1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions 2006 10 13 N-STATUS Replaced by WSB-M2D402-A3 2004 07 14 Revised Para 3.0 inserted; para 3.18 the “B“ suffix for materials used in 1980 vehicles and the “C“ suffix for materials used in the 1982 Escort/Lynx carlines as support padding for sea
2、t cushions and backs. The two basic types of applications for high resilience polyurethane foam are: Type I Used as the support padding for bench and bucket seat cushion constructions and when border or support wires are contained integrally within the foam. Type II Used as the support padding for b
3、ench and bucket seat constructions when a lower load bearing foam is desired, and die cut parts for door panel and vacuum shaped seat inserts. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements F
4、or Production Materials (WSS-M99P1111-A). 3.1 CONDITIONING All test specimens shall be preflexed twice to 80 - 90% of their thickness (unless otherwise noted), then conditioned (post cured) at 23 +/- 2 C and 50 +/- 5% relative humidity for 7 days minimum prior to testing (unless otherwise noted) and
5、 tested under same conditions. The post cure time shall commence from time of demolding part. When test specimens are submitted to Ford Motor Company for evaluation and if the test specimens (or parts from which test specimens will be obtained) have previously been post cured 7 days at the suppliers
6、 plant, then the test specimens (or part) need only to be preflexed twice (80 - 90%) as above, then conditioned 2 h at above temperature and relative humidity prior to testing. 3.2 DENSITY, Core, kg/m3 (ASTM D 2406, Suffix “W“, sample size 75 x 75 x 75 mm, 7 mm below the top molded surface of the sa
7、mple part) ENGINEERING MATERIAL SPECIFICATION ESB-M2D221-A/B/C Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 2 of 6 Condition sample for 2 h prior to evaluation. No 7 day post cure required. A B C Type I 38 min 34 min 27 - 43 Type II 27 min 27 min 27 - 43 3.3 MAT
8、ERIAL AND TEST SPECIMEN For all foam samples, the following material properties shall be determined on specimens that are free of the top molded surface (unless otherwise noted) voids, hard spots and densification lines. Such test specimens shall be cut from a plane whose top surface is approximatel
9、y 7 mm below the top molded surface of the sample or part. A B C 3.3.1 Tensile Strength, kPa, min 103 83 83 (ASTM D 1564, Suffix “T“) 3.3.2 Heat Aged Tensile Strength, 75 75 75 % of Original, min (ASTM D 1564, Suffix “A“) 3.3.3 Elongation, % min 150 150 120 (ASTM D 1564, Suffix “T“) 3.3.4 Tear Resis
10、tance, N/m, min (ASTM D 1564, Suffix “G“) Type I 263 263 210 Type II 210 210 210 3.3.5 Compression Set, normal, 20 20 20 % max (FLTM BN 115-07, all thicknesses) Test Method: 75% constant deflection, shall be computed on original deflection. All set values are obtained on specimens defined by para. 3
11、.1 and 3.3 and the 25 mm dimension of the test specimen shall be obtained perpendicular to the part top molded surface. For parts less than 25 mm thick, two 12.7 mm thick specimens may be plied up to 25 mm thickness with 12.7 mm dimension cut as above. Computed deflection shall be controlled to +/-
12、0.05 mm. 3.3.6 Compression Set, Steam 30 30 30 Autoclave Aged, % max (FLTM BN 115-07, all thicknesses) Test Method: Determine normal compression set on similar test specimens that were steam autoclave aged (as defined in FLTM BO 12-1) for 3 h at 19 +/- 10 kPa and/or 104 +/- 5 C, then dried 3 h at 10
13、4 +/- 3 C in a convection oven, followed by 2 h conditioning at 23 +/- 2 C and 50 +/- 5% relative humidity. ENGINEERING MATERIAL SPECIFICATION ESB-M2D221-A/B/C Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 3 of 6 3.4 ASSEMBLY Cushions Parts or specimens submitted
14、 to BEPE for source approval evaluation under this specification, or submitted at the request of the Body Materials and Corrosion Protection Engineering Department must exhibit a 222 N IRGL value that is 50 +/- 8% of the 4.4 N IRGL, or as specified on the engineering drawing. Seat Backs Only Parts o
