Test Specification

Climatic test for bonded joints and

composite materials on trim parts

April 2006
8 245 193

PR 308.2
U.P.G.: 06.96

Note on information responsibility:

The user of technical specifications shall be obliged to verify the validity of the technical specification in
the system TEREG or via the information logistics department.

Preliminary remark
PR 308.2 replaces PR 308.1 and is valid as of 07.04.2006.

Page 1 of 9

Department

Compiled by:

Name/Signature

EK - 510

Hucke

Superior

EK - 510

Koensgen

Head of department

EI-51

Albiez

Head of department

EI-33

Amann

Head of department

EI-32

Demmel

BMW AG All rights reserved.

Date

7.04.2006

Seite 2
PR 308.2: 2006

CONTENTS:
Page

GENERAL
1.1

Scope

1.2

Information protection

1.3

Quoted standards and specifications

1.4

Scope and purpose

1.5
General test conditions
1.5.1 Number of test specimens
1.5.2 Test set-up

TEST CHAMBER

4
4
4

2.1

General

2.2

Documentation

TEST CYCLES

EVALUATION CRITERIA

4.1

Test procedure

4.2

Documentation and evaluation

4.3

Supplementary tests

Page 3
PR 308.2 : 2006

NRCL No.

ZI

Section
No.

E4087.N
E4962.W

A
B

deleted

Change documentation
Brief description
Released for production
Completely revised
Translation

Date

Responsible

15.01.00
7.04.06
19.05.09

Funk
Hucke
Zill, TI-510

Page 4
PR 308.2: 2006

General

1.1

Scope

The test specification is an integral and binding part of the specification book, quality specification and/or
drawing. It shall be applied under the following conditions:
Release investigations in case of new designs
Release investigations for components of sub-suppliers
Design changes compared to engineering release level
Depending on the particular concept and based on findings in the development process, further tests may be
required over and above those described herein, which would have to be agreed and coordinated with the
responsible BMW test department. Tests that are carried out within the scope of initial sample inspection shall be
agreed with the responsible BMW quality departments.

1.2

Information protection

This document is subject to the information protection regulations according to BMW-Guideline-6 dated
15.07.2002 "Security, information protection, fire prevention".

1.3

Quoted standards and specifications

DIN Standards:
DIN 53 357 Testing of plastic sheets, adhesion tests

1.4

Scope and purpose

The climatic test serves to validate bonded joints or similar joints such as lamination, back compression
moulding, in-mould lamination, back foaming, moulding and welding. This testing method must always be applied
when the material joint is more chemical and not mechanical (e.g. screws, staples, rivets, hot riveting).

1.5

General test conditions

1.5.1 Number of test specimens

The test shall be carried out on at least 5 new parts in all material variants.
If colour has an influence on the production process, the different colours must also be tested.

1.5.2 Test set-up

Spatial arrangement of test specimens should correspond to fitment position in vehicle. Parts can also be tested
in mounted condition. If the degrees of freedom of mounting points and contact geometries have an influence on
bonded joints, the fitment condition in the vehicle must be simulated on at least one part.
When testing in unmounted condition, the following should be observed:
No contact with walls and floor of climatic chamber.
Spatial arrangement identical to fitment position in vehicle.

Page 5
PR 308.2 : 2006

Test chamber

2.1

General

It must be assured that all test specimens in the climatic chamber are subjected to the same test conditions. Any
interaction of test specimens (e.g. deformation due to stacking of specimens) must be ruled out.
The climatic chamber used must capable of realising the specified cycles in the specified time (especially the
changing speed of temperature and humidity).
If one of the components or an assembly is deformed during the test, only the bonded joint or material joint must
be evaluated and not the deformation. The evaluation of component behaviour (e.g. discolouration or
deformation) shall be subject to the currently valid version of PR 303.

