1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions Rev 2 2009 10 14 Revised See Summary of Revisions B. Witkowski, NA 2009 01 29 Revised Revised, See Summary of Revisions B.Witkowski, FNA/ J. Williams FOE2007 07 10 Released B. WitkowskiPrinted copies are uncontrolled Copyright 2009, Ford Globa
2、l Technologies, LLC Page 1 of 7 PERFORMANCE, POLYMERIC FOAM FOR SEATING APPLICATIONS, WSS-M15P20-B1 INCLUDING CUSHIONS, ARMRESTS, AND HEADRESTRAINTS PERFORMANCE, POLYMERIC FOAM FOR SEATING APPLICATIONS, WSS-M15P20-B2 INCLUDING CUSHIONS, ARMRESTS, AND HEADRESTRAINTS FOR APPLICATIONS WITH BIO-BASED OR
3、 RECYCLED MATERIAL CONTENT 1. SCOPE This specification defines the material performance requirements for seating foam, including head restraints, cushions, bolsters, and armrests. The materials used are typically polyurethane, however, this specification also covers the attachment of materials that
4、would be provided on a finished part, such as hook/loop fastener, scrim, etc. Foam materials (die cut, molded, etc.) adhered to a molded pad shall meet the requirements of the finished pad as well. 2. APPLICATION WSS-M15P20-B1/B2 This specification is for material used in all seat cushions and backs
5、, armrests, head restraints, armrests, and other foam trim items related to seating construction. This specification covers the foam performance requirements with respect to foam material properties and additional specifications cover the application of the assemblies, which are listed below. For se
6、at cushions/backs this specification covers attached components such as fasteners, anti-squeak coatings, and molded in fabrics. These specifications should be used together to define the performance requirements of the affected component. WSB-M15P26-C ARMREST, UNITIZED, FORMED, PERFORMANCE WSD-M15P3
7、9-A PERFORMANCE, FABRIC COVERED MOULDED PARTS WSB-M15P43-A PERFORMANCE, HEADREST, BLOW MOLDED, FOAM INJECTED 2.1 LIMITATIONS This material is susceptible to compression set damage when exposed to steam. Use of excessive steam in the seat assembly process can damage urethane flexible foam. Seating as
8、sembly plant steaming practices should be reviewed before releasing parts using this material. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). ENGINE
9、ERING MATERIAL SPECIFICATIONWSS-M15P20-B1/B2Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 2 of 7 3.2 PRECONDITIONING All test samples must be crushed at demold in a manner that is consistent with production intent. They shall be cured for at least the minimum tim
10、e period specified in the Control Plan prior to hardness testing and a provision must exist to correlate the short-term IFD values to a fully cured sample. PPAP samples shall be cured for a minimum of 7 days prior to all other physical property testing. The samples must be conditioned in the lab env
11、ironment, 23 + 2 C and 50 + 5% RH, for a minimum of 12 hours prior to testing. Except where noted, all tests will be performed on core specimens cut at a minimum of 10 mm below the molded surface of the sample and they shall have their longest dimension at right angles to the direction of the foam r
12、ise. This will place that dimension parallel to the top surface. Specimens shall be taken from in and around the IFD circle and they shall be free of densification layers or any portion where there is an obvious defect, such as voids. These statements supersede the specimen preparation instructions
13、contained in the methods that exist outside of this document. 3.3 MATERIAL AND TEST SPECIMEN Cell Structure, Physical Characteristics The molded foam pads shall meet the requirements for allowable defects as outlined in the Engineering Specifications for seating pads or as defined on the Engineering
14、 Drawing, the foam shall have a uniform cell structure. All foam samples shall be cut from production parts that are free of the top molded surface (unless otherwise noted within the specification below, or in the applicable test method), voids, hard spots, and densification lines. Specimens shall b
15、e obtained from molded parts. If part thickness or configuration makes it too difficult to obtain usable test specimens, surrogate test blocks molded from the same material may be used, with approval from Materials Engineering. This is particularly applicable to small parts (arm rest, released soft
16、molded trim pieces, etc. for seating applications) All tests will be performed on core specimens cut at a minimum of 10 mm below the molded surface (unless specified with skin) and shall have their longest dimension at right angles to the direction of the foam rise. This will place that dimension pa
17、rallel to the top surface. All tests shall be performed using a sample size of 3, (unless noted in the section) with the average of the samples reported, unless otherwise specified. All testing shall be done on parts made with production mold release agents, anti-squeak surface treatments, molded in
18、 fabrics, or other miscellaneous materials. Densities/firmness will vary by application, and the Release Engineer should consult Comfort Engineering if there are issues with density and firmness of the parts. Non-cushion soft trim applications (also referred to as small part applications)- This perf
19、ormance specification is applicable to small parts items that are manufactured with foam formulations also used in head restraint or seating applications. For items requiring surrogate blocks to be used for qualification, such as final parts are not of sufficient size to allow for sample specimens t
20、o be prepared, a surrogate block of the identical formulation may be used. Density, index, and key process parameters shall be kept consistent between the manufacture of the part and the surrogate block, and be provided to seat engineering or materials engineering. ENGINEERING MATERIAL SPECIFICATION
21、WSS-M15P20-B1/B2Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 3 of 7 3.3.1 Density, Core, min kg/m3As specified on the Engineering (ASTM D 3574, Test A) Drawing. Sample size 50 x 50 x 25 mm minimum, taken inside or as close as possible to the IFD circle. A minimu
22、m of 24 hour ageing period prior to test is required. Molded density based on part volume shall be reported for small parts or multi-firmness or multi-density pads , and an applicable surrogate test blocks shall be made at this density for other tests in subsequent sections of this specification. 3.
