1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2006 05 04 N-STATUS Replaced by WSS-M99P32-B; Ins 3.0; Del 3.1, 3.2 3.17 & 4 A. Reaume 1984 09 12 Released CAO1-PR526402 1982 09 08 Released CGMI-DR-500498 No.1 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page
2、 1 of 5 PADDING, COMPOSITE, POLYESTER SHEETING/ ESB-M17H151-A NEEDLED POLYESTER/POLYURETHANE FOAM, HEAT BONDING GRADE NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a trilaminate material consisting of a blow needled polyester fiber foundation pad, with polyuret
3、hane foam on one side and a polyester sheeting on the other side. The polyurethane foam is selectively die cut and stripped away to expose the pad, which is coated with a thermoplastic bonding resin in the areas to be bonded. 2. APPLICATION This specification was released originally for material use
4、d in side trim panels manufactured by a heat bonding method. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. In addition to the requirements listed herein, the finished assembly must also meet the engineering requirements of ESB-M15P4-B. The
5、 polyester sheeting and the polyurethane foam must meet all requirements of their respective specifications. Unless stated otherwise, specification requirements which follow shall be for the total composite, less the locally applied bonding resin. 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS M
6、aterial suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.3 APPEARANCE The padding may be colored by addition of a non-staining or non-bleeding pigmented dye for purpose of supplier identification. This dye shall not interfer
7、e with any of the other material requirements listed herein. 3.4 COMPOSITION Polyester Foundation Pad: Fiber 0.7 tex Polyester, 51 mm staple Pad Binder PVC Polyester Sheeting ESB-M9H92-A, ESB-M9H79-A, or other sheeting approved in this application by B&CE Textile Acoustic Engineering Polyurethane Fo
8、am: ESB-M4D113-C, Type III ENGINEERING MATERIAL SPECIFICATION ESB-M17H151-A Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 2 of 5 Bonding Resin: Thermoplastic Polyester Resin selectively applied to the polyester foundation pad in areas requiring bonding. Note: Bot
9、h the foundation pad binder and the bonding resin shall be compatible with the bonding grade cover materials and the approved bonding quality sub-foundation or foundation board employed. 3.5 CONSTRUCTION The fibers of the foundation pad shall be arranged in a random manner, and extend from the top s
10、urface to the bottom surface, so that delamination cannot occur at any plane within the thickness of the pad during handling and assembly operations. The polyester sheeting shall be heavily needled and resin bonded to one side of the foundation pad and shall be completely adhered to the foundation p
11、ad. The polyurethane foam shall be lightly needled to the other side of the foundation pad. The polyurethane foam is selectively die cut, stripped away and a thermoplastic resin is applied to the foundation pad in the stripped areas for heat bonding. 3.6 THICKNESS, +/- 10% (FLTM BN 014-02 (inactive
12、with no replacement named, except stack 3 pieces of material) Composite (total) 12 mm Foam 6 mm 3.7 WEIGHT 3.7.1 Foam, min 0.14 kg/m (FLTM BN 106-01) 3.7.2 Foundation Pad & Sheeting 0.31 - 0.37 kg/m (FLTM BN 106-01) 3.7.3 Foundation Pad Binder 4 - 6% of Foundation Pad and Sheeting Weight Test Method
13、 . Take three 100 x 100 mm samples of the foundation pad and sheeting, one from the center and one from each side, across the roll. . Finely chop samples using a blender or equivalent method. . Place samples in a large tarred weighing bottle. . Oven dry at 102 +/- 3 C until a constant weight is obta
14、ined. Record final sample weight as (W1). . Transfer sample to a beaker and add methyl isobutyl ketone (temperature 23 +/- 2 C). Use a minimum of 15 weights of solvent to one of padding. . Allow sample to stand for 24 h. Stir occasionally. ENGINEERING MATERIAL SPECIFICATION ESB-M17H151-A Printed cop
15、ies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 3 of 5 . Filter solution twice through a +/- 80 screen mesh filter or equivalent method. . Collect all the fibers and oven dry at 102 +/- 3 C to a constant weight. Record final weight as (W2). . % Binder = W1- W2x 100 - W13.8 BR
