1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2009 07 28 N-STATUS No Replacement Named Y. Bankowski, NA 2005 01 14 Revised Inserted 3.0; Deleted 3.1 1967 07 03 Released AW1 #1049 Printed copies are uncontrolled Copyright 2009 Ford Global Technologies, LLC Page 1 of 3 LAMINATE, POLYVINYL C
2、HLORIDE - POLYURETHANE FOAM METAL ESB-M4D257-A NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a polyvinyl chloride, polyurethane foam, metal laminate suitable for the manufacturing of die stamped parts. 2. APPLICATION This specification was released originally f
3、or material used as a lower instrument panel cover or for other interior trim applications. 3. REQUIREMENTS 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). 3.2 APPEA
4、RANCE (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 3.3.1 Metal Backing May be a CRLC steel chemically cleaned prior to lamination and treated to prevent corrosion. Other met
5、als such as aluminum, may be used provided the type and quality is specified on the engineering drawings. 3.3.2 Vinyl Film Shall conform to requirements of ESB-M2F102-A. 3.3.3 Urethane Foam Cell Structure Porosity 40-60 Cells/in (1.6-2.4 Cells/cm) Compression Set, max 50% (ASTM D 1564, Method “B“, 2
6、2 h at 70 +/- 1 C, 50% constant deflection. computed on original deflection) Resistance to Deterioration No cracking or crumbling ENGINEERING MATERIAL SPECIFICATIONESB-M4D257-A Printed copies are uncontrolled Copyright 2009 Ford Global Technologies, LLC Page 2 of 3 Test Method: A specimen 2 x 6 in (
7、50 x 150 mm) is subjected to humidity aging outlined in FLTM BO 012-01 and subsequently bent 180 around a 1/4 in (6.4 mm) mandrel. 3.4 DIMENSIONS The thickness of the vinyl film, urethane foam and metal backing and total thickness of the laminate shall be specified on the engineering drawings along
8、with other part dimensions. 3.5 BEND TEST The laminate shall bend 180 around a 1/2 in (12.7 mm) mandrel without damage to the vinyl film or the adhesive bond, when all edges are sealed by dielectric process. 3.6 FILM ADHESION (ASTM D 413, Machine Method, 1 in (25 mm) wide test specimens) The adhesio
9、n between the vinyl film and metal backing shall be 15 lb (67 N) minimum on flat surfaces and 10 lb (44.5 N) minimum in areas where the metal has been stretched 15% or more. 3.7 RESISTANCE TO ELEVATED TEMPERATURE No evidence of shrinkage, loss of grain, color change, or delamination of the film afte
10、r a flat sheet or formed part has been exposed to a temperature of 88 +/- 1 C for 8 h. 3.8 ABRASION (FLTM BN 108-02, 1000 g load, CS #10 wheels) The wear pattern and color shall be compatible in appearance with adjacent unabraded area Production materials shall exhibit abrasion properties equal to o
11、r better than the approved sample (based on suppliers test data and test specimens as reviewed by the Textile Section) on file in the Textile Section, Body Materials Engineering Department. Painted, metallic, and other vinyl surface coatings shall withstand 250 cycles. The color of the base vinyl co
12、ating shall be compatible with the metallic surface and shall in no instance be of a lighter color than the surface. 3.9 COATING ADHESION (FLTM BI 106-01, Part “B“, except do not scribe lines) The tape shall not lift or delaminate the paint or surface coating. 3.10 FADE (SAE J 1885) The vinyl coatin
13、g shall not stain, exhibit color tone change or change in hue, in accordance with rating 4-5 of the AATCC Gray Scale for Evaluating Change in Color (10 Step) after 120 SFH exposure. Production materials shall exhibit light-fastness qualities equal to or better than the approved sample (based on supp
14、liers test data and test specimens as reviewed by the Textile Section) on file in the Textile Section, Body Materials Engineering Department. 3.11 FLEXIBILITY AFTER AGING The coated surface of the laminate shall exhibit no crazing or cracking when folded 180 around a 1/2 in (12.7 mm) diameter mandre
15、l (coating side out) after the Fade test (para 3.10). ENGINEERING MATERIAL SPECIFICATIONESB-M4D257-A Printed copies are uncontrolled Copyright 2009 Ford Global Technologies, LLC Page 3 of 3 3.12 CROCKING - WET AND DRY (FLTM BN 107-01) Shall correspond to rating 5 when compared to the AATCC chart for
16、 measuring the transference of color. 3.13 HEAT AGING No evidence of tackiness, or exhibit staining, color tone change or change in hue, in excess of a 3 rating of the AATCC Gray Scale for Evaluating Change in Color (10 Step). Any “spotty“ or nonuniform staining or discoloration shall be cause for r
17、ejection. Production materials shall exhibit heat aging qualities equal to or better than the approved sample (based on suppliers test data and test specimens as reviewed by the Textile Section) on file in the Textile Section, Body Materials Engineering Department. Test Method: Place samples with 1/
18、4 in (6.4 mm) of foam backing in an air circulating oven at 102 +/- 3 C for 7 days. Remove and examine for discoloration. 3.14 H2S STAINING (FLTM AN 102-01) The coated surface of the laminate shall show no discoloration. 3.15 MIGRATION STAINING (FLTM BN 103-01) The vinyl surface of the laminate shal
19、l show no evidence of injurious exudation, adhesion (tackiness), separation, color transfer, or flattening of the embossing when placed face to face with itself or materials of the 2F4-9-62 series. 3.16 FOGGING (SAE J 1756) Light transmission, min 75 3.17 RESISTANCE TO HUMIDITY The vinyl film and ad
20、hesive bond shall show no evidence of deterioration, or shall the metal backing show evidence of corrosion when a laminated sheet or formed part is exposed at 98 +/- 2% relative humidity at 38 +/- 1 C for a period of 100 h. 3.18 ODOR Not disagreeable, either wet or dry. 3.19 FLAMMABILITY, max 4 in (
21、101 mm)/min (FLTM BN 024-02, without the lot sampling plan) In addition, the test specimen shall not exhibit any flashing or sudden flaming on either surface in excess of the above maximum value. 3.20 MATERIAL ACCEPTABILITY The criterion for material acceptability shall be based on the materials appearance and performance during and after the manufacturing of formed parts.
