1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Release No. Revisions 2009 11 19 N-STATUS No replacement named J. Crist, NA 1988 06 24 CVR-PF103640 Released Page 1 of 5 LAMINATE, POLYVINYL CHLORIDE SKIN ESB-M4D411-B POLYVINYL CHLORIDE FOAM - POLYVINYL CHLORIDE SKIN - RIGI
2、D SUBSTRATE - FORMED TRIM ASSEMBLY - LOW FOG NOT TO BE USED FOR NEW DESIGN 1. SCOPE: The material defined by this specification is a color pigmented tri-laminate construction consisting of polyvinyl chloride skin, polyvinyl chloride foam, and polyvinyl chloride skin. This laminate is a vacuum formed
3、 and adhesively and/or mechanically bonded to a preformed rigid substrate. 2. APPLICATION: This specification was released for a low fog material for the 1988 Aerostar trim panels. The materials are controlled by the requirements contained herein and in ESB-M15P4-B, or as defined on the engineering
4、drawing. 3. REQUIREMENTS: 3.1 STATISTICAL PROCESS Suppliers must conform to the requirements of Ford Quality System Standard Q-101. A mutually acceptable Control Plan as described therein is required for material/source approval. Appropriate statistical tools must be used to analyze process/product
5、data so that variation in the final product is continuously reduced. 3.2 CONDITIONING All test values indicated herein are based on materials conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for 24 h prior to testing and tested under the same controlled condition
6、s. 3.3 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared and/or thermal analysis of material/parts supplied to this specification. The IR spectra and thermograms established for initial approval shall constitute the reference standard and shal
7、l be kept on file at the designated material laboratory. All samples shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.4 APPEARANCE The color, pattern, and finish shall match the approved Design Center master sample, or shall
8、be as specified on the engineering drawing. ENGINEERING MATERIAL SPECIFICATION ESB-M4D411-B Page 2 of 5 3.5 SKIN - FOAM - SKIN LAMINATE 3.5.1 Thickness Vinyl Skin-Top-Embossed 0.35 - 0.43 mm Vinyl Foam 1.44 - 1.75 mm Vinyl Skin-Bottom 0.13 - 0.20 mm Total 1.92 - 2.38 mm Test Method: Cut 12.7 x 75 mm
9、 samples from separate areas of the test specimen and examine the cross sectional view of the skin to foam laminate using a measuring magnifier (ex. Bausch & Lombs Measuring Magnifier (7X), Catalog No. 81-34-35 with the in (mm) system scale No. 81-34-37, or equivalent). Measure the thickness of each
10、 component and the total thickness of the laminate at several points along the cut surface of the cross section. 3.5.2 Tensile Strength, min 3.1 MPa (ASTM D 1564, any direction) 3.5.3 Elongation, min 200 % (ASTM D 1564, any direction) 3.5.4 Tear Strength, min 12 kN/m thickness (ASTM D 1004, any dire
11、ction) 3.5.5 Bend Test No cracking, (Before and after heat aging crazing, or 7 dayts at 82 +/- 2 C whiteness Test Method: Bend sample 180 against itself. 3.5.6 Cold Flexibility Shall remain (FLTM BN 2-1, before and after flexible and not heat aging 7 days at 82 +/- 2 C crack at -29 C 3.5.7 Scuffing
12、50 cycles (FLTM BN 8-4, “A“ head, 907 g load) The surface shall show no evidence of breakthrough, rupture, lifting or excessive scuffing. 3.5.8 Abrasion, min 500 Cycles (FLTM BN 8-2, 1000 g load) The surface shall show no evidence of wearthrough, and the color of the abraded area shall be compatible
13、 in appearance with the adjacent unabraded area. 3.5.9 Crocking (FLTM BN 7-1, also use M14J148 Naphtha to soak crocking cloth, 10 strokes) The crocking cloth shall not exhibit any crocking on specimens as received, after 7 days at 102 C and after 120 SFH exposure. ENGINEERING MATERIAL SPECIFICATION
14、ESB-M4D411-B Page 3 of 5 3.5.10 Coating Adhesion (FLTM BI 6-1, part “B“, except do not scribe lines) The tape shall not lift or delaminate the surface coating. 3.5.11 Migration Staining FLTM BN 3-1) The surface shall show no evidence of injurious exudation, adhesion (tackiness), separation, color tr
15、ansfer, or flattening of embossing when placed face to face with itself or a contrasting color of current vinyl seating material. 3.5.12 Accelerated Weathering Resistance (FLTM BN 1-1 or SAE J 1885) Carbon Arc or Xenon Arc Exposure AATCC Rating 4, minimum 200 SFH at 90 C or 225.6 Kjoules 3.5.13 Fogg
16、ing (FLTM BO 116-3) Fog Number, min 60 Any fog film present shall be examined for the formation of droplets or coalescence into a clear film. Such conditions, if present, shall be cause for rejection. 3.5.14 Heat Aging The surface shall show no evidence of tackiness or staining, loss of embossing or
