Tests Windshield Mounting. according to. Federal Motor Vehicle Safety Standard 49 CFR (FMVSS 212)

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1 TÜV Rheinland Group Test Report No. 113XS Test Item : 1 Hour Glass Bonding Adhesive and Vehicle : 2002 Ford Mondeo Applicant : EMFI S.A.S., Haguenau Cedex, France Documentation Tests Windshield Mounting according to Federal Motor Vehicle Safety Standard 49 CFR (FMVSS 212) This test report serves solely as test documentation. TÜV Rheinland Kraftfahrt GmbH Technologiezentrum Verkehrssicherheit Typprüfstelle Fahrzeuge/Fahrzeugteile 113XS0245.doc Page 1 Am Grauen Stein, D Köln (Poll)

2 TÜV Rheinland Group Test Report No. 113XS Test Item : 1 Hour Glass Bonding Adhesive and Vehicle : 2002 Ford Mondeo Applicant : EMFI S.A.S., Haguenau Cedex, France 1. Introduction This test report describes the test of the windshield retention for motor vehicles during a crash-test. Upon request of the applicant, TÜV Rheinland Kraftfahrt GmbH has tested screen bonding products used for the fixation of a windscreen in a vehicle with regard to the FMVSS 212. The tests were conducted to determine if the screen bonding products meet the requirements specified under item 3. of this test report Name and address of the applicant : EMFI S.A.S. rue Ettore Bugatti Haguenau Cedex France 1.2. Name and address of the manufacturer : UK PLC Ratcliffe Road Atherstone, CV91PJ UK 2. Description of the test object Technical description Characteristics Test vehicle : The tests were performed on a 2002 model Ford Mondeo 4 door saloon with twin airbags. The vehicle was soaked at 20 C at 50% humidity prior to windshield installation, which was carried out by 24 Screen Savers Ltd. according to HMLC Windscreen adhesive installation procedure (see Appendix 2) : Right hand driven vehicle with driver and passenger airbag system. 50% Hybrid-III Dummy on driver and passenger side. : 2002 Ford Mondeo 4 door saloon VIN: WFO4XXGBB42G33236 Test weight in test condition including 93% fuel, nominal fluids and 2 occupants 1.745,5 kg TÜV Rheinland Kraftfahrt GmbH Technologiezentrum Verkehrssicherheit Typprüfstelle Fahrzeuge/Fahrzeugteile 113XS0245.doc Page 2 Am Grauen Stein, D Köln (Poll)

3 TÜV Rheinland Group Test Report No. 113XS Test Item : 1 Hour Glass Bonding Adhesive and Vehicle : 2002 Ford Mondeo Applicant : EMFI S.A.S., Haguenau Cedex, France The vehicle was subjected to a 100% frontal impact by being propelled into a immovable crash block at 30mph (48km/h), as per FMVSS 212 Section 5. The crash test dummies were restrained by means of the vehicle s seat belts and the airbags were triggered by the impact. The vehicle was impacted 1 hour after the windscreen was fitted. Specimen description and part numbers : 1 Hour HMLC Glass bonding adhesive, part numbers and (Manufacturer documentation see Appendix 3) 3. Test basis and test equipment 3.1. Test basis Federal Motor Vehicle Safety Standard 49 CFR (FMVSS 212) at last amended by 60 FR ( ) 3.2. Testing device (s), Crash-test laboratory and climatic chamber of: MIRA Ltd. Watling Street Nuneaton Warwickshire CV10 0TU England Used equipment and calibration see Appendix 1 4. Description of the test 4.1. Date of the test : Place of the test : Nuneaton, England 4.3. Scope of the test : The objective of the tests was to verify if the test object is able to guaranty the retention of the vehicle windshield during a crash. TÜV Rheinland Kraftfahrt GmbH Technologiezentrum Verkehrssicherheit Typprüfstelle Fahrzeuge/Fahrzeugteile 113XS0245.doc Page 3 Am Grauen Stein, D Köln (Poll)

