FORD WSS-M15P45-C-2018 ASSEMBLY PERFORMANCE INSTRUMENT PANEL AND SOFT INTERIOR COMPONENTS FLEXIBLE COVER SKIN MATERIAL TO BE USED WITH FORD WSS-M99P1111-A .pdf

1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 02 2018 03 02 Editorial Corrected reference suffixes S. Gatzek, NA 2017 06 27 Editorial Corrected footer A. Collins, NA 2016 05 19 Released S. Gatzek, NA Controlled document at www.MATS Copyright 2018, Ford Global Technologies, LLC Page

2、1 of 15 ASSEMBLY PERFORMANCE, INSTRUMENT PANEL AND SOFT WSS-M15P45-C INTERIOR COMPONENTS, FLEXIBLE COVER SKIN MATERIAL 1. SCOPE The material defined by this specification is an instrument panel assembly, instrument panel component, floor console armrest, valence panel, steering wheel airbag cover, h

3、ush panel, door panel or wrapped pillar, which utilizes a flexible (soft) cover skin material over a hard substrate with or without foam or spacer fabric, and with or without a topcoat. 2. APPLICATION This specification was released originally for material used for all soft interior components, not

4、including seat trim covers, molded/foam-in-place armrests and headrests. This specification includes top-coated (added for gloss control, haptics and/or cleanability) and in-mold coated (IMC) skins. Instrument panels containing an integrated airbag system must also meet any additional specifications

5、 on the Engineering Document. All painted flexible cover skins (through a secondary process) shall meet the requirements of WSS-M2P188-B1/latest. All soft skins or fabrics for armrests and door panels must also meet the requirements of WSS-M8P3-E1/E2/E3/latest (flexible polymeric films), WSS-M99P43-

6、C/latest (leather) or WSS-M8P18-B1/B2/B3/B4/latest (fabrics). EXCLUDED The following applications are excluded from this specification. hard instrument panels, hard door panels, finish panels (WSS-M15P4-Glatest) package trays (WSS-M15P6-E/latest) steering wheels (WSS-M98P12-B/latest) headliners (WSS

7、M15P27-F/latest) carpeting substrate (WSS-M8P16-B/latest) appliqus (WSS-M15P34-E/latest) sun visors (WSS-M98P3-B/latest) molded headrest (WSS-M15P39-B/latest) molded armrests (WSS-M15P26-D/latest) and interior elastomers (WSS-M9P8-B/latest) Testing must be conducted on parts at DV and PV unless spe

8、cified otherwise by Ford Engineering. See Tables 1 no spewing, wrinkling, distortion, blistering, warping, delamination, blushing, hazing, milking, waviness, or other objectionable visual appearance. Any spotty or non-uniform staining or discoloration shall be cause for rejection. For topcoated poly

9、meric cover skin materials, a color shift that reverses after 16 h Xenon weathering, per 3.8.1 is acceptable 2) Functionally - no excessive expansion, shrinking, or warping that will interfere with normal functional operations. 3) Dimensionally - no movement exceeding what is required on the Enginee

10、ring drawing from the original installed position during or after the test. Dimensional exceptions to these requirements may be allowed by Core Engineering. 3.4.1 Short Term Heat, Humidity and Cold Cycle For leather wrapped parts, ensure the component is positioned in the test chamber so no condensa

11、tion from the test equipment can drip and pool on the part surface during the test cycle. Note that stages do not include ramp times to transition from level to level. Each specimen can have different size, geometry, etc. which impacts ramp times; therefore, each transition period will vary in lengt

12、h of time. Total test time should exceed 38 h due to time required to transition from level to level. 3.4.1.1 Horizontal or vertical parts AT OR ABOVE THE BELT-LINE (e.g. wrapped pillars, soft instrument panels) 5 h at -30 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 100+/- 2 C 30 min at 23 +/-

13、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 -30 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 100 +/- 2 C ENGINEERING MATERIAL SPECIFICATION WSS-M15P45-C Copyright 2018, Ford Global Technologies, LLC Page 4 of 15 3.4.1.2 Horizontal or vertical part

14、s BELOW THE BELT-LINE (e.g., door panels, soft consoles, wrapped glove box doors and other non-sun loaded parts) 5 h at -30 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 90+/- 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 -30 +/-

