1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions 2007 07 31 Revised Inserted 3.0; Deleted 3.1, 3.11 & 4 1985 04 08 Released CSP1-CR528675 J.E. Greenup Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 1 of 4 TRIM ASSEMBLY, DOOR PANEL INSERT ASSEMBLY BONDED E
2、SB-M15P24-A 1. SCOPE This specification defines the minimum durability and performance requirements of door trim panel inserts, where various materials are combined to provide a multilayered assembly having decorative and/or functional features. 2. APPLICATION This specification was originally relea
3、sed for the 1985 Thunderbird/Cougar and 1986 Taurus door trim panel insert assemblies. 3. REQUIREMENTS All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5% relative humidity for 24 h prior to testing and tested under the same contr
4、olled conditions. Door trim panel insert assemblies shall also meet the requirements of ESB-M25P4-A, Flammability Requirements - Non-Metallic Materials for FMVSS 302. 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requir
5、ements For Production Materials (WSS-M99P1111-A). 3.2 APPEARANCE (FLTM BI 109-01) The color, pattern, and finish shall match the approved Design Center master sample, or shall be as specified on the engineering drawing. Production door panel inserts shall not exhibit any evidence of adhesive bleed t
6、hrough on any exposed surface or edge when installed in car position. Crushing or creasing of the material surface shall not be accepted. Any future interior trim applications of this multilayer laminate process must be approved by Design Center Appearance Surveillance personnel, as well as Body and
7、 Chassis Engineerings Trim Engineering and Materials and Corrosion Protection Engineering activities. 3.3 CONSTRUCTION AND COMPOSITION Adhesive bonded multilayered laminate assemblies shall consist of the following layers of materials: 1) An approved interior trim material, bodycloth, or vinyl coate
8、d fabric. 2) For vinyl materials, a layer of spunbonded polyester fabric saturated with polyurethane adhesive.* 3) Open-celled polyurethane foam (6.35 mm thick) saturated with polyurethane adhesive.* ENGINEERING MATERIAL SPECIFICATION ESB-M15P24-A Printed copies are uncontrolled Copyright 2007, Ford
9、 Global Technologies, LLC Page 2 of 4 4) Layer of spunbonded polyester fabric saturated with polyurethane adhesive.* 5) Steel substrate with zinc chromate and phosphate coatings applied. 6) Polyurethane foam layer that has been saturated with polyurethane adhesive. * *NOTE: Proprietary formulation p
10、olyurethane adhesive supplied by processor. 3.4 DIMENSIONAL STABILITY The trimmed assembly, during or after the test, shall exhibit no visible and objectionable appearance such as: Lifting of bonded edges Wrinkling Distortion Blistering Delamination Blushing, hazing, or milking of the decorative sur
11、face Expansion, shrinkage, or warpage, which will interfere with normal functional operations or cause objectionable and unsightly gaps. Test Method: Conduct with the trim assembly mounted on an actual or simulated production support foundation with the approved retention methods. The assembly shall
12、 be subjected to the following environmental cycle: 24 h at 95 - 100% R.H. and 38 2 C 24 h at 82 2 C in an air circulating oven 24 h at 95 - 100% R.H. and 38 2 C 24 h at 82 2 C in an air circulating oven 1 h conditioning at 23 2 C and 50 5% relative humidity 3.5 INDENTATION AND RECOVERY Shall show t
13、otal recovery. (FLTM BO 111-02, Method “B“) Minor visible wrinkles are permissible. 3.6 COLD IMPACT The assembly shall show no evidence of cracking or breaking and shall fully recover from indentation in the time required for the assembly to return to 23 2 C. ENGINEERING MATERIAL SPECIFICATION ESB-M
14、15P24-A Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 3 of 4 Test Method: Age the assembly or a section of the mounted assembly 24 h at 82 +/- 2 C, then condition for 5 h at -30 C. Remove from the cold box and immediately (within 10 s), drop the rubber ball from
15、a height of 610 mm on the assembly. The rubber ball shall weight 4.5 kg, be 127 mm in diameter, and 60 5 durometer. 3.7 COLOR AND APPEARANCE PROPERTIES 3.7.1 Fade (SAE J 1885, AATCC Evaluation Procedure 1) In Vehicle Sunlight AATCC Rating Exposure Level Test Exposure After Exposure Moderate exposure
16、 120 SFH(fade- 4 minimum upper trim panels, ometer) at 63 C and/or 12,500 Langleys* *Exposed under glass at 45 south in Florida. Test Method: The materials shall be exposed to dry fadeometer testing and shall be viewed for and rejected if any non-uniform staining or discoloration is noted. 3.7.2 Hea
17、t Aging The assembly shall exhibit no visible or objectionable wrinkles, distortion, blistering, delamination, edge lifting, blushing, haziness or expansion, shrinkage or warpage. In addition, the materials shall not exhibit any tackiness, loss of grain, or change in color more severe than a 4 ratin
18、g when evaluated after exposure per AATCC Evaluation Procedure 1. The assembly shall be rejected if adhesive, or other non-uniform staining or discoloration is noted. Test Method: Age the mounted assembly (actual or simulated) for 7 days at 83 2 C in an air circulating oven. 3.7.3 Coating Adhesion T
19、he tape shall not (FLTM BI 106-01, Part B) lift or delaminate the surface coating on assemblies having vinyl coated coverstock. 3.7.4 Crocking (FLTM BN 107-01, AATCC Evaluation Procedure 3) Minimum Rating Dry 4 Distilled Water Wet 4 Solvent (Naptha)* Wet 4 *(Solvent test only for vinyl materials, fi
20、ve crocking cycles required). ENGINEERING MATERIAL SPECIFICATION ESB-M15P24-A Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 4 of 4 3.7.5 Sunlamp Aging 4 minimum rating (FLTM BO 115-01, AATCC Evaluation Procedure 1) No non-uniform staining or discoloration is perm
21、itted. Test Method: Place a 100 x 100 mm sample in sunlamp cabinet for 200 h at 63 2 C. 3.8 ADHESION AND BONDING PROPERTIES 3.8.1 Bond Strength, min (FLTM BN 113-01) Around the perimeter Original 4.4 N of insert assembly Aged 3.3 N Water Immersed 3.3 N Test Method: Cut test samples 25 mm x 150 mm fr
22、om a production bonded insert assembly and test per FLTM BN 113-01. 3.8.2 Resistance to Heat Aging of Bonded Assemblies (FLTM BN 113-02) Place the bonded assembly in an oven, and examine and report any loosening or separation of the bonds or loss in loft 10 min. after each exposure. 3.8.3 Functional
23、 Acceptability of Bonded Assemblies The criterion for functional acceptability shall be the assemblys job performance. This means that the composition and formulation of all materials in the bonded assembly must permit a satisfactory bond under approved production conditions. All shipments of compon
24、ent assembly materials (cover materials, foam, adhesive, etc.) shall be equal in bonding properties to the original material approved for production by the fabricator. Samples of original approved materials shall be retained for reference purposed by the fabricator. Evaluation of functional acceptab
25、ility shall be performed with materials stored under production conditions. 3.9 FLAMMABILITY In order to comply with Federal Motor Vehicle Safety Standard No. 302, the materials, portions of components, and composites shall not burn or transmit a flame across its surface at a rate of more than 101 mm per minute. To demonstrate compliance, the sample size and method of testing shall be in accordance with FLTM BN 024-02 and meet the requirements of ESB-M25P4-A.
