1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions 2006 10 20 N-STATUS Replaced by WSB-M2D402-A3; Inserted 3.0; Deleted 3.12, 3.15 & 4 1979 10 16 Revised Revised 3.2.1 BO-A-3422/CAJI-D2-5817521 1971 10 01 Released ESB-M4D113-C Printed copies are uncontrolled Copyright 2006, Ford Global Techno
2、logies, LLC Page 1 of 6 POLYURETHANE FOAM, FLEXIBLE SLAB AND MOLDED ESB-M4D113-C NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a flexible slab or molded polyether urethane foam. 2. APPLICATION This specification was released originally for the following materia
3、ls: Type I Seat cushions: Molded and slab foam normally 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 Seat backs: Molded and slab foam normally used as the support padding for bench and b
4、ucket seat back constructions when a lower load bearing foam is desired and where support wires are not integrally contained within the foam. Type III Inserts: Slab foam normally used in the construction of fales sewn pleated seat inserts, vacuum shaped seat inserts and side trim panels. 3. REQUIREM
5、ENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material 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 preflexed twice, to 80-90% of their thickness (unless otherwise not
6、ed) then conditioned at 23 + 2 C and 50 + 5% relative humidity for 7 days* minimum prior to testing. *From time of demolding molded part or from time of slab bun cure. 3.2 MATERIAL AND TEST SPECIMEN PROPERTIES For all foam samples, the following material properties shall be determined on specimens t
7、hat are free of skin (unless otherwise noted), voids, hard spots and densification lines. Test specimens shall be cut from a plane whose top surface is approximately 1/4 in (6.4 mm) below the top skin surface of the sample or part, except Type III ENGINEERING MATERIAL SPECIFICATION ESB-M4D113-C Prin
8、ted copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 2 of 6 Type I Type II Type III (Core) (Core) (Section) Cushions Backs Inserts 3.2.1 DENSITY, lbs/ft3 1.5 (24) 1.5 (24) 1.4 (22) (kg/m3), min (ASTM D 3574, Sample Size 3 x 3 x 3 in (75 x 75 x 75 mm) Condition sample for 24
9、 h prior to evaluation. No 7 day post cure required. 3.2.2 Tensile Strength, 12 (83) 12 (83) 12 (83) psi (kPa), min (ASTM D 1564, Suffix “T“) 3.2.3 Heat Aged Tensile Strength 75 75 75 % of original, min (ASTM D 1564, Suffix “A“) 3.2.4 Elongation, % min 170 150 170 (ASTM D 1564, Suffix “T“) 3.2.5 Tea
10、r Resistance, 2.0 (350) 1.7 (300) 1.7 (300) lb/in (N/m), min (ASTM D 1564, Suffix “G“) 3.2.6 Compression Set (Normal)*, max Type I For parts under 2 in (50 mm) thick 30% For parts 2 in (50 mm) thick & over 25% Type II For parts under 2.5 in (63 mm) thick 30% For parts 2.5 in (63 mm) thick & over 25%
11、 Type III 15% 3.2.7 Compression Set (Steam Autoclave Aged)*, max Type I For parts under 2 in (50 mm) thick 35% For parts 2 in (50 mm) thick & over 30% Type II For parts under 2.5 in (63 mm) thick 35% For parts 2.5 in (63 mm) thick & over 30% Type III 20% Note: Part thickness measurement shall be tak
12、en at center of Indentation Residual Gage Load (IRGL) circle. *Normal Test Method: ASTM D 1564, Method “B“, 75% constant deflection, shall be computed on original deflection. All set values are obtained on specimens defined by para. 3.1 and 3.2 and 1 in (25 mm) dimension of the test specimen shall b
13、e obtained perpendicular to the part surface. For parts less than 1 in (25 mm) thick, two 1/2 in (13 mm) thick specimens may be plied up to 1 in (25 mm) thickness with 1/2 in (13 mm) dimension cut as above. Computed deflection shall be controlled to + 0.002 in (0.05 mm). ENGINEERING MATERIAL SPECIFI