15、r specimens must exhibit 222 N IRGL of 42 +/- 8% of the 4.4 N IRGL, or as specified on engineering drawing. 3.4.1 Load Indentation (SAE J815, steps 1 - 4 only) Parts tested with, and on top molded surface. Values and test location as specified on the engineering drawing. 3.4.2 Load Indentation (FLTM
16、 BN 15-6) Parts tested with, and on top molded surface. Compressing test areas (e.g., bolster and insert areas) and test values shall be as specified on the engineering drawing. 3.5 RESISTANCE TO DETERIORATION 3.5.1 Loaded Height Change, % change from original A B C +/-10 +/-10 +20 -10 Test Method:
17、Cut out a test specimen measuring 150 x 150 x 50 mm with top molded surface. Measure the 111 N and 222 N loaded height (IRGL) according to SAE J 815. Age the specimen for 3 h at 19 +/- 10 kPa and/or 104 +/- 5 C in the steam autoclave, followed by drying in the oven at 70 C for 3 h. After conditionin
18、g for 2 h at 23 +/- 2 C and 50 +/- 5% relative humidity, redetermine the 111 N and 222 N height as above. Calculate and report the percent height change. H2 - H1 % HT Change =- x 100 H1 H1 = Original Height at 111 N or 222 N H2 = Autoclave Exposed Sample Height at 111 N or 222 N 3.5.2 Compression Lo
19、ad Deflection Change, +/- 20% from max original (Using 323 cm2 area compression plate, speed of deflection 50 mm/min) ENGINEERING MATERIAL SPECIFICATION ESB-M2D221-A/B/C Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 4 of 6 Test Method: Cut out a test specimen mea
20、suring 150 x 150 x 50 mm with top molded surface. Determine the thickness of the specimen under 4.4 N preload, then the compression load in N at 50% deflection. Age the specimen for 3 h at 19 +/- 10 kPa and/or 104 +/- 5 C in the steam autoclave, followed by drying in the oven at 70 C for 3 h. After
21、conditioning for 2 h at 23 +/- 2 C and 50 +/- 5% relative humidity, redetermine the compression load in N at 50% deflection. Compute the percent change in compression load. L2 - L1 % Change in 50% Compression Load = - x 100 L1 L1 = Original 50% Load L2 = Aged 50% Load 3.5.3 Flexibility No cracking o
22、r crumbling Test Method: A specimen 50 x 150 x 25 mm shall be subjected to autoclave aging outlined under FLTM BO 12-1 and subsequently bent 180 around a 6.4 mm diameter mandrel. 3.6 LOW TEMPERATURE LOAD COMPRESSION (ASTM D 1564, Suffix “D“, test specimen size is 150 x 150 x 50 mm, speed of deflecti
23、on 50 mm/min) Maximum Change From Original 50% Test Method: At room temperature, determine the initial thickness of the specimen under 4.4 N preload, then the compression load at 25% deflection. Condition the specimen for 2 h at -34 C. Remove from the cold chamber and within 2 min obtain the load ag
24、ain at 25% deflection. Compute the change in compression load. E - D x 100 C = - D C = % Change in Compression Load D = Compression Load at Room Temperature E = Compression Load After -34 C Exposure 3.7 FATIGUE RESISTANCE (FLTM BO 12-4, 375 x 300 mm x 50 mm thick (maximum) sample with molded top sur
25、face.) Loaded height loss requirements at 222 N as follows: Cushions (267 N shear load roller assembly) Height Loss, max 20% Seat Backs (133 N shear load roller assembly) Only Height Loss, max 20% Excessive surface foam deterioration apparent after 20,000 cycles shall be cause for rejection. ENGINEE
26、RING MATERIAL SPECIFICATION ESB-M2D221-A/B/C Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 5 of 6 3.8 ODOR No offensive odor before or after deterioration test (para. 3.5.1). 3.9 STAINING None Test Method: Typical white ESB-M2F76 supported vinyl trim material sha
27、ll be placed in intimate contact over 100 x 100 mm specimens of the foam. Expose the assembly under the fluorescent sunlamps as described in FLTM BO 115-01 for 150 h at 63 +/- 3 C. 3.10 FOGGING (SAE J 1756) Light Transmission, min 95 3.11 SOLVENT RESISTANCE No tackiness or evidence of foam deteriora
