Ford FLTM BN 115-07 Permanent Compression Deformation of Polyurethane Foam

The “Ford FLTM BN 115-07 Compression Permanent Deformation of Polyurethane Foam” standard, developed by Ford Motor Company (Ford), describes a test method used to determine the compression permanent deformation of seat-grade polyurethane foam. This method measures the ability of foam materials to recover their original thickness after being compressed for a specific period under controlled conditions. It is primarily applied to automotive seat cushions, headrests, armrests, and other interior foam components.

Polyurethane foam is widely used in vehicle seat systems due to its comfort and energy-absorbing properties. During vehicle use, the seat foam is repeatedly subjected to the weight of the passenger and prolonged loading. If the foam does not return to its original shape properly after compression, it can become permanently deformed, reducing comfort and support.

The Ford FLTM BN 115-07 standard evaluates the following aspects:

• Permanent thickness loss after compression.
• Elastic recovery properties
• Long-term seating comfort performance
• Material strength under continuous load
• Consistency of foam quality across production batches.

In this method, a foam sample is compressed to a predetermined deflection and held in this state for a specific time and temperature. After the load is removed and the sample is allowed to return to its original state, the remaining deformation is measured. The result is reported as a percentage of the compression residual deformation, representing the amount of residual deformation relative to the original deflection. A lower compression residual deformation value indicates better recovery and higher material elasticity.

Typical evaluation parameters include:

• Measuring the initial thickness of the foam sample.
• Compressing the sample to a specific percentage of its thickness.
• Maintaining compaction under controlled environmental conditions.
• Releasing the compression.
• Allowing for a recovery period.
• Measurement of the final thickness and calculation of the percentage of permanent compression deformation.

The Ford FLTM BN 115-07 standard is commonly used in the following areas:

• Seat cushion foams
• Seat back foam
• Header foams
• Armrest padding
• Interior comfort filling systems
• Flexible polyurethane seat materials

The Ford FLTM BN 115-07 standard is often used in conjunction with other foam evaluation methods, such as those listed below:

• Density determination
• Indentation force deviation
• Tensile strength test
• Tear resistance test
• Fatigue and endurance assessments

Together, these tests provide a comprehensive evaluation of the performance of polyurethane foam in automotive seat applications.

The Ford FLTM BN 115-07 standard is considered important because it evaluates whether foam materials can regain their original shape after prolonged compression. This standard verifies the flexibility and recovery properties of polyurethane foam used in automotive interiors. In automotive seating systems, this property directly affects comfort, durability, and perceived vehicle quality. This standard is considered necessary for the following reasons:

• It preserves seat comfort: Car seats are constantly subjected to the weight of passengers. Foam with poor compression and permanent deformation performance can become permanently compressed, leading to the following consequences:
  • Reduced cushioning
  • Loss of support
  • Increased driver and passenger fatigue.
  • Decreased overall comfort.

This standard helps ensure that the seat foam remains comfortable for the life of the vehicle.

• Prevents permanent deformation: Over time, the following can develop in low-quality foam:
  • Sagging seat cushions
  • Flattened supports
  • Deformed armrests
  • Shapeless headrests

This testing method identifies materials that are likely to deform during use by measuring the permanent thickness loss after compression.

• Enhances long-term durability: Automotive manufacturers expect seat materials to maintain their performance for many years. This standard helps engineers select foams that can withstand repeated loading and prolonged use without significant degradation.
• It enhances the perception of vehicle quality: Customers often assess vehicle quality based on the feel and appearance of the seats. Shape-retaining foam contributes to this:
  • Better fit and workmanship.
  • Improved appearance over time.
  • Higher customer satisfaction
  • Improved brand reputation
• Supplier material consistency is ensured: This standard provides a uniform testing method for evaluating foam supplied by different manufacturers. This allows Ford and its suppliers to:
  • Comparing materials objectively
  • Verifying compliance with technical specifications.
  • To maintain consistent production quality.
• Reduces warranty and service costs: Seats that lose their shape prematurely can lead to customer complaints and warranty claims. Testing the foam before production helps identify potential problems early, reducing the following:
  • Field failures
  • Replacement costs
  • Warranty expenses
• It supports safety and ergonomics: Although primarily a comfort test, foam recovery also affects the passenger's posture and support. Seats that retain their intended shape help maintain the following:
  • Correct sitting position
  • Ergonomic support
  • Driver comfort on long journeys.

In conclusion, the Ford FLTM BN 115-07 standard is a critical quality and durability test for automotive seat materials. By measuring the remaining permanent deformation after controlled compression, this method ensures that polyurethane foams maintain their comfort, flexibility, and structural integrity throughout the vehicle's lifespan. This standard plays a vital role in material qualification, supplier verification, and long-term seat performance validation.

For many years, our organization, with its competent and experienced staff, has been understanding the needs of its customers, providing the advanced testing services they require, and assisting them in the establishment, implementation, and improvement of management systems. Within this framework, we also provide testing services to businesses in accordance with the Ford FLTM BN 115-07 standard.