1、 WORLDWIDE ENGINEERING STANDARDS Material Specification General GMW15058 Polyurethane Foam for Trim Pads, Headliners, Sealing and Insulators Copyright 2010 General Motors Company All Rights Reserved November 2010 Originating Department: North American Engineering Standards Page 1 of 9 1 Scope Note:
2、Nothing in this standard supercedes applicable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Material Description. Polyurethane (PUR) foam based on polyester or polyether polyol. 1.2 Symbols. Not applic
3、able. 1.3 Typical Applications. For manufacturing of foam, cut and laminated upholstery fabrics. See 3.2 for material categorization. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ASTM D737 ISO 1798 ASTM D925 I
4、SO 1856 ASTM D3574 ISO 1923 FMVSS 302 ISO 3386-1 ISO 105-A02 ISO 8067 ISO 845 ISO 9327 2.2 GM Standards/Specifications. GMW3001 GMW4659 GMW3059 GMW6992 GMW3205 GMW8081 GMW3221 GMW14357 GMW3232 GMW14358 GMW3235 GMW15634 GMW3259 3 Requirements 3.1 General. This material is a flexible, open-cell polyur
5、ethane foam based on polyester or polyether polyol whose composition and properties suit the application stated in 1.3. This particularly applies to its fatigue resistance, permanent set, humidity ageing and loss of elasticity. The foam shall be uniform in foam structure, cell size and mechanical pr
6、operties. Unfoamed areas and densifications (streaks) are not permissible. The foam shall not cause skin irritations or have an offensive odor. The surface of the foam shall be open or porous to ensure sufficient breathing activity. Once a foam type has been approved and released, a substantial chan
7、ge of the formulation which could adversely affect the subsequent processing or serviceability is not permitted unless this change has been previously tested and approved for release by Global Material Engineering. The thickness of the foam types shall be specified by the Design department depending
8、 on the quality/type of the upholstery fabric to be used. 3.2 Material Categorization. The material shall be categorized by type according to backing type and density. 3.2.1 Backings. If required by the GM material engineer, a suffix shall be identified for foam release. 3.2.1.1 Suffix B. When follo
9、wed by the Suffix B, the foam is to be bonded to a scrim backing to provide additional backing support. 3.2.1.2 Suffix C. When followed by the Suffix C, the foam is to be bonded to a lightweight scrim backing to provide minimal backing support in trim cover applications. 3.2.1.3 Suffix D. When follo
10、wed by the Suffix D, the foam is to be backed with a low friction polyethylene film or coating to provide ease of seat assembly. 3.2.2 Density (ISO 845/ASTM D3574). See Table 2. 3.2.2.1 Type A1 to A5. These types are general purpose material used in applications where higher density is not required
11、such as trim pads and insulators. 3.2.2.1.1 Type A1. PUR foam with medium density. 3.2.2.1.2 Type A2. PUR foam based on polyether with low density and low compression force deflection. 3.2.2.1.3 Type A3. PUR foam based on polyether with low density and medium compression force deflection. Copyright
12、General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15058 Copyright 2010 General Motors Company All Rights Reserved November 2010 Page 2 of 9 3.2.2.1.4
13、 Type A4. PUR foam based on polyether with medium density and medium compression force deflection. 3.2.2.1.5 Type A5. PUR foam based on polyether with high density. 3.2.2.2 Type B1 to B2. These types are used primarily in trim cover applications where a higher density product is desired for seating
14、areas. 3.2.2.2.1 Type B1. PUR foam based on polyether with high density. 3.2.2.2.2 Type B2. PUR foam based on polyether with medium density. 3.2.2.3 Type C1 to C3. These types are used primarily for special trim cover effects where a softer product is desired for seating areas. 3.2.2.4 Type D1. This
15、 type is a low density version for non-seating areas of a seat trim cover. 3.2.2.5 Type E1 to E5. These types are used as foam for flame-bonded textile laminates in low thicknesses, and in applications where compression set is not a concern. 3.2.2.5.1 Type E1. PUR foam based on polyether with high d
16、ensity. 3.2.2.5.2 Type E2. PUR foam based on polyether with low density. 3.2.2.5.3 Type E3. PUR foam based on polyether with medium density. 3.2.2.5.4 Type E4. PUR foam based on polyester with low density. 3.2.2.5.5 Type E5. PUR foam based on polyester with medium density. 3.2.2.6 Type F1 to F3. The
