DBL_5463_2002-09

DBL_5463_2002-09
DBL_5463_2002-09

September 2002

Mercedes-Benz

Supply Specification

Light multi-layer sound insulations for internal and external applications

DBL 5463

BQF available o

Additional DaimlerChrysler Standards required:DBL 5306, DBL 5307, DBL 8585.

Supersedes Edition: -Refer to section Changes

Continued on pages 2 to 8

Issued by:

DaimlerChrysler AG 70546 Stuttgart Standards (EP/QIN)Technical responsibility (Name): Wei?Department: VWL Plant: 050Telephone: (+49) 7031 90-87656HPC: F 105Technical coordination by PWT

Plant 50, Department VWL Name: Dr. Herrmann

Telephone: (+49) 7031 90 – 2461HPC: 050 F 105

Confidential! All rights reserved. Distribution or duplication in part or in whole without prior written approval of DaimlerChrysler AG is not permitted.

In case of doubt, the German language original should be consulted as the authoritative text.

Overview of product versions Table 1

Product versions, broken down according to place of application:Product versions Internal/External component Maximum temperature exposure Examples

(The PV indicated on the drawing shall apply)

.00Internal component 90°C - Insulation luggage compartment area, door area .01Internal component 120°C - Insulation inner firewall, parcel shelves, rooflining . 09External component 120°C - Insulation under covers .10External component 150°C - Insulation engine compartment

.11External component 200°C - Insulation firewall outside, component compartment wall .12

External component

250°C

- Insulation transmission tunnel

Abbreviated designation : e.g. Compound part DBL 5463.00

1.APPLICATIONS

As acoustic parts for internal and external vehicle compartments.

2.MATERIALS

---

For surface materials and substrates refer to the specific drawings and the relevant individual material DBLs. The technical values of the initial materials shall correspond to the individual material DBLs, e.g.DBL 5450, DBL 5452, DBL 5454, DBL 5455, DBL 5456, DBL 5460, DBL 5462, DBL 5869 etc.For PV 10 to PV 12 (external parts), no surface fleece made from purely vegetable fibres and/or manmade cellulosic fibres may be used (max. 30 % by weight in fibre blend).Note: wherever possible, avoid resins emitting formaldehyde or phenol.

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DBL 5463 : September 2002

2.MATERIALS (continued)

2.1Fastening and making-up parts

In accordance with drawing. 3.CHARACTERISTICS

3.1General requirements

--The parts shall be free of production defects of any type which would impair the processing and utiliza-tion properties or the appearance. No CFCs shall be used for the manufacture and processing of mate-rials.

Acoustic parts:

The bond between the surface material and the substrate must be even, sufficiently strong (free of dust and fluff) and resistant to ageing. For this purpose, the substrate surface must be suitably conditioned / provided in a form with good gluing capability. Also, the surface material must be turned over and glued at the outside edges with sufficient strength and without disturbing overlaps. The pull-out forces of glued on, riveted or integrated fastening or making-up parts (retainers, clips or similar) must correspond to the specifications on the drawings.

Their shape must comply with the dimensions specified in the drawing or the functional instructions. The bond between cover material and the inside material as well as between the inside material and substrates must be firm enough to ensure that no separation can occur during assembly or use (e.g. as a result of release agent residues).

3.1.1Only for internal components PVs 00 and 01

-The availability of a certificate of testing in accordance with the following method is defined as an over-riding requirement for adherence to the emission values for interior trim materials: DC work instruction for the determination of gaseous and condensable emissions with thermo desorption (refer to DC test instruction PB VWT 709). Test execution: Institut Fresenius Angewandte Festk?rperanalytik, Hauert 9, D-44227 Dortmund.

In particular, in the case of substances listed in the latest edition of the DFG MAK (industrial threshold value) list under "Carcinogenic", categories 1 to 3, as well as under "Pregnancy", categories A and B, and under "Mutagenic", categories 1 to 3, the supplier is required to continuously minimize the concen-tration and emission at least in accordance with the state of the art, even when the values have fallen below the required DBL threshold values.

