1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 08 2018 03 12 Revised See Summary of Revisions for Details P. Konopka NA 2018 02 09 Revised See Summary of Revisions for Details P. Konopka NA 2015 06 29 Revised See Summary of Revisions for Details J. Crist, NA Controlled document at ww
2、w.MATS Copyright 2018, Ford Global Technologies, LLC Page 1 of 24 GLASS, PERFORMANCE, SAFETY, FLOAT LAMINATED WSS-M28P1-B1 FOR WINDSHIELDS LAMINATED FOR SIDE GLASS AND BACKLITES WSS-M28P1-B2 LAMINATED FOR ALL OTHER GLASS APPLICATIONS WSS-M28P1-B3 TEMPERED FOR SIDE GLASS AND BACKLITES WSS-M28P1-B4 TE
3、MPERED FOR ALL OTHER GLASS APPLICATIONS WSS-M28P1-B5 POLYCARBONATE (PC) COATED, FOR SIDE GLAZING AND BACKLITES WSS-M28P1-B6 POLYCARBONATE (PC) COATED, FOR ALL OTHER GLAZING APPLICATIONS WSS-M28P1-B7 1. SCOPE The following specifications define performance requirements for: B1 - Laminated products fo
4、r windshields. B2 - Laminated products used in areas such as side glass and backlites. B3 - Laminated products used anywhere driver visibility is not a concern such as roof glazing or behind the B pillar on trucks. B4 - Tempered products used in areas such as side glass and backlites. B5 - Tempered
5、products used anywhere driver visibility is not a concern such as roof glazing or behind the B pillar on trucks. B6 - Polycarbonate (PC) coated products used in areas such as fixed side glazing and fixed backlites. B7 - Polycarbonate (PC) coated products used anywhere driver visibility is not a conc
6、ern such as fixed roof glazing or behind the B pillar on trucks. 2. APPLICATION These specifications were released originally for processed safety glazing that meet all Governmental and other standards (reference para 3.8) used for glazing motor vehicles. 3. REQUIREMENTS 3.1 APPROVED SOURCES This sp
7、ecification is performance based and does not have approved sources. All test plaques must go through process conditions identical to that of final production parts. 3.4 APPEARANCE Automotive windows are defined as “appearance items“ according to AIAG (Automotive Institute Action Group) Production P
8、art Approval Process (PPAP). This requires that adequate approval of appearance criteria must be defined and adhered to. Since this specification is the sole definition of such criteria, adherence to it satisfies the intent of PPAP Appearance Item Requirements, therefore, no additional appearance ap
9、proval reporting is required. ENGINEERING MATERIAL SPECIFICATION WSS-M28P1-B1/B7 Copyright 2018, Ford Global Technologies, LLC Page 2 of 23 3.5 TRADEMARK The trademark shall meet all criteria of the local or intended market requirements and shall include any additional information required by the co
10、untry of intended use. The trademark shall be legible from inside or outside the vehicle and the location of the trademark shall be designated and/or approved by all responsible activities of the Ford Motor Company. The trademark location shall be shown on the engineering drawing. The trademark may
11、be applied using ceramic coatings in glass or via a printing, laser part marking, tool marking, film lamination, or film insert molding (FIM) procedure in polycarbonate. In the case of polycarbonate glazing, the method or methods allowable shall be specified on the engineering document. Reference: R
12、QT-011101-12080, RQT-001800-004030 1.0 mm dia. (6 allowed), no more than 6 total for backlites and quarter windows, 150 mm separation. Adhesion chips are not allowed. Bloom Not allowed Bulls eyes Permitted if not visible at in vehicle position Dig/rub Not allowed Etch mark, crush Not allowed Optical
13、 distortion Distortion permitted within 10 mm of paint edge, otherwise must be approved by boundary sample review and signoff. ENGINEERING MATERIAL SPECIFICATION WSS-M28P1-B1/B7 Copyright 2018, Ford Global Technologies, LLC Page 4 of 23 Area A Area B Lint (laminated Heavy 0.5-5.0 mm and Medium 10.1-
14、20.0 mm no more than 2 in a 305 mm dia.; Medium 3.0-10.0 mm and Light 20.1-40.0 mm no more than 3 in a 305 mm dia.; Light 6.0-20.0 no more than 4 in a 305 mm dia. Edge Treatment (Shiners, etc.) Refer to SAE J673 for glass edge definition. Specific edge requirements identified on part drawing. Tool m
15、arks, including mold marks, cloth marks, screen marks, and tong marks. Not allowed Not allowed unless agreed upon in approved boundary sample Water stain Not allowed 3.12.2 Vinyl Defects for Laminated Glass Products (B1, B2, along the edge closest to the “C“ region, a smear protruding 2 mm is allowe
16、d Incorrect Print Dots The incomplete printing of the 1.0 x 6.0 mm allowed, 305 mm separation. ENGINEERING MATERIAL SPECIFICATION WSS-M28P1-B1/B7 Copyright 2018, Ford Global Technologies, LLC Page 7 of 23 missing or run together desired image on the surface of a part reference Design Rule FX-011100-
17、0012 Defect Definition of Defect Acceptance Criteria Edge of print not consistent Printing edge has inconsistent smoothness and straightness Saw tooth 0.5 mm peak height permitted, 0.5 to 1.0 permitted over 150 mm length per edge Grid Color Variations in color due to silver on different surfaces are
