1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions Ver. 4 2009 04 23 N-STATUS Replaced by WSS-M15P45-B Y. Bankowski, NA 2004 11 19 Revised Entire specification has been revised C. Lin, M. Quirolo, L. Soreide 1999 07 14 Activated J. Skelly, L. Soreide Printed copies are uncontrolled Copyright 2
2、009, Ford Global Technologies, LLC Page 1 of 8 PERFORMANCE, INSTRUMENT PANEL ASSEMBLY, WSS-M15P45-A FLEXIBLE COVER SKIN MATERIAL NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is an instrument panel assembly which utilizes a flexible cover skin material. Tu-tone co
3、ver skin must also meet the requirements of this specification. 2. APPLICATION This specification was released originally for material used in the instrument panel environment. Instrument panels containing an integrated airbag system must also meet any additional specifications on the Engineering Do
4、cument. Hard instrument panels should be tested to WSS-M15P4-E. This specification is based on virgin material only. The use of in-house regrind is not allowed unless approved by Materials Engineering. If approved, the part must then be validated during PV testing with the documented level of regrin
5、d noted on the part drawing. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 APPEARANCE 3.2.1 Color Matching with Artificial Light (FLTM BI 109-0
6、1, Visual Assessment) The color, pattern and finish shall match the approved Design Center master sample, or shall be as specified on the Engineering Document. 3.2.2 Gloss (FLTM BI 110-01, ASTM D523) As specified on the Engineering Document ENGINEERING MATERIAL SPECIFICATIONWSS-M15P45-APrinted copie
7、s are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 2 of 8 3.3 BOND STRENGTH - PEEL ADHESION, min 3.3.1 Initial Bond Strength, Peel Adhesion, min (ISO 2411, Standard Method, 300 mm/minute FLTM BN 151-05, any direction) Flexible cover-skin layer 175 N/m and 100% foam tear to foam (C
8、ohesive) Cover-stock to substrate 880 N/m and 100% foam tear (where applicable) (Cohesive) Foam to substrate 400 N/m and 100% foam tear (Cohesive) 3.3.2 After Sunload Bond Strength, Peel Adhesion, min (DVM-0038-IP, 440 hours at 113 C, ISO 2411, Standard Method, 300 mm/minute FLTM BN 151-05, any dire
9、ction) Flexible cover-skin layer +/- 25% and 100% foam tear, to foam (Cohesive) Cover-stock to substrate +/- 25% and 100% foam tear (where applicable) (Cohesive) Foam to substrate +/- 25% and 100% foam tear (Cohesive) 3.4 RESISTANCE TO ABRASION, min Rating 6 (SAE J 948, CS-10 wheels, 500g, 250 cycle
10、s) The surface shall show no evidence of wear through, and the color of the abraded area shall be acceptable in appearance according to DVO-0009-IP. Painted airbag system, tu-tone, No wear-through and secondary paint applications, (SAE J 948, CS-10 wheels, 500g, 1,000 cycles, min) Measure and report
11、 the paint film thickness of the panel. Run a min of 1000 cycles. Run an additional 200 cycles for every 5 microns increment over 25 microns of paint thickness. No evidence of lifting, peeling, or excessive scuffing. 3.5 RESISTANCE TO SCUFFING, min Rating 6 (SAE J365, 250 cycles) The surface shall s
12、how no evidence of wear through, and the color of the scuffed area shall be acceptable in appearance according to DVO-0009-IP. No permanent parallel deformation to the surface. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P45-APrinted copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC
13、 Page 3 of 8 Painted airbag system, tu-tone, No wear-through and secondary paint applications, (SAE J365, 1,000 cycles, min) Measure and report the paint film thickness of the test specimen. Run a min of 1000 cycles. Run an additional 200 cycles for every 5 microns increment over 25 microns of paint
14、. No evidence of lifting, peeling, or excessive scuffing. No permanent parallel deformation to the surface. 3.6 INDENTATION AND RECOVERY Complete recovery (FLTM BO 111-02) Method B for laminate system with foam thickness less than 6 mm Method A for all other foam containing systems Minor visible ski
15、n wrinkles evident after the allotted recovery time, but not evident after an additional 1 h recovery, shall be considered acceptable. 3.7 RESISTANCE TO MIGRATION STAINING, Rating 5 AND BLOCKING, min (FLTM BN 103-01) For first color submissions of each new technology only. No evidence of injurious e