The supplier is responsible for checking whether the version in his possession is the latest version. For enquiries on threshold values, please apply to Lothar.Kante@https://www.360docs.net/doc/1618233379.html,.

-The materials used shall fulfill the following requirements in their installed state when tested in accor-dance with the test instructions: "Formteile für den Fahrzeuginnenraum - Bestimmung der Abgabe von Formaldehyd, Ammoniak und Phenolen - Me?verfahren in der 1 m3- Kammer“ (draft October 1994,

issued by Arbeitskreis "Kfz.-Formteile - einfache Prüfmethoden“ under the leadership of FhG-WKI,

Bienroder Weg 54 E, D-38108 Braunschweig):

- Formaldehyde emission:initial value max. 0,2 ppm, in equilibrium max. 0,05 ppm

- Phenol emission:max. 0,04 ppm

- Ammonia emission:minimal

Measurements shall be carried out on finished parts under the following testing conditions:

- temperature65 °C

- relative humidity11 %

- cabinet load 2 m2 per m3

- change of air0,5 h-1

The consistency of production with regard to formaldehyde release shall be tested by means of a sim-ple method and documented, e.g. bottle method (determination of formaldehyde release of molded

parts by the bottle method, VDA recommendation 275- DKF, Ulrichstr. 14, D-74321 Bietigheim) or gas analysis method DIN-EN 717-2 (was: DIN 52 368 - Beuth Verlag GmbH, D-10772 Berlin). It is a condi-tion, however, that this value is determined already for the initial sample. For this reason, it must also be indicated on the acceptance test certificate.

3.2Shape, dimensions, cut-outs and markings

In accordance with drawing and/or template.

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DBL 5463 : September 2002 3.1General requirements (continued)

3.3Color

In accordance with order and approval

3.4Electrostatic charging

The acoustic parts shall not be electrostatically charged during use.

3.5Noise emission

The acoustic parts shall not cause any disturbing noise during use (rattling, flutter)

3.6Corrosion resistance of the attached metal parts

The corrosion protection shall comply with the following DBLs:

DBL 7391.40Coating / Paintwork for components subject to high exposure to corrosion

DBL 7392.10Surface protection / Paintwork; corrosion

DBL 8451Surface protection for ferrous materials

4.TECHNICAL DATA

Refer to Table 2, pages 5 to 8.

5.TEST METHODS

Refer to DIN/EN/ISO or DBL 5306, Part II and DBL 5307.

Test sequence:-=no test

+=test

5.1Separating force for laminated parts (cover material/substrate)

The test shall be carried out in analogy with the separation test in accordance with DIN 53 357 immedi-ately after the specified storage periods. Test specimens shall be taken in longitudinal, transverse and diagonal directions and must provide a representative cross-section of the complete part.

5.2Climatic resistance tests

Evaluation criteria:

The parts shall not demonstrate any changes interfering with the application in comparison with the as-supplied state (e.g. warping, flattening, deflection, shrinkage and extension of the finished parts (max.

2,5%), detachment of the surface material and of the fastening and making-up parts, glue

embrittlement, blistering, impressions and piercing, waviness, brittleness and cracking, tackiness,

marked swelling, spalling, layer and fiber separation of the substrate or similar.) Weld joints must

remain firm.

Temperature requirements deviating from the functional instructions:

Test sequence:

1. 2. 3.climatic cycle tests

all constant climates low temperature storage

5.3Test with resistance to radiant heat

The test is conducted in analogy with DBL 5307.5.2.

Test equipment: refer to DBL 5307.5.2.1

Test specimens and test specimen arrangement: refer to DBL 5307.5.2.2

Changes over DBL: The test is generally performed on specimens in product thickness.

Test execution:

Place the specimen underneath the heat lamp and switch on the heat lamp. The distance of the lamp to the test specimen is selected depending on the required maximum temperatures specified for the relevant product versions. Refer to Table 1.

In the case of external components, radiate the side facing the heat source. The test period is 6 hours for PVs 10 and 11 and 2 hours for PV 12.

Assess the specimens 30 minutes after the end of the test.

