1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2007 07 10 Activated B. Witkowski Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 1 of 10 PERFORMANCE, INNER BODY WATERSHIELD, NON-EXPOSED, WSS-M15P36-A3 SELF-SUPPORTING, PRESSURE SENSITIVE ADHESIVE, REPOSITI
2、ONABLE PERFORMANCE, INNER BODY WATERSHIELD, EXPOSED, WSS-M15P36-A4 SELF-SUPPORTING, PRESSURE SENSITIVE ADHESIVE, REPOSITIONABLE 1. SCOPE These specifications define the minimum performance requirements of inner body watershields. They are composed of a pressure sensitive adhesive bead on one side of
3、 a polymeric base material affixed to production painted inner body assemblies. The polymeric base material typically has three-dimensional thermoformed features that permit conformation to uneven surfaces where mechanical hardware and wiring is present. The watershield shall have sufficient inheren
4、t stiffness to permit ease of handling and positioning/repositioning during assembly without wrinkling, folding, or bending. 2. APPLICATION These specifications were released to define the performance of polymeric watershields where removal and repositioning may be performed within 72 hours after ap
5、plication without damage. The constructions described in these specifications are for use within the internal body spaces such as the door inner, quarter panel, liftgate, and similar enclosed regions. WSS-M15P36-A3: For watershields not requiring compliance to FMVSS 302 (not exposed to the vehicle i
6、nterior-covered by interior trim panel). WSS-M15P36-A4: For watershields requiring compliance to FMVSS 302 (exposed to the vehicle passenger interior-such as “stripped chassis units“). Note: Some pressure sensitive adhesives can soften above 80 C allowing the watershield to slide downward. If the th
7、ree-dimensional design features of the watershield or trim panel interference do not prevent sliding, additional mechanical fastening features may be required. Pressure sensitive adhesives may not be applied to contaminated, moist, or chilled surfaces. Contamination of the adhesive during watershiel
8、d installation (i.e., lint from gloves) must be avoided. 3. 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). Additionally, approval to this specification
9、 assumes that the finished article meets all applicable SDS, CETP, ES, and Functional Trial requirements. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P36-A3/A4 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 2 of 10 3.2 WATERSHIELD STORAGE STABILITY AND SEPARATION BEH
10、AVIOR (BLOCKING) This test evaluates the resistance of stacked production parts from adhering to one another during transportation and storage. Table 1 is provided as a reference for test requirements. Table 1 Test Matrix Test Requirement Material As Received Summer Cycle Winter Cycle Thickness X Fl
11、ammability (WSS-M15P36-A4 only) X Odor X Fogging X Water Absorption X Mildew Resistance X Low Temperature Flexibility X Separation Behavior X X Dimensional Stability X X Adhesive Bridging X Water Leak Test & Repositionability X Tensile Load to Break X Elongation X Tear Strength X Initial Peel Adhesi
12、on X Peel Adhesion after Humidity Aging X Peel Adhesion after Heat Aging X Test Method: Production parts with pressure sensitive adhesive bead, (including release papers), shall be stacked and subjected to conditions described below. The number of parts in a stack and their orientation shall be the
13、same as that of actual shipping and storage, if production storage and shipping racks have a vertical orientation, three panels may be used for the following test. Partial panels may be used for the separation behavior and dimensional stability testing, provided that documentation is provided to pro
14、ve part orientation. (Note: 5 watershields may be used in place of a full stack, provided that a mass equivalent to a full stack of watershields (less the 5 parts for the test) is placed evenly over the top of the panels. Documentation should be provided for the number of panels tested, their orient
15、ation, and the type of shipping/storage system used. 3.2.1 Simulated Summer Storage Conditions: Place the stack of watershields horizontally in an oven maintained at 70 +/- 2 C for 8 hours. Carefully remove the stack from the oven, lifting from the bottom, and allow it to rest undisturbed for 16 hou
16、rs at 23 +/- 2 C at 50 +/- 5% R.H. Repeat this for a total of 10 heat cycles. Material may rest between oven exposures at 23 +/- 2 C at 50 +/- 5% R.H. for a period of 48 hours maximum to accommodate weekend downtime, with a maximum of two downtime periods for the test. At the end of 10 cycles, turn
17、the stack over and individually separate the bottom three watershields by peeling them off at a 90 angle and evaluate samples per section 3.4.6.1. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P36-A3/A4 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 3 of 10 3.2.2 Simul
18、ated Winter Storage Conditions: Place a stack of watershields horizontally in a freezer maintained at 30 +/- 2 C for 8 hours. Carefully remove the stack from the freezer, lifting from the bottom, and allow it to rest undisturbed for 16 hours at 23 +/- 2 C at 50 +/- 5% R.H. Repeat this for a total of
19、 10 cold cycles. Material may rest between oven exposures at 23 +/- 2 C at 50 +/- 5% R.H. for a period of 48 hours maximum to accommodate weekend downtime, with a maximum of two downtime periods for the test. At the end of 10 cycles, turn the stack over and individually separate the bottom three wat
20、ershields by peeling them off at a 90 angle and evaluate samples per section 3.4.6.2. 3.3 BASE MATERIAL WSS-M15P36-A3 WSS-M15P36-A4 3.3.1 Thickness, mm, min As specified on the As specified on the (ISO 1923) Engineering Drawing Engineering Drawing 3.3.2 Flammability, max Not Required 100 mm/minute (