4 TÜV Rheinland Group Test Report No. 113XS Test Item : 1 Hour Glass Bonding Adhesive and Vehicle : 2002 Ford Mondeo Applicant : EMFI S.A.S., Haguenau Cedex, France The tests were carried out under control of the following representative of UK: - Mr. Gavin Phipps 5. Test results Windshield periphery: Right side 2090 mm Pre test measurement Left side 2090 mm Total 4180 mm Right side 2090 mm Post test measurement Left side 2090 mm Total 4180 mm Temperature of the windshield molding during test 20 C Area of retention failures Remarks : no failures occurred : none Fotos : see Appendix 1 The test object is able to guaranty the retention of the vehicle windshield during a crash according to FMVSS 212 Section Appendices 1. MIRA test Result sheet page 1 to HMLC Windscreen adhesive installation procedure page 1 3. Manufactures documentation (Version 4, November 2009) page 1 to 5 TÜV Rheinland Kraftfahrt GmbH Technologiezentrum Verkehrssicherheit Typprüfstelle Fahrzeuge/Fahrzeugteile 113XS0245.doc Page 4 Am Grauen Stein, D Köln (Poll)

5 TÜV Rheinland Group Test Report No. 113XS Test Item : 1 Hour Glass Bonding Adhesive and Vehicle : 2002 Ford Mondeo Applicant : EMFI S.A.S., Haguenau Cedex, France The test report contains page 1 to 5 and Appendices 1 to 3. It is only permitted to publish this report formal and in content unchanged and completely including all appendices except with the approval of the testing laboratory TÜV Rheinland Kraftfahrt GmbH, Am Grauen Stein, Cologne in writing. Cologne, rg Dipl.-Ing. Rudolf Gerlach TÜV Rheinland Kraftfahrt GmbH Technologiezentrum Verkehrssicherheit Typprüfstelle Fahrzeuge/Fahrzeugteile 113XS0245.doc Page 5 Am Grauen Stein, D Köln (Poll)

6 Test Result Sheet Customer: Ratcliffe Road Atherstone CV9 1PJ Customer Contact: Gavin Phipps Authority: Andy Chequer Witnesses: Gavin Phipps Prepared By: Test Objective To test supplied vehicle and screen bonding products for UK Plc against FMVSS212 The test was performed on a 2002 model Ford Mondeo 4 door saloon with twin airbags. The vehicle was soaked at 20 C at 50% humidity prior to windscreen installation, which was carried out by 24 Screen Savers Ltd. It was then subjected to a 100% frontal impact by being propelled into an immovable crash block at 30mph (48km/h), as per FMVSS212 Section 5. The crash test dummies were restrained by means of the vehicle s seat belts and the airbags were to be triggered by the impact. The vehicle was impacted 1 hour after the windscreen was fitted. Specimen Description and Part Numbers 1 hour HMLC glass bonding adhesive, part numbers and Test Number J6113 Andy Chequer Concurred By: Test Date 03/12/10 Joanne Gleave Date: Test Equipment MIRA Crash Laboratory MIRA Climatic Chamber Driver and Passenger non-instrumented HIII 50 th percentile test dummies 2002 Ford Mondeo 4 door, KS52 URU MIRA Ltd All rights reserved, subject to client contract. Information contained in this document may not be published in any form of advertising or other matter without prior agreement of the managing director of MIRA. MIRA Ltd. Registered Office: Watling Street Nuneaton Warwickshire CV10 0TU England Tel: +44 (0) Fax: +44 (0) Registered in England No VAT Registration GB Test Result Sheet Page 1 of 19

7 Results The windscreen remained bonded all the way around the periphery and no lifting of the screen was observed. As such the product met the standards of FMVSS212. Attachments Appendix A - Pre and Post test photographs Appendix B - Equipment Calibration Certificates Appendix C Vehicle Weight Test Result Sheet Page 2 of 19

