DBL_5610_2006-05
Daimler-Benz
Supply Specification
Safety windows for vehicle glazing
DBL 5610
BQF available
Edition 05/2006
Additional DaimlerChrysler Standards required: MB Special Terms, DBL 5555, DBL 7904, DBL 8585
Supersedes edition: 12/97
Refer to Section Changes on page 12
Product versions and examples
Product version (PV) Window type / Abbreviated designation Construction Windshields (WS) DBL 5610.00 Laminated safety glass (LSG-WS) clear DBL 5610.01 Laminated safety glass (LSG-WS) clear, heated DBL 5610.10 Laminated safety glass (LSG-WS) heat-insulating DBL 5610.11 Laminated safety glass (LSG-WS) heat-insulating, heated DBL 5610.12 Laminated safety glass (LSG-WS) heat-insulating, infrared reflecting DBL 5610.13 Laminated safety glass (LSG-WS) heat-insulating, heated, infrared reflecting DBL 5610.20 Laminated safety glass (LSG-WS) heat-insulating, band filter DBL 5610.21 Laminated safety glass (LSG-WS) heat-insulating, band filter, heated DBL 5610.22 Laminated safety glass (LSG-WS) heat-insulating, band filter, infrared reflecting DBL 5610.23 Laminated safety glass (LSG-WS) heat-insulating, band filter, heated, infrared
reflecting
Rear window (RW) made of LSG DBL 5610.30 Laminated safety glass (LSG-RW) clear, heated DBL 5610.40 Laminated safety glass (LSG-RW) heat-insulating, heated DBL 5610.41 Laminated safety glass (LSG-RW) heat-insulating, band filter, heated DBL 5610.42 Laminated safety glass (LSG-RW) heat-insulating, heated, infrared reflecting DBL 5610.43 Laminated safety glass (LSG-RW) heat-insulating, band filter, heated, infrared
reflecting
Side and rear windows, roof windows made of SSG or plastic DBL 5610.49 Plastic windows made of PC clear or tinted DBL 5610.50 Single-layer safety glass (SSG) clear DBL 5610.59 Plastic windows made of PC heat-insulating DBL 5610.60 Single-layer safety glass (SSG) heat-insulating DBL 5610.61 Single-layer safety glass (SSG) for sliding roof
heat-insulating, tinted dark
DBL 5610.62 Single-layer safety glass (SSG) for glass roof
heat-insulating, tinted dark
DBL 5610.63 SSG windows for roof windows with splinter protection sheeting
heat-insulating, tinted dark
DBL 5610.70 Single-layer safety glass (SSG) clear, heated DBL 5610.80 Single-layer safety glass (SSG) heat-insulating, heated Insulating safety glass (ISG) DBL 5610.90 Insulating safety glass (ISG) clear DBL 5610.91 Insulating safety glass (ISG) heat-insulating Side and roof windows made of LSG DBL 5610.92 Laminated safety glass, part-tempered (LSG-PT)
heat-insulating
DBL 5610.93 Laminated safety glass, part-tempered (LSG-PT)
heat-insulating, infrared reflecting
DBL 5610.95 Laminated safety glass (LSG) heat-insulating DBL 5610.96 Laminated safety glass (LSG) heat-insulating, infrared reflecting DBL 5610.97 Laminated safety glass (LSG) heat-insulating, tinted dark Continued on pages 2 to 33
Issued by:
DaimlerChrysler AG 70546 Stuttgart
Standards(EP/QDN)
Technical responsibility (name): Leupolz / Ullmann Department: PWT/VWK Plant: 050 Phone: +49(0)7031 90-44269 HPC: X685 Technical coordination by PWT / Materials and Process Engineering
Plant 050, Department PWT/VWK Name: Dr. Schuh Telephone +49(0)7031-90-44270 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.
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DBL 5610 : 05/2006
Abbreviated designations
On drawings, in the block for material Glass DBL 5610.xx
1. Field of application, general requirements
1.1 Application:
1.1.1 Product versions 00 to 23:
Windshields (WS)
1.1.2 Product versions 30 to 97:
Rear (RW), side and roof windows
requirements
1.2 Basic
requirements:
1.2.1 Statutory
Besides directives 92/22/EEC and 77/649/EEC, the following legal stipulations shall be ob-
served:
ECE Regulation R 43
FMVSS 205 (USA)
GB 9656-2003 (China)
MOTC Directions Components (Taiwan – the relevant regulations shall be observed)
The manufacturer shall obtain type approval from the competent testing authorities. Where sta-
tutory regulations of other countries are not covered by the above, such requirements shall be
considered and fulfilled separately.
1.2.2 Marking
The windows shall be provided with the specified type approval mark. Position, size and circum-
ference shall be in accordance with the specifications on the drawing.
version
1.2.3 Antenna
Refer to drawing / component requirement specifications / functional instructions
condition
1.2.4 Supply
The windows shall be supplied in dirt-free, industrially clean condition, i.e. only small amounts of
dust shall adhere to the windows. No contamination or residues from production (e.g. from re-
lease agents) shall be present which could impair testing, further processing and adhesive
bonding.
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DBL 5610 : 05/2006
2. General properties of the materials, raw materials and supply condition
2.1. Laminated safety glass (LSG): PVs 00 to 43, 92 to 97
Consisting of two silicate glass panes connected by a film (e.g. polyvinyl butyral).
2.2. Single-layer safety glass (SSG): PVs 50, 60-63, 70, 80
Consisting of a silicate glass pane which has been subjected to a special heat treatment.
2.3. Insulating safety glass (ISG): PVs 90 and 91
Consisting of two SSG layers separated by a closed gap.
2.4. Laminated safety glass, part-tempered (LSG-PT): PVs 92 and 93
Consisting of two thermally part-tempered silicate glass panes connected by a film (e.g. polyvi-
nyl butyral).
