1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions 2006 09 21 Revised Inserted 3.0; Deleted 3.1, 3.2, 3.3, 3.12, 3.13 Revised A2 L. Koth/C. Thomas 1979 12 17 Released CHJ2RD8274001292 K. Gillis Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 1 of 4 SOUND ABS
2、ORBER, OPEN CELL, POLYETHER ESE-M99G133-A2 POLYURETHANE FOAM 1. SCOPE The material defined by this specification is a polyether polyurethane foam faced with polyethylene terephthalate film and backed with a polyethylene terephthalate pressure sensitive adhesive. Both facing and backing substrates sh
3、all be bonded to the foam without an adhesive during the casting of the foam. 2. APPLICATION This specification was released originally for material used on the air induction system to reduce exterior noise levels to comply with Federal regulations. 3. REQUIREMENTS Material specification requirement
4、s are to be used for initial qualification of materials. 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). 3.4 FACING MATERIAL The facing material shall be biaxially o
5、riented polyethylene terephthalate film with foam side coated with aluminum. Aluminum coating shall be continuous with no visible defects, 0.01 micrometre minimum thickness. The facing material shall be bonded to the foam without an adhesive during the casting of the foam. 3.4.1 Thickness, mm 0.024
6、+/- 0.012 (ASTM D 1777) 3.4.2 Bond Strength 0.35 N/mm width (Film to foam, 180 pull. Pressure Sensitive Tape Council Test Method 1) 3.5 FOAM REQUIREMENTS Foam shall be polyether polyurethane type. 3.5.1 Thickness, mm 23 - 28 (ASTM D 3574) ENGINEERING MATERIAL SPECIFICATION ESE-M99G133-A2 Printed cop
7、ies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 2 of 4 3.5.2 Density, kg/m3 29 - 39 (ASTM D 3574) 3.5.3 Tensile Strength, 96.5 kPa, min (ASTM D 3574) Elongation, % 200 3.5.4 Permeability, 6 - 18 cgs 25 mm thick Rayles/cm (ASTM C 522) The lateral air flow resistivity shall be
8、measured from a ring shaped specimen in accordance with ASTM C 522 (specimen mounting assembly and mounting plate). Samples shall be tested from random locations on production parts without inclusion of edge seal. O.D. 101.6 mm I.D. 28.6 mm 3.6 BACKING MATERIAL The backing material is to be polyethy
9、lene terephthalate film bonded without adhesive to the foam and coated with an acrylate based pressure sensitive adhesive. 3.6.1 Adhesion to Foam, min 0.35 N/mm width The backing film shall adhere to the foam with the specified strength when peeled at an angle of 180 and at a rate of 305 mm/minute.
10、3.6.2 Film Carrier Thickness, min 0.0112 mm (ASTM D 1777 foam and adhesive removed with chloroform) 3.6.3 Adhesive Release Liner Requirements 36 kg tan Kraft paper polyethylene coated one side, silicone coated on the side towards the adhesive. 3.7 PRESSURE SENSITIVE ADHESIVE Adhesive shall be an acr
11、ylate based material. 3.7.1 Thickness, min 0.063 mm (ASTM D 1777) Difference between backing thickness with and without adhesive shall be considered adhesive thickness. ENGINEERING MATERIAL SPECIFICATION ESE-M99G133-A2 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Pag
12、e 3 of 4 3.7.2 Adhesive Strength, min 0.88 M/m (PSTC-1) width Adhesive to stainless steel panel aged 24 h at 23 +/- 2 C. 3.7.3 Service Temperature +65 C (PSTC-1) Expose a sample adhered to stainless steel panel for 24 h. Remove and allow to set at 23 +/- 2 C for 24 h. Decrease in adhesive strength f
13、rom original (average) in para 3.7.2 shall be 7.5% maximum. 3.8 EDGE SEAL All exposed edges of the fabricated foam parts are to be coated with compound which shall be continuous and non-cracking. The compound must also withstand exposure to water and hydrocarbon liquids such as diesel fuel for a min
14、imum time duration of 24 h at ambient temperature. The test material shall not indicate delamination or deterioration of the edge seal. Test Method: Prepare test samples, 50 x 150 mm, each of which shall include one corner sealer on two adjacent edges. Condition test samples for 2 h at 70 C. Then al
15、low test samples to cool to 23 +/- 2 C. Immerse the edge sealed corner of the two test samples one into water and the other in diesel fuel for a period of 24 h at 23 +/- 2 C. 3.9 COLD FLEXIBILITY No cracking or delamination of the film facing Test Method: Cut two test specimens 50 x 150 mm. Age test
16、 samples for 4 h at an ambient temperature of -24 C. Bend the two test samples 180 around a temperature conditioned 25 mm diameter mandrel, facing side out. 3.10 HEAT RESISTANCE No delamination of the film to foam bond at elevated temperature by visual inspection. Test Method: Expose two test specim
17、ens, in air at a temperature of 120 C in a mechanical convection oven for 1 h. Remove from oven and visually inspect film surface. ENGINEERING MATERIAL SPECIFICATION ESE-M99G133-A2 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 4 of 4 3.11 SOUND ABSORPTION, min (ASTM C 423-84A, E 795) Frequency Hz Sound Absorption Coefficient 125 0.20 250 0.81 500 0.61 1000 0.73 2000 0.71 4000 0.69 NRC 0.70 No variance of Sound Absorption Coefficient greater than (-.01). No variance of NRC greater than (-.05).
