NBSIR 80-2035

JILL UUI I m NOT REMO'

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Bicycle Wheel Rim Reflective

Materials Test Method

Development

Samuel D. Toner

Stanley K. Wakamiya

Product Safety Technology Division

Center for Consumer Product Technology

National Engineering Laboratory

National Bureau of Standards

U.S. Department of Commerce

Washington, D.C. 20234

April 1980

Sponsored by:

Consjjmer Product Safety Commission

5401 Westbard Avenue

Bethesda, Maryland 20016

NBSIR 80-2035

BICYCLE WHEEL RIM REFLECTIVE

MATERIALS TEST METHOD

DEVELOPMENT

Samuel D. Toner

Stanley K. Wakamiya

Product Safety Technology Division

Center for Consumer Product Technology

National Engineering Laboratory

National Bureau of Standards

U.S. Department of Commerce

Washington, D.C. 20234

April 1980

Sponsored by:

Consumer Product Safety Commission

5401 Westbard Avenue

Bethesda, Maryland 2001

U.S. DEPARTMENT OF COMMERCE, Philip M. Klutznick, Secretary

Luther H. Hodges, Jr., Deputy Secretary

Jordan J. Baruch, Assistant Secretary for Productivity, Technology, and Innovation

NATIONAL BUREAU OF STANDARDS, Ernest Ambler, Director
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At the request of the Consumer Product Safety Commission (CPSC), a program was established in the Product Safety Technology Division of the

National Bureau of Standards to evaluate reflective materials applied to

bicycle wheel rims. The purpose of this program” was to develop proposed

test methods for determining the abrasion and peel resistance of pressure

sensitive reflective tape on bicycle rims.

Current regulations promulgated by the CPSC for bicycles, 16 CFR

1500. 18(a) (12) and Part 1512, do not include tests for retroreflective

materials applied to or incorporated into bicycle wheel rims. A

retroreflective material is one that reflects light back in the general

direction of the source of the incident light. At the present time, there

is one such commercial product available, in the form of a pressure

sensitive tape, which is intended for use in lieu of spoke reflectors or

retroreflective tires, on bicycles which are not equipped with caliper

brakes. Consequently, a major objective of this program was to develop a prototype abrasion test apparatus, and attempt to establish test parameters

using this material as a model. The intent was to make the test apparatus

and testing procedures sufficiently broad in scope as to be amenable,

without major modifications, for evaluating other types of reflective

materials such as paint, lacquer, or integrally molded-in reflective

materials that might be developed in the future.

The requiranents for abrasion resistance, and the photometric methods

of measuring the retroreflectance of tires are addressed respectively in

paragraphs 1512.16 and 1512.18 of the current regulations. However, the

abrasion tests prescribed for compliance testing of the tires is not

directly applicable for use on the wheel rims. Therefore, the intent of

this program was to develop a test apparatus that would be useful in

compliance testing of the reflective materials after they were placed on the rim. The tape manufacturer has proposed an abrasion test based on

modifications of Federal Test Method Standard No. 141 A, Method 6142,

entitled "Scrub Resistance." This method, designed to evaluate the scrub

resistance of paints, involves the use of an apparatus which imparts a reciprocating motion to a brush lengthwise across a test panel. To use

this procedure for compliance testing would necessitate renoval of several

pieces of the reflective tape, each about 6.4 cm (2.5 in) in length, from

the rim. Since a major criterion, established by the CPSC, was that the

reflective material be difficult to r®nove, the use of the modified Method

6142, for compliance, was essentially precluded.

A second area of concern was the peel resistance of the tape. There

is no counterpart for this property in the tires, since the reflective

material is molded into the sidewalls and cannot be peeled off. Peel

adhesion strength and tensile breaking strength of the tape were determined

as a potential aid in establishing a compliance test for peel resistance.

Abrasion Tester Development

In developing the abrasion tester, the following design parameters

were established:

- 2 -

1 . the abrader would be a circular wire-bristle brush

2. the brush would be motor driven to provide for controlled speed

3. the brush and motor would be mechanically balanced so that a known force could be applied to the brush

4. the wheel would be rotated continuously in order to uniformly

abrade the reflective material around the complete circumference

5. the wheel mounting would be such that an entire wheel assembly

could be ronoved from a bicycle and then tested with little or no modification.

Figure 1 and 2 are illustrations of the completed prototype test

apparatus. Since the reflective tape was 0.32 cm (0.125 in) in width, a 1.27 cm (0.5 in) - diameter wire brush was selected as the abrader to

ensure that the tape would be abraded across its width, and that a scrubbing action would be produced along both edges. The brush shank was

attached to the end of the shaft of a variable speed motor by means of a chuck. The motor was mounted on a clamp so that the brush bristles were

pointing downward. The motor clamp was attached to a pivot mounted on miniature ball bearings. A threaded rod containing a counterweight was

attached to the opposite side of the pivot. This arrangement provided a means of balancing the weight of the motor and brush. Any known weight

placed on top of the motor was then transmitted directly to the material

under test. This assombly was then clamped to the platform of a scissors

jack, which allowed positioning of the brush immediately above the surface

of the reflective tape prior to addition of the test load. A strobe light

was used to check the rotational speed of the brush and a motor speed

control was used to adjust the brush speed to the desired number of

revolutions per minute (rpm).