16、xudation, adhesion (tackiness), separation, color transfer, staining, or flattening of the embossing when material is placed in the following positions: Top surface to top surface Top surface to standard vinyl test material Top surface to back surface 3.8 COATING ADHESION (where applicable) 5% paint
17、 removal (FLTM BI 106-01, Method D) Less than 5% paint removal with no complete diamonds removed. Six lines in each direction should make up the grid. The overall dimensions should be at least 25 mm wide by 50 mm long from the widest and longest points unless restricted by part size. 3.9 WATER RESIS
18、TANCE 96 h (FLTM BI 104-01) No blistering, dulling, exudation, softening, dulling, color change in excess of AATCC Eval. Proc. 1 Rating 4, or loss of adhesion per para 3.8 is permitted, within 30 minutes of removal from water. 3.10 RESISTANCE TO SCRATCHING, max Rating 1 (FLTM BN 108-13, 2N force, 1
19、mm scratch pins, change in gloss is acceptable) No whitening ENGINEERING MATERIAL SPECIFICATIONWSS-M15P45-APrinted copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 4 of 8 3.11 RESISTANCE TO HEAT AGING (ISO 188/ASTM E 145, Type IIA, 500 h at 120 +/- 2 C) Test Method: Suspend
20、 a sufficient amount of composite construction, taken from instrument panel brow area, in an air circulating oven for all heat aging tests. After heat aging, cut the test specimens and condition them for 24 h at 23 +/- 2 C and 50 +/- 5% relative humidity prior to testing. 3.11.1 Color Stability, min
21、 Rating 3 (ISO 105-A02/AATCC Evaluation Procedure 1) Shall show no evidence of tackiness, spewing, or exhibit staining. Shall not exhibit color tone change, or change in hue in excess of Delta Ecmc=3.0. Any spotty or non-uniform staining or discoloration shall be cause for rejection. A color shift t
22、hat reverses after 16 h Xenon weathering, per 3.12.2 is acceptable. 3.11.2 Cold Flexibility No cracks (180 bend at -20 C over a 20 +/- 1 mm diameter mandrel, sample size 50 x 150 +/- 1 mm) 3.11.3 Elongation at Break, Change from Original Value, max 50% (100% absolute (ISO R 527, type 2/ASTM D 638, e
23、longation minimum) type M-II, 100 mm/minute test speed) 3.12 RESISTANCE TO FADE The material shall not exhibit staining, color tone change or change in hue in excess of specified CMC readings, after exposure in accordance with Fade Testing below. Read and report the gloss change. In addition, there
24、shall be no cracking, crazing or other deterioration. The material must remain flexible and exhibit no cracking when bent around a 20 +/- 2 mm mandrel after the specified exposure. Remove foam and bend with foam side of skin to the mandrel. 3.12.1 Florida Weathering under Glass, Rating 4, min (FLTM
25、BI 160-01, under glass, 5 South direct, backed, 12 months, AATCC evaluation procedure 1) (New technology approval if mutually agreed upon by the Materials Engineering and Design Activities.) ENGINEERING MATERIAL SPECIFICATIONWSS-M15P45-APrinted copies are uncontrolled Copyright 2009, Ford Global Tec
26、hnologies, LLC Page 5 of 8 3.12.2 Xenon Arc Weather-o-meter (DVM-00067-MA, ISO 105-A02/AATCC Evaluation Procedure 1) In Vehicle Sunlight Exposure Level Test Exposure AATCC Rating After Exposure, min 3.12.2.1 Low exposure: lower trim panels below armrest level 225.6 kJ/m2Rating 4 3.12.2.2 Moderate ex
27、posure: upper trim panels and armrest 601.6 kJ/m2Rating 4 3.12.2.3 High exposure: trim panel rollover, pillars, and garnish moldings, 1052.8 kJ/m2Rating 4 3.12.2.4 Severe exposure: IP top and defroster grille 3609.6 kJ/m2Rating 4 The materials shall be rejected if adhesive staining or other non-unif
28、orm staining results from material incompatibility. These exposure levels were obtained from measuring sunload in vehicles. When using optional cut-off filters, and use an appropriate wavelength to monitor the irradiance. Calibration should be performed at the monitored wavelength. The xenon arc pan
29、el size shall be approximately 60 x 150 mm with 1/3 area protected from exposure. Duplicate panels are required, one for appearance evaluation and one for coating adhesion after water immersion if applicable. After the color and gloss measurements, one of the weathered panels shall be subjected to t
