FORD WSS-M8P16-B-2016 PERFORMANCE CARPET FLOOR AND TRIM TO BE USED WITH FORD WSS-M99P1111-A .pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 2 2016 07 08 Revised See Summary of Revisions L. Sinclair, NA 2014 07 24 Revised See Summary of Revisions L. Sinclair, NA 2010 07 16 Activated J. Williams, EU, L. Sinclair, NA Controlled document at www.MATS Copyright 2016, Ford Global T

2、echnologies, LLC Page 1 of 15 PERFORMANCE, CARPET, FLOOR AND TRIM WSS-M8P16-B 1. SCOPE The materials defined by this specification are automotive quality carpet assemblies, for floor, door trim, seat backs in exposed load compartment applications and exposed load floors whether molded or otherwise f

3、abricated. 2. APPLICATION This specification was released originally for passenger compartment floor coverings and other automotive trim applications. 2.1 LIMITATIONS The use of non woven carpets is not applicable to first row seat backs (full covering) but may be used in the toe kick area or with c

4、aution on second and third row seats. Potential concerns may arise with fiber snagging and pilling. Use only in areas with limited customer interactions. Vacuumability of non-wovens is difficult due to the construction, pet hair, debris can become entrapped in the loops of the non woven construction

5、. Vacuumability can be significantly improved by switching to a tufted product. 3. REQUIREMENTS 3.1 APPROVED SOURCES This specification is performance based and does not have approved sources. 3.2 CONDITIONING AND TEST CONDITIONS All test values are based on material conditioned for not less than 24

6、 h prior to testing in a controlled environment of 23 +/- 2 C and 50 +/- 5% relative humidity. Testing of the material should occur in the conditioning environment or soon after removal. 3.3 PERFORMANCE CRITERIA 3.3.1 In addition to the requirements listed herein, the individual carpet assembly comp

7、onents shall meet all the requirements of the applicable material specifications for the carpet, padding, adhesive, barrier, or trim application as well as any functional/SDS requirements as outlined by Engineering. Material specification requirements are to be used for initial qualification of mate

8、rials. 3.3.2 Insulation materials shall meet the requirements of WSS-M99P32-D1/latest. Mold in Color plastic components shall meet the requirements of WSS-M15P4-G/latest. Toe pads/foot rest covers shall meet the requirements of WSS-M15P37-C1. 3.4 SAMPLE SELECTION See Table 1 and 2 for sample size an

9、d testing requirements. When production test specimens are taken from an area in the carpet with padding, the padding should be stripped away as much ENGINEERING MATERIAL SPECIFICATION WSS-M8P16-B Copyright 2016, Ford Global Technologies, LLC Page 2 of 15 as possible before evaluation, unless otherw

10、ise specified. For floor carpet applications, test specimens for strength and abrasion properties shall be taken from molded or stressed areas of the carpet assembly, i.e. the front footwell unless otherwise specified. The roll stock will be reviewed for initial approval. Final approval will be gran

11、ted on a program by program basis on the molded product once the specification testing is reviewed and signed off on by Materials Engineering. 3.5 APPEARANCE The color, pattern, and finish shall match the approved Design Center master sample. 3.6 WEIGHT (FLTM BN 106-01) The weight shall be as specif

12、ied in the individual material specification and Floor Carpet Construction Supplement. The weight per square meter is applicable to rollstock carpet. For tufted carpets the supplier shall calculate the total fiber weight after subtracting the actual weight of the primary backing for each batch and s

13、hall not use the nominal value. 3.7 COMPOSITION AND CONSTRUCTION Shall be as specified on the Material Specification. The Floor Carpet Supplement Form shall be completed and submitted to Materials Engineering with the construction package. Backcoating: The backcoating shall form a continuous and uni

14、form coating over the back of the carpet so that all pile fibers are covered. Also, the backcoat shall show no evidence of cracking or crumbling during any of the evaluations required within the specification and during normal field conditions. The backcoat shall thoroughly saturate the base of the

15、pile fiber bundles to ensure adequate fiber lock. Penetration of the backcoat through to the face of the carpet shall be controlled to provide the required resistance to abrasion and fiber loss, but backcoat shall not be visible on the face of the pile fiber. If the carpet does not have a back coati

16、ng it shall be a fused backed carpet. Adhesion: The carpet material and substrate shall be properly bonded together with the backcoating and/or adhesive where necessary, to ensure that the various components of the finished carpet assembly do not delaminate under normal handling and shipping operati

17、ons. Adhesion properties must meet requirements in WSS-M99P32-D1/latest. Secondary Backing Fabrics/Heavy Layer (if applicable): The secondary fabric/heavy layer shall be uniformly and continuously bonded across the entire carpet and shall be free of voids and tears. 3.8 PHYSICAL PROPERTIES In additi