2.5. Laminated safety glass with infrared reflecting coating (LSG-IR): PVs
12,13,22,23,42,43,93,96
The IR reflecting layer system lying protected within the composite can be applied directly onto
the glass or inserted into the composite on a carrier film (PET) between sandwich films.
Besides metallic coatings, dielectric layers / films are also used.
2.6. Plastic windows made of polycarbonate (PC): PVs: 49 and 59
Consisting of transparent polycarbonate (e.g. AG type Makrolon, Bayer) in the transparent area,
tinted PC or PC/PET, if required with filler or glass fibers (e.g. Makroblend, Bayer) in edge area
and a scratch-resistant coating on the basis of thermally curable polysiloxane paints (e.g. AS
4000, Bayer GE Silicons).
The windows are produced using the two-component injection molding method, then provided
with scratch-resistant coating and encapsulated in a further step, e.g. with a thermoplastic elas-
tomer (TPE).
In the event of any deviating manufacturing process or window structure, additional acceptance
conditions shall be specified following discussions with the responsible departments PWT/VWK
and PWT/VBT or the responsible process/materials departments of the relevant receiving plant.
3. Dimensions and tolerances / Form of supply
Refer to drawing / component requirement specifications / functional instructions
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DBL 5610 : 05/2006
4. Technical data
Drawing requirements, requirement specification requirements and functional instructions have
priority.
The listed Tables are included in the Annex.
Tables A
Overview of technical requirements for safety glass made of silicate glass
Table Type of requirement Covered contents Annex
Page A1 a Definition of appearance characte-
ristics
Surface, glass and composite characteristics p. 13
A1 b Requirements for appearance cha-racteristics p.
13
A2 a Definition of characteristics on
encapsulations and extrusions Material, cleaner, primer, casting, trimming
surface characteristics
p. 15
A2 b Requirements for characteristics of encapsulations and extrusions p.
16
A3 Optical requirements Refractive power, reflection optics, optical data p. 17 A4 Geometrical requirements Glass cutting, edge support, edge waviness,
end tangent angle, main and cross bending
p. 18 A5 Special
requirements Temperature resistance, corrosion, stress
state, abrasion, black print, silver print, insulat-
ing glass requirements
p. 19
A6 Requirements for adhesive bonding and encapsulation Light / UV transmission, roughness, bondabil-
ity, adhesion of encapsulations
p. 20
A7 Requirements of the adhesive bond-ing of
rain and light sensors Definition and requirements for the bonding of
rain and light sensors
p. 21
Tables B
Overview of technical requirements for safety glass made of plastic
Table Type of requirement Covered contents Annex
Page B1 Requirements for appearance cha-
racteristics
Injection molding, coating characteristics p. 22
B2 a Definition of characteristics on
encapsulations and extrusions Material, cleaner, primer, casting, trimming
surface characteristics
p. 24
B2 b Requirements for characteristics of encapsulations and extrusions p.
25
B3 Optical
requirements Reflection optics, optical data p. 26 B4 Geometrical requirements Edge support, edge waviness, end tangent,
curvature
p. 27
B5 a Requirements for plastics Density, residue on ignition, notched impact
strength
p. 28
B5 b Requirements for coatings Color, optics, layer thickness, adhesive
strength
p. 29
B6 Requirements for adhesive bonding and encapsulation Light / UV transmission, roughness, bondabil-
ity, adhesion of encapsulations
p. 32
Page 5
DBL 5610 : 05/2006 5. Tests
5.1. Performance of visual inspections
Minimum standards for visual inspection workplaces for a qualitative control of vehicle glazing
are defined below. Any deviating test stations and test methods shall be agreed with the re-
sponsible quality departments of the receiving plants.
General Requirements
?Test stations shall be adequately illuminated. The light shall not dazzle the operator exces-sively. The light source shall illuminate the complete window to be inspected.
?The light source shall be designed so that a luminous intensity of at least 800 to 1000 Lux is measured on the window to be inspected.
?The windows shall be clean so that all characteristics can be detected reliably.
?An inspection distance of between 0 and 80 cm shall be maintained for the detection of de-fects. Identified defects shall be analyzed, if required. The subsequent assessment shall be
performed at an inspection distance of 70 cm.
?The test period shall be selected appropriately to allow all appearance characteristics to be detected and assessed reliably.
?Appropriate measuring equipment shall be used for the assessment of defect sizes.
?Each operator entrusted with inspecting the windows shall have access to the test instruc-tions.
?Test equipment shall be designed such that damages can be reliably avoided.
Requirements for permanently installed inspections:
?All windows shall be inspected against a black background with direct illumination in trans-mission.
?Laminated safety glass and plastic windows shall always be tested additionally against a white background in transmission.
?Plastic windows shall be tested additionally in the transparent area between polarizing fil-ters with illumination from behind in transmission.
?The windows shall be inspected in reflection for surface defects. In this process, a light source shall be capable of being reflected across the whole window range.
?The operators entrusted with the inspection of the windows shall be trained at regular inter-vals with regard to defect patterns and the requirements of DaimlerChrysler AG under this
Supply Specification. The operator shall be informed of any complaints regarding unde-
tected defective windows of the customer and downstream production processes.
5.2. Adhesion testing of adhesive systems for vehicle windows
Evidence of adhesion testing with the relevant data/documents (e.g. indication of screen print-
ing paste, roughness values and transmission values) shall be submitted together with the initial
sample inspection report. Tests shall be performed on initial sample parts.
5.2.1. Substrate requirements of bonding surfaces
In order to avoid any impairment of the bondability and bonding process, the following condi-
tions on the bonding surfaces for direct glazing of the windows (screen printing, black printing,
float glass surface, plastic surface etc.) shall be ensured:
Surface: industrially clean, free from oil and grease, no contamination from release
agents
(e.g.from glass encapsulation process)
Roughness: refer to Tables A6 / B6
Transmission: refer to Tables A6 / B6
Adhesive systems: The adhesive systems to be used for the determination of the bondability
and their processing instructions will be determined and provided by the re-
sponsible area of the receiving plant.
