INVOICE FOR ISSUE OF TOYOTA ENGINEERING STANDARD no.: T1SK6505G6 TITLE : CAULKING SPONGE SEALANTS cLASS: C¢ PUBLICATION RECORD (Astorisk mark "*” inthis standard denotes the changed portion from previous issue.) © PILKINGTON * 60 2008 RECEBIDO lp Revised (“t” Omitted) Changed terus and explanation, vy 96. 3. 18 Due Engineesing Information System Planning Dept Eopinestog Adminisraon Di. ‘TOYOTA MOTOR CORPORATION NOTE: In the case of revision, the okt standard which has ben issued belore should be discarded in proper manner (such as shredding or firs) to avoid possible use of obsolete standards information.CONFIDENTIAL DO NOT REPRODUCE @P)| TOYOTA ENGINEERING STANDARD |T $ {65 056 CAULKING SPONGE SBALANTS 1. Scope This standard covers caulking sponge sealants (hereinafter referred to as “sealants”) used in the welded portions of automobiles, such as between the roof side weather strip retainers, roof drip moldings. etc., and the vehicle body, for protection against water and dust. Remark: In this standard, units and numerical values given in { } are based on the customary units system and are given for reference. 2. Classification and Chemical Composition ‘The classification and chenical coaposition of sealants are listed in Table 1: Table 1 ] Cain of fame | ite of class | aateriat cade Aonlicatons text \ yer [Lape tavees T rotesose-aat | Sen-ciose cxtt ure sya | terylic tase | tot rip wide \s ed at 0 or bisher deflection” | Toresosa-ua2 | etic runber (Gott type) [purl rer base | ins, ets ‘expe tase [fer comination| Gant at 508 or Hider deflection ™ cass 2] | Taesose-a0t [ l clas call tne arctic | soot eee tng |e Saree [ind a 104 cele eaten iniors ete. | Used at 03 oF higher deflection” | : ss | rocesose-ae [rscesse-anar rer Gard tne) Notes:(1) Sealants shall have a tape layer on one surface as shown in Fig. 1 unless i otherwise specified, TSK6505G-2B2W, however, is a sealant with tape layers on both surfaces. 2 5.08, 0°s 200 o% Foamed layer were Pre ‘Tape layer Fig. 1 Structure of Caulking Sponge Sealants (2) A butyl rubber type tape (242, 282 or 282) is recommended as the tape layer for olefin base substitutes (e.g.. polypropylene. BPDM rubber. etc. ). (2) The tape layer aust tightly adhere to the substitute. 1 Prepared'and Writen by T Ergincenng Admini i ____ Organic Material, Dept. |e TOYOTA MOTOR CORPORATION | ae Jesuoisteas 3 Fd Revteg: | ee ue eel Mar. 1996 Teagan SE a evn ey bn mn "ier dega captains or sd a mone open Tye octet 1712CONFIDENTIAL - 00 NOT REPRODUCE P| TOYOTA ENGINEERING STANDARD |TS K6505G¢ 3. Quality 3,1 General Conditions 3.1.1 Appearance The foamed layer shall be uniform, free from large cavities and foreign matter, and evenly impregnated with binder. 3.1.2 Workability Sealants shall be free from abnormalities that gay impede workability, such as flow, excessive adhesion to operator's fingers, etc. 3.1.3 Toxicity Sealants shall not generate odor or toxic gas, and shall not cause irritation or rashes to operator’ s skin upon touch during normal working process, 3.2 Properties Sealants shall conform to Tables 2 and 3, as tested by the test wethod specified under Section 4: Teble 2 Properties a TAL Pe a “Density Ge7a"y 50 to 160 100 to 10 ee Wa) 48 to 17 245 to 392 ~ tkgt/ca'} {0.5 to 1.8) {2.5 to 4.0} Compression | 50 4 cospression 20 max. 76. oax, set___(%)_ [80 X compression 50 wax. 85 max. Deflection ®, $5 to 80 10 to 30 Paint film shall be free from discoloration or contamination, and the sealant shall be free Paint film contaninat ion from conspicuous brittleness. Slight discolora~ tion of the paint fil limited to the area di- | rectly beneath the sealant is acceptable. 