1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 02 2015 02 27 Editorial See Summary of Revisions L. Sinclair, NA 2013 10 31 Revised See Summary of Revisions L. Sinclair, NA 2013 07 17 Released L. Sinclair, FNA Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LL
2、C Page 1 of 12 PERFORMANCE REQUIREMENTS, PACKAGE TRAY ASSEMBLY WSS-M15P6-E 1. SCOPE This specification defines the standardized characteristics required for package tray assemblies with carpeted, woven/knitted, painted or other decorative surfaces. 2. APPLICATION This specification was released orig
3、inally for performance requirements for rear package trays. Limitation: Foam is not allowed for use in visible areas due to UV stability issues (degradation). 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standar
4、d Requirements For Production Materials (WSS-M99P1111-A). 3.1.1 In addition to the requirements listed herein, the individual assembly components shall meet all the requirements of the applicable material specifications for the face material and substrate components. Material specification requireme
5、nts are to be used for initial qualification of materials. 3.1.2 Materials used in interior applications must meet the requirements outlined in WSS-M99P2222-D1/Latest, Performance, Vehicle Interior Environment Quality Material/Component Requirements. Data must be obtained by the appropriate vehicle
6、milestone on the assembly. 3.1.3 Painted components within the package tray shall meet the requirements of WSS-M2P188-A1/latest for paint over plastic or WSS-M2P190-A/latest if paint over metal. 3.1.4 Mold in Color plastic components shall meet the requirements of WSS-M15P4-F. 3.1.5 Labels on the pa
7、ckage tray must meet the appropriate suffix of WSS-M99P41-A10-A72/latest. 3.1.6 Any additional materials on the face of the package tray, such as air extractor grills or coverings must conform to the appearance section of this specification if not addressed in one of the above specifications. 3.2 SA
8、MPLE SELECTION See Table 1 for sample size and testing requirements. Production test specimens shall be taken from a flat area on the package tray away from any attachments. 3.3 APPEARANCE (FLTM BI 109-01) ENGINEERING MATERIAL SPECIFICATION WSS-M15P6-E Copyright 2015 Ford Global Technologies, LLC Pa
9、ge 2 of 12 The color and face construction shall match the approved Design Center master sample, or shall be as specified on the engineering drawing. 3.4 COMPOSITION AND CONSTRUCTION The face material shall be as specified on the material specification and/ or the Engineering Drawings. The substrate
10、 composition shall be as specified on the Engineering Drawing and/or the Material Specification as required. Backcoating (If applicable): The back coating shall form a continuous and uniform coating over the back of the face material so that the entire backing of the face material is covered. Also,
11、the backcoat shall show no evidenced of cracking or crumbling during any of the evaluations required within the specification and during normal field conditions. The backcoating shall thoroughly saturate the base of the fibers to ensure adequate fiber lock. Penetration of the backcoat through to the
12、 face of the material shall be controlled to provide the required resistance to abrasion and fiber loss, but the backcoat shall not be visible on the face of the material. Adhesion: The face material and substrate shall be properly bonded together with the backcoating and/or adhesive where necessary
13、, to ensure that the various components of the finished package tray assembly does not delaminate under normal handling and shipping operations. 3.5 ASSEMBLY TESTING 3.5.1 Short Term Heat, Humidity and Cold Cycle (ISO 105-A02/ AATCC Evaluation Procedure 1) Conduct then test with the trim assembly mo