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DBL 5610 : 05/2006
5.2.2. Aging and adhesion testing
Apply the adhesive to the pretreated initial sample to assess adhesion and aging resistance.
The pretreatment system (activator / primer) shall be applied and flashed off according to the
relevant processing instructions.
Before adhesion testing using the peel test, the sample shall be conditioned following aging sto-
rage for 24 h in standard atmosphere (23°C, 50% rel. humidity). The aging storages shall be
performed in sequence on one and the same test specimen.
PWT
PP
32643 ?Peel
test PA
?Storage at room temperature PA PP PWT 32644
PP
32645
PWT
storage PA
?Water
PWT
32646
storage PA
PP
?Cataplasm
5.2.3. Assessment
Following all aging storages, a cohesive fracture pattern is required in the adhesive (adhesion
rating 5). Adhesion peeling of the adhesive is not permitted.
Adhesion rating 5 100% cohesive break adhesive
Adhesion rating 4 5% cohesive break adhesive
Adhesion rating 3 50% cohesive break adhesive
Adhesion rating 2 25% cohesive break adhesive
Adhesion rating 1 0% cohesive break, 100% adhesion break
5.3. Adhesion testing of glass encapsulations
Evidence of the adhesion test of glass encapsulations shall be documented in the initial sample
inspection report.
The glass encapsulation shall be tested by means of the peel test (in accordance with PA PP
PWT 32643) and should display a cohesive fracture pattern, if possible.
If an adhesion break occurs in the area of the encapsulation during peel testing, the 90° peel test
shall be performed. The requirements are listed in Tables A6 / B6
Adhesion shall be ensured across the complete bonding area between the window and the en-
capsulation (glass surface, C-shape).
Before adhesion testing, the samples shall be conditioned for 24 h in standard atmosphere
(23°C, 50% rel. humidity).
the transmission optics
of
5.4. Determination
During the determination of the transmission optics, the optical distortions caused by the win-
dow are assessed. The window shall be inclined along its vertical axis at an angle correspond-
ing to its installation position in the vehicle. The measurement shall be made perpendicular to
the horizontal axis corresponding to a vertical viewing direction. For side windows, an additional
measurement is carried out at an angle of 45° relative to the horizontal axis.
The horizontal line projection method in accordance with DIN 52305 shall be used for testing. In
this process, stripes are projected onto a white screen. The stripe width without glass pane shall
be 12 mm. If optical refractive powers are present in the window, the stripe width changes.
Page 7
DBL 5610 : 05/2006 The following assessment criteria shall be fulfilled by the window:
The stripe width shall not be above or below the limit values at any position on the projection
screen,
and
within a 300 mm dia. circle on the projection screen (corresponding to 150 mm on the window),
the difference between two stripe widths shall not exceed the maximum permissible value. The
limit values apply both to horizontal and vertical stripe orientation.
The determination of the refractive power can also be performed with suitable test equipment,
e.g. from ISRA. Care shall be taken in the selection of the equipment and filter settings so that a
correlation to the horizontal line slide (raster) method is made. If the setting is correct and with
identical test orientation, areas with 0 mdpt refractive power show a stripe width of 12 mm in the
horizontal line pattern. A refractive power of approx. 42 mdpt causes a change of 1 mm in the
stripe width whereby positive refractive powers result in a reduction, and negative refractive
powers result in an increase of the stripe width.
The assessment is generally made in the complete transparent area of the window whereby an
edge zone of 20 mm max. may be disregarded. If the required limit values cannot be maintained
in certain areas of the window in a reliable process for production reasons, a zone definition
shall be agreed no later than within the context of initial sampling.
5.5. Testing of electric connections
Evidence of a minimum load carrying capacity shall be provided for electric connections.
5.5.1. Requirements for electric contacts
Electric contacts (e.g. connectors and plug-and-socket connections) applied to the surface of
windows which do not have a connection cable and are only connected with a cable during as-
sembly at DaimlerChrysler AG, shall be loaded with a test force of 40N in plug-on direction. In
this process, no plastic deformation or tear-off of the electric contact shall occur.
5.5.2. Requirements for electric cables
Electric cables shall be loaded with a tensile load perpendicular to the component surface. This
shall not result in any damage to the plug, cable or connection (e.g. the bonding of a conductor)
to the component.
Cable with cross-section <1,0mm2: Test force 10N
Cable with cross-section >1,0mm2: Test force 40N
5.6. Material technology tests on plastic windows
Tests Units Specifications Remarks
Density g/cm3 DIN EN ISO 1183 Buoyancy method
Residue on ignition % DIN EN ISO 3451
Tensile test
- Modulus of elasticity - Yield stress
- Tensile strain at break MPa
MPa
%
DIN EN ISO 527 Test specimens: type 5A / 1BA
3-point bending test
- Flexural modulus
- Flexural stress at 3,5% strain MPa
MPa
DIN EN ISO 178 Dynstat test, paint in tensile zone
Impact test
- Impact strength
- Notched impact strength
kJ/m2 DIN 53 435 Dynstat test, paint in tensile zone Charpy impact strength kJ/m2 DIN EN ISO 179 Paint in tensile zone
Page 8
DBL 5610 : 05/2006 - unnotched
- notched
Puncture impact test
DIN EN ISO 6603-2 Paint in tensile zone, assessment of fracture pattern
Heat aging Heating cabinet in accor-
dance with DIN 53508
7 days at 100°C
Weathering
- Natural weathering - Artificial weathering DBL 5555 Part II, Sections
6.1 and 6.2, DBL 7399
Assessment in accordance with DBL 5555
Section 6.2
Resistance to chemicals and service fluids DIN EN ISO 4599
(in analogy)
Assessment of surface and environmental
stress cracking, bent strip method
5.7. Paint technology tests on plastic windows
5.7.1. Weathering
Natural weathering: Refer to DBL 5555 Part II, Section 6.1 and DBL 7399.
