1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2003 01 29 Revised Para 3.0 inserted ; Para 3.1, 3.26, 4 deleted 1978 11 22 Metricated, Renumbered & Retyped CAHI-RD572066-182 1964 05 15 Released ESB-M3E4-A DT1 #677 Printed copies are uncontrolled Page 1 o
2、f 6 Copyright 2002, Ford Global Technologies, Inc. FIBERBOARD (PANEL), LAMINATED - POLYETHYLENE LINED ESB-M3E4-A COATED ESB-M3E4-C 1. SCOPE The material defined by these specifications is a laminated, polyethylene interlined, kraft paper liner, panelboard (ESB-M2E4) that has a vinyl, pyroxylin or eq
3、uivalent surface appearance coating. 2. APPLICATION These specifications were released originally for material used for headlinings, door panels, and package tray applications. 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Stand
4、ard Requirements 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. 3.3 CONSTRUCTION Shall be constructed of a core of kraft and mixed fib
5、ers. The core shall be free of residual asphalt and other contaminators, which might cause sew line stains. Laminated to each side of the core shall be a continuous film of polyethylene to which is also laminated a kraft paper liner. The kraft paper liners shall form the outer faces of the base boar
6、d. The face side of the board shall be pyroxylin or vinyl coated. 3.4 DIMENSIONS (SAE J 315 b or ASTM D 645) As specified on engineering drawings and as noted in para 3.4.1 and 3.4.2. 3.4.1 Flat Panels Thickness variations of any one board shall not exceed +/- 5 % of the thickness specified on the e
7、ngineering drawings. ENGINEERING MATERIAL SPECIFICATION ESB-M3E4-A ESB-M3E4-C Page 2 of 6 Copyright 2002, Ford Global Technologies, Inc. 3.4.2 Formed Panels The thickness of the flat areas of formed panels shall be maintained within +/- 10% of the thickness specified on the engineering drawing. 3.5
8、BURSTING STRENGTH, min 4 psi/0.001 in (SAE J 315 b or ASTM D 774) (1.1 MPa/mm) of thickness 3.6 STIFFNESS (ASTM D 747, Tinius Olsen, direct load reading at 5 angle, 4 in/lb (0.45 J) load, 1 in (25 mm) span, 1 x 3 in (25 x 75 mm) sample) 0.100 in 0.080 in 0.060 in 0.040 in (2.54 mm) (2.03 mm) (1.52 m
9、m) (1.02 mm) WMD 45-55 35-45 25-35 15-25 AMD 25-35 20-30 15-25 10-20 3.7 DIMENSIONAL STABILITY (SAE J 315 a, Method “B“ & “C“) Expansion, % max Contraction, % max WMD +0.62 -0.62 AMD +0.62 -0.62 3.8 MOISTURE CONTENT, max 7 % (SAE J 315 B or ASTM D 644) 3.9 WATER ABSORPTION, max 20 % (SAE J 315 B or
10、SAE J 315, 24 h immersion) 3.10 WARP, max 4 % (FLTM BS 2-1, 24 h water immersion) 3.11 TENSILE STRENGTH, min (ASTM D 828) WMD 5.6 lb/0.001 in (100 kgf / mm) of thickness AMD 1.8 lb/0.001 in (32.2 kgf / mm) of thickness ENGINEERING MATERIAL SPECIFICATION ESB-M3E4-A ESB-M3E4-C Page 3 of 6 Copyright 20
11、02, Ford Global Technologies, Inc. 3.12 ADHESION, min 1 lb/in (FLTM BN 15-1) (175 N/mm) of width The polyethylene films and adhesives employed shall result in a firm bond between the plies to hold the assembly together during production handling, and for the normal life of the assembly, at the vario
12、us extreme temperatures and humidity conditions encountered under service operating conditions. 3.13 RESISTANCE TO WRINKLING OR BLISTERING After 10 complete cycles the coated facing lamination of the material shall show no discernible wrinkles, blisters, distortion, or separation. Test Method: Rest
13、a 10 x 10 in (250 x 250 mm) test specimen on its edge for 4 h, in a vertical position, in a humidity cabinet maintained at a temperature of 38 +/- 1 C and a relative humidity of 98 +/- 2 %. At the termination of the moisture exposure period, lay the test specimen on a horizontal plane, coated surfac
14、e up, and expose to the direct rays of the light source as described in FLTM BO 115-01 for 4 h at 63 +/- 3 C. Then expose at 23 +/- 2 C for 16 h with the test specimen in a horizontal position, coated side up. The 3 exposures detailed above constitute one cycle and shall be repeated 9 additional tim
15、es for a total of 10 complete exposure cycles. 3.14 FLEXIBILITY Material intended for headlinings or similar applications, where the parts will be subjected to a bend in the installation, shall show no evidence of cracking or breaking when tested as outlined below: Test Method: Cut three 3 x 12 in (
16、75 x 300 mm) samples from each direction of the test specimen. Bend each of the samples (painted side down) 90 around a 5 in (127 mm) diameter mandrel. 3.15 ABRASION, min 100 cycles (SAE J 315 b or FLTM BN 108-02, 250 g load, CS #10 wheels) The materials wear pattern and color shall be compatible in
17、 appearance with the adjacent unabraided area and shall be equal to or better than that exhibited by the master sample (as approved for production by the Textile Section, Body Materials Engineering Department) on file in the testing laboratories. 3.16 SCUFFING, min 10 cycles (SAE J 315 b or FLTM BN
18、108-04, “A“ head, 2 lb (907 g) load) The scuff pattern and color shall be compatible in appearance with the adjacent unscuffed area and shall be equal to or better than that exhibited by the master sample (as approved for production by the Textile Section, Body Materials Engineering Department) on f
19、ile in the testing laboratories. ENGINEERING MATERIAL SPECIFICATION ESB-M3E4-A ESB-M3E4-C Page 4 of 6 Copyright 2002, Ford Global Technologies, Inc. 3.17 FADE, min 120 SFH (SAE J 315 b or SAE J 1885) The coating shall not stain, exhibit color tone change, or change in hue in accordance with rating 5