14、CATION ESB-M4D113-C Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 3 of 6 * Steam Autoclave Aged 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 2.8 + 1.5 psi (19 + 1
15、0 kPa) and/or 104 + 5 C, then dried 3 h at 70 + 1 C om a convection oven, followed by 24 h conditioning at 23 + 2 C and 50 + 5% relative humidity. 3.3 ASSEMBLY Type I Parts or specimens submitted to BEO for source approval evaluation under this specification, or submitted at the request of the Body
16、Materials Engineering Department must exhibit a 50 lb (222 N) IRGL value that is 50 + 5% of the 1 lb (4.4 N) IRGL, or as specified on the engineering drawing. Type II Parts or specimens must exhibit 50 lb (222 N) IRGL of 42 + 8% of the 1 lb (4.4 N) IRGL, or as specified on the engineering drawing. 3
17、.3.1 Load Indentation Type I & II (SAE J 815, steps 1-4 only, molded parts tested with top skin, one side) Values as specified on the engineering drawing. 3.3.2 Compressed Slab Foam Load Indentation Type III (When used as pleat filler in fales sewn seat inserts, the compressed foam shall meet the fo
18、llowing 50 lb (222 N) IRGL values. Original Thickness Under 1 lb (4.4 N) Preload +0.9, -0.01 in (+2.3, -0.3 mm) 50 lb (222 N) IRGL* 0.250 in (6.35 mm) 0.06 - 0.16 in (1.5 - 4.1 mm) 0.375 in (9.53 mm) 0.10 - 0.20 in (2.5 - 5.1 mm) 0.500 in (12.7 mm) 0.14 - 0.24 in (3.6 - 6.1 mm) 0.625 in (15.88 mm) 0
19、.18 - 0.28 in (4.6 - 7.1 mm) 0.750 in (19.05 mm) 0.20 - 0.30 in (5.1 - 7.6 mm) 1.00 in (25.4 mm) 0.30 - 0.40 in (7.6 - 10.2 mm) 1.25 in (31.75 mm) 0.40 - 0.50 in (10.2 - 12.7 mm) * Test Method: SAE J 815, steps 2 & 4 only, with no preflexing and with the 50 lb (222 N) IRGL values obtained within 5 s
20、 of load application. 3.4 RESISTANCE TO DETERIORATION 3.4.1 Load Indentation, change from original, max 15% Test Method: Cut a test specimen 6 x 6 x 2 in (150 x 150 x 50 mm). Measure the 25 lb (111 N) and 50 lb (222 N) height according to SAE J 815. Expose sample 3 h in humidity cabinet, remove and
21、condition per FLTM BO 012-01. Determine heights at 25 lb (111 N) and 50 lb (222 N) after humidity exposure. Calculate and report the percent height change. ENGINEERING MATERIAL SPECIFICATION ESB-M4D113-C Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 4 of 6 % Ht c
22、hange = H1 - H2 - H1 H1 = Original height at 25 lb (111 N) or 50 lb (222 N). H2 = Humidity exposed sample height at 25 lb (111 N) or 50 lb (222 N). 3.4.2 Flexibility No cracking or crumbling Test Method: A specimen 2 x 6 x 1 in (50 x 150 x 25 mm) shall be subjected to humidity aging (FLTM BO 012-01)
23、 and subsequently bent 180 around a 1/4 in (6.4 mm) diameter mandrel. 3.5 LOW TEMPERATURE LOAD COMPRESSION, 65% change from original load compression, max (ASTM D 1564, Suffix “D“, test specimen 6 x 6 x 2 in (150 x 150 x 50 mm) Test Method: At room temperature, determine the initial thickness of the
24、 specimen under 1 lb (4.4 N) preload, the compression load at 25% deflection. Condition the specimen for 5 h at -34 C. Remove from the cold chamber and within 2 min obtain the load value at 25% deflection. Compute the change in compression load. C = E - D x 100 - D C = % change in compression load D
25、 = Compression load at room temperature E = Compression load after -34 C exposure 3.6 FATIGUE RESISTANCE (FLTM BO 012-04, 15 x 12 (375 x 300 mm) x 2 in (50 mm) max thickness sample with skin on top surface) Loaded Height Loss Requirements at 50 lb (222 N), max Type I (60 lb (267 N) shear load roller