Artificial weathering: Refer to DBL 5555 Part II, Section 6.2 and DBL 7399.
The specimens which are subjected to mechanical tests subsequently shall be stored in stan-
dard atmosphere in accordance with DIN 50014 (23/50) for 72 hours. The weathered specimen
side shall be within the exposed tension zone during all tests.
5.7.2. Testing of resistance to chemicals and service products
The test shall be carried out in accordance with DIN EN ISO 4599, assessment of environ-
mental stress cracking, bent strip method. Test specimens shall be taken from the finished parts
in agreement with the testing department of the plants (e.g. 80 x 27 x 1.2-2.5mm).
Unpainted component areas
Commercially available chemicals and service products shall be tested specific to each part.
The selection shall be agreed with the development department and the testing department of
the plants. (The relevant laboratory instructions are available from PWT/VWL.) Tests with pe-
ripheral fiber elongation approx. 0.3% shall be carried out.
1st cycle:
Store bending template with clamped specimen at room temperature for 15 minutes. Immedi-
ately afterwards, soak a wad of cotton wool in the test medium, place on specimen and leave
for 15 minutes. Then leave to flash off for 15 minutes.
2nd cycle:
Then perform 2nd cycle in the same way as 1st cycle.
Assessment after completion of 2nd cycleThe test specimen shall be assessed with the naked
eye as follows:
Grade Characteristic
1no visible changes
2surface dull
3fine cracks
4significant cracks, break
Requirement: compliance with grade 1 is required; in agreement with the development depart-
ments and the testing departments of the plant, grades 2 or 3 are also permitted in special ca-
ses.
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DBL 5610 : 05/2006 Painted component areas:
Exposure to stress takes place at a peripheral fiber elongation of 0,7%. For this purpose, test specimens shall be taken from the part as described above. Care shall be taken to ensure that the test specimens are relatively flat and correspond to the dimensions.
In addition to the test media to be agreed under Section 4.3.2, the relevant solvent compositions of the coating shall be tested separately on unpainted substrate surfaces.
Care shall be taken to ensure that no unprotected edge areas are wetted. The soaked felt shall be covered with a tight-fitting, sealed watch glass.
The duration of the exposure and the assessment shall be carried out in analogy with the un-painted parts.
5.7.3. Cross cut / St Andrews cross with adhesive tape tear-off test
The area to be assessed shall be cleaned using IPA and dried for approx. 15 min at 23 ± 2 °C before the cross cut/St Andrews cross is applied. The cross cut shall be applied at right angles using a multiple blade cutter, blade distance 1,5 mm (irrespective of the paint layer thick-
nesses). Cutting depth through to the substrate. The St Andrews cross shall be applied with an Erichsen cutter 463, blade width 1mm, cutting angle approx. 30°, approx. 100 mm long. Cutting depth also through to the substrate. 19 mm wide Tesa adhesive tape, Type 4122 PV 0 trans-parent, manufactured by Beiersdorf, Hamburg, shall be used for all adhesive tape tear-off tests (cross-cut and St Andrews cross).
Prior to the application of the tape, care shall be taken that the scratch traces reaching the sub-strate are smoothed with a brush and an additional suitable object such as a finger nail. Care shall be taken to ensure that the complete Tesa adhesive tape surface rests on the paintwork over its full surface, is pressed on firmly by hand, and is pressed into the scratch traces with the fingernail, and is then abruptly torn off at great speed vertically in an upward direction.
In the case of cross-cuts, the Tesa adhesive tape is pressed down and then torn off following the scratch traces in a lengthwise and transverse direction. In the case of the St Andrews cross, the Tesa adhesive tape is also applied centrally over both scratch traces in analogy and torn off individually in a sudden movement.
A recovery period of 1 hr / 24 h at 23 2°C shall be observed if the adhesion test is preceded
by a climate, hot water or other test. Apply the scratch traces immediately before the test.
5.7.4. Multi impact stone chip resistance test
The test shall be carried out with an apparatus developed by DaimlerChrysler (drawing no. PM
36 dated 1962-08-14 or latest edition) using morainic gravel, granulation 5 to 8 mm.
Apparatus supplier: Notter, D-71732 Tamm/Ludwigsburg,
Gravel supplier: Baustoffhandlung Firma Mayer, D-71063 Sindelfingen
At the beginning of each stone chip resistance test, 300 g of new, sieved gravel shall be used.
The gravel shall be projected continuously to a test specimen section at a pressure of 0,7 bar (guideline value) at an air volume rate of 175 10 l/min at 23 °C 3°C. The pressure and flow rate shall be determined using suitable calibration methods.
The test specimen shall be glued over its entire surface and without blisters on a steel sheet (dimensions 200 x 200 x 0,75 mm) using a two-component coating material Baryskin V606 pro-duced by Stankiewicz, D-29205 Celle.
Drying period: ≥ 16 h at 25 ± 3°C
Adhesive thickness: ≤ 2,5 mm
The test duration and the impact pattern shall be agreed and coordinated with PWT/VBT Sin-delfingen or the Process / Materials Engineering department of the receiving plant.
Page 10
DBL 5610 : 05/2006
5.7.5. Steam jet test
Refer to DBL 5555, Section 6.4.
5.7.
6. Alternating climate test
The alternating tests consist of 3 cycles. The parts/segments shall be stored hanging freely.
The assessments shall be carried out 1 hour and 24 hours after the 3rd cycle.