30、he water immersion test for 24 h per FLTM BI 104-01 and evaluated per para 3.9. For routine color approval of existing technologies programs accelerated weathering results will be used for approval until natural weathering results are available. Note: In case of differences in the test results betwe
31、en Florida exposure and the accelerated weathering the results of the Florida exposure shall prevail. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P45-APrinted copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 6 of 8 3.13 FOGGING (SAE J1756, 3 h at 100 C heating, 21 C cooling pl
32、ate, post test conditioning 1 h and 16 h) Fog Number, min 70 No formation of clear film, droplets or crystals. 3.14 FLAMMABILITY (ISO 3795 / SAE J369) Burn Rate, max 100 mm/minute 3.15 DIMENSIONAL STABILITY (ISO 105-A02/AATCC Evaluation Procedure 1) The instrument panel pad assembly shall remain rel
33、atively unaffected by the exposure cycle during and after the test: 1) no wrinkling, distortion, bridging, blistering, delamination, blushing, hazing, exudation, or milking on visible surfaces; (2) no expansion, shrinkage, or warping that will interfere with normal functional operations or cause obj
34、ectionable visual appearance. Subject instrument panel to the following environmental cycle: 5 h at -40 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 100 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 2 h at 50 +/- 2 C and 95 +/- 5% R.H. 30 min at 23 +/- 2 C and 50% R.H. 5 h at -40 +/- 2 C 30 min at 2
35、3 +/- 2 C and 50% R.H. 5 h at 100 +/- 2 C 3.16 SOILING AND CLEANABILITY (FLTM BN 112-08, ISO 105-A02/AATCC Evaluation Procedure 1) Cleanability Rating 3 3.17 RESISTANCE TO CLEANING AGENTS, max Rating 4 discoloration (FLTM BN 107-01, 10 cycles, AATCC Evaluation Procedure 2) Test Procedure: Saturate w
36、hite cotton cloth with the cleaners listed. Evaluation according to the AATCC Scale. Cleaners: 1) Deionized water 2) Window cleaner with ammonia, see para 4.1 3) All purpose cleaner, see para 4.1 4) Dry (no cleaners or water) ENGINEERING MATERIAL SPECIFICATIONWSS-M15P45-APrinted copies are uncontrol
37、led Copyright 2009, Ford Global Technologies, LLC Page 7 of 8 3.18 RESISTANCE TO WINDOW CLEANER, Rating 4-5 WITH AMMONIA, min (DVM-0015-MA) Window cleaning solution must contain at least 1% Butyl cellusolve. Test procedure: Prepare test samples by placing 2.0 ml of cleaner on the sample. A non-react
38、ive washer may be used to control the location of the cleaner on the sample. Expose the sample at room temperature for 1 h, rinse with tap water, and dry carefully with a clean paper towel; do not rub spots. Evaluate per ISO 105-A02/AATCC Evaluation Procedure 1. No film softening allowed. 3.19 RESIS
39、TANCE TO SUNTAN LOTION, Rating 3 AND INSECT REPELLENT, min (DVM-0036-MA and DVM-0039-MA) 3.20 RESISTANCE TO WATER AND, Rating 4 - 5 SOAP SPOTTING, min (FLTM BI 113-01, ISO 105-A02/AATCC Evaluation Procedure 1) No film softening allowed for either solution. 3.21 ODOR, max Rating 2 (FLTM BO 131-01) 3.
40、24 RESISTANCE TO DYNAMIC EXUDATION, min Rating 4-5 (ISO 105-A02/AATCC Evaluation Procedure 1, 168 h exposure) Place full construction samples in a chamber that can maintain the conditions of 70% +/- 5% RH & 70 C +/- 2 C Whitening, blooming, spewing, exudation, etc on the surface of the samples shall
41、 be cause for rejection. To be used for initial technology approval only. 3.26 THERMAL SHOCK TEST FOR PAINT ADHESION, min Rating 19 (FLTM BI 107-05, for topcoated or tu-tone) No loss of gloss or any other surface deterioration. 3.27 CLEANING REMOVAL RESISTANCE Rating 4 (FLTM BN 107-01, 500 Cycles) T
42、est Method: Place the painted vinyl strip on the crockmeter and apply 3 ml of vinyl cleaner (EOAZ-19521-AA) to the contact surface. Perform 500 cycles, rinse the cleaner off the strip, and evaluate the percentage of paint removal to the substrate. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P45-APrinte
43、d copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 8 of 8 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 4.1 CLEANING AGENTS (See para 3.17) 1) Window cleaner with ammonia 2) All Purpose Cleaner ZC-38-A* *or Ford Motor Company Recommended Equivalents
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