23、3.2 Indentation Force Deflection Test values as specified on (ASTM D 3574, Test B1, 50% the Engineering Drawing deflection) requirements, test fixtures, values and locations as specified on the Engineering Drawing. 3.3.3 Hysteresis Loss Test values as specified on (ASTM 3574 Test X 6Procedure A) the
24、 Engineering Drawing requirements, test fixtures, values and locations as specified on the Engineering Drawing. 3.3.4 Tensile Strength (ASTM D-3574 test E), 3.3.4.1 Tensile Strength & Elongation Report 3.3.4.2 Heat Aged Tensile Strength, 75% of unaged (Condition per ASTM 3574, Test K for heat age) v
25、alue must be Report original and aged values with elongation) retained 3.3.5 Tear Resistance, min (ASTM D624, Die C, 10mm sample thickness) Cushions 450 N/m Backs 450 N/m Head Restraints & non-cushion soft trim Report 3.3.6 Wet Compression Set, % loss, Max (ASTM D 3574, Test D, L ,Ct Calculation 50%
26、 compression) Cushions 15% Back 2Head Restraints & non-cushion soft trim Report For seat cushion and back formulations that cannot meet the above requirement, must also be tested to Autoclave Aged compression set per FLTM BN 115-07, 75% deflection computed on original thickness. Acceptance criteria
27、for materials tested to Autoclave Aged compression set are: Cushions 15% Backs 25% Test Method: Autoclave age test specimens per paragraph 6 of test procedure and condition test specimens 1 h after drying. Calculate autoclave aged compression set per below: The reported value shall be the average va
28、lue based on a 5 part evaluation (15 specimens). ENGINEERING MATERIAL SPECIFICATIONWSS-M15P20-B1/B2Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 4 of 7 Calculations: Ct = to - tf x 100 - to Ct - Compression set expressed as a percentage of the original thickness
29、to - Original thickness of test specimen tf - Final thickness after removal from test fixture per test procedure 3.3.7 Fogging (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 16 h) Fog Number, min 70 The formation of clear film, droplets or crystals is cause for rejectio
30、n. Samples are to be prepared with skin, and include mold release agents and anti-squeak or other applied treatments prior to fog testing and allowed to age per 3.2 Preconditioning. 3.3.8 Odor, max Rating 3 (FLTM BO 131-03)3.3.9 Wet Aged CFD Loss, max. (ASTM D 3574, Test C, L) Cushion 10% Back 10% H
31、ead Restraints & non-cushion soft trim Report 3.3.10 Fatigue Resistance, Constant Force Pounding, max (for seat cushions only) (ASTM D 3574, Test I3, Procedure B, 40% compression) One test specimen is required, skin shall not be removed from specimen for this test. Loss of Hardness 25% Loss of Thick
32、ness 5% 3.3.11 Compression Force Deflection Curve Report Supplier will provide stress/strain values from 0-75% compression for each material, sample per ASTM 3574, Test C, 75%, report a minimum of 200 data points. 3.3.12 Flammability, max 100mm/min Must comply with ES-E97B-1011014-AA, Flammability,
33、Interior Trim 3.3.13 Staining, max change 20 ENGINEERING MATERIAL SPECIFICATIONWSS-M15P20-B1/B2Printed copies are uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 5 of 7 Test per method: Test Materials 1. Glass bottle, 2.0 L +/- 200 ml, with a metal screw foil-lined cap. The cap diame
34、ter shall be at minimum 60 mm. 2. Lightest color test vinyl fabric to be used on vehicle program, or white, unsupported PVC film, unembossed, # 103-01, or alternately GM Vinyl Coated Fabric (Prado Grain), available from Test Fabrics1, cut into an 80 mm diameter disc or a circular size that fits tigh
35、tly into the bottle cap. 3. Specimen cut from a molded part, 70 x 70 x 30 mm (+/- 2 mm on either dimension) with skin on the 70 x 70 mm face. Note 1: Test Fabrics, Inc., 415 Delaware Avenue, PO Box #26, West Pittison, PA 18643 USA Tel: 570-603-0432, Fax: 570-603-0433, E-mail: Test Equipment 1. Air-
36、circulating oven capable of maintaining a temperature of 100 2 C for 72 hours (temperature should be recorded or monitored). 2. Color spectrophotometer. Test Procedure 1. Check to ensure the glass bottles and lids are clean and free from contaminants. Prepare two bottles: a control bottle with no fo