28、tion Test Method: Immerse specimens of the foam in the following approved fabric and upholstery cleaners for a period of 1 h each at 23 +/- 2 C. . M14J503, petroleum naphthol spirits . ESF-M8B12-A, denaturated alcohol . 50% soap solution (ESB-M1B9-A or 2% solution “Lux“ liquid) and water 3.12 CELL S
29、TRUCTURE, PHYSICAL CHARACTERISTICS AND ALLOWABLE DEFECTS The molded foam pads shall meet the requirements for allowable defects as outlined in the engineering specification for seating pads as defined on the engineering drawing. 3.13 FLAMMABILITY In order to comply with Federal Motor Vehicle Safety
30、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. 3.14 PERFORMANCE - EN
31、VIRONMENTAL AGING All materials, portions of components, and composites defined by this specification that have not been treated, modified or reformulated and exceed a maximum burn rate of 76 mm per minute as specified by the Flammability Lot Sampling Plan for FLTM BN 024-02, must be evaluated for p
32、ermanency of the materials flame retardant properties per ESB-M25P3-A according to the accelerated environ-mental aging requirements applicable to the basic material category of this particular specification. Any material, portions of components, and composites defined by this specification that hav
33、e been treated, modified or reformulated to conform to Flammability Lot Sampling Plan of FLTM BN 024-02, regardless of maximum burn rate, must be evaluated for both permanency of materials flame retardant properties and changes in mechanical, chemical and physical properties per ESB-M25P3-A applicab
34、le to the basic materials category of this particular specification. ENGINEERING MATERIAL SPECIFICATION ESB-M2D221-A/B/C Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 6 of 6 3.15 FLAMMABILITY TEST PROGRAM Materials, portions of component, and composites governed
35、by this specification must also comply with the requirements of ES-D3AB-11014-AA. 3.16 AIR PERMEABILITY min 1.5 x 10-2m3/m2s (ASTM D 737, 12.5 mm H20, (125 Pa) Pressure Drop, with modification as follows:) Cut one test specimen 150 x 150 x 25 mm, including the molded top uncut surface. The specimen
36、location shall be from the center of the IRGL circle or as specified on the engineering drawing. Condition the test specimen for 30 min at 23 +/- 2 C and 50 +/- 5% relative humidity prior to testing. Mount the test specimen (with the molded top surface facing down) on the Frazier permeability instru
37、ment without the use of the beveled ring. Adjust the inclined manometer (pressure drop across foam sample) to 12.5 mm of H2O (125 Pa) pressure before recording the height on the vertical manometer. Report the air flow in m3/m2s using the calibration chart supplied with the instrument. 3.17 BALL REBO
38、UND, Height, min, mm A B C 305 203 203 Test Method: Test specimen shall be 375 x 375 x 100 mm and shall include the top molded surface. Ball shall be 50 mm in diameter, case hardened steel (RC 58-68) and shall weigh 535 +/- 5 g. Drop height to top surface of specimen shall be 1270 mm. Rebound height
39、 shall be visually determined by means of a suitable scale located adjacent to the test specimen. Test results shall be the average of 5 drops, with each drop contacting a different area on the surface during the test. Rebound height shall be measured by viewing bottom edge of ball (avoiding paralla
40、x). 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of these specifications. 5.1 The following is required by the Body Materials and Corrosion Engineering Department for source approval evaluation. . Two current Ford seat cushions or backs. . Two 375 x 375 x 101 mm test blocks. . A BAE 7183 flammability certification. . Complete test data to the specification, including load deflection test data on molded parts. . A Material Compliance Sheet, form 1464, filled out by the appropriate Ford Purchasing activity.