14、unted on an actual or simulated production support foundation with the approved retention methods. In order to test the effects of temperature fluctuations combined with humidity (so called “thermal fatigue”) the composite is subjected to the following cyclic loading: 5 h at -30 +/- 2 C 30 minutes a
15、t 23 +/- 2 C and 50% R.H. 5 h at 100 +/- 2 C 30 minutes at 23 +/- 2 C and 50% R.H. 2 h at 50 +/- 2 C and 95 +/- 5% R.H. 30 minutes at 23 +/- 2 C and 50% R.H. 5 h at -30 +/- 2 C 30 minutes at 23 +/- 2 C and 50% R.H. 5 h at 100 +/- 2 C Requirements: The trimmed assembly, after the test, shall exhibit
16、no visible and objectionable appearance such as: wrinkling, distortion, blistering, delamination, blushing, hazing, or milking of the decorative surface, or expansion, shrinkage, or warpage which will interfere with normal functional operation. . The trimmed assembly shall not exhibit movement in ex
17、cess of 3.0 mm at the specified points. These points shall be determined in agreement with PD Engineering prior to testing. Parts must be measured before testing, at greatest movement during exposure and after exposure. Measurements can be taken at the end of every cycle. If measurements are taken a
18、llow an additional 30 minutes to take measurements and to allow the chamber to stabilize prior to the next cycle. Measure and record the gap at ENGINEERING MATERIAL SPECIFICATION WSS-M15P6-E Copyright 2015 Ford Global Technologies, LLC Page 3 of 12 specified points. Also report the difference from t
19、he original gap measurement. Test report to include sketch of part with the measurement points indicated. 3.5.2 Long Term Heat Aging Rating 4 min (7 days at 100 +/- 2 C, ISO 105-A02 / AATCC Evaluation Procedure 1) The trimmed assemblies shall remain relatively unaffected by the exposure cycles durin
20、g and after the tests as demonstrated: The cover materials and scrim shall show no evidence of tackiness, exhibit a color tone change or exhibit fiber deterioration. Any “spotty“ or non-uniform staining or discoloration shall be cause for rejection. The cover materials and scrim shall not delaminate
21、 or bridge from substrate after exposure. Functionally no excessive expansion, shrinking or warping that will interfere with normal functional operations is allowed. Dimensionally the trimmed assembly shall not exhibit movement in excess of 3.0 mm at the specified points. These points shall be deter
22、mined in agreement with PD Engineering prior to testing. 3.5.3 Impact Test Method: (Gardner Instruments Impact Tester or equivalent). Using a 900 g falling weight with a hemispherical nose diameter of 12.7 +/- 0.1 mm and a platform below the test sample with a target hole of 16.26 +/- 0.025 mm diame
23、ter, test at the noted force below. 23 +/- 2 C 5.0 J The assembly shall show no evidence of cracking or breaking and shall fully recover from indentation in the time required for the assembly to recover to 23 +/- 2 C. 3.5.4 Droop (supported package trays only) 100 mm max Test Method: Extend 1/2 the
24、length, longest dimension, of a finished part, trim side up, over the end of a suitable flat surface. After one minute, measure the maximum amount of deflection, relative to the flat surface, of the unsupported end of the part. 3.5.5 Sag 12 mm max Test Method: Mount package tray in a production repr
25、esentative metal retainer buck. Place a 900 g weight with a contact area of 50 x 50 mm on the package tray at 3 non adjacent unsupported positions. Place buck in an air circulating oven at 100 +/- 2 C for 7 days. Remove, take weights off, and allow to condition for 24 h at 23 +/- 2 C prior to evalua
