1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions 2006 10 17 N-STATUS Replaced by WSB-M2D402-A3 2004 09 21 Revised Para 3.0 inserted; para 3.1, 3.2, 3.3, 3.7, 3.8 & 4 deleted 1989 09 29 Released SM/EQ035825 TP K. Gerhards Printed copies are uncontrolled Copyright 2006, Ford Global Technologi
2、es, LLC Page 1 of 4 POLYURETHANE (PUR) FOAM, MOLDED WSK-M2D416-A HIGH RESILIENCE NOT TO BE USED FOR NEW DESIGN 1. SCOPE The material defined by this specification is a cold cured, molded, high resilience polyurethane foam. 2. APPLICATION This specification was released originally for material used i
3、n seat cushions and backs. 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). 3.4 APPEARANCE The foam shall have a homogeneous medium sized cell structu
4、re with no large voids or solid spots which may impair the serviceability of the part. 3.5 TEST SPECIMEN The following material properties shall be determined on specimens taken from the core 6-10 mm from the surface skin, unless otherwise specified. These specimens shall be free of voids, hard spot
5、s and densification lines. 3.5.1 Density, Core, min 40 kg/m3 (ISO 845/ASTM D 3574, Test A, 3.5.2 Tensile Strength, min 110 kPa (ISO 1798/ASTM D 3574, Test E, 50 mm bench marks, 5 specimens minimum) 3.5.2.1 Elongation at Break, min 100% (Test according to para 3.5.2) 3.5.3 Tear Strength, min 170 N/m
6、(ISO DIS 8067/ASTM D 3574, Test F, 50 mm/minute test speed) 3.5.4 Compression Set, max 14% (ISO 1856, Method A/ASTM D 3574, Test D, Ct calculation, 22 h at 70 C, 50% deflection, 3 specimens minimum.) ENGINEERING MATERIAL SPECIFICATION WSK-M2D416-A Printed copies are uncontrolled Copyright 2006, Ford
7、 Global Technologies, LLC Page 2 of 4 3.5.5 Heat Aging (ISO 2440/ASTM D 3574, Test K, 22 h at 140 +/- 2 C) 3.5.5.1 Compression Deflection Stress Change, max 25% (ISO 3386/1, 40% compression, 100 x 100 x 50 mm specimen, 100 +/- 20 mm/minute test speed, 3 specimens minimum) 3.5.6 Humidity Aging (AUTOC
8、LAVE) (ISO 2440/ASTM 3574, Test J, 100 x 100 x 50 mm specimen, 5 h at 120 C) 3.5.6.1 Compression Deflection Stress Change, max 30% (Test acc. to para 3.5.5.1) 3.5.6.2 Compression Set, max 30% (Test acc. to para 3.5.4) 3.5.7 Staining None Test Method: Cover an approx. 100 mm x 100 mm x 10 mm foam spe
9、cimen (with surface skin on one side) with a section of light colored standard vinyl (FLTM BN 103-01). Expose assemblies (surface skin of foam facing light source) for 150 h in the Fluorescent Sunlamp Cabinet (equipment as specified in FLTM BO 115-01). Control specimens of vinyl should also be expos
10、ed. Evaluate the standard material after cooling to room temperature. 3.5.8 Fogging, min (FLTM BO 116-03) Fog Number, min 70 Formation of excessive amounts of clear film or droplets is cause for rejection. 3.5.9 Odor, max Rating 2 (FLTM BO 131-01/SAE J1351) 3.5.10 Ash Content, max 1% (ISO 247, Metho
11、d B/ASTM D 1278, 800 +/- 25 C) 3.5.11 Flammability (ISO 3795) Burn Rate, max 100 mm/minute ENGINEERING MATERIAL SPECIFICATION WSK-M2D416-A Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 3 of 4 3.6 FINISHED PART 3.6.1 Load Indentation (IRGL Value) - NAAO ONLY tbd (
12、SAE J815, steps 1-4 only) Values and test locations as specified on the engineering drawing. 3.6.2 Product Indentation Hardness Characteristics - EAO ONLY 3.6.2.1 Indentation Hardness at 40% Indentation (H2): As specified on Engineering Drawing. Each individual value must meet the hardness requireme
13、nt. 3.6.2.2 Sag Factor, min 2.8 3.6.2.3 Recovery, min 80% TEST METHOD A: For parts with parallel surfaces in the test area: ISO 2439, Method B, with the following extension: after measuring the 65% indentation hardness release the load to a rest compression of 25%. Maintain this rest compression for
14、 30 s and measure the force. This figure is used as RH1 for the calculation of the recovery. CALCULATIONS: H3 Sag Factor = - H1 H1 = Indentation Hardness at 25% compression H3 = Indentation Hardness at 65% compression RH1 Recovery = - x 100 H1 H1 = Indentation Hardness at 25% compression RH1 = Resid
15、ual Indentation Hardness as 25% rest compression TEST METHOD B: For parts with non-parallel surfaces at the test area Place the part on a matrix that matches the surface contour of the bottom side of the part. The matrix shall have vent holes as described in ISO 2439. Cavities which improve the seat
16、 comfort, however, should not be supported. Test area shall be put in horizontal position. Measure the total height of the part and the matrix with the indentor foot using a preload of 5 N. ENGINEERING MATERIAL SPECIFICATION WSK-M2D416-A Printed copies are uncontrolled Copyright 2006, Ford Global Te
17、chnologies, LLC Page 4 of 4 Remove the part and measure the average height of the matrix with the indentor foot. Calculate the parts thickness and measure the indentation hardness characteristics as outlined under para 3.6.2) 3.6.3 Fatigue Resistance - NAAO ONLY (FLTM BO 012-04, 375 x 300 x 50 mm sa
18、mple with molded top surface. Record the average loss of thickness value of 3 specimens tested at 222 N) 3.6.3.1 Seat Cushions Use 267 N Force and fatigue for 20,000 cycles . Loss of Thickness, max tbd % 3.6.3.2 Seat Backs and Center Arm Rests Use 133 N Force and fatigue for 10,000 cycles . Loss of
19、Thickness, max tbd % Excessive surface foam deterioration or foam splitting after required fatigue cycles shall be cause for rejection. 3.6.4 Fatigue Resistance - EAO ONLY (Record the average value of 3 specimens tested) 3.6.4.1 Loss of Hardness, max 25% 3.6.4.2 Loss of Thickness, max 5% TEST METHOD
20、 A: For molded parts with parallel surfaces in the test area ISO 3385 applies. TEST METHOD B: For molded parts with non-parallel surfaces in the test area ISO 3385 applies, but with the exception that the part shall be mounted on the matrix used for the determination of the indentation hardness characteristics. The determination of “Loss of Thickness“ is not required for these parts. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 RECYCLING CODE PUR
