1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 4 2017 05 23 Revised See Summary of Revisions 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 2017, Ford Global Technologies, LLC
2、Page 1 of 6 LAMINATE, THERMOPLASTIC 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 cross-linked polyolefin foam bonded to a TPO cover material
3、. 2. APPLICATION This specification was originally released for a non-score seamless PAB instrument panel application for the Eco Sport program. This laminate is positively vacuum formed and then adhesively bonded to a rigid substrate. Parts using this specification shall meet the appropriate perfor
4、mance specification WSS-M15P45-C/Latest Instrument Panel and Soft Interior Components, Flexible Cover Skin Material Performance specification and the Craftsmanship compression/deflection criteria per ARL 17-0229 for IP upper unless otherwise mutually agreed between Product Development and Materials
5、Engineering. 2.1 LIMITATIONS This material is not to be used for instrument panel applications where laser scoring of the skin is required for airbag deployment. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification requires the use of approved sources. Only the sources identified on the Ford Appr
6、oved 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 at or available externally through a Ford Materials Engineer. 3.2 APPEARANCE The color, pattern, finish, hand, gloss, grain, tactile
7、 effect and construction shall match the approved Corporate Design master sample. 3.3 FOAM/SKIN LAMINATE CONSTRUCTION PROPERTIES 3.3.1 Dimensions* (Foam/skin laminate thickness) TPO Skin 0.60 mm nominal Cross-Linked Polyolefin Foam 2.50 mm nominal Total Report, mm ENGINEERING MATERIAL SPECIFICATION
8、WSS-M98D39-A4 Copyright 2017, Ford Global Technologies, LLC Page 2 of 6 * Skin and foam 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 thick
9、ness of each layer and the total thickness of the composite at several points along the cut surface of a cross section. 3.3.2 Tensile Strength 1.3 MPa min (ISO 37, Type 1/ASTM D 412, Die C, 25 mm bench marks, 5 specimens min, any direction) 3.3.2.1 Elongation, 300% min (Test according to 3.3.2, use
10、of an extensometer, laser or other vision system should be used to ensure accuracy) 3.3.3 Tear Strength 12 N/mm min (ISO 34, Method B, procedure (a)/ASTM D 1004, any direction) 3.3.4 Hardness, Durometer A - Skin 85 +/- 7 or as listed (ISO 868 /ASTM D 2240, 15 s dwell; layer the skin specimens on the
11、 Ford ASL to a minimum thickness of 6 mm) 3.3.5 Hardness, Durometer A Bilaminate Composite* Report (ISO 868 /ASTM D 2240, 15 s dwell, test with film/foil side up; layer the composite samples to a minimum thickness of 6 mm) *Foam density will impact the overall composite hardness and may vary based o
12、n program targets and part design; composite hardness as specified on Engineering Document 3.3.6 Peel Adhesion (Top Foil to Foam) (ISO 2411/FLTM BN 151-05, 180o peel, 300 mm/minute, any direction, test specimen must be 50 mm in width) 3.3.6.1 Original 0.6 N/mm min or 100% foam tear 3.3.6.2 After 240
13、 hours at 107 +/- 2 C 0.6 N/mm min or 100% foam tear 3.4 COLOR AND APPEARANCE PROPERTIES The following tests (para 3.4.1 3.4.5) 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 show no evidence of wea
14、r through. A slight change in gloss is acceptable and will be evaluated by Ford Materials Engineering. 3.4.2 Resistance to Scuffing (SAE J365, 250 cycles) The surface shall show no evidence of wear through. A slight change in gloss is acceptable and will be evaluated by Ford Materials Engineering. E
15、NGINEERING MATERIAL SPECIFICATION WSS-M98D39-A4 Copyright 2017, Ford Global Technologies, LLC Page 3 of 6 3.4.3 Soiling and Cleanability (FLTM BN 112-08, AATCC Evaluation Procedure 2) Standard Soil Rating 4 min Grease Rating 4 min Coffee Rating 4 min 3.4.4 Resistance to Cleaning Agents (FLTM BN 107-
16、01, 10 cycles, AATCC Evaluation Procedure 2) Test Procedure: Saturate the white cotton cloth with the cleaners listed and begin testing within 10 seconds of saturating the cloth. Cleaners Agents: 1) Deionized water Rating 4 min 2) Window cleaner Rating 4 min 3) All-purpose cleaner Rating 4 min 4) Dr
17、y (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 Rating 4 min 7) 100% Ethanol Report only 3.4.5 Resistance to Sunscreen Lotion Rating 3 max and Insect Repellent No loss of adhesion (FLTM BI 113-08, Method
18、 A, 23 oC and 74 oC) The following tests (para 3.4.6 3.4.9) conducted on the flat stock material may be used as surrogate data for the WSS-M15P45-C/latest component testing: 3.4.6 Paint Adhesion Top Coat Grade 0 max (FLTM BI 106-01, Method C) The tape shall not lift or delaminate the surface coating