26、 assembly) 35% Type II & III (30 lb (133 N) shear load roller assembly) 25% 3.7 ODOR The foam shall exhibit no offensive odor after deterioration test of para. 3.4.1. 3.8 STAINING None Test Method: Typical white ESB-M2F76 supported vinyl trim material shall be placed in intimate contact over 4 x 4 i
27、n (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. ENGINEERING MATERIAL SPECIFICATION ESB-M4D113-C Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 5 of 6 3.9 FOGGING (SAE
28、J 1756) Light transmission, min 95 3.10 SOLVENT RESISTANCE No surface tackiness or evidence of foam deterioration. Test Method: Immerse specimens of the foam in the following approved fabric and upholstery cleaners: . M-14J503 petroleum naphthol spirit . ESF-M8PB12-A denatured alcohol . 50% soap sol
29、ution, ESB-M1B9-A and tap water for a period of 1 h each at 23 + 2 C. 3.11 CELL STRUCTURE, PHYSICAL CHARACTERISTICS AND ALLOWABLE DEFECTS The slab and molded foam pads shall meet the requirements for allowable defects as outlined in the engineering specification for seating pads (ES-D2AB-6564850-AA)
30、 as defined on the engineering drawing. 3.13 ESB-M4D113-C FLAMMABILITY 3.13.1 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
31、minute. To demonstrate compliance, the sample size and method of testing shall be in accordance with FLTM BN 024-02. 3.13.2 Performance - Environmental Aging Requirement All materials, portions of components, and composites defined by this specification that have not been treated, modified or reform
32、ulated and exceed a maximum burn rate of 3.0 in (76 mm) per minute as specified by the Flammability Lot Sampling Plan of FLTM BN 024-02, must be evaluated for permanency of the materials flame retardant properties per ESB-M25P3-A according to the accelerated environmental aging requirements applicab
33、le 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 Lot Sampling Plan of FLTM BN 024-02, regardless of maximum burn rate, mus
34、t 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. 3.13.3 Flammability Test Program Materials, portions of components, and
35、composites governed by this specification must also comply with the requirements of ES-D3AB-11014-AA. ENGINEERING MATERIAL SPECIFICATION ESB-M4D113-C Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 6 of 6 3.14 ASH CONTENT, max 5.0% (ASTM D 586) A conditioned core s
36、ample of 1 + 0.2 g shall be taken and ignited in a constant weight crucible per ASTM D 586. The foam may be ignited and burned, outside the muffle furnace, prior to ashing for 1 h at 925 + 25 C. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meetin
37、g the requirements of this specification. 5.1 Dimensions of the test specimens required by the Body Materials Engineering Department for source approval evaluation: Type I & II Molded Type III 15 x 15 x 1/2 in (380 x 380 x 13 mm) 1 pc. no skin 1 pc. no skin 15 x 15 x 1 in (380 x 380 x 25 mm) 1 pc. n
38、o skin 1 pc. no skin 15 x 15 x 4 in (380 x 380 x 100 mm) 1 pc. top skin one side 1 pc. no skin 15 x 15 x 2 in (380 x 380 x 50 mm) 2 pcs. top skin one side 2 pcs. no skin 15 x 15 x 2 in (380 x 380 x 50 mm) 2 pcs. no skin - 15 x 15 x 2-1/2 in(380 x 380 x 63 mm) 2 pcs. top skin one side 2 pcs. no skin The above specimens shall be prepared from the same foam formula intended for source approval and shall be cut from finished foam parts whenever possible. 5.2 REFERENCE ENGINEERING SPECIFICATION FOR FOAM DEFECTS ES-D2AB-6564850-A Pad Assembly, Seat (Defects in Molded Urethane Seat Pads)