21、ISO 3795/SAE J369) 3.4 BASE MATERIAL WITH ADHESIVE Note: Generic base material description and adhesive type will be documented in the Approved Source List in the General Comments Section. 3.4.1 Odor, max Rating 3 (SAE J1351) 3.4.2 Fogging, min 70 (SAE J1756, 3 h at 100 C heating, 21 C cooling plate
22、, post test conditioning 1 h and 16 h. Include a quantity of adhesive at the same ratio of adhesive to base material as that of the complete watershield. Bond aluminum foil to the exposed adhesive and place sample with polymer base material on top, aluminum foil covered adhesive facing downward into
23、 the test vessel.) 3.4.3 Water Absorption, % by weight, max 5% (ASTM D 1056) Include a quantity of adhesive at the same ratio of adhesive to base material as that of the complete watershield. 3.4.4 Mildew Resistance No evidence of mildew (168 h, 38 C +/- 2 C, 95% R.H. Prepare and odor rating of 2 10
24、0 mm x 300 mm test pieces with adhesive) maximum 3.4.4.1 Evaluate panel for formation of mold and mildew growth via visual inspection, noting any growth, black/white spots, any evidence of growth will be considered a failure. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P36-A3/A4 Printed copies are unco
25、ntrolled Copyright 2007, Ford Global Technologies, LLC Page 4 of 10 3.4.4.2 Evaluation of objectionable odor shall be performed as follows. (A modification of the odor test.) After exposure in 3.4.4, remove specimen from chamber and have first of three panelists draw air over panel with a cupped han
26、d and slowly inhale. Score based on scale below. Return sample to environmental chamber for 15 minutes, remove and have second panelist evaluate, return for additional 15 minutes, and have final panelist evaluate. Report median and range of ratings for the three panelists. Odor Scale 1) No noticeabl
27、e odor 2) Slight, but noticeable odor 3) Definite odor, but not strong enough to be offensive 4) Strong offensive odor 5) Very strong offensive odor 3.4.5 Low Temperature Flexibility No cracking of polymeric base Prepare three 25 mm x 150 mm strips of base material by cutting from watershield parall
28、el and perpendicular to part. Condition test strips and a 13 mm diameter mandrel at -30 +/- 2 C for 4 h. Bend the conditioned strips 180 around the mandrel, within 3 seconds while in the cold chamber. 3.4.6 Separation Behavior No tearing of release paper, adhesive or the base material. 3.4.6.1 Condi
29、tioned by Summer Storage Cycle 3.4.6.2 Conditioned by Winter Storage Cycle 3.4.7 Dimensional Stability after Simulated Storage and Per limits on Separation: Watershields shall meet all dimensional engineering drawing requirements as described in the engineering drawing after storage and separation a
30、s described in 3.2.1 and 3.2.2. 3.4.8 Adhesive Bridging Test (Figure 1), max 3 mm Test Method: This test simulates a wire bundle passing beneath a watershield that is adhered to standard painted surfaces. Note: For assemblies with base materials that are thicker and/or not easily elongated and are s
31、pecifically designed to accommodate the passage of wire bundles (i.e., a thermoformed tunnel) this test may be omitted and shall be noted as such on the engineering drawing. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P36-A3/A4 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, L
32、LC Page 5 of 10 Required materials: Standard steel panels 100 mm x 300 mm minimum with approved paint coatings (see paragraph 4.3 for a recommended source). One 12.5 mm diameter x 100 mm long steel Bridging Mandrel with the center of the end of the mandrel clearly marked or scribed. Two 10 mm diamet
33、er x 100 mm long steel Application Mandrels. Test strips of base material approximately 25 mm x 200 mm with adhesive beads applied along one edge in the long dimension. The adhesive bead shall be the same as in production. Any suitable fast set adhesive to affix mandrel to paint panel. 2 kg roller (
34、ASTM D 1000) Test Procedure: 1. Prepare 10 test assemblies using standard paint panels. Center the 12.5 mm bridging mandrel perpendicular to the long dimension of the painted panels and affix using the fast set adhesive. Allow the fast set adhesive to cure. 2. Lay the prepared test strip with pressu
35、re-sensitive adhesive bead face down across the bridging mandrel and apply each end to the paint panel. Keep the test piece slightly taut but do not stretch (Figure 1a). 3. Press the two application mandrels firmly on the back surface of the test pieces against both sides of the bridging mandrel (Fi
36、gure 1b). With that the application mandrels in place, roll the entire test assembly twice with the 2 kg roller. Slide the application mandrels toward the ends of the test strip. Avoid stretching the test pieces. 4. Mark and measure (to the nearest 1 mm) the distance between the points where no adhe
37、sive is bonded to the paint panel and the center of the bridging mandrel (Figure 1C). 5. Allow the 10 assemblies to remain undisturbed horizontally for 24 hours at 23 +/- 2 C and 50 +/- 5% R.H. Evaluate for loss of adhesion using the results from step 4 as a baseline. The adhesion loss measurements
38、shall be less than 3 mm. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P36-A3/A4 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 6 of 10 6. Using 5 of the assemblies from step 5 above, cycle the assemblies through the following environmental cycle two times. Evaluate fo
39、r loss of adhesion using the results from step 4 as a baseline. Report the individual values for loss of adhesion. 5 h at -40 C +/- 2 C 30 min at 23 C and 50% +/- 5% R.H. 5h at 80 C +/- 2 C 30 min at 23 C and 50% +/- 5% R.H. 2 h at 50 C +/- 2 C and 95% +/- 5% R.H. 30 min at 23 C and 50% +/- 5% R.H.
