, Monsanto has developed a color stable material to meet stricter UV stability requirements. This material, an ASA polymer, has properties similar to ABS and excellent melt-flow which allows molding of large and complex parts. The product can be readily colored and has outstanding color stability as demonstrated by accelerated UV as well as actual outdoor testing.
Bhombal, A. Hameed, Paster, Karen J., Peng, Fred M.
Procedure for Visual Evaluation of Interior and Exterior Automotive TrimJ361_198503 (Historical)3/1/1985
This SAE Recommended Practice applies to parts and materials used in vehicle manufacture which are intended to be acceptable color matches to a specified standard. This document is intended for use with parts or materials which are opaque or nearly so. Materials covered by this document include topcoat paint finishes, interior soft trim, interior and exterior hard trim, and exterior film and flexible trim. Purpose The intent of this document is to precisely specify procedures for the visual evaluation of appearance of colored materials or parts incorporated in the manufacture of vehicles. The document provides a consistent engineering practice for the determination of visual color difference between materials or parts of the same or like materials. A suitable fixture providing daylight, fluorescent, and horizon lighting conditions is necessary for this evaluation.
Textile and Flexible Plastics Committee
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