17、 increase in gloss, and color tone change or change in hue below a rating of 4 on the AATCC Gray Scale for Evaluating Change in Color (10 step). 3.5.15 Odor No offensive or objectionable odors 3.5.16 Dimensional Stability Shall show no evidence of delamination or blistering, and no more than +/- 10
18、% dimensional change in either machine or across the machine direction on a 300 x 300 mm test specimen hung vertically in an oven at 88 C for 7 days. Mark off lines 250 mm long for dimensional determination. 3.5.17 Peel Adhesion, Skin to Foam, min (FLTM D 413, Machine Method, 1 in 25 mm strip specim
19、en, any direction) Room Temperature 0.5 kN/M ENGINEERING MATERIAL SPECIFICATION ESB-M4D411-B Page 4 of 5 Expose samples at 0.5 kN/M 102 +/- 3 C for 30 min (Condition for 30 min at room temperature and test) 3.5.18 Soiling, max “G“ gloss 15 % (FLTM BN 12-1) “H“ gloss 30 % 3.6 RIGID SUBSTRATE Rigid su
20、bstrates, such as ESB-M2E16-B or equivalent dimensionally stable substrates, shall meet the requirements of their respective engineering specifications, as well as the assembly requirements specified herein. 3.7 ASSEMBLY 3.7.1 Dimensional Stability The formed trim assembly shall not exhibit any shri
21、nkage or expansion to the extent of causing unsightly wrinkles, pull outs, distortion, cover delamination, loss of surface grain or design features in any portion of the assembly. Dimensional change shall not exceed +/- 1.0 % in any direction. Test Method: Attach assembly to a trim buck, mark off li
22、nes 250 mm long for the dimensional determination, and expose assembly in the “in-car“ position to the following conditions: . 4 h at 88 C +/- 1 C . 4 h at 38 +/- 1 C and 100 +/- 5 % relative humidity . 16 h at -29 C Repeat above for 4 cycles, measure dimensional change, and examine for defects. 3.7
23、.2 Peel Adhesion, Skin-Foam-Skin to Rigid Substrate, min (ASTM D 413, Machine Method, 1 in (25 mm) strip specimen) Room Temperature 880 N/m width Tested at 93 +/- 3 C after 132 N/m width 1 h exposure at this temperature 3.7.3 Heat Aging The formed trim assembly shall not exhibit any evidence of wrin
24、kling, warpage, blistering, or loss of embossing of the vinyl surface, flattening or collapse of the vinyl foam (vinyl surface waviness), pull outs or tearing of sewn or bonded seams, and delamination of the foam when bonded to the substrate. The visible exposed cover area that is formed over the ri
25、gid substrate shall not exhibit any visible readthrough on the vinyl surface, such as vacuum holes, adhesive build up, or mold parting lines. Dimension change shall not exceed +/- 1.0 % in any direction. Test Method: Mark off lines 250 mm long for the ENGINEERING MATERIAL SPECIFICATION ESB-M4D411-B
26、Page 5 of 5 dimensional determination, and suspend the assembly in a 88 +/- 3 C air circulating oven for 7 days. Measure dimensional change after 1 h at room temperatures and examine for defects. 3.7.4 Accelerated Weather Resistance (FLTM BN 1-1 or SAE J 1885) The surface of assembly shall not stain
27、, exhibit color change below rating 4 of the AATCC Gray Scale for Evaluating Change in Color (10 step) after 200 SFH carbon arc or 225.6 Kjoules xenon arc exposure. 3.8 FLAMMABILITY (ISO 3795/SAE J 369) Burn Rate, max 100 mm/min 3.9 SUPPLIERS RESPONSIBILITY All materials supplied to this specificati
28、on must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any change in the properties, composition, construction, color, processing or labeling of the material originally approved under this specification, whether or not such changes af
29、fect the materials ability to meet the specification requirements, the Supplier shall notify Purchasing, Toxicology and the affected Materials Engineering activity of the proposed changes and obtain the written approval of the Materials Engineering activity. Test data, test samples and a new code id
30、entification are to be submitted with the request. 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 specifie
31、d on the engineering document for the application. 4. APPROVAL OF MATERIALS: Materials defined by this specification must have prior approval by the responsible Materials Engineering activity. Suppliers desiring approval of their materials shall first obtain an expression of interest from the affect
32、ed Purchasing, Design and Materials Engineering activity. Upon request, the Supplier shall submit to the affected Materials Engineering activity its own laboratory report to the specification (test results, not nominal values), the material designation and code number, and test specimens for Ford evaluation. Upon approval, the material will be added to the Engineering Material Approved Source List.
