FORD WSS-M15P20-B1-2015 PERFORMANCE POLYMERIC FOAM FOR SEATING APPLICATIONS INCLUDING CUSHIONS ARMRESTS AND HEADRESTRAINTS TO BE USED WITH FORD WSS-M99P1111-A .pdf

1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 3 2015 12 09 Revised See Summary of Revisions B. Witkowski, NA 2009 10 14 Revised See Summary of Revisions B. Witkowski, NA 2007 07 10 Released B. Witkowski Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC Pag

2、e 1 of 6 PERFORMANCE, POLYMERIC FOAM FOR SEATING APPLICATIONS, WSS-M15P20-B1 INCLUDING CUSHIONS, ARMRESTS, AND HEADRESTRAINTS PERFORMANCE, POLYMERIC FOAM FOR SEATING APPLICATIONS, WSS-M15P20-B2 INCLUDING CUSHIONS, ARMRESTS, AND HEADRESTRAINTS FOR APPLICATIONS WITH BIO-BASED OR RECYCLED MATERIAL CONT

3、ENT 1. SCOPE This specification defines the material performance requirements for seating foam, including head restraints, cushions, bolsters, and armrests. The materials used are typically polyurethane, however, this specification also covers the attachment of materials that would be provided on a

4、finished part, such as hook/loop fastener, scrim, etc. Foam materials (die cut, molded, etc.) adhered to a molded pad shall meet the requirements of the finished pad as well. 2. APPLICATION WSS-M15P20-B1/B2 This specification is for material used in all seat cushions and backs, armrests, head restra

5、ints, armrests, and other foam trim items related to seating construction. This specification covers the foam performance requirements with respect to foam material properties and additional specifications cover the application of the assemblies, which are listed below. For seat cushions/backs this

6、specification covers attached components such as fasteners, anti-squeak coatings, and molded in fabrics. These specifications should be used together to define the performance requirements of the affected component. WSB-M15P26-C ARMREST, UNITIZED, FORMED, PERFORMANCE WSD-M15P39-A PERFORMANCE, FABRIC

7、 COVERED MOULDED PARTS WSB-M15P43-A PERFORMANCE, HEADREST, BLOW MOLDED, FOAM INJECTED 2.1 LIMITATIONS This material is susceptible to compression set damage when exposed to steam. Use of excessive steam in the seat assembly process can damage urethane flexible foam. Seating assembly plant steaming p

8、ractices should be reviewed before releasing parts using this material. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification is performance based and does not have approved sources. 3.2 PRECONDITIONING All test samples must be crushed at demold in a manner that is consistent with production inten

9、t. They shall be cured for at least the minimum time period specified in the Control Plan prior to hardness testing and a provision must exist to correlate the short-term IFD values to a fully cured sample. PPAP samples shall be cured for a minimum of 7 days prior to all other physical property test

10、ing. The samples must be conditioned in the lab environment, 23 + 2 C and 50 + 5% RH, for a minimum of 12 hours prior to testing. Except where noted, all tests will be performed on core specimens cut at a minimum of 10 mm below the molded surface of the sample and they shall have their longest dimen

11、sion at right angles to the direction of the foam rise. This will place that dimension parallel to the top surface. ENGINEERING MATERIAL SPECIFICATION WSS-M15P20-B1/B2 Copyright 2015, Ford Global Technologies, LLC Page 2 of 6 Specimens shall be taken from in and around the IFD circle and they shall

12、be free of densification layers or any portion where there is an obvious defect, such as voids. These statements supersede the specimen preparation instructions contained in the methods that exist outside of this document. 3.3 MATERIAL AND TEST SPECIMEN Cell Structure, Physical Characteristics The m

13、olded foam pads shall meet the requirements for allowable defects as outlined in the Engineering Specifications for seating pads or as defined on the Engineering Drawing, the foam shall have a uniform cell structure. All foam samples shall be cut from production parts that are free of the top molded

14、 surface (unless otherwise noted within the specification below, or in the applicable test method), voids, hard spots, and densification lines. Specimens shall be obtained from molded parts. If part thickness or configuration makes it too difficult to obtain usable test specimens, surrogate test blo

15、cks molded from the same material may be used, with approval from Materials Engineering. This is particularly applicable to small parts (arm rest, released soft molded trim pieces, etc. for seating applications) All tests will be performed on core specimens cut at a minimum of 10 mm below the molded

16、 surface (unless specified with skin) and shall have their longest dimension at right angles to the direction of the foam rise. This will place that dimension parallel to the top surface. All tests shall be performed using a sample size of 3, (unless noted in the section) with the average of the sam

