FORD WSS-M15P45-C-2016 ASSEMBLY PERFORMANCE INSTRUMENT PANEL AND SOFT INTERIOR COMPONENTS FLEXIBLE COVER SKIN MATERIAL TO BE USED WITH FORD WSS-M99P1111-A .pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 0 2016 05 19 Released S. Gatzek, NA Controlled document at www.MATS.com Copyright 2016, Ford Global Technologies, LLC Page 1 of 15 ASSEMBLY PERFORMANCE, INSTRUMENT PANEL AND SOFT WSS-M15P45-C INTERIOR COMPONENTS, FLEXIBLE COVER SKIN MATE

2、RIAL 1. SCOPE The material defined by this specification is an instrument panel assembly, instrument panel component, floor console armrest, valence panel, steering wheel airbag cover, hush panel, door panel or wrapped pillar, which utilizes a flexible (soft) cover skin material over a hard substrat

3、e with or without foam or spacer fabric, and with or without a topcoat. 2. APPLICATION This specification was released originally for material used for all soft interior components, not including seat trim covers, molded/foam-in-place armrests and headrests. This specification includes top-coated (a

4、dded for gloss control, haptics and/or cleanability) and in-mold coated (IMC) skins. Instrument panels containing an integrated airbag system must also meet any additional specifications on the Engineering Document. All painted flexible cover skins (through a secondary process) shall meet the requir

5、ements of WSS-M2P188-B1/latest. All soft skins or fabrics for armrests and door panels must also meet the requirements of WSS-M8P3-E1/E2/E3/latest (flexible polymeric films), WSS-M99P43-C/latest (leather) or WSS-M8P18-B1/B2/B3/B4/latest (fabrics). EXCLUDED The following applications are excluded fro

6、m this specification. hard instrument panels, hard door panels, finish panels (WSS-M15P4-Glatest) package trays (WSS-M15P6-E/latest) steering wheels (WSS-M98P12-B/latest) headliners (WSS-M15P27-F/latest) carpeting substrate (WSS-M8P16-B/latest) appliqus (WSS-M15P34-E/latest) sun visors (WSS-M98P3-B/

7、latest) molded headrest (WSS-M15P39-B/latest) molded armrests (WSS-M15P26-D/latest) and interior elastomers (WSS-M9P8-B/latest) Testing must be conducted on parts at DV and PV unless specified otherwise by Ford Engineering. See Tables 1 no spewing, wrinkling, distortion, blistering, warping, delamin

8、ation, blushing, hazing, milking, waviness, or other objectionable visual appearance. Any spotty or non-uniform staining or discoloration shall be cause for rejection. For topcoated polymeric cover skin materials, a color shift that reverses after 16 h Xenon weathering, per 3.8.1 is acceptable 2) Fu

9、nctionally - no excessive expansion, shrinking, or warping that will interfere with normal functional operations. 3) Dimensionally - no movement exceeding what is required on the Engineering drawing from the original installed position during or after the test. Dimensional exceptions to these requir

10、ements may be allowed by Core Engineering. 3.4.1 Short Term Heat, Humidity and Cold Cycle For leather wrapped parts, ensure the component is positioned in the test chamber so no condensation from the test equipment can drip and pool on the part surface during the test cycle. Note that stages do not

11、include ramp times to transition from level to level. Each specimen can have different size, geometry, etc. which impacts ramp times; therefore, each transition period will vary in length of time. Total test time should exceed 38 h due to time required to transition from level to level. 3.4.1.1 Hori

12、zontal or vertical parts AT OR ABOVE THE BELT-LINE (e.g. wrapped pillars, soft instrument panels) 5 h at -30 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 100+/- 2 C 30 min at 23 +/- 2 C and 50% R.H 2 h at 50 +/- 2 C and 95 +/- 5% R.H. 30 min at 23 +/- 2 C and 50% R.H 5 h at -30 +/- 2 C 30 min at

13、 23 +/- 2 C and 50% R.H. 5 h at 100 +/- 2 C ENGINEERING MATERIAL SPECIFICATION WSS-M15P45-C Copyright 2016, Ford Global Technologies, LLC Page 4 of 15 3.4.1.2 Horizontal or vertical parts BELOW THE BELT-LINE (e.g., door panels, soft consoles, wrapped glove box doors and other non-sun loaded parts) 5

