1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 1 2018 04 13 Editorial Corrected numbering in 3.4.2.1 M. Nestorowich, NA 2018 03 26 Released S. Gatzek, M. Nestorowich, NA Controlled document at www.MATS Copyright 2018, Ford Global Technologies, LLC Page 1 of 6 LAMINATE, THERMOPLASTIC
2、OLEFIN (TPO) SKIN/ WSS-M98D39-A5 CROSS-LINKED POLYOLEFIN FOAM, DENT RESISTANT, DOOR PANEL AND INTERIOR TRIM APPLICATIONS 1. SCOPE The material defined by this specification is a formed assembly consisting of cross-linked polyolefin foam bonded to a TPO cover material. This laminate is either negativ
3、ely vacuum formed for typical in-mold-grain process or positively vacuum formed and then adhesively bonded to a rigid substrate. 2. APPLICATION This specification was released originally for material used in door trim applications utilizing the IMGL process. 2.1 LIMITATIONS This material is not to b
4、e used for instrument panel applications. 3. REQUIREMENTS 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 l
5、ist of approved sources is located within Ford at or available externally through a Ford Materials Engineer. 3.2 PERFORMANCE REQUIREMENTS Parts using this specification shall meet the appropriate performance specification WSS-M15P45-C/Latest Instrument Panel and Soft Interior Components, Flexible C
6、over Skin Material Performance specification and the Craftsmanship compression/deflection criteria per ARL: 17-0209 for door and console armrests, 17-0220 for door upper roll unless otherwise mutually agreed between Product Development and Materials Engineering. 3.3 APPEARANCE The color, pattern, fi
7、nish, hand, gloss, grain, tactile effect and construction shall match the approved Corporate Design master sample. 3.4 FOAM/SKIN LAMINATE 3.4.1 Dimensions* (Foam/skin laminate thickness) TPO Skin 0.48 - 0.68 mm Cross-Linked Polyolefin Foam 2.00 - 3.20 mm Total 2.48 - 3.88 mm ENGINEERING MATERIAL SPE
8、CIFICATION WSS-M98D39-A5 Copyright 2018, Ford Global Technologies, LLC Page 2 of 6 Measure the thickness of each layer and the total thickness of the composite at several points along the cut surface of a cross section. * Skin and foam thickness may differ from the listed values based on program tar
9、gets and part design; skin and foam thickness, tolerances for each layer and total thickness as specified on Engineering Document. 3.4.2 Tensile Strength, 1.3 MPa min (ISO 37, Type 1/ASTM D 412, Die C, 500 mm/min, 25 mm gauge length, 5 specimens min, any direction) 3.4.2.1 Elongation, 300% min (Test
10、 according to 3.4.2, use of an extensometer, laser or other vision system should be used to ensure accuracy) 3.4.3 Tear Strength, 12 N/mm min (ISO 34, Method B, procedure (a)/ASTM D 1004, any direction) 3.4.4 Hardness, Durometer A - Skin Report (ISO 868 /ASTM D 2240, 15 s dwell, layer the skin speci
11、mens To a minimum thickness of 6 mm) 3.4.5 Hardness, Durometer A Bi-laminate Composite* 50 +/- 5 (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 on
12、 program targets and part design; composite hardness as specified on Engineering Document 3.4.6 Peel Adhesion (Top Skin to Foam) (ISO 2411/FLTM BN 151-05, 180o peel, 300 mm/minute, any direction, test specimen must be 50 mm in width) 3.4.6.1 Original 0.6 N/mm min or 100% foam tear 3.4.6.2 After 168
13、hours at 90 +/- 2 C 0.6 N/mm min or 100% foam tear 3.4.7 Static Indentation and Recovery 0.75 mm, average (FLTM BO 041-01, mm deflection after 96 hours no single value over 1 mm 5 measurement locations minimum) 3.5 COLOR AND APPEARANCE PROPERTIES The following tests (para 3.5.1 3.5.5) need to be tes
14、ted on a textured or grained top film: 3.5.1 Resistance to Abrasion (SAE J948, CS-10 wheels, 500 g load, 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. ENGINEERING MATERIAL SPECIFICATION WSS-