18、 acceptable. Defect Definition of Defect Acceptance Criteria Bus bar visibility through decoration layer Not allowed Discoloration from heater grid, antenna, bus bar Discoloration of bus typically due to oxidation. Not allowed on blackout area Allowed on bus bar due to oxidation Silver void on heate
19、r grid, antenna, or bus bar Allowable only if not visible from outside of vehicle and part performance is not affected. May be repaired (touch ups) if void is less than 3 mm in diameter and part performance is not affected post touch up. 3.12.5.4 Polycarbonate Decoration Defects (Laser, Tool obscura
20、tion, Film Insert Molding or Lamination) Defect Definition of Defect Acceptance Criteria Coating defect over laser decoration Delamination or cracking of coating with genesis from the edge of the laser part mark. This may occur when laser part marking occurs after coating procedure and the laser pow
21、er is too high. No damage to coating system that exceeds 0.1mm from edge of laser mark. Coating defect over tool marking Coating drips, runs, and or build up due coating over laser part marking. This may occur when laser part marking occurs before coating procedure No drips, build up, or run visible
22、 in area “A” or “B”. Defects in the “C” area are allowed, so long as they do not result in cracking or delamination of coating. Wrinkling of Film Film folds or wrinkles during the manufacturing process, resulting in wrinkled lines in the in the glazing piece. Not allowed in “A” and “B” areas Film De
23、lamination Film delaminates from PC substrate or coating delaminates from film Not allowed in any area. Air, oil, or moisture Penetration (bubbles) Air, oil, or water pockets trapped underneath film. None allowed in areas “A” and “B”. For area “C” 1.5mm diameter allowed. Dirt/foreign Material Dirt o
24、r foreign material stuck between the film and the PC. Area “A“: not allowed Area B: 1.5 mm, 305 mm separation Area C: 1.5 mm, 305 mm separation 3.12.6 Optical Defects All types of optical defects (e.g. bulls eyes, cloth marks, and ripple) shall be inspected using a point source light (see Glossary)
25、as shown in Figure D1. The test part is mounted at vehicle installation angle and is located between the point source light and a white projection board so that the projected light passes through the glazing before reaching the projection board. The total distance between the point source light and
26、projection board is 8m, with the test part is halfway between. The test part (excluding backlites) is rotated around its vertical axis as needed to simulate views from the side. The inspector observes the ENGINEERING MATERIAL SPECIFICATION WSS-M28P1-B1/B7 Copyright 2018, Ford Global Technologies, LL
27、C Page 8 of 23 projected image and reports the part unacceptable if variations in the brightness of the projected image are extreme. A photograph of the projected image will be required for some reports. Figure D1. Point source light test. When the point source image is hard to interpret, the test p
28、art is also inspected using the zebra test, as shown in Figure D2. The test part is mounted at vehicle installation angle and is located between the inspector and a zebra board (see Glossary) so that the inspector can see the appearance of the stripes through the test part. The total distance betwee
29、n inspector and the zebra board is 8m, and the test part is halfway between. The test part (excluding backlites) is rotated around its vertical axis as needed to simulate views from the side (cross car). The inspector observes the apparent shape of the stripes and reports the part unacceptable if an
30、y of the stripes appear excessively wavy. A photograph of the zebra board through the test part will be required for some reports. Figure D2. Zebra test. 3.13 OBSCURATION AND PRINTING IN GLAZING 3.13.1 Glass Ceramic Coatings Decorative ceramic coatings (ceramic frits) must meet all requirements of W
31、SS-M99P6-C1/C2 (most current version) and be chosen from the Ford Approved Source list (ASL). They must also be specified on the engineering drawing. Conductive coatings, such as painted antennas and heated grids for backlites, must meet all requirements of WSB-M12P2-B/B2 (most current version) and
32、be chosen from the Ford Approved Source list (ASL). They must also be specified on the engineering drawing. The Tier 1 supplier must meet all USCAR-40 Lead Free Solder Validation Test Plan requirements with new lead free terminals. Any deviations must be approved by Core Glass Engineering. Electrica
33、lly heated glass must also conform to all SDS requirements. ENGINEERING MATERIAL SPECIFICATION WSS-M28P1-B1/B7 Copyright 2018, Ford Global Technologies, LLC Page 9 of 23 3.13.2 Polycarbonate Conductive inks and pastes the following are references for performance: Conductive pastes, such as printed a