14、 h at -30 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 90+/- 2 C 30 min at 23 +/- 2 C and 50% R.H 2 h at 50 +/- 2 C and 95 +/- 5% R.H. 30 min at 23 +/- 2 C and 50% R.H 5 h at -30 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 90 +/- 2 C 3.4.1.3 Other non-sun loaded floor level parts that dont

15、meet the dimensional or functional requirements when tested at 90 C (e.g., scuff plates, kick panels, map pocket opening of door trim and below) 5 h at -30 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 80+/- 2 C 30 min at 23 +/- 2 C and 50% R.H 2 h at 50 +/- 2 C and 95 +/- 5% R.H. 30 min at 23 +/

16、- 2 C and 50% R.H 5 h at -30 +/- 2 C 30 min at 23 +/- 2 C and 50% R.H. 5 h at 80 +/- 2 C 3.4.2 Long Term Heat Exposure / Sun Load 3.4.2.1 Soft Instrument Panels with or without integrated floor consoles Sun Load per IP-105: 107 C surface temperature via heat lamps with a chamber temperature of 90 C

17、for 242 hours 3.4.2.2 Horizontal or vertical parts AT OR ABOVE THE BELT-LINE (e.g. wrapped pillars; soft upper door trim rollover for aged peel adhesion only): 7 days at 100 +/- 2 C 3.4.2.3 Horizontal or vertical parts BELOW THE BELT-LINE (e.g., door panels and soft consoles that are not integrated

18、with the instrument panel; soft upper door trim panels dimensional and visual): 7 days at 90 +/- 2 C 3.4.2.4 Other non-sun loaded floor level parts (e.g., scuff plates, kick plates, door trim bottom surface). 7 days at 80 +/- 2 C For Instrument Panels Only (para 3.4.3. 3.4.4): Test Method: After Lon

19、g Term Heat Exposure / Sun Load (3.4.2), cut test specimens (remove foam and substrate) and condition them for 24 h at 23 +/- 2 C and 50 +/- 5% relative humidity prior to performing the following test: ENGINEERING MATERIAL SPECIFICATION WSS-M15P45-C Copyright 2016, Ford Global Technologies, LLC Page

20、 5 of 15 3.4.3 Cold Flexibility No cracks (180 bend at -30 C for a minimum of 4 hours over a 20 +/- 1 mm diameter mandrel, sample size approximately 50 x 150 mm) 3.4.4 Elongation of Flexible Coverskin 50% max change from (ISO 37, Type 1, 500 mm/minute test speed) original value Excludes leather whic

21、h must meet requirements in WSS-M1F25-F/latest. 3.5 180 DEGREE PEEL ADHESION STRENGTH (FLTM BN 151-05, 300 mm/minute cross head rate, test specimens must be 50 mm wide, report peel adhesion strength using integral method; arithmetic mean of 5 test specimens, cut in any direction). FLTM BN 152-01 Det

22、ermination of Bond Strength Using the Wedge Method, may be required for systems with a thick foam layer that breaks when folded back on itself, Use of this test method and acceptance criteria must be agreed upon with Ford Materials Engineering and PD Engineering. If the layers comprising the interfa

23、ce to be evaluated cannot be separated during test specimen preparation, the peel adhesion bond will be deemed too strong to separate and be judged as meeting the requirement. Peel adhesion is applicable for systems comprised of layers that are chemically or adhesively bonded together. Examples of s

24、pecifications for these systems are listed below: Instrument Panels: Foam in Place: WSS-M4D983-A3, WSS-M4D985-A3, WSS-M4D980-A, M4D1059-A, WSS-M4D1060-A Vacuum Forming In Mold Graining (IMG) / In Mold Grain Lamination (IMGL): WSS-M98D39-A2, WSB-M98D18-B2 Leather Wrapped Systems: WSS-M1F25-B Polymeri

25、c Skin Wrapped Adhesive Systems: WSS-M2F206-A3, WSS-M2F207-A2/A3, WSS-M2F208-A3 All Other Parts: Foam in Place: WSS-M4D983-A3, WSS-M4D985-A2, WSS-M4D980-A, M4D1059-A, WSS-M4D1060-A Back Injection Molded Systems: WSS-M5H40-B3 Vacuum Forming In Mold Graining (IMG) / In Mold Grain Lamination (IMGL): WS

