1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2013 10 04 N Status No replacement named D. Murtonen, NA 2000 09 25 Revised Updated A. Cockman 1991 10 08 NB00I10043054129 Released B. H. Chen AJS Page 1 of 6 Copyright 2013, Ford Global Technologies, Inc. L
2、AMINATE, NYLON FABRIC/POLYURETHANE FOAM, ESB-M5H9-F CHALET PATTERN ESB-M5H9-G NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a napped nylon knitted fabric, flame or adhesively laminated to a flame bondable polyether urethane foam. 2. APPLICATION The ESB-M5H9-F s
3、pecification was released originally for material used as a surface cover material for cut and score headliners and sunvisors. The ESB-M5H9-G specification was released originally for cover material on molded glass fiber, one-piece headliners. The ESB-M5H9-G cover material must always be bonded 100
4、% to a substrate material to form a composite (Reference: ESB-M5H9-G Flammability paragraph). 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. In addition to the requirements listed herein, the material when used in a unitized headliner assem
5、bly, or bonded to any substrate, shall also meet the requirements of ESB-M15P1-C when tested as a unitized or bonded one-piece headliner assembly. Other applications of this material, such as trim covers for quarter trim panels, require conformance to the WSB-M15P4-D specification. 3.1 QUALITY SYSTE
6、M REQUIREMENTS Material suppliers and part producers must conform to the Companys Quality System Requirements. 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS IR spectra and thermograms established for initial approval shall constitute the reference standard and shall be kept on file at the d
7、esignated material laboratory. All samples shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. ENGINEERING MATERIAL SPECIFICATION ESB-M5H9-F/G Page 2 of 6 Copyright 2013, Ford Global Technologies, Inc. 3.3 CONDITIONING AND TEST CO
8、NDITIONS All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. 3.4 APPEARANCE (FLTM BI 109-01) The color, pa
9、ttern and finish shall match the approved Design Center master sample, or shall be as specified on the engineering drawing. 3.5 ROLL GOODS QUALITY The laminate shall be uniformly bonded, and the fabric shall not delaminate from the foam during shipment, handling, or in-plant processing. 3.6 COMPOSIT
10、ION (ASTM D 629) Fabric 100 % nylon Foam Polyether urethane Adhesive (if employed) As specified on the Approved Source List 3.7 FABRIC REQUIREMENTS The following shall apply or be conducted on unbonded fabric: 3.7.1 Yarn Description and Construction (ASTM D 1244) Face 4.4 tex f 28 (nylon, dull) Foam
11、 4.4 tex f 12 (nylon, dull) 3.7.2 Yarn Count 15 - 18 Wales/cm (ASTM D 3887) 15 - 18 Courses/cm 3.7.3 Weight, min 76.3 g/m2(FLTM BN 106-01) 3.7.4 Knitting Machine Gauge 32 gauge 3.7.5 Method of Dyeing Piece dyed 3.7.6 Surface Finish Napped ENGINEERING MATERIAL SPECIFICATION ESB-M5H9-F/G Page 3 of 6 C
12、opyright 2013, Ford Global Technologies, Inc. 3.8 FOAM REQUIREMENTS The foam shall be polyether polyurethane and shall conform to ASTM D 3574 USU E J2. The following tests shall be conducted on foam removed from the finished fabric/foam laminate or from surrogate foam samples when the laminate is le
13、ss than 4 mm thick. 3.8.1 Tension Test, min 80 kPa (ASTM D 3574, test E) 3.8.2 Steam Autoclave Aging (ASTM D 3574, tests E and J2) Retained Tension, min 70 % of original (After two autoclave cycles, for 10 h total exposure) Specimen preparation: Cut out 25 mm wide strips from the fabric/foam laminat
14、e. By hand, carefully peel or cut the foam away from the fabric, taking care to minimize damage to the foam. Die cut tension specimens from the foam. Allow the specimens to recover from cutting and handling. Measure and record the thickness of the specimens. Expose and test. 3.9 FABRIC/FOAM LAMINATE
15、 REQUIREMENTS 3.9.1 Thickness, Range Production Samples As specified on engineering or pattern drawings Source Approval 4.25 +/- 0.63 mm and Master Samples 3.9.2 Ply Adhesion, both directions min (ASTM D 413, Machine Method, Strip Specimen Type A, 50 mm/minute Crosshead Speed) Original 4.4 N* After
16、Water Immersion 1.8 N *The fabric shall not separate cleanly from the foam surface (fabric specimen shall exhibit foam particles adhered to the peeled surface). In those cases where a sustained peel cannot be obtained due to the foam tearing or breaking away completely from the fabric, ply adhesion
