TOYOTA ENGINEERING STANDARD

NO.: TSM1501G

TITLE: Cellular rubber materials

CLASS: C2
Established/Revised: Rev. 9 ( Nov. 2009 )

This standard has been revised as a result of the following changes:

(1) Material Marking Section has been added.
(2) applicable standards have been modified.

Prepared and Written by: Engineering Data Planning Dept.

Organic Material Dept. Engineering Data Control and
Vehicle Material Engineering Div. Management Div.
ⒸTOYOTA MOTOR CORPORATION
 CONFIDENTIAL DO NOT REPRODUCE
CLASS
TOYOTA ENGINEERING STANDARD TSM1501G C2
Cellular rubber materials

1. Scope
This standard covers the method of classifying cellular rubber materials to be used for automotive
parts, according to the material properties. It does not apply to Ebonite cellular rubbers and latex
foam rubbers. As to the functions, performances, and design qualities of the products as automotive
parts or as themselves, conform to the requirements specified in separate drawings and other
documents.
The parts made of materials provided by this standard shall conform to prohibitions and restrictions for
substances of environmental concern in TSZ0001G. Exempt uses specified by EU ELV Directive
shall conform to the latest version of the Directive.

2. Definitions
The definitions used in this standard are as follows:
(1) Cellular rubber
Rubber containing cells or pores in which the cells are open, closed, or both.
(2) Rubber
Includes both natural rubbers and synthetic rubbers.
(3) Sponge rubber
A cellular rubber consisting of open cells.
Remark: To produce a sponge rubber, an inflating agent (or foaming agent) is added to a rubber
compound so that it generates a gas and expands the rubber during the vulcanization
process. The rubber is calendered into sheets or strips, extruded, or molded into
desired shapes by a metal mold or vulcanizer.
(4) Expanded rubber
A cellular rubber consisting of closed cells. It is also called closed cell sponge.
Remark: To produce an expanded rubber, a rubber compound is mixed with a gas-generating
blowing agent. The compound is then heated under compression in a metal mold.
When the compound is released from the mold after a predetermined time, the blowing
agent gasifies explosively, creating numerous closed cells in the vulcanized rubber
(primary vulcanization). It is further vulcanized in a metal mold (secondary
vulcanization) to the desired sizes and shapes. The expanded rubber produced in this
process does not absorb water, and is calendered into sheets and strips or molded into
various shapes.
(5) Skin
A relatively dense layer at the surface of a cellular rubber, formed by contact with the mold or
cover plate during production, is called natural skin.
Remark: Application of solid rubber skin coating is required for some products. In such a case,
the thickness of the solid rubber skin being applied should be selected appropriately.
Solid rubber skin coating is effective for parts that are subject to abrasion, or need water
or gas impermeability, or for parts requiring special ozone resistance (or weather
resistance). The rubber material for the skin to be applied should have sufficient
adhesion to sponge.
(6) Fuel oil B
A mixture made by mixing isooctane and toluene in the volume ratio of 7 to 3.

NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard.
- The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they Rev. 9
are no longer necessary due to the termination of the work concerned or the revision of current version of this standard,
- This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed
in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation..
Nov. 2009

1 / 11
 CONFIDENTIAL DO NOT REPRODUCE

TOYOTA ENGINEERING STANDARD TSM1501G

3. Classification
Cellular rubbers are classified into six groups shown in Table 1, according to the type that represents
cell structure and the class that represents oil resistance. They are further divided according to the
grade of hardness (25% compressive load) as shown in Attached Tables 1 and 2.

Table 1 Classification of Cellular Rubbers According to Type and Class

Example of material
Type Class Cell structure Property (1)
code (for reference)
A No oil resistance is required NR, SBR, EPDM
Open cell
1 B Low swelling property NBR, CO, ECO
(Open cell sponge)
C Medium swelling property CR, CSM
A No oil resistance is required NR, SBR, EPDM
Closed cell
2 B Low swelling property NBR, CO, ECO
(Expanded rubber)
C Medium swelling property CR, CSM

Note (1): The material codes comply with the ASTM standard.

4. Quality
When tested in accordance with the test method specified in Section 8, the quality of cellular rubbers
shall meet the basic requirements given in Attached Tables 1 and 2. However, when there are
additional quality requirements, conduct the tests in accordance with the test methods that correspond
to the suffixes in Table 2. The test results shall satisfy the criteria specified in Attached Tables 1 and
2. For any special requirements, the criteria shall be given separately in the related drawings after
discussion between the parties concerned.

Table 2 Suffixes and Test Methods

Suffix Required test item Test method
B1 Compression test In accordance with Section 8.4
F1 Low temperature test (-40 )
In accordance with Section 8.6
F2 Low temperature test (-55 )
P Staining test In accordance with Section 8.9
In accordance with requirements given in drawing.
Z Special requirements
The type of polymer may be specified.

