1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 4 2016 07 29 Released Released WSS-M98D39-A4, revised A/A2 S. Gatzek, NA 2012 08 30 Revised See Summary of Revisions Y. Bankowski, NA 2010 10 19 Activated Y. Bankowski, NA Controlled document at www.MATS Copyright 2016, Ford Global Techn
2、ologies, LLC Page 1 of 6 LAMINATE, THERMOPLASTIC OLEFIN (TPO) SKIN/ WSS-M98D39-A CROSS-LINKED POLYOLEFIN FOAM, DOOR PANEL AND INTERIOR TRIM APPLICATIONS LAMINATE, THERMOPLASTIC OLEFIN (TPO) SKIN/ WSS-M98D39-A2 CROSS-LINKED POLYOLEFIN FOAM, VACUUM FORMED INSTRUMENT PANEL APPLICATIONS LAMINATE, THERMO
3、PLASTIC OLEFIN (TPO) SKIN WSS-M98D39-A4 CROSS-LINKED POLYOLEFIN FOAM, NON-SCORE SEAMLESS PAB INSTRUMENT PANEL APPPICATIONS 1. SCOPE The materials defined by this specification are a formed assembly consisting of a cross-linked polyolefin foam bonded to a TPO cover material. 2. APPLICATION WSS-M98D39
4、-A/A2 - These specifications were released originally for material used in interior trim applications, such as the CD391 door trim or for instrument panel applications utilizing the IMGL process. This laminate is either negatively vacuum formed for typical in-mold-grain process or positively vacuum
5、formed and then adhesively bonded to a rigid substrate. WSS-M98D39-A4 This specification was originally released for a non-score seamless PAB instrument panel application for the B515 program. This laminate is positively vacuum formed and then adhesively bonded to a rigid substrate. Parts using this
6、 specification shall meet the appropriate performance specification WSS-M15P45-C/Latest Instrument Panel and Soft Interior Components, Flexible Cover SkinMaterial Performance specification and the Craftsmanship compression/deflection criteria per the appropriate ARL: 17-0209 for door and console arm
7、rests, 17-0220 for door upper roll, and 17-0229 for IP upper unless otherwise mutually agreed between Product Development and Materials Engineering. 2.1 LIMITATIONS WSS-M98D39-A4 Not to be used for instrument panel applications where laser scoring of the skin is required for airbag deployment. 3. RE
8、QUIREMENTS 3.1 APPROVED SOURCES This specification requires the use of approved sources. Only the sources identified on the Ford Approved Source List (ASL) can be used when this specification is listed on the drawing, CAD file, or other documents. The list of approved sources is located within Ford
9、at or available externally through a Ford Materials Engineer. ENGINEERING MATERIAL SPECIFICATION WSS-M98D39-A/A2/A4 Copyright 2016, Ford Global Technologies, LLC Page 2 of 6 3.2 APPEARANCE The color, pattern, gloss level and finish shall match the approved Corporate Design master sample. 3.3 FOAM/S
10、KIN LAMINATE CONSTRUCTION PROPERTIES 3.3.1 Dimensions* (Foam/skin laminate thickness) WSS-M98D39-A/A2 TPO Skin 0.48 0.68 mm Cross-Linked Polyolefin Foam 2.00 - 3.20 mm Total Report, mm WSS-M98D39-A4 TPO Skin 0.60 mm nominal Cross-Linked Polyolefin Foam 2.50 mm nominal Total Report, mm * Skin and foa
11、m thickness may differ from the listed values based on program targets and part design; skin and foam thickness, tolerances for each layer and total thickness as specified on Engineering Document. Measure the thickness of each layer and the total thickness of the laminate at several points along the
12、 cut surface of a cross section. 3.3.2 Tensile Strength 1.3 MPa min (ISO 37, Type 1, 50 mm bench marks, 5 specimens min, any direction) 3.3.2.1 Elongation, 300% min (Test according to 3.4.2) 3.3.3 Tear Strength 12 N/mm min (ISO 34, Method B, Procedure A/ASTM D 1004, any direction) 3.3.4 Hardness, Du
13、rometer A - Skin (ISO 868 /ASTM D 2240, 15 s dwell; layer the skin samples to a minimum thickness of 5 mm) WSS-M98D39-A/A2 Report WSS-M98D39-A4 50 +/- 5 3.3.5 Hardness, Durometer A Bilaminate Composite Report (ISO 868 /ASTM D 2240, 15 s dwell, test with film side up; layer) the composite samples to
