ENGINEERING MATERIAL SPECIFICATION

POLYURETHANE (PUR) FOAM, FLEXIBLE, RESTRICTED FLOW ESA-M4D200-B

1. SCOPE

The material defined by this specification is flexible polyether polyurethane foam. When
uncompressed it allows no air flow due to a high percentage of closed cells and lack of
interconnection between any remaining open cells.

2. APPLICATION

This specification was released originally for material used as gasketing and seals for heater and
air conditioning units.

3. REQUIREMENTS

3.1 RAW MATERIAL

All tests to be performed on, or from 200 x 200 x 25 mm slabs of new uncompressed
material, unless otherwise specified.

3.1.1 Color Charcoal

3.1.2 Density Cored 27 - 40 kg/m3

(ASTM D 3574) Uncored 40 - 56 kg/m3

3.1.3 Tensile Strength, min 69 kPa

(ASTM D 3574)

Elongation, min 125 %

3.1.4 Tear Resistance, min 175 N/m

(ASTM D 3574)

3.1.5 Compression Set, max 15 %

(ASTM D 3574, Method "B",
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50 % at 70 C, 22 h)

3.1.6 Resistance to Deterioration No visible

(FLTM BO 12-1, steps 2, 3, 4, degradation
6, 7 and 8)

3.1.7 Odor

No offensive odor as received and during and after the deterioration test
(para 3.1.6).

Date Action Revisions

2010 01 19 Re-Activated Still being used in North/South America Y. Bankoswki, NA

2009 07 28 N-STATUS No Replacement Named Y. Bankowski, NA

1966 12 22 Released AV2-298
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 ENGINEERING MATERIAL SPECIFICATION

ESA-M4D200-B
3.1.8 Cold Flexibility at - 40 C No cracking

Test Method: Condition 3 specimens, 25 x 50 x 200 mm for a minimum of 5

h in a cold chamber maintained at - 40 C. Without removing from chamber,
bend the specimen 180 degrees around a temperature conditioned mandrel
equivalent in diameter to the thickness of the foam.

3.1.9 Compression Force Deflection, max 6.5 kPa

(ASTM D 3574, Test C, except 65 %
compression, 20 - 50 mm thick specimen
compressed at 254 mm/minute)

Specimens are not to be preflexed prior to test. Reading to be taken

immediately upon reaching the 65 % deflection level. There must be no
audible cracking or snapping indicating rupture of closed cells when foam is
compressed to 65 % deflection.

3.1.10 Ozone Rating Rating 1

(FLTM BP 101-01)

3.1.11 Flammability Self-extinguishing

(FLTM BN 24-2, without the lot (Se/NBR)
sampling plan)

3.1.12 Cell Structure, min 10 cells/10 mm

The material shall have a homogenous fine cell structure free from large
voids or solid spots.

3.1.13 Restriction to Air Flow

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No sudden decrease in pressure, but rather a gradual one. After 30

minutes the pressure shall be 10 kPa min.

Test apparatus shall consist of a 7.6 L paint pressure tank with a 6.4 mm
pipe at least 150 mm long extending from the top outlet. Atop the 6.4 mm
pipe shall be a standard 25 mm pipe flange (29 mm diameter opening). The
tank must be equipped with an air pressure gage having 69 kPa total scale
graduated in 0.7 kPa units.

Place a test piece of foam 150 x 150 x 25 mm over the 25 mm pipe flange.
Place a piece of 1.6 mm screening on top of the test piece. Bolt another 25
mm pipe flange to the one attached to the pressure pot, with the test piece
and screening in between. Tighten the bolts until each is secure, but avoid
tightening any one more than the other.

Introduce a pressure of 35 kPa into the pressure pot, allow the pressure to
build up slowly. Turn off the air supply. Observe the pressure drop over a
30 minute time period. At the end of this period, residual pressure in the pot
must be a minimum of 10 kPa.

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 ENGINEERING MATERIAL SPECIFICATION

ESA-M4D200-B
3.1.14 Water Absorption at 75 % Compression, 280 %
by Weight, max

Test Method: 25 x 25 x 150 mm samples to be submerged in a 300 x 300 x

250 mm tank under 125 mm of water, using 6.4 mm screening to keep
samples positioned. Samples to be weighed and then compressed 75 %
(see attached drawing) prior to immersion. At the completion of 24 h
immersion at 23  2 C, remove for 5  0.5 minutes on a hardware cloth.

Reweigh and calculate average absorption for 3 samples:

B - A x 100
% water Absorption = -----------
A

A = Original weight
B = Weight after immersion

3.2 STATISTICAL PROCESS

Suppliers must conform to the requirements of Ford Quality System Standard Q-101. A
mutually acceptable Control Plan as described therein is required for material/source
approval. Appropriate statistical tools must be used to analyze process/product data so
that variation in the final product is continuously reduced.

3.3 SUPPLIER'S RESPONSIBILITY

All materials supplied to this specification must be equivalent in all characteristics to the
material upon which approval was originally granted.

Prior to making any change in the properties, composition, construction, color,

processing or labeling of the material originally approved under this specification,
whether or not such changes affect the material's ability to meet the specification
requirements, the Supplier shall notify Purchasing, Toxicology and the affected Materials
Engineering activity of the proposed changes and obtain the written approval of the
Materials Engineering activity. Test data, test samples and a new code identification are
to be submitted with the request.

Substance restrictions imposed by law, regulations or Ford, apply to the materials

addressed by this document. The restrictions are defined in Engineering Material
Specification WSS-M99P9999-A1.

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 ENGINEERING MATERIAL SPECIFICATION

ESA-M4D200-B
4. APPROVAL OF MATERIALS

Materials defined by this specification must have prior approval by the responsible Materials
Engineering activity. Suppliers desiring approval of their materials shall first obtain an expression of
interest from the affected Purchasing, Design and Materials Engineering activity. Upon request,
the Supplier shall submit to the affected Materials Engineering activity 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 this specification (test results, not
nominal values), the material designation and code number, and test specimens for Ford
evaluation. Ford's engineering approval of a material will be based on its performance to this
specification and on an assessment of suitability for intended processes and/or applications. Upon
approval, the material will be added to the Engineering Material Approved Source List.

5. GENERAL INFORMATION

The information below is provided for clarification and assistance in meeting the requirements of
this specification.

5.1 RECYCLING CODE

>PUR<

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 ENGINEERING MATERIAL SPECIFICATION

ESA-M4D200-B

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Printed copies are uncontrolled Copyright © 2010 Ford Global Technologies, LLC Page 5 of 5
Copyright Ford Motor Company
Provided by IHS under license with FORD Licensee=Visteon Corp Van Buren/5962532002, User=Exel, Beverly
No reproduction or networking permitted without license from IHS Not for Resale, 03/06/2012 07:53:34 MST