17、se types are used for one-piece headliner applications where compression set is not a concern. 3.2.2.6.1 Type F1. Flexible open cell, polyether PUR foam used for a one-piece headliner where the criteria of meeting the flammability requirements are measured on the finished assembly. The foam must not
18、 contain flame retardant additive. 3.2.2.6.2. Type F2. Flexible open cell, polyether PUR foam used for a one-piece headliner where the criteria of meeting the flammability requirements are measured on the finished assembly. The foam does not contain flame retardant additive. This type of foam has lo
19、wer permeability and is used to reduce mottling/orange peel/foam collapse compared to normal foam and to improve ability to withstand headliner molding conditions at thinner thickness than Type F1. 3.2.2.6.3. Type F3. Flexible open cell polyether PUR foam used for sunshade applications, where, each
20、component of the construction must meet flammability requirements. This foam must contain flame retardant additive, and must not have adverse clickable characteristics (e.g., part edges must not seal or weld on die cutting). 3.2.2.6.4. Type Z. PUR foam which does not fit in the other Types. Specific
21、 Values to be documented on the Certification Data Form. 3.3 Foam Laminations to Cloth or Scrim (Heat, Flame or Ironed). The fire retardant additives contained in the foam must be formulated without the use of Phenyl phosphate esters and/or Cresyl phosphate esters including: Triphenyl Phosphate (TPP
22、) (CAS No. 115-86-6); Cresyl-DiphenylPhosphate (DCPP) (CAS No. 26444-49-5); Dicresyl-PhenylPhosphate (DCPP) (CAS No. 6446-73-1); Tricresyl Phosphate (TCP) (CAS No.1330-78-5). 3.4 Test Piece and Number. If it is not possible to take test pieces from the shaped or fabricated part, then suitable plaque
23、s or parts shall be manufactured for testing (taken from the same manufacturing process, foam formulation, density and compression force deflection). The test piece shall be taken in the same foam structure orientation as in the production part. 3.5 Conditioning. Immediately prior to test, all test
24、pieces shall be predried at 70 3 C and conditioned. The predrying period shall be 16 h for tests conducted after humidity ageing to ASTM D3574-J/GMW14357 and shall be 3 h for other tests. Following predrying, all test pieces shall be conditioned to GMW3221 Code A. 3.6 Required Performance Values. Al
25、l requirements listed in Table 1 shall be fulfilled by the delivered foam and shall be documented by the supplier in the construction data sheet (see Appendix A). 3.7 Basic Foam Physical Properties. All requirements listed in Table 2, Table 3, and Table 4 shall be fulfilled by the delivered foam and
26、 shall be documented by the supplier in the construction data sheet (see Appendix A). Values indicated with “TBD” shall be documented. Values indicated with “Not applicable” are not required. Documentation of additional properties may be required by the approving GM region. Copyright General Motors
27、Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15058 Copyright 2010 General Motors Company All Rights Reserved November 2010 Page 3 of 9 Table 1: Required Perfor
28、mance Values for Documentation Performance Test Method Specified Value Fogging GMW3235 Method B-Y1-T1 (gravimetric, 1 day predrying, +90 C test temperature) 2 mg Flammability Note 1 GMW3232 Must comply to FMVSS 302 Interior Emissions GMW15634 (relative emissions) VOC S-VOC or GMW8081 Report Report 1
29、.0 Resistance to Odor GMW3205 Wet condition (Code A) Rating 6 minimum Dry condition (Code B) Rating 6 minimum Steam Autoclave PUR-Foam-Polyether: 5 h, +120 3 C GMW14357 (ASTM D3574-J2) No visible degradation, specified values per Table 3 and Table 4 PUR-Foam-Polyester: 3 h, +105 3 C GMW14357 (ASTM D
30、3574-J1) No visible degradation, specified values per Table 3 and Table 4 Mildew Note 2 GMW3259 No mildew. Compatibility Note 3 GMW4659 or as specified by GM Materials Engineering ( ASTM D925 Method A) Color Stability of the Cover Layer Color Change Shade Change (if cover layer is leather or plastic
31、 roll good only) Visual evaluation using GMW6992: No color change, slight darkening permissible. No adverse changes in shape, surface condition or in physical or chemical properties. Grayscale to ISO 105-A02 Rating 3 Note 1: F1 and F2 headliner foam meet the flammability requirement only as a compos
32、ite. Note 2: Required only if natural fibers are present in the construction. Note 3: Foam shall meet compatibility in the production intended composite. The test pieces shall be sewn or welded (dependent on use), using production techniques, to all possible combinations of composite materials taken