Method 1: Cycle 1: CC: Mon 7:00 - Wed 17:00 / 80°C recirculating air: Wed 17:00 - Fri
17:00 /
–30°C: Fri 17:00 - Mon 7:00
Cycle 2: 80°C recirculating air: Mon 7:00 - Tue 17:00 / –30°C: Tue 17:00 - Thur 17:00 /
CC: Thur 17:00 - Mon 7:00
Cycle 3: –30°C: Mon 7:00 - Tue 17:00 / CC: Tue 17:00 - Fri 17:00 /
80°C recirculating air: Fri 17:00 - Mon 7:00
Method 2 Cycle 1: 7 days CC / 7 days 80°C recirculating air / 7 days –30°C
Cycle 2: 7 days 80°C recirculating air / 7 days –30°C / 7 days CC
Cycle 3: 7 days –30°C / 7 days CC / 7 days 80°C recirculating air
Application: System and initial samples are tested according to method 1.
Method 2 is only intended for system samples.
Note: The parts/segments shall be transferred to the next climate testing appliance
immediately on completion of one test cycle.
6. Duties of the supplier
See "Purchase Conditions for Production Materials and Spare Parts for Motor Vehicles" and MB
Special Terms and for plastic windows also DBL 5555 Section 3.
7. Samples
See "Purchase Conditions for Production Materials and Spare Parts for Motor Vehicles" and MB
Special Terms (No. 13) and for plastic windows also DBL 5555 Sections 5, 6, 7 and 8.
Additional note for initial sampling:
5 copies each of the following documents shall be submitted together with 5 initial samples:
?VDA cover sheet
?Part history
?Drawing in single copy
? Self-assessment matrix
?Process sequence based on a spatial representation of the production chain (hall layout)
with relevant test items
?Statutory approvals (copy of ECE, DOT, CCC document)
?Measuring reports of the window with measuring specification used
?Evidence of all necessary requirements and tests with tabular overview, unless these are
covered by the statutory approvals (e.g. test records of bonds, refer to Sections 5.2 and
5.3).
?Data sheet "Light and radiation-optical manufacturing information" (glass pane structure,
bending method, precise designation of the films used), refer to enclosure in informative
Annex
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DBL 5610 : 05/2006
8. Deliveries
Refer to "Purchase Conditions for Production Materials and Spare Parts for Motor Vehicles" and
MB Special Terms (No. 13 and No. 16).
9. Marking
Refer to "Purchase Conditions for Production Materials and Spare Parts for Motor Vehicles" and
MB Special Terms (No. 4 and No.24).
In the event of any additional qualitative checks commissioned by the relevant quality assur-
ance departments of the receiving plants, the checked pallets shall be clearly marked with the
test criteria and identified.
10. Packaging
Refer to "Purchase Conditions for Production Materials and Spare Parts for Motor Vehicles" and
MB Special Terms (No. 28 and No. 30).
During packaging of the windows, any additional product-specific requirements of the responsi-
ble logistics departments shall be observed.
Coated plastic windows shall be packaged such that the requirements listed in Table B5b are
fulfilled. The packaging materials shall not impair the paint layer.
11. Dispatch and storability
The products shall be dispatched in crates / containers intended for the relevant windows.
These crates / containers shall be designed so that the possibility of fractures and surface de-
fects and deformation of attached parts is excluded.
Refer to MB Special Terms No. 29 and No. 30.
With regard to the storability of plastic panes, also refer to DBL 5555 Section 13.
12. Special instructions
Any deviating or supplementary requirements indicated on drawings/component requirement
specifications or orders shall be observed. In case of any changes and new type approvals, the
approval shall be submitted to the receiving plant before initial supply.
13. Complaints
Refer to "Purchase Conditions for Production Materials and Spare Parts for Motor Vehicles" and
MB Special Terms (No. 18).
Should any defects be found during testing or application of the parts, the supplier shall be in-
formed of such in a test report. A written statement on this test report is expected in each case
within 20 working days, stating the type and time of any remedial action taken in the meantime
and the production number of the improved delivery. In the event of current problems, the sup-
plier shall take appropriate measures to remedy the situation as quickly as possible.
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DBL 5610 : 05/2006
14. Environmental protection regulations/Industrial safety
Refer to "Purchase Conditions for Production Materials and Spare Parts for Motor Vehicles" and
MB Special Terms (No. 30 and No. 36) as well as Negative Substance List for the Selection of
Materials in accordance with DBL 8585.
15. Recycling
The notes in MB Special Terms (No. 36) and the Negative Substance List for the Selection of
Materials in accordance with DBL 8585 shall be observed.
For plastic panes, encapsulations and attached parts, DBL 5555 Section 12 shall be observed.
The supplier shall take into account recyclability during development. The recycling shall take
the form of material recycling. Should this not be feasible for plastics for technical or economic
reasons, energetic recycling shall be permissible under these exceptional circumstances. The
requirements for components made of regranulated materials are described in DBL 5490.
16. General requirements for PC materials
The general conditions laid down in DBL 5555 shall be observed. MDS data sheet according
VDA volume 2, part 6 (constituents for purchased products) shall be included with the delivery.
17. Other applicable standards
DBL 5555, DBL 7904, DBL 7906, DBL 8585, DIN 50 014, DIN EN ISO 6270-2, DIN 50 021, DIN
52 347, directive 92/22/EEC, ECE R 43, FMVSS 205, MB Special Terms "Purchase Conditions
for Production Materials and Spare Parts for Motor Vehicles"
Changes as against previous edition:
Contents of DBL revised.
Product versions and requirements for plastic windows (PVs 49, 59) as well as LSG for side
and roof windows (95-97) added.
Requirements for encapsulations and extrusions added.
Page 13
DBL 5610 : 05/2006 Annex
Tables A: Technical data for safety windows
made of silicate glass
Table A1 a Definition of aspect characteristics
The production methods used may on occasion result in characteristics within the products which are classi-fied and assessed by this DBL. If these characteristics are within the limits outlined below, the product will be classified as "ok" and may be supplied for series production. Characteristics outside the limits of this DBL shall be assessed as defects and result in a complaint and removal of the product.
