1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2007 11 21 N-STATUS Replaced by WSS-M15P20-B1/B2 B. Witkowski 2005 12 22 Revised 3.6.4, 3.6.11 and 3.6.14 B. Witkowski 1994 08 04 Released NB00I0043054354 J. D. Salow, A. J. Stocki Printed copies are uncontrolled Copyright 2007, Ford Global Te
2、chnologies, LLC Page 1 of 5 POLYURETHANE (PUR) FOAM, HIGH RESILIENT WSB-M2D402-A3 NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a molded high quality, resilient polyether polyurethane seating foam. 2. APPLICATION This specification was released originally for m
3、aterial used in seat cushions and backs when a higher load bearing foam is required. 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). 3.3 PRECONDITION
4、ING All test specimens shall be preflexed twice to 80 - 90% of their thickness (unless otherwise noted), then conditioned (post cured) at 23 +/- 2 C and 50 +/- 5% relative humidity for 7 days minimum prior to testing (unless otherwise noted) and tested under same conditions. The post cure time shall
5、 commence from time of demolding part. When test specimens are submitted to Ford Motor Company for evaluation and if the test specimens (or parts from which test specimens will be obtained) have previously been post cured 7 days at the suppliers plant, then the test specimens (or part) need only to
6、be preflexed twice (80 - 90%) as above, then conditioned. 3.5 DENSITY, Core, min As specified on the (ISO 845/ASTM D 3574, Test A) engineering drawing Sample size 50 x 50 x 25 mm minimum, cut 7 mm below the top molded surface of the sample or part. Take as close as possible to the IFD circle. No 7 d
7、ay post cure required. Report the average value based on a 5 part evaluation. ENGINEERING MATERIAL SPECIFICATIONWSB-M2D402-A3 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 2 of 5 3.6 MATERIAL AND TEST SPECIMEN All foam samples shall be cut from production parts t
8、hat are free of the top molded surface (unless otherwise noted), voids, hard spots, and densification lines. Such test specimens shall be cut from a plane whose top surface is approximately 7 mm below the top molded surface of the sample or part. 3.6.1 Tensile Strength, min* 82 kPa (ISO 1798/ASTM D
9、3574, Test E) 3.6.2 Heat Aged Tensile Strength, min* 75% of original (ASTM D 3574, Test K) 3.6.3 Elongation, min* 80% 3.6.4 Tear Resistance, min* 450 N/m (ASTM D 624, Die C) 3.6.5 Compression Set, normal, max* (FLTM BN 115-07, 75% deflection, computed on original thickness) Cushions 10% Backs 20% Th
10、e reported value shall be the average value based on a 5 part evaluation (15 specimens). Calculations: Ct = to - tf x 100 - to Ct - Compression set expressed as a percentage of the original thickness to - Original thickness of test specimen tf - Final thickness after removal from test fixture per te
11、st procedure 3.6.6 Compression Set, Autoclave Aged, max* (FLTM BN 115-07, 75% deflection computed on original thickness) Cushions 15% Backs 25% Test Method: Autoclave age test specimens per para 6 of test procedure and condition test specimens 1 h after drying. Calculate autoclave aged compression s
12、et per para 3.6.5 (Normal Compression Set). ENGINEERING MATERIAL SPECIFICATIONWSB-M2D402-A3 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 3 of 5 3.6.7 Indentation Force Deflection Test fixtures as required. (ASTM D 3574, Test B1, 50% Test values and test deflecti
13、on. See General location as specified on Information for test block the engineering drawing requirements 3.6.7.1 Sag Factor, min* 2.5% (Ratio of 65%/25% deflection) 3.6.7.2 Recovery, min 80% (Ratio of 25% return value/25% initial value) Test Method: Test should be conducted on the entire production
14、part. After measuring the 65% IFD, release the load to rest compression of 25% and maintain for 60 s. 3.6.8 Staining None (SAE J1885) (The control samples and test samples should have the same visual appearance after exposure) Test Method: Typical light colored WSB-M2F177 or equivalent supported vin
15、yl trim material shall be placed in intimate contact over a 68 x 145 x 6 mm specimen of foam (with surface skin of foam next to vinyl). Cover a similar specimen with the standard vinyl material (FLTM BN 103-01). Control samples of WSB-M2F177 and standard vinyl should also be exposed. Expose all test