33、 at the same time from production to form a test pack. Note, for any changes in the quality of any of the composite materials, compatibility tests shall be repeated. At the discretion of the approving GM Engineer, foam material may be tested to standard composite materials for initial foam approval,
34、 e.g., a standard vinyl. Nevertheless, final foam approval shall be achieved in the production intent composite. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE E
35、NGINEERING STANDARDS GMW15058 Copyright 2010 General Motors Company All Rights Reserved November 2010 Page 4 of 9 Table 2: Foam Types, Density, Nominal Thickness, and Tear Strength All Values in As Received Condition Type Density Nominal Thickness (Report) Typical Applications kg/m mm ASTM D3574/ISO
36、 845 ISO 1923 Note 1 A1 27 Design requirement General Purpose A2 25 to 31 Design requirement A3 25 to 35 Design requirement A4 30 to 40 Design requirement A5 42 to 48 Design requirement B1 43 Design requirement Trim Cover For Seating Area B2 35 to 41 Design requirement C1 24 25 Special Trim Cover Ef
37、fect for Seating Area C2 24 25 C3 27 to 33 Design requirement D1 19 Design requirement Seat Trim Cover for Non-seating Area E1 43 Design requirement Textile Laminates, Sealing in Low Thickness E2 25 to 31 Design requirement E3 32 to 38 Design requirement E4 26 to 32 Design requirement Textile and He
38、adliner Laminates in Low Thickness E5 35 to 41 Design requirement F1 27 to 31 Design requirement Headliner Laminates F2 27 to 31 Design requirement Headliner Laminates for Deep Draw Design and High Temperature Process F3 27 to 31 Design requirement Sunshade and Headliner Laminates with Flame Retarda
39、nt Additive Content Z Values to be documented on the Certification Data Form Note 1: Determination of linear dimensions per ISO 1923. But compressive force of foot is 500 Pa (0.5 kPa) 5% and a 50 0.1 mm diameter pressure. All readings should be taken after the pressure foot has been in contact with
40、the material for at least 5 s. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15058 Copyright 2010 General Motors Company All Rights Res
41、erved November 2010 Page 5 of 9 Table 3: Tensile Strength, Elongation and Tear Strength Type Tensile Strength Elongation Tear Strength As Received condition After Heat Ageing, 22 h at +140 C After Steam Autoclave (see Table 1) As Received Condition After Steam Autoclave (see Table 1) As Received Con
42、dition (kPa) Maximum Change in (%) Maximum Change in (%) (%) Maximum Change in (%) (Nm) ISO 1798 ISO 1798 ISO 1798 ISO 1798 ISO 1798 ISO 8067 A1, B1, C1, C2, D1 82 25 30 150 30 260 A2 110 Report Report 250 Report Report A3, A4 100 Report Report 200 Report Report A5 150 Report Report 170 Report Repor
43、t B2, E2 100 Report 30 250 30 Report C3 100 Report 30 120 Report Report E1 82 25 30 85 40 260 E3 95 Report 10 150 30 Report E4 150 Report 30 250 30 Report E5 200 Report 30 250 30 Report F1, F2, F3 115 20 20 125 30 260 Z Values to be documented on the Certification Data Form Copyright General Motors
44、Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15058 Copyright 2010 General Motors Company All Rights Reserved November 2010 Page 6 of 9 Table 4: Compression Set
45、 and Compression Force Deflection Type Compression Set at 50%, 22 h, 70 C Compression Set at 90%, 22 h, 70 C Compression Force Deflection As Received Condition After Steam Autoclave (see Table 1) As Received Condition As Received Condition After Steam Autoclave (see Table 1) (%) (%) (%) (kPa) Maximu
46、m Change in (%) ISO 1856-A Note 1 ISO 3386-1 Note 1 A1, C1, D1 10 10 25 2.5 to 6 20 B1 10 10 25 Report 20 C2 10 10 25 Report 20 A2, A3 4 Report Report 2 to 4 30 A4 10 Report Report 3.5 to 4.5 Report A5 4 Report Report 3 to 5 Report B2, E2 10 15 Report 2 to 4 30 C3 5 10 Report 2.5 to 4.5 30 E1 Not ap
47、plicable Not applicable Not applicable 6 to 16 50 E3 3 5 Report 3 to 4 35 E4 10 15 Report 3 to 4 30 E5 10 15 Report 3 to 5 30 F1 F2 Note 2 F3 20 20 25 4 to 5.5 50 Z Values to be documented on the Certification Data Form Note 1: Determination of linear dimensions per ISO 1923. But compressive force o
48、f foot is 500 Pa (0.5 kPa) 5% and a 50 0.1 mm diameter pressure. All readings should be taken after the pressure foot has been in contact with the material for at least 5 s. Note 2: Table 5 bellow for F2 headliner foam. Table 5: Permeability Requirements for F2 Headliner Foam Thickness (mm) ISO 9327- Maximum (at 125 Pa) mm3/sec/mm2 ASTM D737 (at 125 Pa) cm3/sec/cm2 2.0 2103 210 2.5 1913 191 3.0 1724 172 3.5 1534 153 4.0 1345 134 4.5 1155 116 5.0 966 97 Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction o