2.2

Documentation

Test procedure must be documented by means of a suitable data logger for each test particularly with regard to
test cycles, temperature and humidity over time.
Proof of regular calibration shall be provided without further request.

Page 6
PR 308.2: 2006

Test cycles
Program
section

Temperature
in [C]

Relative
humidity in [%]

1
2

23

20

3
4

90

5
6
6
7

23
-30

20

23

20

No.

Remark:

Time in
[h]
1

80

Duration of one cycle: 12h

Number of cycles: 20
Total duration of test: 240 h

4
1
1
4
1

Remarks
Starting condition
Heating up and moistening in one hour
without intermediate steps
Cooling and dehumidifying in one hour
without intermediate steps
Humidity of 23C and 20% rel. humidity
Heating up in one hour

Page 7
PR 308.2 : 2006

Evaluation criteria

4.1

Test procedure

The following points should be observed before, during and after the test:
Any deviations of the test specimen from the drawing level shall be documented as described in section 4.2.
All component-related processing parameters and structure with material specification shall be documented
as described in section 4.2, particularly with regard to the adhesive systems used.
Separation of the decor at the edges is not permitted.
There must be no separation of bonded or material joints.
Pull-off forces in the component specifications shall be observed.
Blisters or separation of top layer from sub-layers are not permitted in the visible sections of the component.
Leakage of adhesive in visible sections is not permitted.
Each change during the test must be recorded as described in section 4.2. The following details are required:
- Defect location
- Defect type
- Time of occurrence
Adhesive or material showing through the decor is not permitted.
The final evaluation concerning separation shall be carried out in relation to an untested reference part.
In case of bonded joints, only cohesive break is permitted after a pull-off test.
For foam backings the following applies:
For foam backed surfaces, the foam adhesion value of 2,5 N/cm (with a specimen width of 10 mm). With
the spring balance, pulling force is applied perpendicular to the surface.
The adhesion of PU-foams on inserts of composite materials shall be verified as follows:
First the decor layer is removed. Then the foam is scraped off the substrate by hand. Start by scraping from the
centre of the foamed surface towards the edges holding the knife flat (Material: PA; injection moulding tool No.
3803462 in BMW Plastics Manufacturing Plant in Landshut; blade length 100 mm, chamfered on one side under
45). This test shall be carried out 72 hours after foam backing at the earliest.
The following is applicable for foam film laminated surfaces: Minimum pull-off force = 35 N (specimen width 50
mm) in peel test (testing speed 100 mm/min).
Adhesive break between foam and top coat or between foam and substrate is not permitted.
Project and geometry-related requirements shall be defined for adhesion of PU foams on inserts of composite
parts. The following reference value applies: A minimum of 60% of the surface with cohesive break should be
fulfilled. No adhesive break is permitted in critical, function-relevant areas as well as in boundary areas.

4.2

Documentation and evaluation

All tests and measurements shall be fully documented as described in sections 4.1 and 4.2. The following
information should be noted on all test certificates, temperature and humidity records of the test chamber,
evaluation forms and test reports:
Test specimen: Manufacturer, release level, drawing number, specimen number
Test engineer
Date
Target values (if specified)
File name and path in case of electronic data logging and storage.
Recommendation

Page 8
PR 308.2: 2006

4.3

Supplementary tests

Should the future show that this test specification does not cover all aspects, it is possible to modify the
alternating climate test for specific items in agreement with the responsible testing departments.

Page 9
PR 308.1: 2000-01

Climate chart
Temperature in C

Temperatur in C

Relative humidity in %

Relative Feuchte in %
100

90C

90C

80%

80%

80
60
40
20
0
-20

-30C

-30C

-40
0

10

12

14

16

Zeit in Stunden Time in hours

Zyklusdauer: 12h; Zyklenzahl: 20; Gesamtprfdauer: 240h
Cycle duration: 12 h

Number of cycles: 20

Total testing time: 240 h

18

20

22

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PR 308.2: 2006