26、S-M98D39-A1, WSB-M98D18-B1 Foam Laminated to Leather: WSS-M1F27-B, WSS-M1F29-B Leather or Vinyl Wrapped Systems with Separate Foam Layer: WSS-M1F27-B, WSS-M1F30-B, WSS-M2F212-A, WSS-M2F186-A1/A2 Tri-Laminate Wrapped Adhesive Systems: WSS-M1HXXXX, M2FXXX material specifications with WSS-M8P3 and M8P1

27、8 performance specifications ENGINEERING MATERIAL SPECIFICATION WSS-M15P45-C Copyright 2016, Ford Global Technologies, LLC Page 6 of 15 If minimum requirement is not met, then acceptance must be determined with the IP/PAB technical specialist/SME based on successful PAB deployments. This acceptance

28、must be documented in eFDVS. INSTRUMENT PANELS Examples of Composite Constructions Interface Original After Heat Aging (Para 3.4.2) Foam in Place Systems Polymeric Skin to Foam 175 N/m minimum and cohesive foam tear; no individual value less than 95 N/m 130 N/m minimum and cohesive foam tear; no ind

29、ividual value less than 95 N/m Foam to Substrate Cohesive foam tear Cohesive foam tear Vacuum Forming In Mold Graining/In Mold Grain Lamination Polymeric Skin to Foam Bi-laminate Requirements defined in applicable Ford Material Specification (WSS-M98D39-A2, WSS-M98D18-B2) Foam to Substrate 1200 N/m

30、minimum and cohesive foam tear 900 N/m minimum and cohesive foam tear Leather Wrapped Adhesive Systems Leather to Spacer 1200 N/m minimum 2500 N/m minimum for seamless PAB area 1200 N/m minimum 2500 N/m minimum for seamless PAB area Spacer to Substrate or Subassembly 1200 N/m minimum 2500 N/m minimu

31、m for seamless PAB area 1200 N/m minimum 2500 N/m minimum for seamless PAB area Polymeric Skin Wrapped Adhesive Systems OR Polymeric Skin to Spacer Bi-laminate OR Requirements defined in applicable Ford Material Specification ( WSS-M2F206-A3, WSS-M2F207-A3, WSS-M2F208-A3) Polymeric Skin to Knit Back

32、ing Requirements defined in applicable Ford Material Specification (WSS-M2F207-A2) Spacer or Knit Backing to Substrate 1200 N/m minimum 2500 N/m minimum for seamless PAB area 900 N/m minimum 2500 N/m minimum for seamless PAB area SKIN SUBSTRATE SKIN TO FOAM FOAM TO SUBSTRATE FOAM FOAM TO SUBSTRATE A

33、DHESIVE SKIN/FOAM BI-LAMINATE SUBSTRATE ADHESIVE LEATHER TO SPACER SPACER TO SUBSTRATE SUBSTRATE OR SUBASSEMBLY SPACER LEATHER ADHESIVE SUBSTRATE SPACER TO SUBSTRATE ADHESIVE SKIN/SPACER BI-LAMINATE SUBSTRATE OR SUBASSEMBLY KNIT BACKING TO SUBSTRATE ADHESIVE POLYMERIC SKIN WITH KNIT BACKING ENGINEER

34、ING MATERIAL SPECIFICATION WSS-M15P45-C Copyright 2016, Ford Global Technologies, LLC Page 7 of 15 If minimum requirement is not met, then program specific target must be determined with the system Core Engineering based on successful part performance. This acceptance must be documented in eFDVS. AL

35、L OTHER PARTS Examples of Composite Constructions Interface Original After Exposure (Para 3.4.2) Foam in Place Systems Polymeric Skin to Foam 175 N/m minimum and cohesive foam tear 175 N/m minimum and cohesive foam tear Foam To Substrate 240 N/m minimum and cohesive foam tear 240 N/m minimum and coh

36、esive foam tear Back Injection Molded Systems Back Injection Molded Fabric / Backing To Substrate 440 N/m minimum 440 N/m minimum Vacuum Forming (In Mold Graining/In Mold Grain Lamination) Polymeric Skin to Foam Bi-laminate Requirements defined in applicable Ford Material Specification (WSS-M98D39-A

37、1, WSS-M98D18-B1) Foam to Substrate 440 N/m minimum and cohesive foam tear 440 N/m minimum and cohesive foam tear Foam Laminated to Leather Leather to Foam 175 N/m minimum and cohesive foam tear 175 N/m minimum and cohesive foam tear Leather or Vinyl Wrapped Systems with Separate Foam Layer Leather