34、ntennas and heated grids for backlites, must meet all requirements of WSB-M12P2-B/B2 (most current version). EHBs (electrically heated backlites) must also conform to all applicable SDS requirements. 3.13.3 Ceramic Frits Ceramic frit shall be as specified on the engineering drawing. Materials suppli
35、ed shall meet WSS-M99P6-C1/C2 (most current version), be chosen from the Ford Approved Source List (ASL) and meet all the requirements listed below. 3.13.3.1 Opacity The measurement shall be made using a transmission black and white densitometer e.g. “Tobias Model TBX” or similar, in direct contact
36、with the coating surface. For items B1, B2, B3, B4, B5, B6 UV light transmission must be less than 0.1% (UV absorption must be greater than 99.9%). 3.13.3.2 Color (FLTM BI 109-01 Visual Assessment, SAE J1545, Three-Angle CMC) Color shall match the Master Approved Sample color panel or the initial sa
37、mple as approved by Design Center, if applicable. Ceramic frits shall be as specified on the engineering drawing. Materials supplied shall meet all the requirements listed in those specifications. 3.13.3.3 Ceramic Frit Thickness (ASTM B 487, Non-Metallic Substrates) Coating thickness must be suffici
38、ent to meet all requirements of this material specification. Refer to mutually agreed upon control plan. 3.13.3.4 Ceramic Frit Adhesion Grade 2 max (WSS-M99P6-C1/C2) Adhesion (FLTM BI 106-01, Method B, new knife only), part should be tested in the coating ink/paint configuration as specified on the
39、engineering drawing. 3.14 POLYVINYL BUTYRAL FOR LAMINATED PRODUCTS (B1, B2 and B3) Polyvinyl butyral with or without gradient band shall be as specified on the engineering drawing. Tolerances shall be as specified in the material specifications or on the engineering drawing. 3.14.1 Vinyl Adhesion Pu
40、mmel Test Pummel value 3-6 (Pummel Adhesion Procedure FLTM BU 158-01) This test is conducted to determine the bond between the glass and the vinyl on laminated products. This test is typically used for process control within each plant. Additionally, laminated products with any coating on either of
41、the two inner surfaces must maintain a pummel adhesion value between 3 and 6 after being exposed to the weathering conditions of section 3.16. ENGINEERING MATERIAL SPECIFICATION WSS-M28P1-B1/B7 Copyright 2018, Ford Global Technologies, LLC Page 10 of 23 3.14.2 Bake Test The Bake test is a check for
42、laminate de-airing and moisture content, that if not within correct limits, may lead to in service bubble formation within the PVB or “ice crystal” formation. Acoustic PVB is more susceptible to this failure mode than normal PVB. Bake testing is considered a non-destructive test that should not be p
43、erformed prior to 48 hours after the initial autoclave process to allow the parts to normalize. This test is to be conducted on a full laminated part for initial qualification and shall be tested as specified in the control plan and includes all parts up to and including the PPAP phases. The bake te
44、st shall be repeated for glass thickness changes, glass bending changes, lamination process changes, manufacturing line changes, and PVB changes or as determined by Engineering/STA. Bake parts for 2hrs at 100 C and then inspect for bubbles per the most current version of the ANSI Z26.1. Parts to be
45、tested may be cut to fit the test chamber as long as the entire laminated part is tested. Bake Test inspection criteria (reference section 5.5). Any parts not meeting the ANSI Z26 specification are considered failed and the lamination process must be revised and revalidated by this test. An alternat
46、ive is to autoclave bake test the parts at ambient pressure (14 psi / 96 kPa). A stair step bake test must be performed on an initial qualification part (1 part) and when process parameters are varied from the initial validation. The stair step bake test consists of baking the same part at 110 C, 12
47、0 C, 130 C, 140 C, and 150 C and inspecting for bubbles as above after each bake cycle (each bake cycle is 2 hours). The data is to be recorded for future reference. Any bubble formation at 110 C or above is not considered a failure but should be used to alert the manufacturer to make process change
48、s to improve the de-airing of the lamination. 3.15 ADHESIVE BONDING It is the Tier 1 glass suppliers responsibility to insure that the glass, plastic surfaces and/or ceramic coatings to be adhesively bonded meet all requirements of the following applicable specifications (most current versions). Adh
49、esion testing may be performed by the glass bonding adhesive supplier on behalf of the Tier 1. Testing must be performed on the glass surface intended for bonding (specific ceramic frit, air or tin side of glass) and must be performed with the specific Ford production glass cleaners, primers, and urethanes approved in each region of use. The adhesion system used by each Ford plant receiving the Tier 1 glass must be tested. This does not rep
