1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions 2006 10 18 N-STATUS Replaced by WSB-M2D402-A3 1978 10 31 Metricated , Renumbered and Retyped CAHI-RD572066-153 1972 05 26 Released AB1-302-36-24 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 1 of 5 POLYURE
2、THANE FOAM, HIGH AND MEDIUM DENSITY ESB-M4D262-C NOT TO BE USED FOR NEW DESIGN 1. SCOPE The materials defined by this specification are high and medium density, filled or unfilled, flexible polyether urethane foams. 2. APPLICATION This specification was released originally for the following material
3、s: Type I Seat cushions: Molded and slab, high density 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, Inserts and Center arm rests: Molded and slab, medium densit
4、y foam normally used as the support padding for bench and bucket seat constructions when a lower density, 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
5、 producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). Type I Type II Backs, Inserts 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 the 1 in (25 mm) dimensi
6、on of the test specimen shall be obtained perpendicular to the part surface. For parts less than 1 in (25 mm) thick, two 1/2 in (12.7 mm) thick specimens may be plied up to 1 in (25 mm) thickness with 1/2 in (12.7 mm) dimension cut as above. Computed deflection shall be controlled to +/- 0.002 in (0
7、.05 mm). * Steam Autoclave Aged Test Method: Determine normal compression set on similar test specimens that are steam autoclave aged (as defined in FLTM BO 012-01) for 3 h at 2.8 +/- 1.5 psi (19 +/- 10 kPa) and/or 104 +/- 5 C; then dried 3 h at 70 +/- 1 C in a convection oven, followed by 24 h cond
8、itioning at 23 +/- 2 C and 50 +/- 5% relative humidity. 3.3 ASSEMBLY Type I Cushions: Parts or specimens submitted to BEO for source approval evaluation under this specification, or submitted at the request of the Body Materials Engineering Department must exhibit a 50 lb (222 N) IRGL value that is
9、50 +/- 8% of the 1 lb (4.4 N) IRGL, or as specified on the engineering drawing. Type II Seat backs only: 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. 3.3.1 Load Indentation (SAE J 815, steps 1-4 only, parts test
10、ed with top skin, one side; and inserts tested with no skin or as specified on the engineering drawing.) Values as specified on the engineering drawing ENGINEERING MATERIAL SPECIFICATION ESB-M4D262-C Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 3 of 5 3.3.2 Load
11、 Indentation (FLTM BN 015-06) Compression test areas (e.g., bolster and insert areas) and test values shall be as specified on the engineering drawing. 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
12、mm). Measure the 25 lb (111 N) and 50 lb (222 N) height according to SAE J 815. Expose sample 3 h in steam autoclave, remove and condition per FLTM BO 012-01. Determine heights at 25 lb (111 N) and 50 lb (222 N) after autoclave exposure. Calculate and report the percent height change. % Ht Change =
13、H1 - H2 - H1 H1 = Original height at 25 lb (111 N) or 50 lb (222 N) H2 = Autoclave 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 autoclave aging (FLTM BO 012-01) and sub
14、sequently bent 180 around a 1/4 in (6.4 mm) diameter mandrel. 3.5 LOW TEMPERATURE LOAD COMPRESSION, change, max 65% (ASTM D 1564, Suffix “D“, test specimen is 6 x 6 x 2 in (150 x 150 x 50 mm) Test Method: At room temperature, determine the initial thickness of the specimen under 1 lb (4.4 N) preload
15、, then 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 = Compression load at room tem
16、perature E = Compression load after -34 C exposure 3.6 FATIGUE RESISTANCE (FLTM BO 012-04, 15 x 12 in (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 ENGINEERING MATERIAL SPECIFICATION ESB-M4D262-C Printed copies are
17、 uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 4 of 5 Type I (60 lb (267 N) shear load roller assembly) 30% Cushions* Type II (30 lb (133 N) shear load roller assembly) 20% Seat backs only * Excessive surface foam deterioration apparent after 20,000 cycles shall be cause for reject
18、ion. 3.7 ODOR No offensive odor before or after deterioration test, 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 in (100 x 100 mm) specimens of the foam. Expose the assembly under the fluorescent sunl
19、amps as described in FLTM BO 115-01 for 150 h at 63 + 3 C. 3.9 FOGGING (FLTM BO 16-2) Light transmission, min 95 3.10 SOLVENT RESISTANCE No surface tackiness or evidence of foam deterioration. Test Method: Immerse specimens in the following approved fabric and upholstery cleaners: M-14J503 petroleum
20、 naphtholspirit ESF-M8B12-A denatured alcohol 50% soap solution, ESB-M1B9-A (or “Lux“ liquid) 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 o
21、utlined in the engineering specification for seating pads (ES-D2AB-6564850-AA) as defined on the engineering drawing. 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 acr
22、oss its surface, at a rate of more than 4 in (101 mm) per minute. To demonstrate compliance, the sample size and method of testing shall be in accordance with FLTM BN 024-02. 3.13 PERFORMANCE - ENVIRONMENTAL AGING All materials, portions of components, and composites defined by this specification th
23、at have not been treated, modified or reformulated 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 accelerat
24、ed environmental aging requirements applicable to the basic material category of this particular specification. ENGINEERING MATERIAL SPECIFICATION ESB-M4D262-C Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 5 of 5 Any material, portions of components, and composit
25、es 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, must be evaluated for both permanency of materials flame retardant properties and changes in mechanical, chemical and phy
26、sical properties per ESB-M25P3-A applicable to the basic materials category of this particular specification. 3.14 FLAMMABILITY TEST PROGRAM Materials, portions of components, and composites governed by this specification must also comply with the requirements of ES-D3AB-11014-AA. 3.15 ASH CONTENT,
27、max 50.0% (ASTM D 586) A conditioned core sample 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 prov
28、ided for clarification and assistance in meeting 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 Slab and Molded 15 x 15 x 1/2 in (375 x 375 x 13 mm) 1 pc. no skin 5 x 15 x
29、1 in (375 x 375 x 25 mm) 1 pc. no skin 15 x 15 x 4 in (375 x 375 x 100 mm) * 1 pc. top skin one side 15 x 15 x 2 in (375 x 375 x 50 mm) * 2 pcs. top skin one side 15 x 15 x 2 in (375 x 375 x 50 mm) 2 pcs. no skin 15 x 15 x 2-1/2 in (375 x 375 x 63 mm) * 2 pcs. top skin one side The above specimens s
30、hall be prepared from the same foam formula intended for source approval and shall be cut from finished foam parts whenever possible. * These specimens not required for Type II inserts. 5.2 REFERENCE ENGINEERING SPECIFICATION FOR FOAM DEFECTS ES-D2AB-6564850-AA Pad Assembly, Seat (Defects in Molded Urethane Seat Pads)
