1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2012 10 05 Activated B. Witkowski, NA Controlled document at www.MATS Copyright 2012, Ford Global Technologies, Inc. Page 1 of 6 PERFORMANCE, ROOF STIFFENING PAD ASSEMBLY WSS-M15P53-A 1. SCOPE The material defined by this specification
2、 is fully finished roof stiffening pad assembly consisting of a face material and substrate layers. Pad is sometimes referred to as a DVD pad. 2. APPLICATION This composite assembly is used as a roof stiffening pad for passenger cars and trucks or as specified on the Engineering Drawing. 3. REQUIREM
3、ENTS 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). 3.2 PAD COMPOSITION The roof stiffening pad composition is a sandwich construction, typically consisting of the
4、following A. Polyethylene film B. Kraft paper C. Polyurethane adhesive D. Fiberglass E. Rigid polyurethane foam Pad composition can differ from above but must be noted on product drawing, product drawing requirements take precedent over above. Figure 1 E D C B A ENGINEERING MATERIAL SPECIFICATION WS
5、S-15P53-A Copyright 2012, Ford Global Technologies, Inc. Page 2 of 6 3.3 RIGIDITY AND TEMPERATURE 3.3.1 Determination of flexural rigidity should be performed on the pad using a 3 point bending test. The test is done at room temperature, -40C, and 110C. Note dimensions of test fixture used, and dime
6、nsions of adhesive bead should be equal to product drawing. Assembly stiffness 1.5 N/mm min Assembly bonded to sheet metal stiffness 10 N/mm min 3.3.2 Lower the temperature of the pad to -40C for 4 hours, and then raise the temperature to 110C for 4 hours. After 24 hours at room temperature, measure
7、 the deformation of the pad. Pad Deformation 1 mm max 3.4 FLAMMABILITY (ISO 3795/SAE J369) Burn Rate 100 mm/minute max 3.5 PEEL/ADHESION Min 350 N/m or cohesive failure Test Method: Apply a 10 mm diameter bead of adhesive to a 25 x 380 mm section of reinforcing pad substrate. Immediately bond to the
8、 center of a 50 x 300 mm metal panel per substrates below and compress to 3 mm bondline thickness. Remove any excess adhesive with a spatula or other suitable tool. After complete material cure, expose the samples to the conditions indicated below. After the exposure period, condition the samples fo
9、r 24 h at 23 +/- 2 C (condition 3.5.1 does not require an additional 24 h). Clamp a 90 degree peel test fixture equipped with ball bearing track allowing for a continuous 90 degree peel angle into the jaw of a tensile testing machine. Place the test panel into the fixture. Insert the extended end of
10、 the headliner into cross head jaw. Initiate jaw separation at the rate of 50 mm/minute. Continue the test until all the pad assembly has been removed from the panel. Record the average peel force and mode of failure. Report failure mode, initial peel strength and continued peel strength. Test 5 sam
11、ples per exposure condition. 3.5.1 As received at 23 +/- 2 C 3.5.2 Two weeks at 90 +/- 2 C 3.5.3 Two weeks at 38 +/- 2 C and 98 +/- 2 % relative humidity 3.5.4 Thermal cycle - 5 cycles. One cycle consists of: 4 h at 90 +/- 2 C 4 h at 38 +/- 1 C and 98 +/- 2 % relative humidity 16 h at - 30 +/- 1 C T
12、he above testing must be must be performed on the following substrate/pad combinations. 1) E-Coated Steel 2) Phosphated, non E-Coated steel, non-galvanized 3) Phosphated, non E-Coated steel, galvanized 4) Additional add on components to pad such as butyl/foil pads, etc. ENGINEERING MATERIAL SPECIFIC
13、ATION WSS-15P53-A Copyright 2012, Ford Global Technologies, Inc. Page 3 of 6 Requirements: 100 % cohesive failure of adhesive on production painted panels or substrate breakage above the specified loads. Cohesive Failure is preferred Adhesive failure is acceptable if there is no sign of cohesive fai