15、 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 90 +/- 2 C 3.4.1.3 Other non-sun loaded floor level parts that dont meet the dimensional or functional requirements when tested at 90 C (e.g., scuff plates, kick panels, map pocket opening of door trim and below) 5 h at -30 +/- 2 C 30 min at 23 +/- 2 C a

16、nd 50% R.H. 5 h at 80+/- 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 -30 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 80 +/- 2 C 3.4.2 Long Term Heat Exposure / Sun Load 3.4.2.1 Soft Instrument Panels with or without integrate

17、d floor consoles Sun Load per IP-105: 107 C surface temperature via heat lamps with a chamber temperature of 90 C for 242 hours 3.4.2.2 Horizontal or vertical parts AT OR ABOVE THE BELT-LINE (e.g. wrapped pillars; soft upper door trim rollover for aged peel adhesion only): 7 days at 100 +/- 2 C 3.4.

18、2.3 Horizontal or vertical parts BELOW THE BELT-LINE (e.g., door panels and soft consoles that are not integrated with the instrument panel; soft upper door trim panels dimensional and visual): 7 days at 90 +/- 2 C 3.4.2.4 Other non-sun loaded floor level parts (e.g., scuff plates, kick plates, door

19、 trim bottom surface). 7 days at 80 +/- 2 C For Instrument Panels Only (para 3.4.3. 3.4.4): Test Method: After Long Term Heat Exposure / Sun Load (3.4.2), cut test specimens (remove foam and substrate) and condition them for 24 h at 23 +/- 2 C and 50 +/- 5% relative humidity prior to performing the

20、following test: ENGINEERING MATERIAL SPECIFICATION WSS-M15P45-C Copyright 2018, Ford Global Technologies, LLC Page 5 of 15 3.4.3 Cold Flexibility No cracks (180 bend at -30 C for a minimum of 4 hours over a 20 +/- 1 mm diameter mandrel, sample size approximately 50 x 150 mm) 3.4.4 Elongation of Flex

21、ible Coverskin 50% max change from (ISO 37, Type 1, 500 mm/minute test speed) original value Excludes leather which must meet requirements in WSS-M1F25-B/latest. 3.5 180 DEGREE PEEL ADHESION STRENGTH (FLTM BN 151-05, 300 mm/minute cross head rate, test specimens must be 50 mm wide, report peel adhes

22、ion strength using integral method; arithmetic mean of 5 test specimens, cut in any direction). FLTM BN 152-01 Determination of Bond Strength Using the Wedge Method, may be required for systems with a thick foam layer that breaks when folded back on itself, Use of this test method and acceptance cri

23、teria must be agreed upon with Ford Materials Engineering and PD Engineering. If the layers comprising the interface to be evaluated cannot be separated during test specimen preparation, the peel adhesion bond will be deemed too strong to separate and be judged as meeting the requirement. Peel adhes

24、ion is applicable for systems comprised of layers that are chemically or adhesively bonded together. Examples of specifications for these systems are listed below: Instrument Panels: Foam in Place: WSS-M4D983-A3, WSS-M4D985-A3, WSS-M4D980-A, M4D1059-A, WSS-M4D1060-A Vacuum Forming In Mold Graining (

25、IMG) / In Mold Grain Lamination (IMGL): WSS-M98D39-A2, WSB-M98D18-B2 Leather Wrapped Systems: WSS-M1F25-B Polymeric Skin Wrapped Adhesive Systems: WSS-M2F206-A3, WSS-M2F207-A2/A3, WSS-M2F208-A3 All Other Parts: Foam in Place: WSS-M4D983-A3, WSS-M4D985-A2, WSS-M4D980-A, M4D1059-A, WSS-M4D1060-A Back

26、Injection Molded Systems: WSS-M5H40-B3 Vacuum Forming In Mold Graining (IMG) / In Mold Grain Lamination (IMGL): WSS-M98D39-A1, WSB-M98D18-B1 Foam Laminated to Leather: WSS-M1F27-B, WSS-M1F29-B Leather or Vinyl Wrapped Systems with Separate Foam Layer: WSS-M1F27-B, WSS-M1F30-B, WSS-M2F212-A, WSS-M2F1