18、on to the following minimum requirements, production carpet assemblies must withstand normal handling during shipping and installation, without tearing. For additional information refer to Section 3.7. 3.8.1 Breaking Strength (ASTM D 5034 Grab Method, 305 mm/minute jaw speed) Floor Other Trim Min Mi

19、n WMD 400 N 300 N AMD 400 N 300 N ENGINEERING MATERIAL SPECIFICATION WSS-M8P16-B Copyright 2016, Ford Global Technologies, LLC Page 3 of 15 3.8.2 Tear Strength (Trapezoid) Dry Only (ASTM D 5587, Option 1 (Multiple Peak Force Average) Floor & Trim WMD 90 N min AMD 90 N min 3.8.3 Heat Aging Rating 4 m

20、in (ISO 105-A02/ AATCC Evaluation Procedure 1 Use a sample size of 100 mm x 100 mm) 3.8.3.1 Floor Carpets and Trim Carpets used below the armrest: 7 days at 80 +/- 2 C 3.8.3.2 Exposed Load Floor and Seat Back Applications: 7 days at 90 +/- 2 C No individual yarn or combination of yarns shall exhibit

21、 fiber deterioration or color tone change in excess of the above rating. There shall be no visual deterioration of backcoating. 3.8.4 Stretch and Set (for seat back applications only) (SAE J855) WMD & AMD Stretch 18% max WMD & AMD Set 5% max 3.8.5 Resistance to Mildew (7 days at 98 +/- 2% relative h

22、umidity and 38 +/- 2 C, Specimen size 100 x 100 +/- 2 mm) Remove the part from the cabinet and evaluate (smell the sample) immediately. The part shall exhibit no visible evidence of mildew growth and / or objectionable odor after the 7 day exposure. 3.8.6 Short Term Environmental Cycling Rating 4 mi

23、n (FLTM BO 040-01, Procedure A, 80 C for floor components, 90 C for exposed 2% max Shrinkage/ load floor and seat backs, evaluation on Expansion rolled goods 300 x 300 +/- 2 mm) 3.8.7 Long Term Environmental Cycling Rating 4 min (FLTM BO 040-01, Procedure B, except run 80 C for floor components, 90

24、C for exposed 2% max Shrinkage/ load floor and seat backs, evaluation on Expansion rolled goods 300 x 300 +/- 2 mm) ENGINEERING MATERIAL SPECIFICATION WSS-M8P16-B Copyright 2016, Ford Global Technologies, LLC Page 4 of 15 3.9 WEAR PROPERTIES 3.9.1 Resistance to Abrasion Samples shall be taken from t

25、he front footwell in the designated area (See photograph in Appendix 3). No individual test results shall fall below the number of abrasion cycles specified below. 3.9.1.1 Floor Carpet (SAE J1530-A, 1000 g load,H-18 wheels) Rolled Goods 2000 Cycles Molded Product 1500 Cycles 3.9.1.2 Trim Application

26、s (SAE J1530-A, 500 g load, H-10 wheels) Seat back, 1200 cycles Exposed load floor areas Door Panel /Side Walls 400 cycles Tufted Carpets: There shall be no primary backing visible after abrasion testing in excess of the failure criteria shown in Appendix 1. Nonwoven Carpets: The carpet shall exhibi

27、t no visual evidence of wear through to the foundation of the pile fibers in the abraded area in excess of the failure criteria shown in Appendix 1. No roping is allowed. See Figure 5 for example of roping. 3.9.2 Resistance To Snagging (non woven floor carpets only) 200 cycles (SAE J1530-A, H-18 whe

28、els, 500 g load) Evaluate test specimen every 50 cycles. All other non woven components 50 cycles No evidence of fiber pullout in excess of the minimum failure criteria shown in Appendix 2. 3.9.3 Pile Tuft Pull Strength (Tufted carpets only) (ASTM D1335) 3.9.3.1 Room Temperature 16 N min 3.9.3.2 Tuf

29、t Pull after 7 days at 80+/-2 C Pull at Room Temperature 10 N min 3.10 COMPOSITE TESTING 3.10.1 Short Term Environmental Cycling Rating 4 min (FLTM BO 040-01, Procedure A, 80 C for floor components, 90 C for exposed load floor and seat backs) 3.10.2 Long Term Environmental Cycling Rating 4 min (FLTM

30、 BO 040-01, Procedure B, 80 C for floor components, 90 C for ENGINEERING MATERIAL SPECIFICATION WSS-M8P16-B Copyright 2016, Ford Global Technologies, LLC Page 5 of 15 exposed load floor and seat backs) 3.10.3 Room Temperature Impact Resistance (Load Floors only) (23 +/- 2 C) Rubber Ball 4.5 kg weigh