14、a minimum thickness of 5 mm Foam density will impact the overall composite hardness and will vary based on program targets and part design; composite hardness as specified on Engineering Document 3.3.6 Peel Adhesion of Top Film to Foam (ISO 2411/FLTM BN 151-05, 180o peel 300 mm/minute, any direction
15、, test Specimens must be 50 mm in width) ENGINEERING MATERIAL SPECIFICATION WSS-M98D39-A/A2/A4 Copyright 2016, Ford Global Technologies, LLC Page 3 of 6 3.3.6.1 Original 0.6 N/mm min or 100% cohesive foam tear 3.3.6.2 A: After 168 hours at 90 +/- 2 C 0.6 N/mm min or 100% cohesive foam tear 3.3.6.3 A
16、2/A4: After 240 hours at 107 +/- 2 C 0.6 N/mm min or 100% cohesive foam tear 3.4 COLOR AND APPEARANCE PROPERTIES The following tests (para 3.4.1 3.4.3) need to be tested on a textured or grained top film: 3.4.1 Resistance to Abrasion (SAE J948, CS-10 wheels, 500 g load, 250 cycles) The surface shall
17、 show no evidence of wear through, and the color of the abraded area shall be compatible in appearance with the adjacent unabraded area. 3.4.2 Resistance to Scuffing (SAE J365, 250 cycles) The surface shall show no evidence of wear through, lifting, peeling or excessive scuffing and the color shall
18、be compatible to the adjacent unabraded area. 3.4.3 Soiling and Cleanability (FLTM BN 112-08, ISO 105-A03/AATCC Evaluation Procedure 2) Cleanability Rating 3 min The following tests (para 3.4.4 3.4.8) conducted on the laminate material may be used as surrogate data for the WSS-M15P45-C/latest compon
19、ent testing: 3.4.4 Resistance to Cleaning Agents (FLTM BN 107-01, 10 cycles, AATCC Evaluation Procedure 2) Test Procedure: Saturate white cotton cloth with the cleaners listed. Evaluation according to the AATCC Scale. Cleaners: 1) Deionized water Rating 4 min 2) Window cleaner Rating 4 min 3) All pu
20、rpose cleaner Rating 4 min 4) Dry (no cleaners or water) Rating 4 min 5) Isopropyl Alcohol/DI Water 50/50% by volume Rating 4 min 6) Isopropyl Alcohol/DI Water 80/20% by volume Report only 7) 100% Ethanol Report only 3.4.5 Resistance to Sunscreen Lotion Rating 3 max and Insect Repellent No loss of a
21、dhesion (FLTM BI 113-08, Method A, 23 oC and 74 oC) 3.4.6 Paint Adhesion Top Coat Grade 0 (FLTM BI 106-01, Method C) The tape shall not lift or delaminate the surface coating. ENGINEERING MATERIAL SPECIFICATION WSS-M98D39-A/A2/A4 Copyright 2016, Ford Global Technologies, LLC Page 4 of 6 3.4.7 Resist
22、ance to Interior Weathering (FLTM BO 116-01, ISO 105 A-02/AATCC Evaluation Procedure 1) 3.4.7.1 A: 977.6 kJ/m2 Rating 4 min 3.4.7.2 A2/A4: 3609.6 kJ/m2 Rating 4 min The material shall not exhibit staining, color tone change, change in hue, cracking, crazing, tackiness or other deterioration after ex
23、posure in accordance with testing. Read and report the gloss change. For new coverskin technology, check samples at 526 kJ/m2 intervals and note any changes in appearance. The materials shall be rejected if adhesive staining or other non-uniform staining results from material. 3.4.8 Colorfastness to
24、 Burnt Gas, Rating 4 min (AATCC 23 or equivalent method, 168 hours at 60 C, ISO 105 A-02/AATCC Evaluation Procedure 1; light colors only) 3.4.9 Dimensional Stability, (SAE J883) 3.4.9.1 A: 168 h at 90 +/- 2 C MD & AMD +/- 4% 3.4.9.2 A2/A4: 168 h at 107 +/- 2 C +/- 4% MD & AMD Shall show no evidence
25、of delamination or blistering. For paragraphs 3.5 and 3.6: All materials should be stored in an open environment for 14-28 days after manufacture, and then must be bagged in heat sealed polyethylene (PE) or PE coated aluminum bags for shipping. Parts for testing must be labelled with supplier and da
26、te of manufacture. 3.5 FOGGING, PHOTOMETRIC (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 16 h) Fog Number 70 min No formation of clear film, droplets or crystals. 3.6 ODOR (FLTM BO 131-03) Conditon 1 Rating 3 max Condition 2 Rating 3 max Condition 3 Rating 3 max 3.7 F
27、LAMMABILITY (ISO 3795/SAE J369) Burn Rate 100 mm/minute max 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. Contact for questions concerning Engineering Material Specifications. ENGINEERING MATERIAL S