Assessment criteria:

Autogenous ignition, detachment of individual layers, material embrittlement, material decomposition;

for further assessment criteria, refer to Section 5.2 of this DBL.

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DBL 5463 : September 2002

5.TEST METHODS (continued)

5.4 5.4.1Dimensional stability test

on finished part

Test equipment: - Climatic test cabinet

- Altimeter (digital, analogue)

- Engine hood, body etc.

Accessories:Fasteners

Specimen:Assembly part

Number of specimens:1

Preparation:The body parts (e.g. engine hood) shall be prepared before testing by adding boreholes (d = 10 mm) so that measurement is possible on the side of the

assembly part facing the metal sheet. The arrangement, number and marking

of the boreholes (measuring points) shall be determined for the various parts

in accordance with the drawing.

The assembly parts shall be mounted on the prepared body surfaces using all

fasteners.

Storage:Store the body parts with the attached assembly parts at least 24 h before commencement of the test in accordance with DIN 50 014-23/50-2.

Execution:Measure the distances of the assembly part to the body part using an altimeter at the given boreholes before the specified climatic resistance test in accordance

DBL 5463.

Close the boreholes during the simulation e.g. by means of plugs or stickers.

During simulation, store the part in its installed position.

After all climatic resistance tests specified according to DBL 5463 have been

completed, store the body parts with their mounted assembly parts for at least

24 h in standard atmosphere in accordance with DIN 50 014-23/50-2.

Then measure the distances of the assembly parts to the body part by applying an

altimeter to the given boreholes.

Assessment:Determine the difference in the distance (before / after) of the specified

measuring points in mm.

Target:max. ± 10 mm

5.4.2on standard panels

Test instructions under development.

6.DUTIES OF THE SUPPLIER

Refer to MercedesBenz Special Terms Nos. 13 and 16, Purchasing Conditions for Production Materials and Spare Parts for Motor Vehicles.

7.SAMPLES

Refer to MercedesBenz Special Terms No. 13.

8.SUPPLIES

Refer to MercedesBenz Special Terms No. 13 and DBL 5306, Section 104.

9.MARKING

Refer to MercedesBenz Special Terms No. 4, No. 24, No. 27 and DBL 5306 Section 105.

10.PACKAGING, FORM OF SUPPLY AND DELIVERY CONDITIONS

Refer to MercedesBenz Special Terms No. 30.

Page 5

DBL 5463 : September 2002 11.STORABILITY

Refer to DBL 5306, Section 107.

12.SPECIAL INSTRUCTIONS

Refer to DBL 5306, Section 108.

https://www.360docs.net/doc/1618233379.html,PLAINTS

Refer to MercedesBenz Special Terms No. 16 and Purchase Conditions for Production Materials and

Spare Parts for Motor Vehicles.

14.ENVIRONMENTAL PROTECTION REGULATIONS/INDUSTRIAL SAFETY

Refer to MercedesBenz Special Terms No. 30, No. 36 and DBL 8585 Negative substance list for mate-rial selection.

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DBL 5463 : September 2002

Table 2:

4. Technical

data Product version requirements Test method

000109101112

4.1Material composition and layer

structure with mass per unit area,

or apparent (bulk) density and thickness of individual materials used must be specified on drawing DIN EN ISO 1043 (plastics)

DIN 60 001 (textiles)

DIN ISO 1629 (elastomer)

4.2Technical data

4.2.1Part weight g

4.2.2Total mass per unit area g/m2 4.2.3Technical data of individual

materials in accordance with DBL S: Values and tolerance must be specified on drawing

S: Values and tolerance must be specified on drawing

Values in accordance with DBL for individual material

DIN/EN/ISO 29073 T1

see DBL for individual material

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DBL 5463 : September 2002 4. Technical

data Product version requirements Test method

000109101112

4.3Conditioning of parts Parts shall only be tested after the reaction of the glue or foam has been completed (refer to data sheets). If

no indications are made: storage 48 h min. at room temperature.