Type of characteristic Description of characteristic
1.Surface and glass characteristics
1.1Hairline scratches Fine scratches not detectable with the finger nail
1.2Shaving/scrapings/scratches Surface defects caused by improper handling
(detectable with finger nail)
1.3Conchoidal chipping Glass chippings over surface area
1.4Open scratches with conchoidal chipping Glass chippings emanating from scratches (sharp-
edged conchoidal chipping with notch effect is not
permitted in general)
Unevenness of outer glass surface
1.5Float defects/
tool impressions
1.6 Other edge characteristics Indentations, damage of round shape
1.7Inclusions Inclusions in glass such as silica sand, air or gas
bubbles
2.Characteristics in composite
2.1Blisters Air or gas inclusions within the film or between glass
and film
2.2Film delamination Separation of glass and film composite
2.3Haziness of films Discoloration of laminated film
2.4Fibrous foreign bodies e.g. lint or hairs etc. between glass and film
2.5Point-shaped foreign bodies e.g. release agent residues, sand or dust
characteristics
3 Other
3.1Film protrusion Film protrusion on glass edge across the larger of the
two single panes
3.2Screen-printing characteristics Missing, damaged or not fully printed screen-printing
points / holes (transparent points in full screen printing
area)
Table A1 b Requirements for appearance characteristics
The listed characteristics are only permitted if they do not disturb customers under normal traffic and light conditions.
Visual inspections shall be performed taking into consideration 5.1. "Performance of visual inspections".
The characteristics detected shall be assessed at a test distance of 70 cm. Characteristics which cannot be detected from a distance of 70 cm are not deemed to be characteristics which must be assessed (no clus-ters permitted).
The distance between the individual characteristics to be assessed shall be at least 150 mm for all areas visible in installed condition. Sharp-edged defects which may result in damage to attached parts and/or which may lead to the window cracking due to a notch effect are not permitted in principle. Any deviating requirements shall be agreed with the quality departments of the receiving plants.
Page 14
DBL 5610 : 05/2006
Requirements Appearance characteristic
type Windshields
for areas visible
following installation
in vehicle
PV 00-23All windows with
the exception of
WS
for areas visible
following
installation in
vehicle
PV 30-97
All windows
for areas not visible
following
installation in
vehicle
PV 00-97
1.Surface and glass characteristics
1.1Hairline scratches permitted up to 10 mm permitted up to 20
mm
permitted
1.2Shaving/scrapings/scratche
s not permitted not permitted permitted provided that
the function and
strength are not
impaired
1.3Conchoidal chipping not permitted not permitted permitted up to 2 x 2
mm max. and 1/3 max.
of thickness of single
pane
1.4Open scratches with
conchoidal chipping not permitted not permitted permitted up to 2 x 2
mm max. and 1/3 max.
of thickness of single
pane
1.5Float defects/
tool impressions permitted up to dia.0,5
mm, in the black print
area 0,8 *) mm
permitted up to dia
0,8 mm
permitted
1.6 Other edge defects Edges shall be designed
such that attached parts
and guides are not
damaged. Edges shall be
designed such that
attached parts and
guides are not
damaged.
Edges shall be
designed such that
attached parts and
guides are not
damaged.
Lower edges:
All defects permitted
which do not impair
function and safety
1.7Inclusions
(only completely enclosed
blisters or inclusions are
permitted) permitted up to dia 0,5
mm
permitted up to dia.
0,8 mm
permitted
2.Characteristics in composite
2.1Blisters not permitted not permitted permitted when
function not impaired 2.2 Film delamination not permitted not permitted not permitted
2.3 Haziness of films not permitted not permitted not permitted
2.4Fibrous foreign bodies permitted up to dia. 3
mm extended length permitted up to dia.
10 mm extended
length
permitted
2.5Point-shaped foreign bodies permitted up to dia 0,5
mm permitted up to dia.
0,8 mm
permitted
3 Other
characteristics
3.1 Film protrusion not permitted not permitted not permitted on
running surfaces,
permitted
up to 2 mm, provided
that the installation
situation and
attached parts allow
this
3.2 Screen-printing
characteristics permitted up to dia 0,5
mm
(max 1 missing screen-
printing point <1,2 mm)
permitted up to dia
0,5 mm
(max 1 missing
screen-printing
point <1,2 mm)
permitted
Page 15
DBL 5610 : 05/2006 *) applies to new projects. For parts for which supply contracts were concluded on the basis of DBL edition 12/97 or earlier, characteristics of up to dia. 1,0 mm are acceptable.
Table A2 a Definition of characteristics on encapsulations and extrusions
The production methods used may on occasion result in characteristics within the products which are classi-fied and assessed by this DBL. If these characteristics are within the limits outlined below, the product will be classified as "ok" and may be supplied for series production. Characteristics outside the limits of this DBL shall be assessed as defects and result in a complaint and removal of the product.
Type of characteristic Description of characteristic
1. Material
characteristics
1.1 Degree of gloss Visual effect of encapsulation surface (does surface have a mat
or glossy effect)
1.2 Blisters open Air inclusions in encapsulation material which are open at the
surface (holes in encapsulation).
1.3 Blisters, closed, foreign body
inclusions Air inclusions in encapsulation material below the surface, but whose contours are visible at the surface. Foreign bodies swept away and included by the encapsulation material.
1.4 Missing encapsulation
material, sunk spots Locations in the encapsulation without encapsulation material or with contours deviating from the target shape.
1.5 Release agent impression in
material, (hammer effect;
frosting), impression of foreign
bodies If the encapsulation mold was sprayed with an excessive release agent layer, the release agent residue may scribe through to the encapsulation surface. Contamination and foreign bodies are also visible.
1.6 Flow lines/weld line
Glitter edge Flow lines are visible lines in the encapsulation material which may form as a result of differing flow properties and temperatures during the encapsulation process.
Glitter edges are light edges without black tinting in the transition area from the screen printing to the encapsulation material.
1.7 Parting web (flash) Flash is the designation for very thin material protrusions created
at the mold parting lines.