17、ples reported, unless otherwise specified. All testing shall be done on parts made with production mold release agents, anti-squeak surface treatments, molded in fabrics, or other miscellaneous materials. Densities/firmness will vary by application, and the Release Engineer should consult Comfort En

18、gineering if there are issues with density and firmness of the parts. Non-cushion soft trim applications (also referred to as small part applications)- This performance specification is applicable to small parts items that are manufactured with foam formulations also used in head restraint or seatin

19、g applications. For items requiring surrogate blocks to be used for qualification, such as final parts are not of sufficient size to allow for sample specimens to be prepared, a surrogate block of the identical formulation may be used. Density, index, and key process parameters shall be kept consist

20、ent between the manufacture of the part and the surrogate block, and be provided to seat engineering or materials engineering. 3.3.1 Density, Core, min kg/m3 As specified on the Engineering (ASTM D 3574, Test A) Drawing. Sample size 50 x 50 x 25 mm minimum, taken inside or as close as possible to th

21、e IFD circle. A minimum of 24 hour ageing period prior to test is required. Molded density based on part volume shall be reported for small parts or multi-firmness or multi-density pads , and an applicable surrogate test blocks shall be made at this density for other tests in subsequent sections of

22、this specification. 3.3.2 Indentation Force Deflection Test values as specified on (ASTM D 3574, Test B1, 50% the Engineering Drawing deflection) requirements, test fixtures, values and locations as specified on the Engineering Drawing. 3.3.3 Hardness, Hysteresis, and Comfort Factor Test values as s

23、pecified on (FLTM BO 121-01) the Engineering Drawing ENGINEERING MATERIAL SPECIFICATION WSS-M15P20-B1/B2 Copyright 2015, Ford Global Technologies, LLC Page 3 of 6 requirements, test fixtures, values and locations as specified on the Engineering Drawing. 3.3.4 Tensile Strength (ASTM D-3574 test E), 3

24、.3.4.1 Tensile Strength & Elongation Report 3.3.4.2 Heat Aged Tensile Strength, 75% of unaged (Condition per ASTM 3574, Test K for heat age) value must be Report original and aged values with elongation) retained 3.3.5 Tear Resistance (ASTM D624, Die C, 10mm sample thickness) Cushions 450 N/m min Ba

25、cks 450 N/m min Head Restraints & non-cushion soft trim Report 3.3.6 Wet Compression Set (ASTM D 3574, Test D, L ,Ct Calculation 50% compression) Cushions 15% loss Max Backs 25% loss Max Head Restraints & non-cushion soft trim Report 3.3.7 Fogging (SAE J1756, 3 h at 100 C heating, 21 C cooling plate

26、, post test conditioning 16 h) Fog Number 70 min The formation of clear film, droplets or crystals is cause for rejection. Samples are to be prepared with skin, and include mold release agents and anti-squeak or other applied treatments prior to fog testing and allowed to age per 3.2 Preconditioning

27、. 3.3.8 Odor Rating 3 max (FLTM BO 131-03) 3.3.9 Wet Aged CFD Loss (ASTM D 3574, Test C, L) Cushion 10% max Back 10% max Head Restraints & non-cushion soft trim Report 3.3.10 Fatigue Resistance, Constant Force Pounding (for seat cushions only) (ASTM D 3574, Test I3, Procedure B, 40% compression) One

28、 test specimen is required, skin shall not be removed from specimen for this test. Loss of Hardness 25% max Loss of Thickness 5% max ENGINEERING MATERIAL SPECIFICATION WSS-M15P20-B1/B2 Copyright 2015, Ford Global Technologies, LLC Page 4 of 6 3.3.11 Compression Force Deflection Curve Report Supplier

29、 will provide stress/strain values from 0-75% compression for each material, sample per ASTM 3574, Test C, 75%, report a minimum of 200 data points. 3.3.12 Flammability 100mm/min max (ISO 3795) 3.3.13 Staining 20 max change Test per method: Test Materials 1. Glass bottle, 2.0 L +/- 200 ml, with a me

30、tal screw foil-lined cap. The cap diameter shall be at minimum 60 mm. 2. Lightest color test vinyl fabric to be used on vehicle program, or white, unsupported PVC film, unembossed, # 103-01, or alternately GM Vinyl Coated Fabric (Prado Grain), available from Test Fabrics1, cut into an 80 mm diameter