5. Specimen Sampling
Actual products shall be used for the tests, as a rule. If it is difficult to use the product for the test,
specimens sampled from the product may be used. In this case, however, the section of the product
where the test specimen was sampled shall be expressed clearly. If it is impossible to use an actual
product for the test due to the reason that it is configured complexly or is very small, or because it is
reinforced with a metal or cloth, covered with other material or bonded to a metal, a standard test slab
shall be prepared in accordance with Section 6 after discussion between the parties concerned.

NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard.
- The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they Rev. 9
are no longer necessary due to the termination of the work concerned or the revision of current version of this standard,
- This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed
in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation..
Nov. 2009

2 / 11
 CONFIDENTIAL DO NOT REPRODUCE

TOYOTA ENGINEERING STANDARD TSM1501G

6. Standard Test Specimen and Test Slab

6.1 Standard Test Specimen
The standard test specimen shall be a flat disc with a diameter of 30.00 mm and thickness of at least
6.0(2) mm. Cut off the specimen from either the product or the standard test slab(3) specified in
Section 6.2, as shown in Fig. 1, using a rotary cutter or similar tool to which lubricant has been applied.
Make sure to completely dry the test specimen before the test, when lubricant is used.
Notes:
(2) For a sponge rubber, the conditions of foaming on thin sections 6 mm or less in thickness are
different from those of foaming on sections with thickness of more than 6 mm.
(3) When using a standard test slab, reproduce the product's foaming density, cell size, the ratio of
open- to closed cells, and the vulcanizing conditions as closely as possible.

6.2 Standard Test Slab

Prepare the standard test slab by using an aluminum or steel mold having the dimensions specified in
Fig. 2.

7. Test Specimen Conditioning and Standard Conditions for Testing

Prior to the test, maintain the test specimen for at least 16 h under the standard test conditions of 23
2 in temperature and 50 5% in relative humidity. If the test room conditions differ from the
standard conditions, the temperature and humidity for the test shall be attached to the test results.

NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard.
- The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they Rev. 9
are no longer necessary due to the termination of the work concerned or the revision of current version of this standard,
- This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed
in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation..
Nov. 2009

3 / 11
 CONFIDENTIAL DO NOT REPRODUCE

TOYOTA ENGINEERING STANDARD TSM1501G

8. Test Method
8.1 Dimensions Measurement
Measure the length and width of the test specimen with slide calipers to an accuracy of 0.1 mm(4).
Measure the thickness to an accuracy of 0.02 mm with a dial gage having a measuring surface of
31.8 mm and 25 g that can measure up to 30 mm.
Note (4): When using slide calipers, take care not to press it excessively to avoid bending or
depression of the specimen.

8.2 Compressive Load - Deflection Test

Using a product or the standard test slab, prepare a specimen at least 6.0 mm in thickness with two
parallel surfaces. Measure the thickness in accordance with Section 8.1. Use a compression tester
that can measure the deflection to an accuracy of 0.02 mm or stops automatically at a predetermined
deflection. Set the test specimen in the tester and compress it at a rate of 20 mm/min until the
thickness is reduced by 25% of the original value. Measure the corresponding load. If the
specimen thickness is less than 6.0 mm, thin specimens may be piled up until the thickness of nearly
12.5 mm is obtained. Since the thickness varies from one specimen to another, measure the
thickness of every specimen, and obtain the load required to deflect the specimen by 25%. Express
the load in kPa.

8.3 Air Heat Aging Test (Deflection Load Change Rate)

Sample a 6.0 mm or more thick test specimen(5) from a product or the standard test slab. Measure
its thickness in accordance with Section 8.1. Conduct the compressive load - deflection test in
accordance with Section 8.2 to determine the load required to deflect the specimen by 25%. After
the measurement, place the test specimen in an air heat aging tester conforming to Section 4, JIS K
6257 or Section 3.2.2, ISO 188 that has been conditioned at 70 1 . After aging the specimen for
168 h, take it out of the tester and allow to cool at room temperature (23 2 ) for 2 h. Conduct
the compressive load - deflection test in the same manner as Section 8.2, and determine the
deflection load change rate by using the equation (1).
Equation:

Where,
P: Deflection load change rate (%)
O: Initial deflection load (before aging) (kPa)
A: Deflection load after test (kPa). The deflection should be based on the original specimen
thickness (before aging).
Note (5): Do not use the specimens that have been used for piling up to more than 6.0 mm.

NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard.
- The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they Rev. 9
are no longer necessary due to the termination of the work concerned or the revision of current version of this standard,
- This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed
in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation..
Nov. 2009

4 / 11
 CONFIDENTIAL DO NOT REPRODUCE

TOYOTA ENGINEERING STANDARD TSM1501G

8.4 Compression Set Test

From a product or the standard test slab, prepare a specimen at least 6.0 mm (for sponge rubber) or
at least 12.5 mm (for expanded rubber) in thickness with two parallel surfaces. Measure the initial
thickness in accordance with Section 8.1. Prepare a spacer that can compress the specimen to 50%
of the initial thickness. Prepare also a compression device that conforms to Section 5.2.1, JIS K
6262 or ISO 815-1 and ISO 815-2. Heat the spacer and compression device to the test temperature.
When their temperature reach closely to the test temperature, set the specimen on the compression
device. The test temperature shall be 70 1 for open-cell (sponge) rubbers and 23 2
(room temperature) for closed-cell (expanded) rubbers. In the test, maintain the specimen at the test
temperature for 22 h and remove it from the compression device. Allow the specimen to cool at
room temperature (23 2 ) for 30 min for open-cell (sponge) rubbers, or for 24 h for closed-cell
(expanded) rubbers. Measure the thickness to determine the compression set according to the
equation (2).

where,
to: Initial thickness of specimen (mm)
t1: Specimen thickness after 30 min cooling for open-cell (sponge) rubbers, or after 24 h cooling for
closed-cell (expanded) rubbers (mm)
t2: Spacer thickness (mm)

8.5 Oil Resistance Test

Measure the diameter and thickness of each standard test specimen approximately 12.5 mm in
thickness, in accordance with Section 8.1. After immersing(6) the specimens for 22 h in IRM 903 test
oil (which is specified in ASTM D5964) that has been conditioned at 70 1 in advance, take them
out of the oil. Wipe off lightly the oil attached to the surface(7), and measure the thickness and
diameter again to determine the volume change rate.
Notes:
(6) When immersing the specimens, make sure that they do not float or come into contact with each
other. Do not place a weight on the specimens.
(7) When wiping off the oil, never apply excessive force to the specimen to squeeze the absorbed oil.

NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard.
- The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they Rev. 9
are no longer necessary due to the termination of the work concerned or the revision of current version of this standard,
- This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed
in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation..
Nov. 2009

5 / 11
 CONFIDENTIAL DO NOT REPRODUCE

TOYOTA ENGINEERING STANDARD TSM1501G

8.6 Low Temperature Test

After measuring the thickness of the specimen, which is at least 6.0 mm(8) in thickness, in accordance
with Section 8.1, dry it in a desiccator for 16 h. Then set the specimen in a compression tester(9), and
measure the compressive load - deflection characteristic at room temperature to determine the load
(kPa) required to compress the specimen by 25%. Cool this specimen for 5 h in a low temperature
box controlled at the specified temperature (-40 2 for F1 and -55 2 for F2). After 5 h
cooling, apply the initially determined load immediately to the test specimen while remaining the
specimen in the container. Measure the deflection to determine the deflection change rate by using
equation (3).

where,
C: Deflection change rate (%)
D: Deflection at room temperature (23 2 ) (mm)
E: Deflection at test temperature to be measured 30 s after application of load (mm)
Notes:
(8) The test specimen should be at least 6.0 mm in thickness. Do not use thinner specimens piled up
to this thickness.
(9) The tester should consist of two discs (one stationary and one movable disc) with a diameter of at
least 38 mm, and should be capable of measuring the load applied to the discs and the distance
between them.

8.7 Water Absorption Test(10)

The specimen for this test should be approximately 12.5 mm thick and its area should be 25 cm2.
Measure the mass by using an instrument capable of indicating to an accuracy of 0.1 mg. Immerse
the specimen in distilled water controlled at 23 2 to a depth of 50 mm, and maintain it for 3 min
under a (absolute) pressure of 17.0 kPa (0.17 atm = 17 kN/m2). Return the pressure to the
atmospheric level and maintain the specimen in water for another 3 min. Take out the specimen
from water, wipe the water droplets off the surface, and measure the mass to determine the mass
change rate.
Note (10): The test should be applied only to closed-cell (expanded) rubbers, and open-cell (sponge)
rubbers which are covered completely with a skin. It shall not be conducted on any other
sponge rubbers.

NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard.
- The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they Rev. 9
are no longer necessary due to the termination of the work concerned or the revision of current version of this standard,
- This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed
in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation..
Nov. 2009

6 / 11
 CONFIDENTIAL DO NOT REPRODUCE

TOYOTA ENGINEERING STANDARD TSM1501G

8.8 Liquid Resistance Test

Prepare a test specimen 25 50 mm in area and 6 mm in thickness. Measure the mass to an
accuracy of 0.1 mg. Put the specimen between two 10 mesh corrosion resistant wire nets as shown
in Fig. 3, and place it in a 500 mL glass container. Fill the container gently with approximately 350
mL of fuel oil B, cap the container, and keep it for 168 h in a room controlled at 23 2 .
After the specified time, remove the specimen, wipe off the stain on the surface, and measure the
mass to an accuracy of 0.1 mg in a weighing bottle of a known mass. Determine the mass change
rate.