8 Appendix A - Pre and Post test photographs J6113 front view of windscreen before test Test Result Sheet Page 3 of 19

9 J6113 front view of vehicle before test Test Result Sheet Page 4 of 19

10 J6113 at the point of impact, with windscreen still in position. J6113 showing fully retained windscreen Test Result Sheet Page 5 of 19

11 J6113 view of screen from LH J6113 view of screen from RH Test Result Sheet Page 6 of 19

12 J6113 Post Test showing left hand A pillar detail J6113 Post Test showing header rail detail Test Result Sheet Page 7 of 19

13 J6113 Post Test showing left hand A pillar detail J6113 Post Test showing windscreen base Test Result Sheet Page 8 of 19

14 Appendix B Equipment Calibration Certificates Test Result Sheet Page 9 of 19

15 Test Result Sheet Page 10 of 19

16 Test Result Sheet Page 11 of 19

17 Test Result Sheet Page 12 of 19

18 Test Result Sheet Page 13 of 19

19 Test Result Sheet Page 14 of 19

20 Test Result Sheet Page 15 of 19

21 Test Result Sheet Page 16 of 19

22 Test Result Sheet Page 17 of 19

23 Test Result Sheet Page 18 of 19

24 Appendix C Vehicle Weight All weights in kg Front Rear Total Test Weight (in test condition, incl 93% fuel, nominal fluids and 2 occupants Test Result Sheet Page 19 of 19

25 Appendix 2 to Test Report No. 113XS HMLC Windscreen adhesive installation procedure 1. Remove existing glass from the vehicle using normal tools and techniques 2. Cut the remaining PU pinchweld to leave an adhesive depth of around 1mm. Clean any loose debris and then clean with general purpose adhesive cleaner. Any bare metal areas should be primed using single step low VOC primer, but the remaining PU adhesive does not need to be primed. 3. To prepare the new screen clean the black edge of the screen using Glass cleaner 08631, followed by general purpose adhesive cleaner, used with red scotchbrite. This is to remove any surface contamination before primer application. 4. Shake the single step primer for at least 30 seconds, before applying a coat single step low VOC primer to the black edge of the screen, and allow to flash off for 10 minutes. 5. Apply a bead of / HMLC 1hr windscreen adhesive to the new screen, before fixing in place to the vehicle. 6. Clean any residue from the outside of the screen using glass cleaner

26 Appendix 3 to Test Report No. 113XS Page 1 of 5 European Technical Centre Atherstone UK Effective: November 2009 Supersedes: First Issue Pages: 5 3Automotive Aftermarket Division 58015/50681 High Modulus Low Conductivity 1) Part Number mL Cartridge mL Sausage 2) Description and end uses 58015/50681 is a moisture initiated high modulus low conductivity (HMLC) and fast curing one-component polyurethane adhesive sealant containing isocyanates. It forms a high modulus and flexible joint and can be used to bond glass car windshields in vehicles particularly those made from aluminium. 3) Physical Properties Colour A black thixotropic paste Density at 20 C 1.4 ± Skin formation time at 23 C and 50% Ca 15 minutes RH Cure time at 23 C and 50% RH >4mm / 24 hr Temperature resistance Resistivity - 40 to +90 C 100 million ohms per cm Note: Technical information and data reported in the Technical Data Sheet should be considered representative or typical only and should not be used for specification purpose

27 Appendix 3 to Test Report No. 113XS Page 2 of 5 4) Directions for Use Note: Technical information and data reported in the Technical Data Sheet should be considered representative or typical only and should not be used for specification purpose