60 ¥ deflection water depth 40 am “| 24 win, 30 ¥ deflection: Ty 7 water depth 40 om sin | (hy Test 1 10 ¥ deflection. a eaeaeeeeene ee eee 24 min, eet water depth 40 om ia 0X deflection: : rater depth 40 am 24 in, Water leakage te jesabistea? 3 Fd Revised Mar. 1996CONFIDENTIAL. DO NOT REPRODUCE & TOYOTA ENGINEERING STANDARD | TS K 65 056 Table 2 (Continued) | Properties | ue 2A 2A [_2B1 22__|__280 letaaaak 180 ¥ deflection [eae | — 60 X deflection: | gy | 7] water depth 10 mm 2 | gg | 30% deflection | B.S) = | 10 ¥ deflection: 24 ain, || }~—————— 1 2 | & |_ water depth 10 om |g | [ROX defection eS | £1 = 10 X deflection 24 ain | = — i 1 water depth 10 mm 1 80 X deflection: 2 Wax (_liguid depth 10 am eae | reaover | 40 ¥ deflection: ae resistance | liquid depth 40 mm a a) [0 ¥ deflection: _ 24 ni ' | Liquid depth 40 am cece i 80 deflection: as | betergent |tiguid depth 10 om Ee | cesigtence | 12.% defect ion: re nce | “Liquid depth 40 om fa i wy) | 0% deflection: ees eee | Liquid depth 40 oo . ) 20 to 98 490 to 785 | 50X compression load yet) 2 to 10) {50 to 80} Table 3 ' Itew - Properties ai ai Eo o_o Fool etcenath C80" peeling’ eC cimaed agape are. Cohesive failure (fracture of foamed layer) za|__ | lmediately after | G il Taweately af (2 9 i925 ain, | 69 1071 si, | 20 (021 win | 89 10.71 in | S351 Pen atter Ph) E [eeeae 29 10.5) ain | 7.8 (0.81 ain, | 2.9 (0.3) ain, | 7.8 10.6) win, | eS] [at nign eeapera= | ay a oa 2.0 (0.2) win, | 2.0 (0.21 win, | 0.5 (0.051 win. | 2.0 (0.21 ain. 3 , 8 ter ware water |g Bi [aneroren | ho aie | 29 toa) ele | 0 (0 win | 29 10.9) win |B ay [iasediately after iene adhesion . 6.9 (07) win, | 10.8 (11) in 5.9 (0.6) win, | 10.8 (1.1) min. | EE g[enaner ' aaa 6.9 10.7) ain | te 12) 6.9107 win | 11.8 11.2) ain, Sets cemeare cera wblished? 3 Td Revived Smee & Se Se een an ceelaCoe w Mar. 1996 3712CONFIDENTIAL. D0 NOT REPRODUCE @D TOYOTA ENGINEERING STANDARD | TS K65 05G Table 3 (Continued) Froverties a a Be 2 ae | a] ne mre [oe aa en | 2002 am | ne to am | 202 BE |G] iter ar water $8 | ali 2.0 (0.2) win, | 2.9 (0.4) ain, | 2.0 (0.21 win. | 3.9 (0.4) ain. $5 | 3 cocectoration # bgp teeedlately after ta | 3st 5.9 10.0 ein sin | 5906 aie [ios Lu sj eeie Walter 3B) [Beet 6.9 (0.71 win an [oon ae [rie ia |g | B[Re Res Romer TS ica ain | 20 t0tt win | 0.5 om ain | 20 01 win |B | By Ateer ware water |g [eee [eo twa an [oe toa ain [20002 win | a0 00 win, Towediately after E wn, ain [8 ees 68 nw ua Stoo wim [roa tin g | glenarcer nae Bes ae too a. [ist alam | 88 G0 win, fia 1.2 win B yg per ee Tas woe ain | 20 0.21 aim | 1.0 fo win | 20 (0.21 win ‘After ware water i” Ey [aterm eee [29 co. win. | 39 toi win, | 2.0 (0.2) win, | 39 (04) win, 8 Tasediately after : i ee 05 tos) ain | eet win | 05 West ain | 69 107) ein | 2 Snane ; ; i § | pln ae tag ain [tet ti aim | 05 ost win [15.7 U6) ain E | e[c ner mm [To tea aim | 20 awn | 05 won wn | 20 mal aim | E Maecenas 20 (0.2) win, [10.8 (Lt) win, | 1.0 (0.0 min | 11.8 (12) ai 4 Test Methods 4,1 Specimen Preparation Prepare specimens from products "' and cut to the specified size and thickness, i | | Note:(4) Use only the foamed layers as specinens for the measurement of density, tensile strength. compression set, deflection, and 50 ¥ compression load. | 4.2 Weasurement of Density Prepare specimen of 6 to 10 cm’, and geasure the dimensions to the nearest 1/10 om | vith vernier calipers at 2042 °C. Then aeasure the mass