31、 disc or a circular size that fits tightly into the bottle cap. 3. Specimen cut from a molded part, 70 x 70 x 30 mm (+/- 2 mm on either dimension) with skin on the 70 x 70 mm face. Note 1: Test Fabrics, Inc., 415 Delaware Avenue, PO Box #26, West Pittison, PA 18643 USA Tel: 570-603-0432, Fax: 570-60

32、3-0433, E-mail: Test Equipment 1. Air-circulating oven capable of maintaining a temperature of 100 2 C for 72 hours (temperature should be recorded or monitored). 2. Color spectrophotometer. Test Procedure 1. Check to ensure the glass bottles and lids are clean and free from contaminants. Prepare t

33、wo bottles: a control bottle with no foam sample and a test bottle with foam. 2. Measure the color of the vinyl samples using the spectrophotometer and record the original L* a* b* data. 3. Insert a vinyl disc into the lid of each bottle with face side outwards. 4. Place foam sample on the bottom of

34、 test bottle with skin side facing upwards (towards the lid). The control bottle will have no foam in it. 5. Carefully screw on the lids, ensuring the vinyl discs remain in place, and hand tighten them. 6. Place the closed bottles in the oven and note temperature and time. 7. After 72 hours, remove

35、the bottles from oven, open lids carefully, extract the PVC discs from lids and allow to cool to laboratory conditions, 23 2C, 50 5% RH, for at least 1 hour. 8. Measure the final color of the vinyl samples and again record the L* a* b* data. 9. Using the original and final L* a* b* data, calculate t

36、he E for both vinyl samples (control and test) using the following formula: E = L + a + b 10. To obtain the color change due to the foam, E foam, subtract the E of the control bottle PVC (E control) from the E of the test bottle PVC (E test). ENGINEERING MATERIAL SPECIFICATION WSS-M15P20-B1/B2 Copyr

37、ight 2015, Ford Global Technologies, LLC Page 5 of 6 E test - E control = E foam Note: Glass jars should be washed clean after each test, dried thoroughly, and stored with caps screwed in place to avoid ingress of any chemicals into the jars. Record 1. E of the control bottle and E of the test bottl

38、e, E control and E test. 2. Color Change in Vinyl due to foam, E foam 3.4 BIO-BASED OR RECYCLED CONTENT REQUIREMENTS Report (WSS-M15P20-B2 Only) Each system will have minimum requirements of bio-content/recycled/renewable content in the raw materials, The supplier will present data as to how their m

39、aterial will meet the minimum final content in the finished foam. Production tolerances for minimum and maximum bio content in a given material formulation shall also be reported. The percentage, upper and lower limits, shall be listed on the Engineering Drawing and be reported to Materials Engineer

40、ing and the Design & Release Engineer. The minimum bio-based content for the application shall be 5%, based on the total pad weight. Changes between bio-based and petro-based foams systems, or changes in the level of bio/recycled content, cannot be made without approval from Seat Engineering and Mat

41、erials Engineering. 3.5 MATERIAL CHEMISTRY DEFINITION Report The supplier will define material composition, i.e. polyether urethane, MDI, TDI, MDI/TDI, other blend. 3.6 MISCELLANEOUS PAD FEATURES The Engineering Drawing shall contain the Supplier, Product Code and Trade Name, if additional items suc

42、h as hook/loop fasteners, support wires, anti-squeak coatings, molded-in or post applied fabrics and items that are not listed on the Engineering Drawing, such as processing aids, (anti-squeak agents, mold releases, etc) shall be reported by the supplier to Seat Engineering. 4. GENERAL INFORMATION T

43、he information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression

44、of interest from Purchasing, Design or Product Development, and Materials Engineering. The supplier shall submit a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of the

45、 Material Specification. Tested material samples must be available for review upon request and kept for a minimum of one year. Upon request, the supplier will review the associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford.

46、4.2 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes to the material originally approved, whether or not such changes affect the materials ability to meet the specification

47、 requirements, the supplier shall notify the affected Supplier Technical Assistance (STA), Purchasing, and Materials Engineering ENGINEERING MATERIAL SPECIFICATION WSS-M15P20-B1/B2 Copyright 2015, Ford Global Technologies, LLC Page 6 of 6 activities of the proposed changes (with reasons) by submissi

48、on of a completed Suppliers Request for Engineering Approval, SREA. For parts and components using Ford Engineering Material Specifications, all samples tested to the specifications for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign off must b

49、e kept until Job 1. 4.3 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. The restrictions are identified in the Restricted Substance Management Standard WSS-M99P9999-A1 which is updated yearly. It is the suppliers responsibility to comply with this standard on a continuing basis through IMDS and or GMAP reporting. DV/PV TABLE 5. SUMMARY OF REVISION 2015