26、tion. The assembly shall exhibit no more than 12 mm sagging in the unsupported areas 24 h after weights are removed. After the weights are removed and after 24 h conditioning evaluate the face material to ensure that there is not a permanent set or deformation on the surface from the weights. 3.5.6
27、Surface Laminate Ply Adhesion (FLTM BN 151-05 except Jaw Speed: 305 mm/minute) ENGINEERING MATERIAL SPECIFICATION WSS-M15P6-E Copyright 2015 Ford Global Technologies, LLC Page 4 of 12 The cover stock of the test specimen shall be separated from the substrate by hand and without the use of solvents p
28、rior to pulling. Test for the exposures listed below. Original Adhesion 500 N/m min Heat Aged: 7 days at 100 +/- 2 C 500 N/m min Heat/Humidity: 7 days at 38 +/- 2 C and 300 N/m min 95 +/- 5% relative humidity Tested samples must show evidence of cohesive failure between face goods and substrate. 3.5
29、.7 Dimensional Stability (FLTM BN 105-03, 2 cycles) WMD & AMD 2% max. 3.5.8 Movable Package Tray Testing (5 door package tray) 3.5.8.1 Water Absorption (relative) 20% max (SAE J315) 3.5.8.2 Resistance to Water Spotting (FLTM AN 101-01, ISO 105-A02 / AATCC Evaluation Procedure 1) No spots shall remai
30、n after the distilled water is completely dried off. 3.5.8.3 Scrim Laminate Ply Adhesion (FLTM BN 151-05 except Jaw Speed: 305 mm/minute) The scrim of the test specimen shall be separated from the substrate by hand and without the use of solvents prior to pulling. Test for the exposures listed below
31、 only. Original Adhesion 325 N/m min Heat Aged: 7 days at 100 +/- 2 C 275 N/m min Heat/Humidity: 7 days at 38 +/- 2 C and 165 N/m min 95 +/- 5% relative humidity Samples should not be able to be started by hand and must have 100% cohesive failure. 3.5.9 Speaker Grille Rupture Strength* 67 N min (For
32、 integral perforated speaker grille) *Force required to break speaker grille rib. Test Method: A rib of the speaker grille is placed over a target hole diameter of 75 mm. A steel loading block of 1.6 mm x 9.5 mm is centered on the rib, and the force required to rupture the rib at a rate of 125 mm/mi
33、nute using an Instron measured. ENGINEERING MATERIAL SPECIFICATION WSS-M15P6-E Copyright 2015 Ford Global Technologies, LLC Page 5 of 12 3.6 PHYSICAL/WEAR PROPERTIES 3.6.1 Resistance to Mildew The material shall exhibit no visible evidence of mildew growth and/or objectionable odor after 7 days expo
34、sure in a humidity cabinet maintained at 98 +/- 2% relative humidity and 38 +/- 2 C. 3.6.2 Taber Abrasion (non woven carpet) 1200 cycles (SAE J1530A, 500 g load, H-10 wheels) The sample shall exhibit no visual evidence of wear through to the foundation of the pile fibers in the abraded area in exces
35、s of the failure criteria shown in Appendix 1. No roping or pilling allowed. 3.6.3 Taber Abrasion (knitted fabric) 1200 cycles (SAE J948, 500 g load, CS-10 wheels) The sample shall exhibit no visual evidence of wear through to the foundation of the pile fibers in the abraded area in excess of the fa
36、ilure criteria shown in Appendix 1. Pattern distortion is not allowed after testing. 3.6.4 Resistance to Snagging 50 cycles (SAE J1530A, 250g, H-18 wheels) No evidence of fiber pullout in excess of the minimum failure criteria shown in Appendix 2. Pattern distortion is not allowed after testing. 3.6
37、.5 Air Flow Extractor 3.6.5.1 Poke Test 100 N min (SH-0112, DVM-0112-SH) 3.6.5.2 Poke Test after UV Fade 100 N min (FLTM BO 116-01, ISO 105-A02/ AATCC Evaluation Procedure 1, 2406.4 kJ/m2 ,SH-0112, DVM-0112-SH) 3.7 APPEARANCE PROPERTIES 3.7.1 Resistance to Fade (FLTM BO 116-01, ISO 105-A02/ AATCC Ev