31、t, 127 mm diameter 60 +/- 5, Durometer “A“, Test Method: Conduct this test with the trim assembly mounted on an actual or simulated production support foundation using the approved retention methods. Drop the rubber ball from the height specified below at the impact locations indicated on the Engine

32、ering Drawing. (See Section 4.0 for rubber ball supplier contact information) Drop Height Load Floor 500 mm The assembly shall show no evidence of cracking or breaking on the top or reverse side and shall fully recover from indentation. 3.10.4 Adhesion of Cover Material to Substrate (when adhesively

33、 bonded to a rigid substrate) (FLTM BN 151-05 speed 305 mm/minute.) Original 10 N/mm min Cycled 7 N/mm min (Short Term Environmental Cycling para. 3.10.1) Heat 7 N/mm min (Long Term Heat Exposure para. 3.10.2) Test Method: The above method is to be employed for all dielectric, heat or adhesively bon

34、ded materials. Individual bond lines less than 25 mm must also meet the above minimum requirements when computed on a per mm basis. Special bonded sections such as corrugated design, etc., as well as extra wide bonded areas exhibiting low prorated bond strength values may be accepted provided they h

35、ave been approved by the Design and Release Engineering. 3.11 APPEARANCE PROPERTIES 3.11.1 Resistance to Fade (FLTM BO 116-01, ISO 105-A02/ AATCC Evaluation Procedure 1) Floor Carpets and Trim Carpets used Rating 4 min below the armrest, 225.6 kJ/m2 Trim Carpets used between the beltline Rating 4 mi

36、n and armrest, 601.6 kJ/m2 Exposed Load Floor Carpets, 977.6 kJ/m2 Rating 4 min 3.11.2 Fiber Deterioration after UV Exposure Floor Carpet: SAE J1530-A, 1000 g load,H-18 wheels 1200 cycles Trim applications: SAE J1530-A 500 g load H-10 wheels ENGINEERING MATERIAL SPECIFICATION WSS-M8P16-B Copyright 2

37、016, Ford Global Technologies, LLC Page 6 of 15 Seat Back, Exposed load floor 1000 cycles Door Panel, Side walls 350 cycles No deterioration of fibers or yarns after testing to the applicable exposure levels in section 3.11.1 on molded production components. See Appendix 1 for failure criteria. 3.11

38、.3 Resistance to Crocking (FLTM BN 107-01, ISO 105-A02/ AATCC Evaluation Procedure 2) Dry Rating 4 min Wet Rating 4 min 3.11.4 Soiling and Cleanability Rating 4 min. (FLTM BN 112-08, ISO 105-A02/ AATCC Evaluation Procedure 2) 3.12 ODOR (FLTM BO 131-03) Condition 1 Rating 3 max Condition 2 Rating 3 m

39、ax Condition 3 Rating 3 max 3.13 FOGGING (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 16 h) Fog Number 70 min Formation of clear film, droplets or crystals is cause for rejection For construction approval all materials should be stored in an open environment for 14-28

40、 days after manufacture, and then must be bagged in heat sealed polyethylene (PE) or PE coated aluminum bags for shipping. Materials for testing must be labeled with supplier and date of manufacture. 3.14 FLAMMABILITY (ISO 3795) Burn Rate 100mm/minute max 4. GENERAL INFORMATION This information give

41、n below is provided for clarification and assistance in meeting the requirements 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 Pu

42、rchasing, Design or Product Development, and Materials Engineering. The 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 Specifica

43、tion. Tested material samples must be available for review upon request 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. ENGINEERING MATERIA

44、L SPECIFICATION WSS-M8P16-B Copyright 2016, Ford Global Technologies, LLC Page 7 of 15 4.2 SUPPLIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes to the material originally appro

45、ved, whether or not such changes affect the materials ability to meet the specification requirements, the supplier shall notify the affected Supplier Technical Assistance (STA), Purchasing, and Materials Engineering activities of the proposed changes (with reasons) by submission of a completed Suppl

46、iers Request for Engineering Approval, SREA. For parts and components 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

47、 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed 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 supplie

48、rs responsibility to comply with this standard on a continuing basis through IMDS and or GMAP reporting. Rubber Ball Contact Information Dave Clow, Schap Specialty Machine, Inc 17309 Taft Street Spring Lake, Mi 49456 Ph: (616)846-6530 5. SUMMARY OF REVISIONS 2016 07 08 Updated standard paragraphs

49、in section 3 and 4. And all numbering 2.1 added vacuumability statement 3.3.1 added material to be used for initial qualifications 3.3.2 updated reference specifications 3.5 update statement 3.7 added non backcoated carpet statement 3.8.5 added statement on smelling part directly after testing 3.8.6/7/3.10.1/2 moved to FLTM 3.9.11 removed 4000 cycle requirement. Throw in mats are now assumed to be stand