38、or Vinyl to Scrim 240 N/m minimum 240 N/m minimum Scrim to Substrate 240 N/m minimum 240 N/m minimum Tri-laminate Wrapped Adhesive Systems (Hand Wrapped or Press Bonded) Polymeric Skin/Foam/Scrim Tri-laminate Requirements defined in applicable Ford Material Specification (WSS-M8P3-E3, WSS-M8P18-B2/B

39、3) Scrim to Substrate or Foam Bun 240 N/m minimum 240 N/m minimum Other Wrapped Adhesive Systems (Armrest) Skin/Leather to Substrate or Foam Bun 240 N/m minimum 240 N/m minimum SUBSTRATE OR FOAM BUN SKIN TO SUBSTRATE ADHESIVE SKIN/LEATHER SKIN SUBSTRATE SKIN TO FOAM FOAM TO SUBSTRATE FOAM SUBSTRATE

40、FABRIC/BACKING TO SUBSTRATE FABRIC/BACKING FOAM TO SUBSTRATE ADHESIVE SKIN/FOAM BI-LAMINATE SUBSTRATE LEATHER LEATHER TO FOAM FOAM/SCRIM BI-LAMINATE ADHESIVE LEATHER/VINYL LEATHER/VINYL TO SCRIM SCRIM TO SUBSTRATE SKIN/FOAM/SCRIM TRI-LAMINATE ADHESIVE ADHESIVE SUBSTRATE SUBSTRATE OR FOAM BUN SCRIM T

41、O SUBSTRATE OR FOAM BUN ADHESIVE SKIN/FOAM/SCRIM TRI-LAMINATE ENGINEERING MATERIAL SPECIFICATION WSS-M15P45-C Copyright 2016, Ford Global Technologies, LLC Page 8 of 15 3.5.1 Deep Draw Sectioning For all wrapped adhesive systems (i.e. hand wrapped/pressure assist/IMGL/IMG/Cast) additional sectioning

42、 of the part is required for the deep draw areas. Deep draw areas are defined by a change of contour of 15 mm or more (for example any concave surface such as integral insert/armrest or molded in pockets that have a potential to bridge). Cut the part every 50 mm in these areas to review the bonding

43、of the cover stock and composite (bi/tri laminates) to the substrate. Unacceptable conditions include: Bridging of material (not adhered to substrate) Bubbles/Non-bonded areas 3.6 INDENTATION AND RECOVERY Complete recovery after 1 hour (FLTM BO 111-02, 6.8 kg load) Only applicable for components wit

44、h foam between the skin and substrate. Excludes door trim panel components which must meet the Rolling Sphere Fatigue Test (Para 3.7). Excludes all leather IP systems whose requirements are defined by Core Engineering. 3.7 ROLLING SPHERE FATIGUE TEST For Door Trim Panel Components Only (FLTM BO 113-

45、04, 2000 cycles) Length of stroke to be 200 mm from center point of sphere leaving the length to be evaluated 150mm. The end 25 mm from center of sphere in each travel direction is to be excluded from indent evaluation measurement area. All test results are to be reviewed and signed off by Materials

46、 Engineer and Core Engineering. Deformation (mm) after 24 hours Report Only Deformation (mm) after 48 hours Report Only 3.8 COLOR AND APPEARANCE PROPERTIES Sample shall be tested as part of a production assembly composite (skin and foam or spacer fabric) for instrument panel systems only unless othe

47、rwise indicated. Sample shall be cut from the locations specified. The material shall not exhibit staining, color tone change, change in hue, cracking, crazing, tackiness or other deterioration after exposure in accordance with testing below. Read and report the gloss change. For new coverskin techn

48、ology, check samples at 526 kJ/m2 intervals and note any changes in appearance. The materials shall be rejected if adhesive staining or other non-uniform staining results from material incompatibility. ENGINEERING MATERIAL SPECIFICATION WSS-M15P45-C Copyright 2016, Ford Global Technologies, LLC Page

49、 9 of 15 3.8.1 Resistance to Interior Weathering (FLTM BO 116-01, ISO 105 A-02/AATCC Evaluation Procedure 1) The xenon arc panel size shall be approximately 60 x 150 mm. In Vehicle Sunlight Exposure Level FLTM BO 116-01 Test Exposure AATCC Rating After Exposure, min. Severe Exposure: Instrument panel topper, defroster grille 3609.6 kJ/m2 Ra