FN-QB-049 Plastic Parts and Integrated Components - DV Test Outline

The standard “FN-QB-049 Plastic parts and integrated components - DV test outlines” describes the terminology, technical requirements, and test methods for plastic parts used by Farasis Energy (Ganzhou). This standard applies to plastic parts and integrated components (including raw materials and finished products) used in lithium-ion power battery modules and battery packs manufactured by Farasis Energy (Ganzhou).

For the purposes of this standard, the following definitions apply:

• Plastic parts: Plastics are primarily composed of carbon, oxygen, hydrogen, nitrogen, and other organic or inorganic elements. The final product is solid, but it is in a molten liquid state during the production process. Therefore, it can be heated to melt, pressured to flow, and cooled to solidify, thus forming various shapes.
• Injection molding process: There are many processing techniques for plastic parts, including injection molding, extrusion molding, calendering molding, blow molding, thermoforming, and compression molding. Among these, injection molding is the process of adding granular or powdered raw materials into the chamber of an injection molding machine. The raw materials are heated and liquefied, and under the thrust of the injection molding machine's screw or piston, they enter the mold cavity through the mold nozzle and feeding system, where they harden and take shape. Factors affecting injection molding quality include injection pressure, injection time, and injection temperature. This standard mainly applies to injection molded products, and other process products can be used as a reference.

Unless otherwise specified, all tests and measurements should be carried out in accordance with the GB/T 2421.1 standard, provided that the samples are stored at a room temperature of 23 degrees plus/minus 2 degrees Celsius and a relative humidity of 50 percent plus/minus 5 percent for 24 hours.

The main test methods defined in this standard are:

• Flame retardant test
• Breaking torque/tensile strength test (fasteners)
• Assembly torque test (fasteners)
• Film thickness test (coating)
• Cross-cut test (coating)
• Cleaning test (integrated parts)
• Temperature rise test (integrated parts)
• Neutral salt spray test (with metal materials)
• Insulation performance test
• Strength performance test
• Constant temperature high humidity test
• Temperature shock test
• High temperature high humidity aging test
• High-low temperature cycling test

Design validation tests (DV tests) for plastic parts and integrated components are a vital part of the automotive product development and quality assurance process. These tests verify that plastic components and assemblies meet design specifications, performance requirements, safety standards, and durability expectations before full production approval.

Design validation tests focus on ensuring that prototypes or pre-production parts perform as intended by testing them under simulated or real-world conditions.

Plastic parts are individual components made, molded, or shaped from polymers (e.g., polypropylene, ABS, polycarbonate), such as bumpers, trim pieces, housings, brackets, or interior panels.

Integrated components are more complex assemblies that combine plastics with other elements such as metal inserts, electronics, foams, adhesives, or fabrics (for example, instrument panels with embedded displays, door modules with wiring, or seat structures).

These are common in vehicle interior, exterior, and under-hood applications, where lightweight plastics help reduce weight, improve fuel efficiency, and enable innovative designs.

These tests ensure that the parts can withstand the following:

• Mechanical stresses (e.g., impact, vibration).
• Environmental conditions (e.g., heat, cold, humidity, exposure to UV rays).
• Exposure to chemicals (e.g., liquids, cleaners).
• Safety requirements (e.g., flammability, low emissions for indoor use).
• Functional performance throughout the vehicle's lifespan.

These test results are critical for original equipment manufacturers and suppliers to meet regulatory standards and prevent recalls.

Common verification tests for these parts are usually specified in specific documentation, but generally conform to industry standards (such as ASTM, ISO, SAE). Typical categories include:

• Mechanical: Tensile strength, bending properties, impact resistance (Izod/Charpy), hardness tests. The aim is to evaluate durability, ductility, and fracture resistance.
• Environmental/durability: Thermal cycling, humidity, UV/weather exposure (xenon arc), accelerated aging tests. The aim is to simulate extreme temperatures, sunlight, and humidity.
• Chemical resistance: Tests involving exposure to liquids (oils, fuels, cleaners). The aim is to prevent deterioration or swelling.
• Flammability and emissions (especially indoors): Burn rate, volatile organic compounds/smoking, odor tests. The aim is to maintain safety and cabin pollution levels.
• Dimensional and appearance: Aging resistance, color fastness, and scratch resistance tests. The aim is to maintain fit, appearance, and aesthetics.
• Functional (for integrated components): Assembly compatibility, squeaking and rattling, electrical/mechanical integration tests. The aim is to verify overall system performance.

These tests are performed on samples produced with manufacturing tools and materials. The results are included in approval processes, which typically require third-party laboratories for certification.

For many years, our organization, with its competent and experienced staff, has been understanding the needs of its customers, providing the advanced testing services they require, and assisting them in the establishment, implementation, and improvement of management systems. Within this framework, we also provide testing services to businesses in accordance with the “FN-QB-049 Plastic parts and integrated parts - DV test guidelines” standard.