40、5h at 80 C +/- 2 C 30 min at 23 C and 50% +/- 5% R.H. 5 h at 40 C +/- 2 C 30 min at 23 C and 50% +/- 5% R.H. 5h at 80 C +/- 2 C 7. Using 5 of the assemblies from step 5 above, heat age for 168 hours at 80 C. Evaluate for loss of adhesion using the results from step 4 as a baseline. Report the indivi
41、dual values for loss of adhesion. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P36-A3/A4 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 7 of 10 3.4.9 Water Leak Test and Repositionability (Refer to Figure 2) No evidence of leaking Apply the pressure-sensitive adhesive
42、 bead in a “U“ shape to 3 specimens for each paint system. The test pieces should be approximately 100 mm x 100 mm minimum where 3 U-shaped specimens can fit on one standard paint panel. The adhesive bead profile shall simulate production watershield application. Adhere to paint panels by rolling tw
43、ice with a 2 kg roller, allow panels to sit for 24 hours at 23 +/- 2 C. One panel will be used for testing in each section of 3.4.9.1 to 3.4.9.5. 3.4.9.1 As Received Water Leak Test: Fill the test pieces at the open end of the “U“ shaped assembly with dyed distilled water. Stand the test assemblies
44、vertically on white paper towels for 24 hours at 23 +/- 2 C. Staining of paper towels shall indicate water leakage and be cause for failure. 3.4.9.2 Short Term Repositionability, 15 - 30 seconds after application: Prepare a panel per 3.4.9. Remove the test specimens from the panel by grasping the up
45、per ends. The adhesive must release cleanly with no cohesive failure or transfer of adhesive to the paint panel. There shall be no tearing or excessive deformation of the polymeric base material. Excessive deformation for this specification is defined as variations in thickness, or stretching of the
46、 material to the extent that it cannot be re-applied to the paint panel in the same location as initially installed. Reapply using a 2 kg roller, rolling twice. Allow to rest 24 hours at 23 +/- 2 C. Perform water leak testing per paragraph 3.4.9.1. 3.4.9.3 Long Term Repositionability, 72 hours after
47、 application: Prepare a specimen per 3.4.9, remove test specimens from the panel and evaluate for adhesive loss and polymeric base deformation. Reapply using a 2 kg roller, rolling twice. Allow to rest 72 hours at 23 +/- 2 C. Remove, evaluate for adhesive loss and polymeric base deformation. Reapply
48、 using a 2 kg roller, rolling twice. Allow to rest at 23 +/- 2 C. Perform water leak testing per paragraph 3.4.9.1. ENGINEERING MATERIAL SPECIFICATIONWSS-M15P36-A3/A4 Printed copies are uncontrolled Copyright 2007, Ford Global Technologies, LLC Page 8 of 10 3.4.9.4 Environmental Exposures: Expose th
49、e panel(s) to the following environmental cycle twice: 5 h at -40 C +/- 2 C 30 min at 23 C and 50% +/- 5% R.H. 5h at 80 C +/- 2 C 30 min at 23 C and 50% +/- 5% R.H. 2 h at 50 C +/- 2 C and 95% +/- 5% R.H. 30 min at 23 C and 50% +/- 5% R.H. 5h at 80 C +/- 2 C 30 min at 23 C and 50% +/- 5% R.H. 5 h at -40 C +/- 2 C 30 min at 23 C and 50% +/- 5% R.H. 5h at 80 C +/- 2 C Perform water leak testing per paragraph 3.4.9.1 3.4.9.5 Expose the panel(s) for 168 hours at 38 C at 95 +/- 5 % R. H