27、86-A1/A2 Tri-Laminate Wrapped Adhesive Systems: WSS-M1HXXXX, M2FXXX material specifications with WSS-M8P3 and M8P18 performance specifications ENGINEERING MATERIAL SPECIFICATION WSS-M15P45-C Copyright 2018, Ford Global Technologies, LLC Page 6 of 15 If minimum requirement is not met, then acceptance

28、 must be determined with the IP/PAB technical specialist/SME based on successful PAB deployments. This acceptance must be documented in eFDVS. INSTRUMENT PANELS Examples of Composite Constructions Interface Original After Heat Aging (Para 3.4.2) Foam in Place Systems Polymeric Skin to Foam 175 N/m m

29、inimum and cohesive foam tear; no individual value less than 95 N/m 130 N/m minimum and cohesive foam tear; no individual value less than 95 N/m Foam to Substrate Cohesive foam tear Cohesive foam tear Vacuum Forming In Mold Graining/In Mold Grain Lamination Polymeric Skin to Foam Bi-laminate Require

30、ments defined in applicable Ford Material Specification (WSS-M98D39-A2, WSS-M98D18-B2) Foam to Substrate 1200 N/m minimum and cohesive foam tear 900 N/m minimum and cohesive foam tear Leather Wrapped Adhesive Systems Leather to Spacer 1200 N/m minimum 2500 N/m minimum for seamless PAB area 1200 N/m

31、minimum 2500 N/m minimum for seamless PAB area Spacer to Substrate or Subassembly 1200 N/m minimum 2500 N/m minimum for seamless PAB area 1200 N/m minimum 2500 N/m minimum for seamless PAB area Polymeric Skin Wrapped Adhesive Systems OR Polymeric Skin to Spacer Bi-laminate OR Requirements defined in

32、 applicable Ford Material Specification ( WSS-M2F206-A3, WSS-M2F207-A3, WSS-M2F208-A3) Polymeric Skin to Knit Backing Requirements defined in applicable Ford Material Specification (WSS-M2F207-A2) Spacer or Knit Backing to Substrate 1200 N/m minimum 2500 N/m minimum for seamless PAB area 900 N/m min

33、imum 2500 N/m minimum for seamless PAB area SKIN SUBSTRATE SKIN TO FOAM FOAM TO SUBSTRATE FOAM FOAM TO SUBSTRATE ADHESIVE SKIN/FOAM BI-LAMINATE SUBSTRATE ADHESIVE LEATHER TO SPACER SPACER TO SUBSTRATE SUBSTRATE OR SUBASSEMBLY SPACER LEATHER ADHESIVE SUBSTRATE SPACER TO SUBSTRATE ADHESIVE SKIN/SPACER

34、 BI-LAMINATE SUBSTRATE OR SUBASSEMBLY KNIT BACKING TO SUBSTRATE ADHESIVE POLYMERIC SKIN WITH KNIT BACKING ENGINEERING MATERIAL SPECIFICATION WSS-M15P45-C Copyright 2018, Ford Global Technologies, LLC Page 7 of 15 If minimum requirement is not met, then program specific target must be determined with

35、 the system Core Engineering based on successful part performance. This acceptance must be documented in eFDVS. ALL OTHER PARTS Examples of Composite Constructions Interface Original After Exposure (Para 3.4.2) Foam in Place Systems Polymeric Skin to Foam 175 N/m minimum and cohesive foam tear 175 N

36、/m minimum and cohesive foam tear Foam To Substrate 240 N/m minimum and cohesive foam tear 240 N/m minimum and cohesive foam tear Back Injection Molded Systems Back Injection Molded Fabric / Backing To Substrate 440 N/m minimum 440 N/m minimum Vacuum Forming (In Mold Graining/In Mold Grain Laminatio

37、n) Polymeric Skin to Foam Bi-laminate Requirements defined in applicable Ford Material Specification (WSS-M98D39-A1, WSS-M98D18-B1) Foam to Substrate 440 N/m minimum and cohesive foam tear 440 N/m minimum and cohesive foam tear Foam Laminated to Leather Leather to Foam 175 N/m minimum and cohesive f