15、M98D39-A5 Copyright 2018, Ford Global Technologies, LLC Page 3 of 6 3.5.2 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. 3.5.3 Soiling and Cleanability, (FLT
16、M BN 112-08, AATCC Evaluation Procedure 2) Standard Soil Rating 4 min Grease Rating 4 min Coffee Rating 4 min 3.5.4 Resistance to Cleaning Agents, (FLTM BN 107-01, 10 cycles, AATCC Evaluation Procedure 2) Test Procedure: Saturate the white cotton cloth with the cleaners listed and begin testing with
17、in 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) 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 vo
18、lume Rating 4 min 7) 100% Ethanol Report only 3.5.5 Resistance to Sunscreen Lotion Rating 3 max and Insect Repellent, No loss of adhesion (FLTM BI 113-08, Method A, 23 oC & 74 oC) The following tests (para 3.5.6 3.5.9) conducted on the laminate material may be used as surrogate data for the WSS-M15P
19、45-C/latest component testing: 3.5.6 Paint Adhesion Top Coat Grade 0 max (FLTM BI 106-01, Method C) The tape shall not lift or delaminate the surface coating. 3.5.7 Resistance to Interior Weathering, (FLTM BO 116-01, sample size 60 x 150 mm minimum, AATCC Evaluation Procedure 1) 2406.4 kJ/m2 Rating
20、4 min The material must not exhibit staining, color tone change, change in hue, cracking, crazing, tackiness or other deterioration after exposure in accordance with testing. Any surface blooming/chalking should be easily removed with water. Read and report the gloss change. In addition, the materia
21、l 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 samples at 526 kJ/m2 intervals and note any changes in appearance. ENGINEERING MATERIAL SPECIFICATION WSS-M98D39-A5 Copyright 2018, Ford Global Techno
22、logies, LLC Page 4 of 6 3.5.8 Dimensional Stability +/- 4% (SAE J883, 168 h at 90 +/- 2 C, MD & AMD) The material must show no evidence of delamination or blistering. For paragraphs 3.6 and 3.7: 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. 3.6 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 clea
24、r film, droplets or crystals. 3.7 ODOR (FLTM BO 131-03) Condition 1 Rating 3 max Condition 2 Rating 3 max Condition 3 Rating 3 max 3.8 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. ENGINEERING MATERIAL SPECIFICATION WSS-M98D39-A5 Copyright 2018, Ford Global Technologies, LLC Page 5 of 6 For parts and component
30、s using Ford Engineering Material Specifications, all samples tested to the specifications for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until Job 1. 4.3 RESTRICTED SUBSTANCE MANAGEMENT STANDARD 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 ENGINEERING MATERIAL SPECIFICATION WSS-M98D39-A5 Copyright 2018, Ford Global Technologies, LLC Page 6 of 6 Table 1: Testing Requirements* Paragraphs Number of Specimens Construction Testing MCDCC Testing (New Color/ New Grain) 3.4.1 Dimens
33、ions 3 X 3.4.2 Tensile Strength 3.4.2.1 Elongation 3 3 X 3.4.3 Tear Strength 3 X 3.4.4 Hardness, Durometer A - Skin 5 measurements X 3.4.5 Hardness, Durometer A Bilaminate Composite 5 measurements X 3.4.6 Peel Adhesion of Top Film to Foam: 3.4.6.1 Room Temperature 3.4.6.2 After 168 hours at 90 +/- 2
34、 C 3 per condition X 3.4.7 Static Indentation and Recovery 1 X 3.5.1 Resistance to Abrasion 3 X X 3.5.2 Resistance to Scuffing 3 X New grain only 3.5.3 Soiling and Cleanability 1 per soiling agent X X 3.5.4 Resistance to Cleaning Agents 1 per solution X X 3.5.5 Resistance to Sunscreen Lotion and Ins
35、ect Repellent 1 per condition X X 3.5.6 Paint Adhesion Top Coat 3 X X 3.5.7 Resistance to Interior Weathering 2406.4 kJ/m2 1 X New color/grain combination only 3.5.8 Dimensional Stability 168 h at 90 +/- 2 C, MD & AMD 1 X 3.6 Fogging 3 X X 3.7 Odor 1 per condition X 3.8 Flammability 5 X X *New site approval requires full construction testing