and calculate the i density (kg/a*). itt et Cama pee A gccens coca and Established/ — 3 Td Revised rt Mar. 1996 47/12 Lenee|‘CONFIDENTIAL DO NOT REPRODUCE, P| TOYOTA ENGINEERING STANDARD |T§ K6§505G 4.3 Tensile Strength Prepare dumbbell type specimens as shown in Fig. 2 referring to JiS K 6301 or ASTM D412 from products of 2 to 3 mm in thickness. Measure the thickness of the straight portion in the center of the specimen, Pull the speciaen at a velocity of 50025 an/nin to determine the maximum load upon fracture. Calculate the tensile strength according to equation (1) t @ al iat where, F T: tensile strength (kPa) {kgf/ca*) | F: maximum load (N) {kgf} A: sectional area of specimen (ca*) Report the test data as the mean value of 4 speciaens. If the type of the specimens | used is different from the dumbbell type shown in Fig, 2, report as such. _ 120 i unit: mm | 54.25.1402, 40. Lt" Res A Fig. 2 Specimen | 4.4 Compression Set Prepare specimens of 15 mm thickness and 13 x 30 em size. and measure the thick: ness to the nearest 1/10 mm with vernier calipers. Compress the specimen to 50% and 80 ¥ of the original thickness at 20%2 °C for 24 hours using @ compressor i equipped with spacers and 2 parallel compression plates. Remove the load, and neasure the thickness 30 minutes later for 50% compression and 5 hours later for | 80 ¥ compression, Calculate the compression set (X) according to equation (2). | Report the compression set as the mean value of two specimens. j = —tech fa : c= HL x 100 @) \ | C: compression set (%) to: initial thickness of specimen (mm) | ty: thickness after specified period since load removal (am) te: spacer thickness (am) i igs rerensesccenrenie wot, esablshed? 3 FE Revised Mar, 1996 fonte inna eeCONFIDENTIAL -DO NOT REPRODUCE &Q TOYOTA ENGINEERING STANDARD |T§ K65 056 4.5 Deflection Prepare 15 mm-thick, 40 x 40 mm speciaen, and measure the thickness of specimen to the nearest 1/10 am with vernier calipers: Apply 9.8 KPa (0.1 kgf/ca’) load for 5 sinutes using a compressor with 2 parallel coapression plates. Then aeasure i the thickness and calculate the deflection according to equation (3): i er ce f: deflection (%) initial thickness of specimen (am) | thickness after 9.8 kPa (0,1 kgf/cm’) load is applied to the specimen : for 5 einutes (am) 4,6 Paint Film Contamination Resistance Place a speciaen (length: 100 mm; width: 13 am: thickness: same as product) on a plate (100 x 200 X 1 mm) coated with white baking paint or acrylic paint with txo $4 am holes. Place a stainless steel (SUS 304, 10 = 150 = 1 am) with two #4 am holes on the specimen, Clamp them as shown in Pig, 3 using spacers so that 80 X deflection is applied to the specimen, Expose the specimen in a Weather-O-Meter'®’: ‘°’ for 150 hours. then check for any discoloration or contamination of the paint film or embrittlement of the sealant, Notes:(5) The plate shall be subjected to electrophoretic coating, intersediate coating and top coating according to the coating processes and baking conditions used in production. (6) The conditions for the Weather-O-Meter shall be as follows: arc lamp of AC bipolar type: black panel temperature of 6342 °C; water spray period of 12 minutes per 60 minutes. (1) Use a Sunshine Weather-O-Meter or ultraviolet carbon arc Weather-O-Meter according to the consultation between concerned parties. Esabisned’ 3 td Revise wc dcinaan snow neg bl Ray arpa oes NTs aC Mar. 1996 6712 Heel‘CONFIDENTIAL - DO NOT REPRODUCE P| TOYOTA ENGINEERING STANDARD |TS {65(5G Unit: mm Painted plate Bolt