17、shall be considered acceptable if the peak load prior to break exceeds the above minimum requirement. If the laminate is less than 3.62 mm thick and a numerical ply adhesion value cannot be satisfactorily obtained, ply adhesion shall be acceptable if the fabric cannot be separated cleanly from the f
18、oam. ENGINEERING MATERIAL SPECIFICATION ESB-M5H9-F/G Page 4 of 6 Copyright 2013, Ford Global Technologies, Inc. 3.9.3 Resistance to Abrasion, min 150 cycles (FLTM BN 108-02, 500 g load, CS-10 wheel) No evidence of excessive abrasion or surface breaking, and shall exhibit no evidence of urethane foam
19、 show-through. 3.9.4 Resistance to Fade, min (SAE J 1885 and AATCC Evaluation Procedure 1) 150.4 kJ/m2 Rating 3.0 3.9.5 Resistance to Heat Aging, min Rating 4.0 (7 days at 100 C and AATCC Evaluation Procedure 1) Rate by comparing the overall difference, or contrast, of the tested specimen and origin
20、al textile with the difference represented by the AATCC Gray Scale for Evaluation Change in Color (10 Step). No individual yarn or combination of yarns shall exhibit fiber degradation or color tone change. 3.9.6 Resistance to Crocking, min (FLTM BN 107-01 and AATCC Evaluation Procedure 3) Dry and We
21、t Rating 4.0 3.9.7 Resistance to Bleeding and Rating 4.0 Perspiration, min (FLTM AN 101-01 and AATCC Evaluation Procedure 3) 3.9.8 Soiling and Cleanability (FLTM BN 112-04 and AATCC Evaluation Procedure 1) Soiling Rating 2.0 Cleanability Rating 4.0 After the cleanability test, no stains or rings sha
22、ll be left on the fabric. ENGINEERING MATERIAL SPECIFICATION ESB-M5H9-F/G Page 5 of 6 Copyright 2013, Ford Global Technologies, Inc. 3.9.9 Original Breaking Strength and Resistance to U.V. Degradation, min (FLTM BN 117-03, Method A and SAE J1885) The original breaking strength and percent retained s
23、trength after aging shall be as follows: Wales Courses Original, N, min 200 111 After Aging, Retained Strength, %, min . 112.8 kJ/m2 40 40 . 225.6 kJ/m2 30 30 3.10 ODOR, max Rating 2(SAE J1351) 3.11 FOGGING (SAE J 1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 1 h and 16 h) F
24、og Number, min 60 Formation of clear film, droplets or crystals is cause for rejection. 3.12 FLAMMABILITY (ESB-M5H9-F) (IS0 3795/SAE J 369) Burn Rate, max 100 mm/minute 3.13 FLAMMABILITY (ESB-M5H9-G) (ISO 3795/SAE J 369) This cover material must always be bonded 100 % to a substrate material to form
25、 a composite (localized or spotty adhesion is unacceptable). The composite shall meet the requirements specified on the engineering drawing. ENGINEERING MATERIAL SPECIFICATION ESB-M5H9-F/G Page 6 of 6 Copyright 2013, Ford Global Technologies, Inc. 3.14 ADDITIONAL REQUIREMENTS Additional requirements
26、 for material and/or manufactured parts may be specified on the Engineering drawing, Engineering parts specification, performance specification, System Design Specification (SDS) and/or Component Design Specification (CDS). 3.15 SUPPLIERS RESPONSIBILITY All materials supplied to this specification m
27、ust be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes to the material originally approved under this specification, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier
28、 shall notify the affected Purchasing, and Materials Engineering activities (with reasons) of the proposed changes. Upon notification of the Company, further instructions will be provided. Note: Suppliers should be prepared to provide test data and samples demonstrating compliance to this specificat
29、ion, if requested. Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. The restrictions are identified in Restricted Substance Management Standard WSS-M99P9999-A1. 4. APPROVAL OF MATERIALS Materials defined by this specification for
30、 direct supply to the Company must have prior approval. Certain materials subcontracted by part suppliers may also require prior approval. These include materials critical to the Companys business for regulatory, safety, environmental or compatibility requirements or contractual agreements. Supplier
31、s desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Materials Engineering activity. Upon request, the Supplier shall submit a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of this specification.