General requirements for all climatic cycle tests Time/temperature/relative humidity

Note: All times are exposure times. Tolerances: Temperature ± 1 K; relative humidity ± 3 %; Rate of change of temperature heating: approx. 1,5 K/min, cooling: approx. 1,5 K/min; crossover point temperature/relative hu-midity in heating and cooling phases at 50°C max./ 40%r.h. max.

Climatic resistance tests For requirement text, see Section 5.2, page 4 4.3.1Alternating climates

4.3.1.1Dry-warm/humid-cold

(thermal climate cycle test)+-----30 cycl. {4h / 10°C / 92%

+ 2h / 90°C / max. 20%}

4.3.1.2Dry-hot/humid-cold

(heat climate cycle test)-+++++30 cycl. {4h / 10°C / 92%

+ 2h / 120°C / max. 20%}

4.3.2Constant climates

4.3.2.1Dry-warm endurance test

(thermal test)

+-----7d / 90 °C / max. 20%

4.3.2.2Dry-warm endurance test

(thermal test)

-+++--7d / 120 °C / max. 20%

4.3.2.3Dry-warm endurance test

(thermal test)

--++7d / 150 °C / max. 20%

4.4Low temperature resistance

4.4.1Ball drop test--++++DBL 5306.7.3;

storage 24 h at -40 ±2 °C, drop height: 200mm

4.5Radiant heat resistance test--++++Section

5.3

4.6Dimensional change after

storage in humid atmosphere

per unit of length, maximum %--0,50,50,50,5DIN/ISO 2796, DIN/EN/ISO 2440 1 cycle 5h at 120°C or 1 cycle

24h at 105°C or

7 d 95 ± 2 °C/ 95 ± 5 % r.h.

4.7Cover layer separation force

Minimum N

Refer to Section 5.1

4.7.1after climatic cycle storage5*5*5*5*5*5*For storage, refer to Section 4.3

4.7.2after standard atmosphere storage5*5*5*5*5*5*

4.8Dimensional stability--++++Section

5.4

*or no non-destructive testing possible

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DBL 5463 : September 2002

4. Technical

data Product version requirements Test method (continued)000109101112

4.9Combustion test S: Fulfillment of re-

quirements in accor-

dance with DBL 5307,

PV 10 / PV 20.

----DBL 5307.5.1 / 5.2

4.10Combustion test--S: *S: *S: *S: *DIN/EN 60695-2-1,

test temperature 630°C 4.11Acoustic characteristic values

4.11.1Loss factor

4.11.2Storage module

4.11.3 Absorption

coefficient 4.11.4 Sound

insulation in accordance with drawing and/or functional instructions DIN 53440, VDI 3727, vibrometer

method in analogy with DIN

53426, DIN 52212, DIN 52215

DIN/EN 20140

4.12Behaviour towards service

fluids Grade

DIN/EN/ISO 14419 4.12.1Water (dest. or demineralised)--A A A A

4.12.2Engine oil--A A A A SAE 15w40

4.12.3Diesel fuel--A A A A DIN/EN 590

4.12.4Windshield detergent--A A A A DBL 7530

4.13Test for sound and heat insulation

components with high-pressure

cleaners / steam cleaners --

For assessment refer to functional instructions

Functional instructions Test for

sound and heat insulation com-

ponents using high-pressure

cleaners / steam cleaners by

Deptm. EP/CSA January 2002

4.14Emission analysis

4.14.1VOC value Target value:ppm 4.14.2Fog value Target value:ppm

£ 100

£ 250

£ 100

£ 250

-

-

-

-

-

-

-

-

Critical individual substances shall not exceed the limit/target values indi-

cated in test specification PB VWL 709, Annex 6.

DC test instruction PB-VWL 709;

in case of deviations, the value

indicated in the individual mate-

rial DBLs shall apply.

4.15Odour test

Maximum Grade33----VDA 270; depending on compo-nent size

*The test is deemed passed if one of the following conditions has been fulfilled:

a) no flame or glow process is created.

b) if any flames or any glowing of the test specimen, its environment and the substrate is extinguished within 30 s after removal of the glow-wire,

i.e. t e < t a + 30 s, and if the surrounding parts and the substrate have not been burnt completely.

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