1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions 2006 10 13 N-STATUS Replaced by WSB-M2D402-A3 2004 07 19 Revised Para 3.0 inserted; para 3.13, 3.15 & 4 deleted 1984 08 29 Released DP1-915 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 1 of 4 POLYURETHANE
2、 FOAM, HIGH LOAD BEARING - 42 kg/m3 ESB-M2D221-D NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a molded high load bearing, resilient polyether urethane foam. 2. APPLICATION This specification was released originally for material used in 1986 seat cushions and b
3、acks when a higher load bearing foam is required. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Materials suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.1 CONDITIONING All test specimens shall be prefl
4、exed 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 tested under same conditions. The post cure time shall commence from time of demolding part
5、. 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 plant, then the test specimens (or part) need only to be preflexed twice (80 - 90%) as abov
6、e, then conditioned 1 h at above temperature and relative humidity prior to testing. 3.2 DENSITY, Core, min (Cushions Only) 42 kg/m3 (ASTM D 2406, Suffix “W“, sample size 75 x 75 x 75 mm, cut 7 mm below the top molded surface of the sample or part.) Condition sample for 1 h prior to evaluation. No 7
7、 day post cure required. The reported value shall be the average value based on a 5 part evaluation. 3.3 MATERIAL 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 s
8、pots and densification lines: Such test specimens shall be cut from a plane whose top surface is approximately 7 mm below the top molded surface of the sample or part. 3.3.1 Tensile Strength, min 172 kPa (ASTM D 1564, Suffix “T“) ENGINEERING MATERIAL SPECIFICATION ESB-M2D221-D Printed copies are unc
9、ontrolled Copyright 2006, Ford Global Technologies, LLC Page 2 of 4 3.3.2 Heat Aged Tensile Strength, min 90% of original (ASTM D 1564, Suffix “A“) 3.3.3 Elongation, min 80% (ASTM D 1564, Suffix “T“) 3.3.4 Tear Resistance, min 210 N/m (ASTM D 1564, Suffix “G“) 3.3.5 Compression Set, normal, max (FLT
10、M BN 115-07) Cushions 14% Backs 25% The reported value shall be the average value based on a 5 part evaluation (15 specimens). Test Method: 75% constant deflection, shall be computed on the original deflection. All set values are obtained on specimens defined by para. 3.1 and 3.3 and the 25 mm dimen
11、sion of the test specimen shall be obtained perpendicular to the part top molded surface. Computed deflection shall be controlled to +/- 0.05 mm. 3.3.6 Compression Set, autoclave aged, max (FLTM BN 115-07) Cushions 20% Backs 30% The reported value shall be the average value based on a 5 part evaluat
12、ion (15 specimens) Test Method: Determine normal compression set on similar test specimens that were steam autoclave aged (as defined in FLTM BO 012-01) for 3 h at 19.3 +/- 10.3 kPa and/or 104 +/- 3 C, then dried 3 h at 104 +/- 3 C in a convection oven, followed by 1 h conditioning at 23 +/- 2 C and
13、 50 +/- 5% relative humidity. 3.4 ASSEMBLY REQUIREMENTS Seat Cushions Parts submitted to BEPE for source approval evaluation under this specification, or submitted at the request of the Materials and Corrosion Protection Engineering Department, must exhibit a 222 N IRGL value that is 73 +/- 5% of th
14、e 4.4 N IRGL, or as specified on the engineering drawing. Seat Backs Parts must exhibit a 222 N force deflection value of 55 +/- 3% of the 4.4 N force deflection value, or as specified on the engineering drawing. 3.4.1 Load Indentation - Values and test location as IRGL Value specified on the engine
15、ering drawing. (SAE J 815, steps 1-4 only) Parts tested with, and on top molded surface. ENGINEERING MATERIAL SPECIFICATION ESB-M2D221-D Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 3 of 4 3.4.2 Load Indentation Test areas (e.g., bolster and insert areas) (FLTM
16、BN 15-6) and test values shall be as specified on the engineering drawing. 3.5 AGED LOAD LOSS, max 35% (Required for seat cushions only) Report the average of 5 parts (ASTM D 3574 - Test B1) IFD to 65% deflection at 0.85 mm/s. The complete part shall be tested whenever possible (without support wire
17、s), otherwise a 250 mm by 250 mm by full part thickness (including top and bottom molded surfaces) shall be tested. Determine the initial and aged 65% IFD values. Age the part for 3 h in a steam autoclave maintained at 121 C, followed by 4 h drying at 104 C. Condition at 23 +/- 2 C and 50 +/- 5% RH
18、for 1 h, then determine the aged 65% IFD value per ASTM D 3574-B1. Calculate the % aged load loss as follows: L1 - L2 Aged load loss = - x 100 L1 L1 = initial 65% IFD value L2 = aged 65% IFD value 3.6 AGED FLEXIBILITY No splitting or crumbling Test Method: A specimen 50 x 150 x 25 mm shall be subjec
19、ted to autoclave aging for 5 h at 121 C, followed by 1 h drying at 104 C and subsequently bent 180 around a 6 mm diameter mandrel. 3.7 FATIGUE RESISTANCE (Seat Cushions Only) 14% Height loss, max at 222 N after 20,000 cycles (FLTM BO 12-4, 375 x 300 x 64 mm (minimum thickness) sample with molded top
20、 surface.) Report the average of 3 parts. (Use 267 N shear load roller assembly and preflex sample twice both prior to and after testing.) Excessive surface foam deterioration or splitting apparent after 20,000 cycles shall be cause for rejection. 3.8 ODOR No offensive odor before or after steam aut
21、oclave aging. 3.9 STAINING None Test Method: Typical light colored ESB-M2F126 seating vinyl trim material shall be placed in intimate contact over (100 x 100 mm) specimens of the foam. Expose the assembly for 7 days at 82 +/- 2 C in a convection oven. 3.10 SOLVENT RESISTANCE No evidence of foam dete
22、rioration ENGINEERING MATERIAL SPECIFICATION ESB-M2D221-D Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 4 of 4 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, p
23、etroleum naphthol spirits . ESF-M8B12-A, denaturated alcohol 3.11 CELL STRUCTURE, 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.
24、 3.12 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 4 in (101 mm) per minute. To demonstrate compliance, the sample size and meth
25、od of testing shall be in accordance with FLTM BN 024-02. Substance restrictions imposed by law, regulations or Ford apply to the materials addressed by this document. The restrictions are defined in Engineering Material Specification WSS-M99P9999-A1, unless a different suffix (e.g., A2 or A3) is sp
26、ecified on the engineering document for the application. 3.14 PARTS REQUIRED FOR B&CE APPROVAL The following is required by the Materials & Corrosion Protection Engineering Department for source approval evaluation. . Ten production representative seat cushions or backs. . Ten molded 375 x 375 x 76
27、mm test blocks, molded to the same density and thickness as the parts. . Complete test data to the specification including load indentation test data on 10 molded parts as specified on the engineering drawing. . A Material Compliance Sheet, form 1464, filled out by the appropriate Ford Purchasing activity.
