1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2008 02 08 Activated J.Robincheck, M. Mehandru, C. Ridgard Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 1 of 8 COATING, WEATHERABLE, ABRASION RESISTANT FOR WSS-M99P44-A POLYCARBONATE GLAZING APPLICATION 1.
2、 SCOPE This specification defines the performance of a UV stabilized weatherable coating for polycarbonate. 2. APPLICATION This specification was released to define coating performance of a weatherable, abrasion resistant silicone hardcoat/PECVD (Plasma Enhanced Chemical Vapor Deposition) system for
3、 polycarbonate glazing applications. Typical application includes: rear quarter windows, panoramic roof windows, backlite, and moon roofs. 3. REQUIREMENTS Material Specification requirements are to be used for initial qualification of materials. All parts must also meet the appropriate DVP & R and S
4、ubsystem Design Specification requirements. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A). 3.2 SYSTEM COMPONENTS 3.2.1 Substrate Condition The polycarbonate substra
5、te surface to be coated must be cleaned to ensure the absence of oil or alkaline residues, fingerprints, corrosion, mold release agents, dirt, moisture, and other foreign materials. 3.2.2 System Requirements Material specifications are to be used for initial qualification of materials. A Control Pla
6、n for ongoing production verification is required. Appropriate statistical tools are recommended to be used to analyze process/product data and to assure consistent processing of the materials. 3.2.3 Test Plaques Testing must be conducted on plaques from a production representative process. Test spe
7、cimens should be 3.5 - 6.0 mm thick, glazing grade, polycarbonate specimens with sizes appropriate for specific test method. ENGINEERING MATERIAL SPECIFICATIONWSS-M9P44-A Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 2 of 8 3.2.4 Test Conditions All test values i
8、ndicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5% relative humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. 3.3 APPEARANCE: COLOR, FINISH, SURFACE 3.3.1 Color, Gloss and Clarity Sh
9、all match the Master Approved Sample color panel or the initial sample as approved by Design Center. 3.3.2 Haze As specified in regulatory requirements ANSI Z26.1. (Test method is specified in Test Number 17 and 18.) 3.3.3 Aged Appearance (ASTM D 2616, gray scale) The material shall exhibit a Rating
10、 3 or better (AATCC Evaluation Procedure 1) after exposure to the environments listed in paragraphs 3.4.3, 3.4.4, 3.4.5, 3.4.6, and 3.4.10. 3.3.4 Opacity (For blacked out areas outside of the “Day Light Opening”) Total visible light transmission through the coating shall not exceed 1.0%. The measure
11、ment shall be made using a transmission black and white densitometer (e.g. “Tobias Model TBX“), or equivalent in direct contact with the coating surface. 3.3.5 Coating Thickness (ASTM B 487, PELT, or equivalent) Coating thickness must be sufficient to meet all requirements of this specification and
12、defined on the engineering drawing. Refer to mutually agreed upon control plan. 3.3.6 General The coating shall be cured to a presentable film showing no craters, pinholes, seediness, abnormal roughness or other defects as referenced in WSS-M28P1-B6/B7. ENGINEERING MATERIAL SPECIFICATIONWSS-M9P44-A
13、Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 3 of 8 3.4 RESISTANCE PROPERTIES 3.4.1 Abrasion Resistance Test Number 17 or 18 of latest released ANSI Z26.1, in accordance with ASTM D 1044-05. Test number 17 or 18 should be selected based on ANSI Z26.1 application
14、 definition. Minimum performance level allowed is less than a 10% change from original haze after 500 cycles. In addition, the coating must meet the performance level required for the class of glazing listed on the part drawing and with the level of performance mandated by ANSI Z26.1. 3.4.2 Coating
15、Adhesion, max Grade 2 (FLTM BI 106-01, Method B, carbide tip scribe only) 3.4.3 Water Resistance (FLTM BI 104-01, 240 h) No blistering, dulling, softening, loss of adhesion, and/or any other film failure. After exposure, adhesion testing performance must be met per Para. 3.4.2 within 20 minutes afte