Fig. 3 Example of Immersion Setup

8.9 Staining Test

(1) Cut off a length of 50 mm from the product (if it is difficult to cut off 50 mm, use the product itself),
and place it directly on a coated panel as shown in Fig. 4. Note that the coated panel should be
finished in the same manner as for the vehicle. In addition, the coating color should be white
and a light mica color so that the resulted stain can be detected easily.
(2) With the test specimen secured to the coated panel, expose it in a sunshine weather-O-meter
(black panel temperature: 63 ) for 100 h. The conditions for the sunshine weather-O-meter
shall comply with the accelerated weathering test method specified in Section 5.4, JIS D 0205 or
ASTM G152. Water should be sprayed for 12 min during the exposure for 60 min at a relative
humidity of 50 5%. Make sure to position the specimen with its length directed horizontally
(see Fig. 4).
(3) After the exposure, check the coated panel for any staining.

NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard.
- The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they Rev. 9
are no longer necessary due to the termination of the work concerned or the revision of current version of this standard,
- This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed
in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation..
Nov. 2009

7 / 11
 CONFIDENTIAL DO NOT REPRODUCE

TOYOTA ENGINEERING STANDARD TSM1501G

Fig. 4 Example of Coated Panel with Test Specimen

8.10 Odor Performance Test (Applicable Only to Interior Parts)

(1) Test specimen
A sheet 2 mm in thickness with a surface area determined by Equation (4).

Total surface area of test specimen (mm2) = S0 (V0 / V1) ... (4)

where,
S0: sum of surface areas, exposed to interior, of parts made of the same compound as that of
test specimen (mm2)
V0: volume of can used for testing (liter)
V1: 3000 (liters) (typical interior volume)
(2) Test method
Carry out test in accordance with TSM0505G, Section 8.1.1 "initial smell." Portions that can be
exposed to direct sunlight shall be heated at 100 2 , while portions not exposed to direct
sunlight shall be heated at 80 2 , as a rule.

9. Material Marking
Basically, material shall be marked in accordance with TSZ6005G.

NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard.
- The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they Rev. 9
are no longer necessary due to the termination of the work concerned or the revision of current version of this standard,
- This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed
in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation..
Nov. 2009

8 / 11
 CONFIDENTIAL DO NOT REPRODUCE

TOYOTA ENGINEERING STANDARD TSM1501G

Applicable Standards
TSM0505G Smell quality of non-metallic materials
TSZ0001G Control method for substances of environmental concern
TSZ6005G Indication method of material marking for plastic parts and rubber parts
ISO 188 Rubber, vulcanized or thermoplastic -- Accelerated ageing and heat
resistance tests
ISO 815-1 Rubber, vulcanized or thermoplastic -- Determination of compression set --
Part 1: At ambient or elevated temperatures
ISO 815-2 Rubber, vulcanized or thermoplastic -- Determination of compression set --
Part 2: At low temperatures
JIS D 0205 Test method of weatherability for automotive parts
JIS K 6257 Rubber, vulcanized or thermoplastic -- Determination of heat ageing
properties
JIS K 6262 Rubber, vulcanized or thermoplastic -- Determination of compression set at
ambient, elevated or low temperatures
ASTM D5964 Practice for Rubber IRM 901, IRM 902, and IRM 903 Replacement Oils for
ASTM No. 1, ASTM No. 2, and ASTM No. 3 Oils
ASTM G152 Practice for Operating Open Flame Carbon Arc Light Apparatus for
Exposure of Nonmetallic Materials

NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard.
- The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they Rev. 9
are no longer necessary due to the termination of the work concerned or the revision of current version of this standard,
- This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed
in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation..
Nov. 2009

9 / 11
 CONFIDENTIAL DO NOT REPRODUCE

TOYOTA ENGINEERING STANDARD TSM1501G

Attached Table 1 Open-Cell Rubbers

NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard.
- The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they Rev. 9
are no longer necessary due to the termination of the work concerned or the revision of current version of this standard,
- This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed
in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation..
Nov. 2009

10 / 11
 CONFIDENTIAL DO NOT REPRODUCE

TOYOTA ENGINEERING STANDARD TSM1501G

Attached Table 2 Closed-Cell Rubbers

NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard.
- The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they Rev. 9
are no longer necessary due to the termination of the work concerned or the revision of current version of this standard,
- This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed
in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation..
Nov. 2009

11 / 11