28、PECIFICATION WSS-M98D39-A/A2/A4 Copyright 2016, Ford Global Technologies, LLC Page 5 of 6 4.1 APPROVAL OF MATERIALS Suppliers desiring approval of their materials shall first obtain an expression of interest from Purchasing, Design or Product Development, and Materials Engineering. The supplier shal
29、l submit a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of the Material Specification. Tested material samples must be available for review upon request and kept for
30、a minimum of one year. Upon request, the supplier will review the associated quality control documents (Process Failure Mode and Effects Analysis, Control Plans, Certification testing) with Ford. 4.2 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the mate
31、rial upon which approval was originally granted. Prior to making any changes to the material originally approved, whether or not such changes affect the materials ability to meet the specification requirements, the supplier shall notify the affected Supplier Technical Assistance (STA), Purchasing, a
32、nd Materials Engineering activities of the proposed changes (with reasons) by submission of a completed Suppliers Request for Engineering Approval, SREA. For parts and components using Ford Engineering Material Specifications, all samples tested to the specifications for Design Verification (DV), Pr
33、oduction Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until Job 1. 4.3 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed by regulations or Company direction applies to the materials addressed by this document. The restrictions are identifi
34、ed in the Restricted Substance Management Standard WSS-M99P9999-A1 which is updated yearly. It is the suppliers responsibility to comply with this standard on a continuing basis through IMDS and or GMAP reporting. 5. SUMMARY OF REVISIONS 2016 07 29 Released A4 specification for non-score, seamless i
35、nstrument panel applications. Removed WSS-M99P1111-A Removed WSS-M99P2222-C1/latest Added statement allowing spec value deviations for 3.3.1 (dimensions) and 3.3.5 (composite hardness) Added 3.3.4 Skin Hardness Added 14-28 day bagging requirement for 3. 5 - Fogging and 3.6 - Odor Removed Gravimetric
36、 Fogging Added Isopropyl Alcohol mixes and Ethanol as cleaning agents Removed cleaning agent brands Updated test requirement names to match test methods Added Table 1 for construction vs MCDCC approval Updated to latest standard format 08/30/2012 Update to requirements for Dimensions, Tensile Streng
37、th, Elongation and Adhesion of Top film to Foam 2/13/2012 Released WSS-M98D39-A2. Added WSS-M99P2222-C1/Latest and Gravimetric fogging to A1. 04/20/2011 Update to scope ENGINEERING MATERIAL SPECIFICATION WSS-M98D39-A/A2/A4 Copyright 2016, Ford Global Technologies, LLC Page 6 of 6 Table 1 Paragraphs
38、Number of Specimens Construction Testing MCDCC Testing (New Color/ New Grain) 3.3.1 Dimensions 3 X 3.3.2 Tensile Strength 3.3.2.1 Elongation 3 3 X 3.3.3 Tear Strength 3 X 3.3.4 Hardness, Durometer A - Skin 5 measurements X X 3.3.5 Hardness, Durometer A Bilaminate Composite 5 measurements X X 3.3.6 P
39、eel Adhesion of Top Film to Foam: 3.3.6.1 Room Temperature 3.3.6.2 A: After 168 hours at 90 +/- 2 C 3.3.6.2 A2/A4: After 240 hours at 107 +/- 2 C 1 per condition X 3.4.1 Resistance to Abrasion 3 X X 3.4.2 Resistance to Scuffing 3 X New grain only 3.4.3 Soiling and Cleanability 1 per soiling agent X
40、X 3.4.4 Resistance to Crocking 1 per solution X X 3.4.5 Resistance to Sunscreen Lotion and Insect Repellent 1 per condition X X 3.4.6 Paint Adhesion - Coating 3 X X 3.4.7 Resistance to Interior Weathering 3.4.7.1 A: 977.6 kJ/m2 3.4.7.2 A2/A4: 3609.6 kJ/m2 1 X New color/grain combination only 3.4.8 Colorfastness to Burnt Gas 3 X Light colors or as directed by Materials Engineering 3.4.9 Dimensional Stability 3.4.9.1 A: 168 h at 90 +/- 2 C, MD & AMD 3.4.9.2 A2/A4: 168 h at 107 +/- 2 C, MD & AMD 1 X 3.5 Fogging 3 X 3.6 Odor 1 per condition X 3.7 Flammability 5 X X
