FCA 9.55260 Die-Cut Polyurethane Foam Components Produced from Sheet (URL)

The “FCA 9.55260 Die-Cut Polyurethane Foam Components (URL) from Sheet” standard, developed by Fiat Chrysler Automobiles (FCA), an Italian-American automotive company , describes the requirements, test procedures, and test equipment for die-cut components from sheets of cellular foam.

The components coated with Harein are die-cut from sheets of foam produced by the reaction of polyhydric compounds with isocyanates and water and are characterized by a network of essentially open, interconnected cells. Cellular polyurethane foam components are classified according to compression deflation as shown in the table given in the standard:

Tests shall be performed at least 72 hours after component manufacture and shall normally be performed in an unconditioned environment. In cases of disagreement, tests shall be performed at 23 degrees plus/minus 2 degrees and 50 percent plus/minus 5 percent relative humidity.

The configuration, dimensions and tolerances must comply with the drawings and patterns provided by the manufacturing services and the table given in the standard.

Visually, component surfaces should be smooth and free of tears. Die-cut edges should be cleanly cut.

Its density must be as specified in the “FCA 7.G2000 Combustion behavior” standard.

The tests mainly performed within the scope of this standard are as follows:

• For compression deflection, testing is performed on cylindrical specimens with a diameter of 56,5 mm (25 cm2) and a thickness of 25 to 40 mm. If necessary, several die-cut discs can be combined to achieve the desired thickness. The specimen is placed in the tester. A preload of 50 g plus/minus 5 g is applied and the thickness is measured. The specimen is continued to be compressed at a rate of 50 mm plus/minus 50 mm per minute to reduce the thickness by 2 percent and the corresponding load is recorded. Compression deflection is calculated according to the formula given in the standard. The test result is the arithmetic average of the readings of the three specimens and must meet the requirements.
• When performing the compression test, the test is performed on the specimen as described in this standard. The original thickness of the unrestrained specimen is measured. The specimen is placed on the fixture and compressed to 50 percent of the original thickness. The support/specimen assembly is placed in an oven at 22 degrees plus/minus 70 degrees for 2 hours. The specimen is cooled to ambient temperature for 30 minutes and the final thickness is measured. The compression set percentage under 50 percent constant deflection is calculated according to the formula given in the standard. The test result is the arithmetic average of the readings of the three specimens and must comply with the requirements.
• When testing tensile strength and ultimate elongation, the test is performed on die-cut samples from strips measuring 25 mm x 10 mm x 150 mm. The dimensions and configuration of the samples are shown in the figure. A gauge length of 25 mm is marked with ink using a rubber stamp. The sample is placed in the grips of the dynamometer and subjected to tensile stress at a tensile rate of 500 mm plus/minus 25 mm per minute. The load at break and the percentage of elongation are recorded. The test result is the arithmetic average of the readings for the three samples and must comply with the requirements.
• When performing the aging test, the test is carried out on the samples as described in this standard. The sample is dried in the oven at 70 degrees plus/minus 2 degrees and waited for 25 hours for each 3 mm of thickness. The sample is conditioned at ambient temperature for a minimum of 2 and a maximum of 24 hours. The sample is placed in the test machine. A preload of 15 g plus/minus 50 g is applied for 5 seconds and the thickness is measured under the preload. The sample is continued to be compressed at a rate of 50 mm plus/minus 50 mm per minute to reduce the thickness by 2 percent. The compression is continued for 30 seconds and the corresponding load is recorded. The autoclave is filled with distilled water to a level below the sample to ensure that there is no contact. The thermostat is set at 120 degrees, at which temperature the internal pressure reaches approximately 2 bar. When the water starts to boil, the sample is immersed and the safety valve is left open. The autoclave is allowed to reach pressure saturation as indicated by steam escaping from the valve. The safety valve is closed and the sample is left in these conditions for 5 hours. The load required to reduce the thickness by 50 percent is determined and the percentage of age change in compression deflection is calculated according to the formula given in the standard. The test result is the arithmetic average of the readings of the three samples and must comply with the conditions.
• When performing the cold flexibility test, the test is performed on a sample with dimensions of 150 mm x 50 mm x 15 mm. The sample is conditioned in a low temperature chamber at minus 30 degrees plus/minus 2 degrees for 22 hours. While the sample is still at minus 30 degrees plus/minus 2 degrees, it is rapidly rotated 360 degrees along the main axis. The sample is visually inspected and compared with the requirements.
• In dyeing tests, samples consisting of pads of the material under test covered with trim fabrics or artificial leathers as intended for actual service are prepared using standard production types and light colours. The samples are exposed in the fade-O-meter for 100 hours. Each sample should be exposed together with a sample of the associated trim material. The samples are used for comparison purposes at the end of the test. It is checked that the surface changes in the trim material are within the specified limits.

Our organization, which has been trying to support businesses from every sector with its testing, measurement, analysis and evaluation studies carried out in a wide range for years, has a strong staff that closely follows the developments in the world in the field of science and technology and constantly improves itself. In this context, testing services are also provided to businesses in accordance with the "FCA 9.55260 Sheet-produced die-cut polyurethane foam components (URL)" standard.