1.8 Step jump Step jump between pane and encapsulation material
1.9 Grain characteristics Defects in grain depth or type. Defects in grain pattern.
2 Cleaner, primer and casting characteristics
2.1 Excessive primer Application of primer in areas which should be free from primer.
2.2 Primer contamination Primer residues and impressions on the glass
2.3 Excessive adhesive Adhesive residues in areas which should be free of adhesive.
2.4 Adhesive contamination Adhesive residues and impressions on the glass
3. Trim characteristics/Surface characteristics
3.1 Scratches on glass Refer to definitions in Table A1 a (Sections 1.1 - 1.4)
3.2 Scratches on encapsulation
material - incisions Scratches in the area of the encapsulation material which may be caused, for example, by the trimming process.
3.3 Encapsulation edge with void Encapsulation edge caused by processing
3.4 Surface change Surface change due to processing (cutting, pressure points,
damage) due to handling, transport and storage
3.5 Processing residues Residues of encapsulation materials or other substances. Table A2 b Requirements for characteristics on encapsulations and extrusions
The listed characteristics are only permitted if they do not disturb customers under normal traffic and light conditions.
Page 16
DBL 5610 : 05/2006
Visual inspections shall be performed taking into consideration 5.1. "Performance of visual inspections". The characteristics detected shall be assessed at a test distance of 70 cm.
Characteristics which are so small that they cannot be detected from a distance of 70 cm are not deemed to be characteristics which must be assessed (no clusters permitted).
The distance between the individual characteristics to be assessed shall be at least 150 mm for area 1. Any deviating requirements shall be agreed with the quality departments of the receiving plants.
Table A3 Optical requirements
Requirements for characteristics
Type of characteristic
Area 1
Encapsulations on all glazing parts visible when installed (including areas lying in the shadow.e.g. on sealing lips) PV 00-97 Area 2
Encapsulations on all glazing parts not visible when installed
PV 00-97
1. Material characteristics
1.1 Degree of gloss uniform not assessed
1.2 Blisters open < 0,3 mm permitted
< 1,0 mm in lip area if not
disturbing in installed position permitted when function not impaired
1.3 Blisters, closed, foreign body
inclusions < 0,8 mm permitted
< 1,5 mm in lip area if not
disturbing in installed position
permitted
1.4 Missing encapsulation material,
sunk spots not permitted permitted when function not
impaired
1.5 Release agent impression in
material, (hammer effect;
frosting), impression of foreign
bodies permitted when not visually
disturbing
permitted
1.6 Flow lines/weld line,
Glitter edge not permitted (transition between
screen printing and
encapsulation must be
black/opaque)
permitted
Parting web (flash) permitted if < 0,2 mm and not
visually disturbing.
permitted if < 0,2 mm
1.7 Step jump permitted if < 0,3 mm not applicable
1.8 Grain characteristics not permitted not applicable
2 Cleaner, primer and casting
characteristics
2.1 Excessive primer not permitted permitted outside of adhesive
bead area if specified by
development department and
documented on drawing
2.2 Primer contamination not permitted not permitted
2.3 Excessive adhesive not permitted permitted when installability not
impaired
2.4 Adhesive contamination not permitted not permitted
3. Trim characteristics/Surface
characteristics
3.1 Scratches on glass For requirements, refer to Table A1 b (Sections 1.1 – 1.4)
3.2 Scratches on encapsulation
material - incisions not permitted permitted when function not
impaired
3.3 Encapsulation edge with void not permitted permitted
3.4 Surface change not permitted permitted
3.5 Processing residues must be removed must be removed
Page 17 DBL 5610 : 05/2006
Type of optical requirement PV Requirement Test
method
1 Transmission
optics Refractive power
Windshields
Rear windows LSG
Rear windows SSG
Glass roofs
Side and roof windows
LSG
Complete pane with the
exception of the area
covered by screen printing
/ areas not visible in
installed condition 00 – 23
30 – 43
50, 60,
70, 80
61 - 63
92 - 97
Permissible stripe widths of 12 mm
horizontal line pattern on projection
screen:
8 … 16 mm
Permissible difference of stripe widths
within a circle with a diameter of 300
mm on the projection screen:
maximum 4 mm
alternative measuring method:
permitted refractive powers:
+167 … - 167 mdpt
Permissible difference of refractive
powers
within a circle with a diameter of 150
mm:
maximum 167 mdpt
(the assessment of the circle in the
refractive power pattern is made on
the imaging plane)
Horizontal line method
DIN 52305
Test orientation
according to
installation angle in
vehicle
Manuals of test
equipment
manufacturers (e.g.
ISRA)
For further
instructions, refer to
Section 5.4
2 Reflection
optics
2.1 Windshields,
rear windows,
roof windows 00 – 23,
30 – 43,
61 - 63
No counter bending or sunk spots
permissible
Limit samples in
coordination with the
quality department of
the receiving plant
2.2 Side windows (SSG, LSG) 50 – 97 Requirement according to the
approved sample. Limit samples in coordination with the quality department of the receiving plant
3 Optical
data
Light transmission TL Light reflection RL Energy transmission TE 00, 01,
30, 50, 70
10 - 23
40 - 43,
60, 80,
92 - 96
12,13,22,
23,42,43,
93,96
00 – 23
TL > 89 %
TL = 78 + 3 %, RL < 10 %,
TE < 60 %
TL = 72 + 2 %, RL < 10 %,
TE < 50 %
deviating TL, TE (e.g. for DarkTail,
other glass colors) are permitted if
indicated on drawing
TE <46 %
special requirements for windshields
with combined rain/light sensor Hella
1, Hella 2, Kostal 2 or analog Hella
light sensor
DIN 5033
DIN 5033
ISO 9050
DIN 5033
ISO 9050
ISO 9050
Test method
A 211 007 28 99
Page 18
DBL 5610 : 05/2006
Table A4 Geometrical requirements
The geometrical product requirements for the products shall normally be defined spe-cific to the parts. For information, refer to component requirement specifications, draw-ings, measuring specification and functional instructions. These indications have priority over the requirements indicated below.