20、 of the AATCC chart for measuring transference of color. Production materials shall exhibit light fastness qualities equal to or better than the master sample (as approved for production by the Textile Section, Body Materials Engineering Department) on file in the testing laboratories. 3.18 HEAT AGI
21、NG The coating shall show no more discoloration than the master sample (as approved for production by the Textile Section, Body Materials Engineering Department) on file in the testing laboratories after heat aging in a mechanical convection oven maintained at 82 +/- 3 C for 7 days. 3.19 MIGRATION S
22、TAINING (FLTM BN 103-01, except oven age 48 h) The coating shall not soften and/or stain when a section of the coated pressed wood panel board is placed in direct contact with the materials normally contacted in service. Production material shall exhibit no greater softening, staining and/or color t
23、ransfer than the master sample (as approved for production by the Textile Section, Body Materials Engineering Department) on file in the testing laboratories. 3.20 COATING QUALITY Shall be a good grade, containing enough oil and pigments to give a film of desired softness and color. However, the pla
24、sticizer content shall not be in excess to prevent spewing during the heat aging test in para 3.19. Vinyl, pyroxylin or equivalent coatings may be used which exhibit properties equal to that used on the master sample (as approved for production by the Textile Section, Body Materials Engineering Depa
25、rtment) on file in the testing laboratories. 3.21 OBJECTIONABLE CONTAMINANTS (FLTM AN 101-03, Method “A“) No asphalt or other resins present, that will cause staining of the contact fabric. 3.22 FORMING Material specified for press formed parts (package trays or similar formed applications) made fro
26、m this type of fiberboard may be modified with special thermoplastic resins on the surfaces to provide contours without internal delamination and objectionable wrinkling or cracking of the surface. Since thickness, fabrication techniques, and design shapes will vary, formed painted parts must be sub
27、mitted to Body Engineering for approval prior to production. The formed parts shall meet the following requirements: ENGINEERING MATERIAL SPECIFICATION ESB-M3E4-A ESB-M3E4-C Page 5 of 6 Copyright 2002, Ford Global Technologies, Inc. 3.22.1 Transverse Strength, min (FLTM BS 5-1, 6 in (152 mm) span) W
28、MD 0.11 lb/0.001 in (19.3 N/mm) of thickness AMD 0.06 lb/0.001 in (10.5 N/mm) of thickness 3.22.2 Stiffness After Forming, min (ASTM D 747, Tinius Olsen, direct load reading at 5 angle, 4 in.lb (0.45 J) load, 1 in (25 mm) span, 1 x 3 in (25 x 75 mm) sample) 0.100 in (2.54 mm) WMD 60 A 353.22.3 Bend
29、Test (FLTM BS 4-3) No breakage, and/or delamination of the board, or cracking and flaking of the painted surface on bending. For critical applications bend force and displacement values as specified on engineering drawings must be adhered to. 3.22.4 Humidity Aging No delamination between material la
30、yers and no ply separation after being immersed 24 h in water (room temperature) followed by 7 days aging in a humidity cabinet at 100 % R.H. and 38 C. 3.23 WEIGHT OF COATING In order to meet the physical requirements outlined in this specification, the desired coating weight shall be 1 oz/yd2(34 g/
31、m2). Test Method: Weigh 3 conditioned 4 x 4 in (100 x 100 mm) die cut test specimens. Thoroughly saturate the coated surface with ethyl acetate. Wipe off the coating with saturated cotton swabs until all coating is removed. Allow the test specimen to dry and recondition at 23 +/- 2 C for 24 h. Rewei
32、gh specimens and compute the average weight of the coating on a square yard (square meter) basis. ENGINEERING MATERIAL SPECIFICATION ESB-M3E4-A ESB-M3E4-C Page 6 of 6 Copyright 2002, Ford Global Technologies, Inc. 3.24 ESB-M3E4-A FLAMMABILITY max 4 in (101 mm)/min (FLM BN 24-2, Without the Lot Sampl
33、ing Plan) In addition, the test specimen shall not exhibit any flashing or sudden flaming on either surface in excess of the above max value. 3.25 ESB-M3E4-C FLAMMABILITY 3.25.1 In order to comply with Federal Motor Vehicle Safety Standard No. 302, the materials, portions of components, and composit
34、es shall not burn, or transmit a flame across its surface, at a rate of more than 4 in (101 mm) per min. To demonstrate compliance, the sample size and method of testing shall be in accordance with FLTM BN 24-2. 3.25.2 Performance - Environmental Aging All materials, portions of components, and comp
35、osites defined by this specification that have not been treated, modified or reformulated and exceed a max burn rate of 3.0 in (76 mm) per min as specified by the Flammability Lot Sampling Plan of FLTM BN 24-2, must be evaluated for permanency of the materials flame retardant properties per ESB-M25P
36、3-A according to the accelerated environmental aging requirements applicable to the basic material category of this particular specification. Any material, portions of components, and composites defined by this specification that have been treated, modified or reformulated to conform to Flammability
37、 Lot Sampling Plan of FLTM BN 24-2, regardless of max 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 applicable to the basic materials category of this particular specification. 3.25.3 Flammability Test Program Materials, portions of components, and composites governed by this specification must also comply with the requirements of ES-D3AB-11014-AA.