38、aluation Procedure 1) Xenon Arc Exposure 2406.4 kJ/m2 Rating 4 min The material shall show no change in color tone. 3.7.2 Fiber Deterioration after UV exposure No deterioration of fibers or yarns after testing to the applicable exposure levels in section 3.7.1 on the molded production components. EN
39、GINEERING MATERIAL SPECIFICATION WSS-M15P6-E Copyright 2015 Ford Global Technologies, LLC Page 6 of 12 Taber Abrasion (Carpet) 1000 cycles (SAE J1530A, 500 g load, H-10 wheels) Taber Abrasion (Knitted Fabric) 1000 cycles (SAE J948A, 500 g load, CS-10 wheels) The material shall exhibit no visual evid
40、ence of wear through to the foundation of the pile fibers in the abraded area in excess of the failure criteria shown in Appendix 1. No roping or pilling allowed. Pattern distortion is not allowed after testing. 3.7.3 Resistance to Crocking (FLTM BN 107-01, ISO 105-A03 / AATCC Evaluation Procedure 2
41、) Dry Rating 4 min Distilled Rating 4 min 3.7.4 Soiling and Cleanability (FLTM BN 112-08, ISO 105-A03/ AATCC Evaluation Procedure 2) After Cleaning Rating 3 min 3.8 PHOTOMETRIC FOGGING 70 min. (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 16 h) Formation of clear film,
42、 droplets or crystals is cause for rejection. 3.9 ODOR Rating 3 max. (FLTM BO 131-03) 3.10 FLAMMABILITY (ISO 3795/SAE J369) Burn Rate 100 mm/min.max 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Cont
43、act for questions concerning Engineering Material Specifications. 5. SUMMARY OF REVISIONS 2015 02 27 Editorial Corrected allowed sag mismatch from requirement to text. Was 6 mm in text corrected to 12 mm to match requirement. 2013 10 31 Added back in speaker grille rupture strength (3.5.9)ENGINEERI
44、NG MATERIAL SPECIFICATION WSS-M15P6-E Copyright 2015 Ford Global Technologies, LLC Page 7 of 12 Table 1: Testing Sample Size Test New Construction Rolled Goods * Assembly Testing (DV) Assembly Testing (PV) New Color Only (MCDCC Process) 3.5.1 Short Term Cycling 1 1 3.5.2 Long Term Cycling 1 1 3.5.3
45、Impact 3 per condition 3 3.5.4 Droop 1 3.5.5 Sag 1 1 3.5.6 Surface Laminate Ply Adhesion 3 per condition 3 3.5.7 Dimensional Stability 1 1 3.5.8.1 Water Absorption 1 3.5.8.2 Resistance to Water Spotting 1 3.5.8.3 Scrim Laminate Ply Adhesion 3 per condition 3 3.5.9 Speaker Grille Rupture Strength 3 3
46、 3.6.1 Resistance to Mildew 1 1 3.6.2/3 Taber Abrasion 3 + 1 to failure 3 + 1 to failure 3 3.6.4 Resistance to Snagging 3 3 3 3.6.5.1 Air Extractor Poke Test 15 3.6.5.2 Air Extractor Poke Test after UV Fade 15 3.7.1 Resistance to Fade 1/ surrogate data 1/ surrogate data 1 3.7.2 Fiber Deterioration a
47、fter UV Exposure 1 / surrogate data 1 / surrogate data 1 3.7.3 Resistance to Crocking 1 per condition / surrogate data 1 per condition/ surrogate data 1 per condition 3.7.4 Soiling and Cleanability 1 per condition/ surrogate data 1per condition / surrogate data 1 per condition 3.8 Photometric Foggin
48、g 3 3 3 3.9 Odor 1 per condition 1 per condition 1 3.10 Flammability* X X X *Construction approval of a new face material will not be granted until assembly testing on a production representative substrate and process has been tested. * Sample size is burn rate dependent, FMVSS 302 can be used as su
49、rrogate. Note: For new face material color property data may be surrogate if using carry over fiber suppliers. The numbers in the table represent the number of specimens needed per sample. Tests italicized in the table must have samples reviewed and kept by Materials Engineering for construction package approval ENGINEERING MATERIAL SPECIFICATION WSS-M15P6-E Copyright 2015 Ford Global Technologies, LLC Page 8 of 12 Appendix 1: Taber Abr