16、EAKING LOAD, min (ASTM D 1682, Grab Test Method, average of 5 tests in each direction) WMD and AMD 200 N 3.9 ELONGATION AT 15 LB (67 N) LOAD, max (ASTM D 1682, Grab Test Method - determine concurrently with para 3.8) WMD 10.0% AMD 15.0% 3.10 ADHESION* Sheeting to Foundation Pad The sheeting shall be
17、 heavily needled and adhesively bonded to the foundation pad so that a complete bond is achieved and no delamination of the sheeting will occur. In addition, the adhesion of the sheeting shall be greater than the internal strength of the foundation pad. Polyurethane Foam to Foundation Pad Shall be s
18、ufficient to prevent delamination during normal shipping, handling and manufacturing operations. *Note: In addition to the above requirements, the end user shall determine whether adhesion is adequate based upon satisfactory functional and production experience. 3.11 COMPRESSION AND RECOVERY (FLTM B
19、N 015-01, except use 283.5 g platen) Compression (Dry) 35 - 50% Recovery (Dry), min 80% Recovery (Wet), min 90%3.12 WICKING, max 76 mm (SAE J913, Solution A, check both sides of composite) 3.13 BONDED ASSEMBLY The criterion for material acceptability shall be the assemblys job performance. This mean
20、s that the materials composition and formulation must form a satisfactory bond when bonded to itself or to other approved components in the assembly under approved production conditions. ENGINEERING MATERIAL SPECIFICATION ESB-M17H151-A Printed copies are uncontrolled Copyright 2006, Ford Global Tech
21、nologies, LLC Page 4 of 5 3.13.1 Appearance After Bonding The ultimate use of this material is to provide a heat bonded door panel pleasing appearance and loft. For this reason, finished panels containing the padding must be visually interchangeable with finished panels containing the material upon
22、which approval was originally granted, other conditions being equal. In addition, component parts of the composite pad shall not cause a staining or whitening of the surface trim material after exposure to the heat bonding operation. 3.13.2 Resistance to Elevated Temperatures (FLTM BN 113-02) A bond
23、ed assembly or test sample prepared as in FLTM BN 113-01, shall show evidence of loosening or separation of the bonds or loss in loft after exposure 3.13.3 Objectionable Contaminants (FLTM AN 101-03) Shall be free from residual asphalt and other contaminants which might cause padding to trim cover m
24、aterial contact stains, bondline, or sewline stains. There shall be no evidence of staining. 3.13.4 Bond Strength, Cover Material to Padding, min (FLTM BN 113-01) Original 6.1 N Cycled 5.0 N Wet 5.0 N No bondlines shall fall below the values shown above when evaluated with a control piece of ESB-M1H
25、291-A, Radcliffe bodycloth, or other non-backcoated bodycloth mutually agreed upon by the supplier, end user, and B&CE Textile Acoustic Engineering. 3.13.5 Electrical Properties This material is to be used in a dielectric field for bonding door panels. It must, therefore, be an electrically clean pa
26、d, free of metal particles or other harmful impurities. In the dielectric or radio frequency field there is to be charring, arcing, or burning of the padding, due to impurities in it. Failure an average of 1/2 of one percent of the material to meet this requirement shall be cause for rejection. 3.13
27、.6 Lumpiness Shall contain no lumps, knots, neps or nits of either fiber or resin large enough to result in a lumpy or bumpy or otherwise unsightly appearance in the finished door panel. Such imperfections shall be cause for rejection of the materials. ENGINEERING MATERIAL SPECIFICATION ESB-M17H151-
28、A Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 5 of 5 3.14 FLAMMABILITY In order to comply with Federal Motor Vehicle Safety Standard No. 302, the material portions of components, and composites shall not burn or transmit a flame across its surface, at a rate of
29、 more than 101 mm per min. To demonstrate compliance, the sample size and method of testing shall be in accordance with FLTM BN 024-02. 3.15 FLAMMABILITY TEST PROGRAM Materials, portions of components, and composites governed by this specification must also comply with the requirements of ES-D3AB-11014-AA. 3.16 PLANT PROCESSING FLAMMABILITY (FLTM BN 024-01) Shall not support combustion after being exposed to a standard flame for 30 s at a distance of 25 mm from the tip of the needle.