19、. 3.4.7 Resistance to Interior Weathering (FLTM BO 116-01, sample size 60 x 150 mm minimum, AATCC Evaluation Procedure 1) 3609.6 kj/m2 Exposure Rating 4 min The material must not exhibit staining, color tone change, change in hue, cracking, crazing, tackiness or other deterioration after exposure in
20、 accordance with testing. Any surface blooming/chalking should be easily removed with water. Read and report the gloss change. In addition, the material must remain flexible and exhibit no cracking when bent around a 6.4 mm mandrel (face side out) after exposure. For new cover skin technology, check
21、 samples at 526 kJ/m2 intervals and note any changes in appearance. 3.4.8 Colorfastness to Burnt Gas, Rating 4 min (AATCC 23 or equivalent method, 168 hours at 60 C, AATCC Evaluation Procedure 1; light colors only) 3.4.9 Dimensional Stability, +/- 4% (SAE J883, 168 h at 107 +/- 2 C, MD and AMD) ENGI
22、NEERING MATERIAL SPECIFICATION WSS-M98D39-A4 Copyright 2017, Ford Global Technologies, LLC Page 4 of 6 The material must show no evidence 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
23、 bagged in heat sealed polyethylene (PE) or PE coated aluminum bags for shipping. Parts for testing must be labelled with supplier and date of manufacture. 3.5 FOGGING, PHOTOMETRIC (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, posttest conditioning 16 h) Fog Number 70 min No formation of cle
24、ar film, droplets or crystals. 3.6 ODOR (FLTM BO 131-03) Condition 1 Rating 3 max Condition 2 Rating 3 max Condition 3 Rating 3 max 3.7 FLAMMABILITY (ISO 3795) Burn Rate 100 mm/minute max 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the r
25、equirements of this specification. Contact for questions concerning Engineering Material Specifications. 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. T
26、he supplier shall 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 reque
27、st and kept for 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 characteris
28、tics to the material 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
29、), Purchasing, and 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 Verif
30、ication (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until Job 1. 4.3 RESTRICTED SUBSTANCE MANAGEMENT STANDARD ENGINEERING MATERIAL SPECIFICATION WSS-M98D39-A4 Copyright 2017, Ford Global Technologies, LLC Page 5 of 6 Substance restrictions imp
31、osed by regulations or Company direction applies to the materials addressed by this document. The restrictions are identified 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
32、 through IMDS and or GMAP reporting. 5. SUMMARY OF REVISIONS 2017 05 23 Separated each suffix into individual documents 3.3.2 Corrected test parameters and bar type for tensile and elongation 3.3.2.1 Added use of extensometer or other visual system for measurement 3.4.1 and 2 Clarified assessment st
33、atement (now allows gloss change) 3.4.3, 3.4.4, 3.4.7, 3.4.8 Removed ISO evaluation procedure 3.4.4 Added time limit for starting test after saturating test cloth with cleaner; changed 80/20 IPA from report to requirement Changed which tests are allowed to be used as surrogate for part testing Adjus
34、ted numbering as needed Added Table 1 for construction vs. color /MCDCC testing 05/31/2016 Released A4 specification for non-score, seamless instrument panel applications. Removed WSS-M99P1111-A Removed WSS-M99P2222-C1/latest Added statement allowing spec value deviations for 3.3.1 (dimensions) and
35、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 Fogging Added Isopropyl Alcohol mixes and Ethanol as cleaning agents Removed cleaning agent brands Updated test requirement names to match test methods Added
36、 Table 1 for construction vs MCDCC approval Updated to latest standard format 08/30/2012 Update to requirements for Dimensions, Tensile Strength, 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 Updat
37、e to scope ENGINEERING MATERIAL SPECIFICATION WSS-M98D39-A4 Copyright 2017, Ford Global Technologies, LLC Page 6 of 6 Table 1 Paragraphs 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 Stren
38、gth 3 X 3.3.4 Hardness, Durometer A - Skin 5 measurements X 3.3.5 Hardness, Durometer A Bilaminate Composite 5 measurements X 3.3.6 Peel Adhesion of Top Film to Foam: 3.3.6.1 Room Temperature 3.3.6.2 After 240 hours at 107 +/- 2 C 3 per condition X 3.4.1 Resistance to Abrasion 3 X X 3.4.2 Resistance
39、 to Scuffing 3 X New grain only 3.4.3 Soiling and Cleanability 1 per soiling agent X X 3.4.4 Resistance to Cleaning Agents 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 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 1 X 3.5 Fogging 3 X X 3.6 Odor 1 per condition X 3.7 Flammability 5 X X