37、am sample and a test bottle with foam. 2. Measure the color of the vinyl samples using the spectrophotometer and record the original L* a* b* data. 3. Insert a vinyl disc into the lid of each bottle with face side outwards. 4. Place foam sample on the bottom of test bottle with skin side facing upwa
38、rds (towards the lid). The control bottle will have no foam in it. 5. Carefully screw on the lids, ensuring the vinyl discs remain in place, and hand tighten them. 6. Place the closed bottles in the oven and note temperature and time. 7. After 72 hours, remove the bottles from oven, open lids carefu
39、lly, extract the PVC discs from lids and allow to cool to laboratory conditions, 23 2C, 50 5% RH, for at least 1 hour. 8. Measure the final color of the vinyl samples and again record the L* a* b* data. 9. Using the original and final L* a* b* data, calculate the Efor both vinyl samples (control and
40、 test) using the following formula: E= L + a + b10. To obtain the color change due to the foam, Efoam,subtract the E of the control bottle PVC (Econtrol) from the E of the test bottle PVC (Etest). Etest- Econtrol= EfoamNote: Glass jars should be washed clean after each test, dried thoroughly, and st
41、ored with caps screwed in place to avoid ingress of any chemicals into the jars. Record 1. E of the control bottle and E of the test bottle, Econtrol and Etest. 2. Color Change in Vinyl due to foam, Efoam ENGINEERING MATERIAL SPECIFICATIONWSS-M15P20-B1/B2Printed copies are uncontrolled Copyright 200
42、9, Ford Global Technologies, LLC Page 6 of 7 3.4 BIO-BASED OR RECYCLED CONTENT REQUIREMENTS (WSS-M15P20-B2 Only) Report Each system will have minimum requirements of bio-content/recycled/renewable content in the raw materials, The supplier will present data as to how their material will meet the min
43、imum final content in the finished foam. Production tolerances for minimum and maximum bio content in a given material formulation shall also be reported. The percentage, upper and lower limits, shall be listed on the Engineering Drawing and be reported to Materials Engineering and the Design & Rele
44、ase Engineer. The minimum bio-based content for the application shall be 5%, based on the total pad weight. Changes between bio-based and petro-based foams systems, or changes in the level of bio/recycled content, cannot be made without approval from Seat Engineering and Materials Engineering. 3.5 M
45、ATERIAL CHEMISTRY DEFINITION Report The supplier will define material composition, i.e. polyether urethane, MDI, TDI, MDI/TDI, other blend. 3.6 MISCELLANEOUS PAD FEATURES The Engineering Drawing shall contain the Supplier, Product Code and Trade Name, if additional items such as hook/loop fasteners,
46、 support wires, anti-squeak coatings, molded-in or post applied fabrics and items that are not listed on the Engineering Drawing, such as processing aids, (anti-squeak agents, mold releases, etc) shall be reported by the supplier to Seat Engineering. 4.0 DV/PV TABLE Sample size per specification DV
47、PV 3.3.1 Density X X 3.3.2 Indentation Force Deflection X X 3.3.3 Hysteresis Loss X X 3.3.4.1 Tensile Strength & Elongation X 3.3.4.2 Heat Aged Tensile Strength, X 3.3.5 Tear Resistance, min X 3.3.6 Wet Compression Set, % loss, Max X 3.3.7 Fogging X 3.3.8 Odor X 3.3.9 Wet Aged CFD Loss X 3.3.10 Fati
48、gue Resistance, Constant Force X X 3.3.11 Compression Force Deflection Curve X 3.3.12 Flammability Perform per spec requirements 3.3.13 Staining X 3.4 Bio-based or Recycled Content Requirements X 3.5 Material Chemistry Definition X ENGINEERING MATERIAL SPECIFICATIONWSS-M15P20-B1/B2Printed copies are
49、 uncontrolled Copyright 2009, Ford Global Technologies, LLC Page 7 of 7 5. SUMMARY OF REVISION 2009 10 14 Revised 3.3 (added multi-firmness/multi-density parts), 3.3.6, 3.3.11 2009 01 29 Revised 3.3, (clarified void definition), 3.3.5 (clarified width), 3.3.7, 3.3.8 (updated to global odor methods), 3.3.9 (method update), 3.3.13 (updated staining method), 3.4 (clarified bio-based requirements), 4.0 added DV/PV table.