28 Appendix 3 to Test Report No. 113XS Page 3 of 5 a) Glass preparation: Always ensure that surfaces are clean and free from contamination. Use Glass cleaner or Adhesive cleaner on red Scotch-Brite. Clean with a light action. Wipe over surface with Glass cleaner or Adhesive cleaner on a clean wipe. Shake single step Low VOC primer for 30 seconds before use, ensuring the metal ball contained within is moving freely. Apply a thin layer of singles step Low VOC primer to the glass ceramic and leave for a minimum of 10 minutes (see Fig. 6A). For pre-primed edges, ceramic edges with pre-applied PU and encapsulated edges use the Activator and clean without using red Scotch-Brite. Special instruction: For pre-primed glass, check adhesion of the pre-applied primer before applying Activator. If adhesion is poor remove the pre-applied primer. For glass or tinted glass the 8617 first step primer must be applied before the Low VOC primer. A frame must be applied on the other side in order to avoid U.V. exposure. b) Pinch weld preparation 1) Where original polyurethane adhesive remains on the body frame, clean with Cleaner. Allow to dry before using a knife to reduce the thickness of the polyurethane to 1mm. Apply / HMLC glass adhesive.use single step Low VOC primer to protect any exposed bare metal from corrosion. Do not apply any primer on the old polyurethane adhesive. 2) On a newly painted body frame (paint fully cured), apply Activator.Allow to dry for a minimum of 10 minutes. Extrude a bead of / HMLC Glass Adhesive onto the glass or the body frame (depending on car manufacturers instructions). Install the glass within 10 minutes. Clean any excess adhesive using a clean rag and cleaner. Application temperature is +10 C to +35 C. C) Bonding at 4 C Prepare the bond surface as described in points 1 and 2 above. Install the glass within 10 minutes. Wipe off any excess adhesive using a clean rag and cleaner. If the vehicle is at the roadside turn the engine on, set the air heating system to maximum and adjust the controls so that the hot air is directed onto both the screen and the screen bond. Leave the heaters at this setting for at least 15 minutes. After 15 minutes the heater can be turned off however the vehicle must be left for a further 45 minutes before a safe drive away time is reached. If the screen is fitted in a workshop ensure that the air temperature exceeds 20 C for 15 minutes and that the vehicle is left a further 45 minutes before it is driven away. If Note: Technical information and data reported in the Technical Data Sheet should be considered representative or typical only and should not be used for specification purpose

29 Appendix 3 to Test Report No. 113XS Page 4 of 5 the air temperature is below 20 C follow the procedure described above with the vehicle heaters. Features Advantages Benefits Final Shore A hardness >60 Passes ISO seconds Shearing resistance >2.4MPa Passes ISO 4587 Shearing resistance at 5hr at 23 C and 50% RH >0.9MPa (>130psi) Passes FORD SAE J 1529 Shearing resistance at 7 days at 23 C and 50% RH >3.5MPa (>500psi) Passes FORD SAE J 1529 Modulus G10 >2.2MPa Passes DIN Water and salt spray Excellent resistance Elongation break >300% Passes ISO 37 Modulus at 100% Ca 3.5 MPa Passes ISO 37 Modulus at break >6 MPa Passes ISO 37 Specific resistivity Passes FMVSS 212 (standard automotive crash test) 5) Storage Ca 100 millions ohms per cam 1 hour safe drive away time at 5 C and 50% RH with air bags fitted. Can be used to bond car windscreens during aftermarket repair. This product can be stored for 9 months from the date of batch manufacture (printed on individual packaging) in hermetically sealed original packaging between 5 and 25 C. Store cartridges at approximately 20 C before use 6) Safety Highly flammable. Extinguish all sources of ignition before use. Harmful. Read material safety data sheet before use. Do not breath fumes and do not allow skin contact. Note: Technical information and data reported in the Technical Data Sheet should be considered representative or typical only and should not be used for specification purpose

30 Appendix 3 to Test Report No. 113XS Page 5 of 5 7) Disclaimer All statements, technical information and recommendations are based on tests we believe to be reliable but the accuracy or completeness thereof is not guaranteed. Please ensure before using our product that it is suitable for your intended use. All questions of reliability relating to this product are governed by the Terms of Sale subject, where applicable, to the prevailing law. 3 Automotive Aftermarket United Kingdom plc Phone: Fax: aadenquiries.uk@mmm.com Note: Technical information and data reported in the Technical Data Sheet should be considered representative or typical only and should not be used for specification purpose