38、oam tear 175 N/m minimum and cohesive foam tear Leather or Vinyl Wrapped Systems with Separate Foam Layer Leather or Vinyl to Scrim 240 N/m minimum 240 N/m minimum Scrim to Substrate 240 N/m minimum 240 N/m minimum Tri-laminate Wrapped Adhesive Systems (Hand Wrapped or Press Bonded) Polymeric Skin/F

39、oam/Scrim Tri-laminate Requirements defined in applicable Ford Material Specification (WSS-M8P3-E3, WSS-M8P18-B2/B3) Scrim to Substrate or Foam Bun 240 N/m minimum 240 N/m minimum Other Wrapped Adhesive Systems (Armrest) Skin/Leather to Substrate or Foam Bun 240 N/m minimum 240 N/m minimum SUBSTRATE

40、 OR FOAM BUN SKIN TO SUBSTRATE ADHESIVE SKIN/LEATHER SKIN SUBSTRATE SKIN TO FOAM FOAM TO SUBSTRATE FOAM SUBSTRATE FABRIC/BACKING TO SUBSTRATE FABRIC/BACKING FOAM TO SUBSTRATE ADHESIVE SKIN/FOAM BI-LAMINATE SUBSTRATE LEATHER LEATHER TO FOAM FOAM/SCRIM BI-LAMINATE ADHESIVE LEATHER/VINYL LEATHER/VINYL

41、TO SCRIM SCRIM TO SUBSTRATE SKIN/FOAM/SCRIM TRI-LAMINATE ADHESIVE ADHESIVE SUBSTRATE SUBSTRATE OR FOAM BUN SCRIM TO SUBSTRATE OR FOAM BUN ADHESIVE SKIN/FOAM/SCRIM TRI-LAMINATE ENGINEERING MATERIAL SPECIFICATION WSS-M15P45-C Copyright 2018, Ford Global Technologies, LLC Page 8 of 15 3.5.1 Deep Draw S

42、ectioning For all wrapped adhesive systems (i.e. hand wrapped/pressure assist/IMGL/IMG/Cast) additional sectioning of the part is required for the deep draw areas. Deep draw areas are defined by a change of contour of 15 mm or more (for example any concave surface such as integral insert/armrest or

43、molded in pockets that have a potential to bridge). Cut the part every 50 mm in these areas to review the bonding of the cover stock and composite (bi/tri laminates) to the substrate. Unacceptable conditions include: Bridging of material (not adhered to substrate) Bubbles/Non-bonded areas 3.6 INDENT

44、ATION AND RECOVERY Complete recovery after 1 hour (FLTM BO 111-02, 6.8 kg load) Only applicable for components with foam between the skin and substrate. Excludes door trim panel components which must meet the Rolling Sphere Fatigue Test (Para 3.7). Excludes all leather IP systems whose requirements

45、are defined by Core Engineering. 3.7 ROLLING SPHERE FATIGUE TEST For Door Trim Panel Components Only (FLTM BO 113-04, 2000 cycles) Length of stroke to be 200 mm from center point of sphere leaving the length to be evaluated 150mm. The end 25 mm from center of sphere in each travel direction is to be

46、 excluded from indent evaluation measurement area. All test results are to be reviewed and signed off by Materials Engineer and Core Engineering. Deformation (mm) after 24 hours Report Only Deformation (mm) after 48 hours Report Only 3.8 COLOR AND APPEARANCE PROPERTIES Sample shall be tested as part

47、 of a production assembly composite (skin and foam or spacer fabric) for instrument panel systems only unless otherwise indicated. Sample shall be cut from the locations specified. The material shall not exhibit staining, color tone change, change in hue, cracking, crazing, tackiness or other deteri

48、oration after exposure in accordance with testing below. Read and report the gloss change. For new coverskin technology, check samples at 526 kJ/m2 intervals and note any changes in appearance. The materials shall be rejected if adhesive staining or other non-uniform staining results from material incompatibility. ENGINEERING MATERIAL SPECIFICATION WSS-M15P45-C Copyright 2018, Ford Global Technologies, LLC Page 9 of 15 3.8.1 Resistance to Interior Weathering (FLTM BO 116-01, ISO 105 A-02/AATCC Evaluation Procedure 1) The xenon arc panel size shall be approximately 6