14、lure with the sheet metal. 3.6 WATER ABSORPTION 5 g/m2 max (FLTM BS 004-02, or equivalent ASTM per drawing) 3.7 WEIGHT, g/m2 As specified on the (FLTM BN 106-01) Engineering Drawing 3.8 TRANSVERSE STRENGTH 10 N min (SAE J949, average of maximum loads on 5 samples) Test composite attached to sheet me
15、tal substrate 3.9 DIMENSIONAL STABILITY (SAE J315) After testing there shall be no blistering or loss of adhesion of the surface material and no visible distortion or shrinkage of the component. Method “A“ +/- 0.5% max Method “C“ (following Method A) +/- 0.5% max Or as otherwise specified on the eng
16、ineering drawing. 3.10 ODOR (FLTM BO 131-03) Rating 3 max 3.11 FOGGING (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 1 h and 16 h) Fog Number 70 min Formation of clear film, droplets or crystals is cause for rejection. 3.12 RESISTANCE TO MILDEW The material shall exhib
17、it no visual evidence of mildew growth and/or objectionable odor after 7 days exposure in a humidity cabinet at 38 +/- 2 C and 98 +/- 2% relative humidity. 3.13 INDENTATION AND RECOVERY (FLTM BO 111-02, Method B, except load is 1.5 kg) The indented assembly must return to its original contour within
18、 5 minutes. In addition, the part shall not be damaged during installation in the vehicle. 3.14 IDENTIFICATION MARKING The reverse side of each assembly must be marked in a suitable way to identify its production batch. There shall be no evidence of identification mark bleed through onto the cover m
19、aterials surface, nor any staining of adjacent assemblies during storage. ENGINEERING MATERIAL SPECIFICATION WSS-15P53-A Copyright 2012, Ford Global Technologies, Inc. Page 4 of 6 3.15 SIMULATED IN-CAR ENVIRONMENTAL AGING The assembly shall not show any delamination, loss of embossed definition, exc
20、essive deformation, or any objectionable surface imperfections. The adhesive system shall not show any evidence of delamination or separation from the assembly or mating components. Test Method: Install a complete assembly using production assembly techniques, in an approved test buck or vehicle, re
21、presentative of intended production dimensions. Expose the vehicle (with windows open) or test buck to the following environmental cycle: Automated programmable test cycles based on the listed test conditions may be accepted by prior agreement with the affected Materials Engineering Activity. Ramp s
22、peed 1 to 5 C per minute. Record actual ramp speed on data sheet. . 5 h at - 40 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at 90 +/- 2 C . 30 min at 23 +/- 2 C and 50% R.H. . 16 h at 50 +/- 2 C and 95 +/- 5% R.H. . 30 min at 23 +/- 2 C and 50% R.H. . 5 h at - 40 +/- 2 C . 30 min at 23 +/- 2 C
23、 and 50% R.H. . 5 h at 90 +/- 2 C 4. GENERAL INFORMATION This information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. 4.1 ADHESIVE BEAD SIZE Use two different sized
24、triangular adhesive beads. The outer bead provides a vacuum seal, whereas the inner bead is only for bonding. Each bead must have a set amount of stick through. See release drawing for bead dimensions and requirements. For read through, a smaller gap between the roof panel and the pad is preferable.
25、 A wider flat bead can reduce read through. Bead sizing: relationship between inner and outer DVD pad = pad assembly ENGINEERING MATERIAL SPECIFICATION WSS-15P53-A Copyright 2012, Ford Global Technologies, Inc. Page 5 of 6 Figure 3: Bead sizing after installed 4.2 ADHESIVE BEAD LAYOUT Distance from
26、edge of pad to center of outside bead 15 mm Gap between inside bead to centerline of outside bead 20 mm Maximum distance between centerline of beads 125 mm Figure 4: Example of Roof Stiffening Pad Adhesive Strategy ENGINEERING MATERIAL SPECIFICATION WSS-15P53-A Copyright 2012, Ford Global Technologies, Inc. Page 6 of 6 4.3 SOLAR LOADING No Read through Simulated vehicle level solar load testing should be performed to evaluate part performance, no read through of the bonded assembly is allowed. Adhesive application should be production intent and per product drawing.