16、 samples for 225.6 kJ. Remove from Xenon Weatherometer and examine. 3.6.9 Fogging (FLTM BO 116-03) Fog Number, min 70 The formation of droplets or coalescence into a clear film is cause for rejection. 3.6.10 Odor, max Rating 2 (FLTM BO 131-01/SAE J1351) 3.6.11 Load Indentation Test areas (e.g. bolst
17、er and (FLTM BN 015-06) insert areas) and test values shall be as specified on the engineering drawing ENGINEERING MATERIAL SPECIFICATIONWSB-M2D402-A3 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 4 of 5 3.6.12 Aged Load Loss, max 35% (ASTM D 3574, Test B1, 65% d
18、eflection, avg. of 5 parts, required of seat cushions only) The sample size shall be 100 x 100 x 50 mm with the top molded surface. Determine the initial and aged 65% CFD values. Age the part for 3 h in a steam autoclave maintained at 120 +/- 2 C followed by 4 h drying at 104 C. Condition at 23 +/-
19、2 C and 50 +/- 5% relative humidity for 1 h, then determine the aged 65% IFD value. Aged Load Loss = L1 - L2 x 100 - L1 L1 = initial 65% IFD value L2 = aged 65% IFD value 3.6.13 Aged Flexibility No splitting or crumbling Test Method: A specimen 50 x 150 x 25 mm shall be subjected to autoclave aging
20、for 5 h at 120 C, followed by 1 h drying at 104 C and subsequently bent 180 around a 6 mm dia mandrel. 3.6.14 Fatigue Resistance, max height loss* 14% (FLTM BO 012-04, 20,000 cycles, avg of 3 parts, 222 N height loss) Seat Cushions - use a 267 N shear load roller assembly. Seat Backs - use a 133 N s
21、hear load roller assembly. Preflex test samples twice both prior to and after testing. The sample size shall be 375 x 300 x 64 mm (minimum thickness) with top molded surface. Excessive surface foam deterioration or splitting apparent after 20,000 cycles shall be cause for rejection. 3.6.15 Fatigue R
22、esistance Constant Force Pounding, max* (ISO 3385/ASTM D 3574, Test I3, 80,000 cycles, 50% compression) Loss of Hardness 25% Loss of Thickness 5% 3.6.16 Resilience, Ball Rebound, min 40% (ASTM D 3574, Test H) 3.6.17 Cell Structure, Physical Characteristics and Allowable Defects The molded foam pads
23、shall meet the requirements for allowable defects as outlined in the engineering specification for seating pads as defined on the engineering drawing. ENGINEERING MATERIAL SPECIFICATIONWSB-M2D402-A3 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 5 of 5 3.6.18 Flam
24、mability (ISO 3795/SAE J369) Burn Rate, max 100 mm/minute *Deviations from the above specification requirements must be listed on the engineering drawing with concurrence from Interior Materials Engineering and Seat Engineering. 5. GENERAL INFORMATION The information below is provided for clarificat
25、ion and assistance in meeting the requirements of this specification. 5.1 SEAT PAD FIXTURE BLOCKS . All pads have a block. . The block design is established at the preliminary EU of the seat pad drawing. . The block will support the 200 mm compression circle designated on the pad. . The block will b
26、e large enough so that no part of the pad touches the table. Large pads are to be supported to prevent cantilevering of the pad. . The block should orient the top surface of the pad parallel to the indenter foot +/- 5. . The block will correspond to the underside of the pad, including coring. The pl
27、ane parallel to the bench line will be defined as Datum “A“. Datum “B“ will be defined as a positive locator (pad to block). Datum “C“ - one side of coring - all other surfaces will have a 2 mm clearance pad to block. . Drawings will have adequate views to enable fabrication of blocks. . The block i
28、s defined by a work line representing the compression equipment table base and a true view of the seat pad showing periphery of the block. A minimum of two sectional views is required in addition to the work line. The side view center line section and the cross section with base line block size peri
29、phery are established by the Design Engineer, (380 x 380 mm, minimum). . Pin blocks to table to ensure the indenter foot coincides with the 200 mm compression circle, (for repeatability of check). Pin at center of 200 mm circle. . The block will be made from a stable material - REN 450 plastic/maple/mahogany - call out on drawing. . The 50% IFD will be based on foam height above the block zero indenter foot on block. 5.2 RECYCLING CODE (PUR)