clamping <> Stainless steel Ze 4,7 Water Leakage Tests 4.7.1 Test 1 Insert a speciaen of 245 am in length between rigs made of stainless steel SUS 304 ith 1 om thickness, as shown in Fig. 4. Clamp the rigs with bolts using spacers so that the deflection specified in Table 4 is given to the specimen, and seal both ends. Thirty minutes after the specimen is set, pour water to 40 mm depth. Check for water leakage every one hour up to 24 hours. Silicone sealant or Unit: om butyl rubber tape Caulking sponge / __> Seal both ends ip with bolts Spacer ‘Esublished! 3 Fd Revised 1/12 caer ae Con Mar. 1996. :CONFIDENTIAL DO NOT REPRODUCE | TOYOTA ENGINEERING STANDARD |T § 65 (5G Table 4 Deflection in relation to initial thickness 2aT 2A 60% 281 30.8 282 10%) 282 o% 4.7.2 Test 2 Using the rigs shown in Fig. 4 of Section 4.7.1, apply deflection A (see Table 5) to the specisen for one hour using spacers. Then change the spacer thickness so that deflection B is applied (see Table 5), After 30 minutes, pour water into the tester to 10 mm depth, and determine the time until water leakage occurs. Table 5 Deflection A | Deflection B 2 —e 80 x 60 281 30% 10 ¥ 282 20 ¥ 10 -¥ 4.8 Wax Remover Resistance Using the rigs shown in Fig. 4 of Section 4.7.1, apply the deflection specified in Table 6 to the specimen using spacers. Thirty minutes after the specimen is set, pour wax remover“ to 10 am depth for Class 2A sealants and to 40 nm depth for Class 28 sealants. Determine the time until wax remover leakage occurs. Note: (8) The wax remover used shall be selected according to consultation between concerned parties. Table 6 ee Deflection 2AL age 2BL 282 10% 2B2W ox Esubished? 3 rd Revised Mar. 1996CONFIDENTIAL - DO NOT REPRODUCE @D TOYOTA ENGINEERING STANDARD | TS K6505G 4.9 Detergent Resistance Using the rigs shown in Pig. 4 of Section 4.7.1, apply the deflection specified in Table 6 to the specimen using spacers, Thirty minutes after specinen is set, pour sarket detergent” (surface tension: 3 to 3.5 x 10°* N/m) to 10 am depth for Class 2A sealants and to 40 mm depth for Class 2B sealants. Deteraine the time until detergent leakage occurs. | Note:(9) The detergent used shall be selected according to consultation between concerned parties. | 4.10 80 X Compression Load ‘The size of the specisen shall be 100 ma in length 100 em in width and 10 a9 in thickness, Compress the specimen to 50 % of its original thickness using a tester with a plate of 110 mm length, 110 mm width and 10 mm thickness at a compression velocity of 200 ma/min. Measure the hardness 10 seconds later. Report the 50 % compres- sion load as the mean value of at least three specimens. | 4.11 Peel Strength | 4111 Peel Strength between Foamed Layer and Tape Layer [180° T-Peel Test] i Pee! a 15 x 250 X 5 am specimen between the foamed layer and tape layer : frog its one end to 100 am in length, making sure not to damage the foamed 1 layer. Apply a lining® to the tape layer as shown in Fig, 5, and pull the specimen''” at a tensile velocity of 200 un/min using a tensile tester (equivalent to 4.9 kX (500 kgf} load cell) in the standard state (2042 °C and 6542 ¥ RH). Notes:(10) Use a polyester film (thickness: 0.1 mm) as the lining material, unless otherwise specified. (AD) Apply a knife slit between the foamed layer and the tape layer before the tensile test (point A in Fig, 5). Established / 3rd Revises no Mar. 1996(CONFIDENTIAL. - D0 NOT REPRODUCE @P)| TOYOTA ENGINEERING STANDARD |T§ (65 (5G unit: mn a Chuck (load cell side) . Foaned layer Lining Chuck (vertically moving side) Fig. 5 4.11.2 Peel Strength between Substitute and Tape Layer (90° Peel Test] (1) Types of substitutes The test shall be carried out using five types of substitutes —— SUS. polypropylene, plasticized polyvinyl chloride, ABS resin and EPDM rubber. More specific types and sizes of the substitutes shall be determined according to the consultation between concerned parties. (2) Test method Prepare 15 x 250 x 5 wm sealant specimens, and apply a lining’'* to the tape layer of each specimen in 120 mm length from one end. Place it on the substitute (as specified in (1) above) degreased using isopropyl alcohol. etc.. with its tape layer facing downwards. Using one reciproca- tion of @ roller‘ at a speed of 50 ma/s, press!” the non-lined portion of the specimen against the substitute. After adhesion, measure the maximum load using the tensile tester as shown in Fig. 6 at a tensile velocity of 300 am/min. Repeat the test 3 times, and report the strength as the mean value. Notes:(12) Use a roller of about 45 am width, 83 am dianeter and 2.0 kg ass covered with a rubber layer of 6 mm thickness and a spring hardness (iS) of 80. (43) When pressing, sake sure that the load of the roller alone is applied to the sealant. TRE Sata casi wna cg cma sete, a lesubinneds 3 Fd Revised ieee eee ear ae apes Mar, 1996 TDi aa ieee aaCONFIDENTIAL: 00 NOT REPRODUCE & TOYOTA ENGINEERING STANDARD | TS K 65 056 (Chuck (load call side) Lining Prassure sensitive |___— Fonsed layer | adhesive double costed tape Jig Substitute c Substl tute, i Chuck (vertically moving side) Fig. 6 (3) Immediately after adhesion Press the sealant against the substitute in the standard state (20 °C. 85 4 RH), Five minutes later, measure the peel strength in the standard state according to (2) above. (4) 24 h after adhesion Press the sealant against the substitute in the same manner as in (3) above, then let them stand for 24 hours in the standard state. Measure the peel strength in the standard state according to (2) above. (5) At high temperature Press the sealant against the substitute in the same manner as in (4) above, then heat thea for 24 hours in an atosphere of 80 C. Measure the peel strength in the atmosphere of 80 °C according to (2) above. (6) After warm water deterioration Press the sealant against the substitute in the same manner as in (4) above, then warm them for 10 days in water at 40 ‘C. Then take them out of water ‘and measure the peel strength in the standard state according to (2) above within one hour. mee, jEstaisted? «3 Td Revised: Mar. 1996CONFIDENTIAL DO NOT REPRODUCE P| TOYOTA ENGINEERING STANDARD | TS K6505¢ APPENDIX _CAULKING SPONGE SBALANTS 1. Scope This Appendix covers caulking sponge sealants specified in previously issued drawings, which are subject to the application of the old standard. It is desirable that the naterial codes are updated to new codes when the drawings are revised or renewed by | engineering changes. For newly developed drawings, indicate the new codes, The new codes shall be in | accordance with the Text of this standard. 12. Material Codes | Material codes specified in this Appendix are in accordance with Appendix Table 1. Appendix Table 1 Classification] Material code t ‘TSK6505-2A1 A [skes0s-212 Class 2 ‘TSK6505-281 B ‘TSK6505-2B2 TSK6505-2B20 3, Specified Contents Sage as the Text of this standard. Applicable Standards | JIS K 6301 Physical Testing Methods for Vulcanized Rubber ASTM D412 Test Methods for Rubber Properties in Tension Esubisned? 3 Fd Revised Mar, 1996