16、r removal from water. 3.4.4 Heat Aging Resistance, min Rating 4 (90 +/- 2 C, 240 hours, AATCC Evaluation Procedure 1) After exposure, adhesion testing performance must be met per Para 3.4.2. 3.4.5 Humidity Resistance (98% relative humidity, 38 +/- 2 C, 240 hours) No blistering, dulling, softening, a
17、nd/or loss of adhesion. After exposure, adhesion testing performance must be met per Para 3.4.2. 3.4.6 Fluid Spotting Resistance, min Rating 4 (FLTM BI 168-01, Method A, AATCC Evaluation Procedure 1) Test Fluids: (As identified in method under, “Body and Exterior Trim use“) No dulling, surface disto
18、rtion or permanent softening permitted. After exposure, adhesion testing performance must be met per Para 3.4.2. ENGINEERING MATERIAL SPECIFICATIONWSS-M9P44-A Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 4 of 8 3.4.7 Acid Resistance, min Grade 4 (ASTM C 724) The
19、 ceramic or non-ceramic coating shall be exposed to both Citric Acid and Hydrochloric Acid as specified in ASTM C 724. 3.4.8 Alkali Resistance Grade 4 Test Method: Immerse a 100 X 100 x 5.6 mm coated glass sample in a 5% Sodium Hydroxide by weight and water solution at 23 +/- 2 C for 15 minutes, rem
20、ove samples and examine. There shall be no removal of any decorative coating, and plaque shall be rated as a Grade 4 in accordance with ASTM C 724. Grade 4 is defined as a definite stain with a gross color change or strongly iridescent visible at angles less than 30 and which may blur reflected imag
21、es. 3.4.9 Abrasion Resistance by Falling Sand, Delta Haze 4% max (ASTM D 968, Method A with 3.0 kg of sand) 3.4.10 Environmental Cycling, 15 cycles (FLTM BQ 104-07, Procedure 10) Evaluation after 20 h conditioning at 23 +/- 2 C. No evidence of cracks, no blistering, no change in appearance or other
22、failure when compared with an original non-aged part. After exposure, adhesion testing performance must be met per Para 3.4.2. 3.4.11 High Performance Adhesion Thermal Shock No loss of adhesion (FLTM BI 107-05) to the substrate or between film layers Alternate method Resistance Against High Pressure
23、 Cleaner No loss of adhesion (FLTM BO 160-04, Method B) 2 mm2max, Euro Prior to testing the coated surface shall be X-scribed through to the substrate (30 angle). The test must be performed on the X-scribe. 3.4.12 Compatibility of Decorative Material with Adhesive Must conform to the adhesion requir
24、ements listed in the current direct glazing specification(s) or as identified on the appropriate Subsystem design specification (See Para. 4.2). Test to be conducted by the adhesive supplier. ENGINEERING MATERIAL SPECIFICATIONWSS-M9P44-A Printed copies are uncontrolled Copyright 2008, Ford Global Te
25、chnologies, LLC Page 5 of 8 3.4.13 Odor, Max (For interior surface area materials only) (FLTM BO 131-01) Rating 2 or (SAE J1351) Rating 3 3.4.14 Fogging, Min (For interior surface area materials only) 70 (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 1 h and 16 h) Forma
26、tion of clear film, droplets or crystals is cause for rejection. 3.5 WEATHERING The following tests are to be conducted for initial qualification of new materials (e.g. new inner laminates, new glass coatings, new tinting chemistries, new polycarbonate system materials) and/or processes. This specif
27、ication represents the minimum weathering durability required for Glazing. Any revisions to composition, processing, or construction must be reviewed with the appropriate engineering activities and comply with the Suppliers Ongoing Responsibilities per WSS-M99P1111-A. Appearance Evaluation: After ex
28、posure, the material shall exhibit no checking, blistering, loss of adhesion, delamination, microcrazing, excess color change, change in haze not greater than , 7% for AS2 and AS4 parts and 12% for AS3 and AS5 parts or as defined on engineering drawing, or change in appearance in excess of Rating 4
29、(AATCC Evaluation Procedure 1). Laminated/coated parts must also pass the Pummel Test (WSS-M28P1-B6/B7, Para. 3.13.1) after exposure. Definition of horizontal versus vertical application can be found at the end in Table 3. In the event of differences between accelerated testing (3.5.1) and outside e