Ite m Type of requirement PV Type of window
Requirement [in mm] 1 Cutting tolerance glass 00 – 97 WS, RW, SW +/- 0,75 2 Edge support tolerance in direction of surface normal 00 – 97 WS, RW, SW +/- 1,0
3
Edge waviness
00 – 97 *)
WS, RW, SW
Outline:
maximum 0,75 mm / 100 mm Surface edge support: maximum 1 mm / 100 mm 50, 60-80 RW, SW Single-layer safety glass: +/- 1,5 4 End tangent angle
(measured between 5 mm and 35 mm edge distance)
00-43, 92-97 WS, RW, SW Laminated safety glass: +/- 2,5 5 R&L sensor area: deflection at chord length 200
00-23 WS
1,6 + 0.8/-1
6 Curvature of glass deflection
00 – 97
00 – 23 *)
WS, RW, SW WS
- Jumps not permitted, continuous transitions
- No counter bending permissible (no sign reversal of curvature) - No sunk spots permitted
Harmonious curvature for wiped area: dR/dx < 27 (meaning: maximum permissible change of radius of 4000 over 150mm length)
00-43 WS, RW Tolerance band 5mm 7 Cross bending
50,60,92-97 SW +1,0 -0,5 8 Main bending 50,60,92-97 SW
+ -1,5
*) Requirement for new projects. These requirements do not apply to parts for which supply contracts were concluded on the basis of DBL edition 12/97 or earlier.
Page 19
DBL 5610 : 05/2006
Table A5 Special requirements
1 Temperature resistance laminated window 00 – 43,
63,
92 – 97
The windows shall be heat resistant, i.e. no blisters or peeling may occur in the intermediate layer.
Recirculating air cabinet 100 °C / 120 min
2 Thermal shock resistance 00 – 43,
63, 92 – 97 After a storage period of 16 h at
-40°C and 8 h at +80 °C no reduction in translucency, no cracks and no other changes shall occur.
3 cycles alternating shock
3
Resistance to tropical atmospheres 00 – 43, 63, 92 – 97 The windows shall be resistant to discoloration of the surface and
intermediate layers in tropical and
subtropical zones. No separation of layers or blistering shall occur. After 240 h, discoloration of the composite film up to max. 2 mm from the edge is permissible.
DIN EN ISO 6270-2:2005 CH 240 h
4
Corrosion resistance of IR reflecting coating 12, 13, 22, 23, 42, 43, 93, 96 After 720 h, no corrosion shall be present at IR reflecting coating. For
metallic coatings, a sufficiently wide
coating-free zone shall be provided on visible edges.
DIN 50 021 SS
5
Toughening for LSG-PT 92 – 93 To ensure adequate transverse rupture
strength, the surface compressive strength shall be at least 30 MPa.
ASTM C1279 method A
(measuring points and measuring direction shall be agreed specific to each component)
6 Stress state
50, 60-63, 70, 80
00 – 23
00 – 43 92 - 97
Under polarized light, a uniform stress distribution over the whole window shall be evident. Edge stress zone of the individual panes max. 20 mm uniform all around with compressive stress at the glass edge > 8 MPa,
then tensile stress zone < 8 MPa, inner area almost free of stress No tensile stress is permitted in laminated windows outside the edge stress zone
Edge stress measuring unit e.g. ASTM C1279
method B,
ASTM C1279
method A (measuring points
and measuring direction shall be agreed specific to each component)
7 Abrasion resistance
00 – 23 T H100 < 0,6 % T H1000 < 2,0 % DIN 52 347 - 100-G-A
DIN 52 347 - 1000-G-A
Page 20
DBL 5610 : 05/2006
Table A6 Requirements for adhesive bonding and encapsulation
8 Visual requirements for black print
00 - 97
The coating shall be free of defects so that a black primer application and glue beads or conductors do not shine through. The color of the screen print shall be selected in accordance with the approved color sample.
9 Visual requirements for silver print
00 - 97
The silver print shall always be applied on the tin bath side of the glass. 10 Float drawing direction 00 - 43
Drawing lines from the float process shall be vertical on windshields. (The float structure shall always be parallel to the longitudinal vehicle axis.)
11 Strength of electric connections
00 - 97
Evidence of the minimum loading capacity shall be provided.
Refer to notes Section 5.5 12 Arrangement of heating wires
30 - 43
Arrangement of heating wires at regular distances according to the arrangement of the busbars according to drawing in straight or wavy installation.
The displacement of the heating conductors over a length of 20 mm shall be no more than .+/- 0,5 mm.
13 Insulating glazing
13.1 Visible edges 90 - 91
A dip in the seal is permitted provided that it is uniform and a line with a width < 0,5 mm is visible between the C edge of the outer pane and the seal when observed through the window.
13.2 Butyl cord
90 - 91 The butyl cord shall not be visible at an angle of 45° to the normal. 13.3 Bonding
90 - 91 In accordance with DBL 7904
13.4 Further requirements
90 - 91
Refer to functional instructions 140 760 00 00
1 Requirements for glass/black print and surface at the bonding position 1.1 Light transmission TL UV transmission TUV 00 – 97 TL < 0,1 % TUV < 0,1 % DIN 5033
ISO 9050
1.2 Adhesive properties 00 – 97 Rating 5 Refer to Section 5.2 1.3 Roughness 00 – 97 Rz<15 μm, Ra < 1,5 μm Refer to Section 5.2 2 Requirements for encapsulations
2.1 Peeling resistance 00 - 97 ≥ 2,0 N/mm in 90° peel test Refer to Section 5.3 2.2
Peel test 00 - 97 Cohesive fracture pattern
Refer to Section 5.3 (in accordance with PA PP PWT 32643)