30、xposures (3.5.2), results of the outside samples shall govern, also for strained methods. 3.5.1 Glazing Materials - Xenon Arc Weatherometer (SAE J2527 Boro/Boro method.) Testing required to 12 years Arizona equivalent or failure as shown in Table 1. Minimum approval requirement is 10 years Arizona e
31、quivalent as shown in Table 1 or as required on engineering drawing. The weathering data correlation data shown in Table 1 is for IR absorbing polycarbonate. Translation to other tints of polycarbonate can be done using the methodology found in Appendix A. ENGINEERING MATERIAL SPECIFICATIONWSS-M9P44
32、-A Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 6 of 8 Application Type Panel Strain Material Color Min Reqmt SAE J2527 Boro/Boro (Hours) 10 Yr Ariz Equiv SAE J2527 Boro/Boro (Hours) 12 Yr Ariz Equiv Horizontal 0 Black 18200 21900 Horizontal 0 Privacy 20000 2400
33、0 Horizontal 0 Solar 18200 21900 Vertical 0 Black 10000 12000 Vertical 0 Privacy 11000 13200 Vertical 0 Solar 10000 12000 Table 1 3.5.2 Natural Weathering Florida and Arizona Exposure 12, 24, 36, 60, 120, (SAE J1976, Procedure A, 5 facing south) and 144 months 3.5.3 Polycarbonate Strained Weathering
34、 Methods (NEED TO ADD SDS REQUIREMENT) Calculated application strain level not to exceed 0.34%. For applications exceeding 0.34%, system will need to be requalilfied. Application strain level must be calculated and recorded on the Engineering drawing. 3.5.3.1 Accelerated Xenon Arc Weatherometer (SAE
35、 J2527 Boro/Boro method.) For minimum exposure requirements see Table 2. 3.5.3.2 Outdoor - Florida and Arizona exposure (SAE J1976, procedure A) For minimum exposure requirements see Table 2. Application Type Panel Strain Material Color Min Reqmt SAE J2527 Boro/Boro (Hours) 10 Yr Ariz Equiv SAE J252
36、7 Boro/Boro (Hours) 12 Yr Ariz Equiv Horizontal 0.34 Black 12133 14600 Horizontal 0.34 Privacy 13333 16000 Horizontal 0.34 Solar 12133 14600 Vertical 0.34 Black 6666 8000 Vertical 0.34 Privacy 7333 8800 Vertical 0.34 Solar 6666 8000 Table 2 ENGINEERING MATERIAL SPECIFICATIONWSS-M9P44-A Printed copie
37、s are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 7 of 8 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 4.1 COMPOSITION 4.1.1 Weathering Layer / Wet Coat Typical materials are: 1)
38、Siloxanes or other similar inorganic/organic hybrid structures produced by sol-gel chemistry. 2) Acrylic cured polymers. A primer layer may be applied to the substrate to ensure adhesion between the wet coat and the polycarbonate. All coating/weatherable layer materials are assumed to be more stable
39、 than the PC substrate. The film or coating itself should be resistant to UV and hydrolytic degradation. Any coating or adhesion promoter shall not contain any commercial substance(s) that may degrade the performance of the polycarbonate glazing system. The supplier will furnish the range of operati
40、ng conditions under which the wet coating can be applied to meet performance criteria of this specification. 4.1.2 PECVD Coating (optional) The supplier will furnish the range of operating conditions under which the PECVD coating can be applied to the PECVD layer to meet performance criteria of this
41、 material specification. 4.2 HARDNESS (ASTM D 1474) Record value at target film and bake conditions. Shall be sufficiently cured at time of packing to withstand normal handling without damage. ENGINEERING MATERIAL SPECIFICATIONWSS-M9P44-A Printed copies are uncontrolled Copyright 2008, Ford Global T
42、echnologies, LLC Page 8 of 8 4.3 RELATED SPECIFICATIONS Glazing Performance Specification - WSS-M28P1-B1/B2/B3/B4/B5/B6/B7 Direct Glazing Specifications - WSB-M2G316-B WSS-M2G316- /B2/B3/B4 (North America) WSK-M11P57-A1/A2/A3/A4 (Europe) STJLR.51.5002 (JLR) Table 3 Definition of Horizontal and Verti
43、cal Application Appendix A Translation between IR and non IR. If a number has been established Y MJ or Y hours for one resin type: 1stMeasure the temperature in the weather-ometer of substrate, resin1, Twom1.2ndMeasure the temperature in the weather-ometer of 2ndsubstrate, resin2, Twom2. Rate ratio, RRwom= exp(Ea/R)(1/Twom1 1/Twom2) where Eais in cal/mol (for PC R = 5000 cal/mol), R = 1.987, and temperature is in Kelvin). X MJ/m2at 340 nm in WOM of resin 2 = (Y MJ/m2 at 340 nm)/RR, this can of course also be done with hours.