The wheel mount consisted of a rectangular open-ended box, of

sufficient width to accommodate wheels up to 71 cm (28 in) in diameter.

The top and bottom panels were slotted to allow the wheel axle to be

positioned and fastened in place. The box was mounted on both ends with a single bolt and nut to a pair of vertical supports. This arrangement

permitted the wheel to be tilted downward from a horizontal plane. This

allowed wheels with varying rim geometries to be positoned so that the

reflective material surface would be essentially normal to the brush

bristles during the abrasion test. For driving the wheel, an electric

motor was attached to the box, and an idler of appropriate diameter affixed

to the end of the motor shaft. A constant speed motor, operating at 72

rpm, was selected for this purpose. A microswitch-activated electric

counter, mounted on the box, monitored the number of wheel revolutions

during tests.

Prior to the start of this program, several 51 cm (20 in) diameter

bicycle wheels had been submitted by the CPSC to demonstrate the use of the

reflective tape. These wheels were not suitable for the actual testing
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program, because of varying degrees of damage, some intentional, to the

tape. They did provide a means for preliminary evaluation of various test

parameters, and for testing the functionality of the test apparatus.

Test Parameter Development

An arbitrary decision was made to revolve the rim at 25.4 cm (10 in)

per second (about 10 rpm for a 51 cm (20 in) wheel). To achieve this, a 5.72 cm (2.25 in) diameter, grooved, metal idler was attached to the

constant speed motor, and adjusted to contact the tire tread surface of the

fully inflated tire. In preliminary tests, the steel wire brush was

rotated around an axis perpendicular to the tape surface at approximately

800 rpm. This parameter was selected because it is comparable with the

linear speed of the brush used in the Scrub Resistance testing apparatus.

Various loads, ranging from about 3.9 to 9.8 N (0.86-2.2 Ibf) were applied

to the brush. These preliminary procedures did not result in any evident

problems with the basic concept of the test apparatus. Since the tape was

affixed to the wheel rim by means of a pressure sensitive adhesive, a primary concern was that the test load, applied to the brush, would not

physically distort the tape, and that the rotational speeds of the brush

and/or the wheel would not produce sufficient frictional heat to cause

distortion. Visual examination indicated the presence of abrasion damage,

especially at the higher loading levels. The extent of abrasion with

respect to compliance requironents for the retroreflective properties could

not be estimated. However, there was no other visual evidence of damage to

the tape in terms of distortion or tearing, that might have an adverse

effect on its retroreflective properties or that would not be consistent

with actual use conditions.

Six new 51 cm (20 in) and three 71 cm (28 in) rims, with factory

applied tape on both sides, were obtained through the CPSC. Attempts to

obtain the requisite components needed to construct complete wheels with

these rims were not successful, since wheel hubs apparently are not readily

available as replacement parts. Subsequently, a temporary modification of

the apparatus was made in order to mount the rims for testing. A circular

metal plate, having a diameter of approximately 0.64 cm (0.25 in) greater

than a 51 cm (20 in) wheel rim was fabricated. This plate was attached to

a shaft and bearing assembly, substituting for the wheel axle. Clamps,

designed for insertion into the spoke holes, were located on the plate

inside the rim. The 5.72 cm (2.25-in) metal idler was replaced by one of

approximately 3.18 cm (1.25 in) in diameter, to which a piece of 1.3 cm

(0.5 in) thick foam rubber was attached, as a means of rotating the metal

plate. No other modifications were required for the abrasion apparatus.

However, a modification was required for the device used to mount the rim

for the measuranent of the retroreflective properties.

Test Procedures

On the basis of the preliminary evaluation, a wheel rotation speed of

25.4 cm (10 in) per second, and a brush speed of 800 rpm, were used for the

tests on the new rims. Four rims were abraded on one side. The force

- 4 -

applied to the wire brush was either 4.9 or 9.8 N (1.1 or 2.2 Ibf), and the

rims were rotated for either 1000 or 2000 revolutions.

These four rims plus a fifth unabraded rim were submitted to the NBS

Radiometric Physics Division for photometric measurements. Prior to

conducting these measur orients, the exposed metal portions of the rims were

masked with an opaque, matte black tape. The retroflective properties of

both the abraded and unabraded tape on each of the rims were determined.

Results of Abrasion Tests on the Retroreflective Properties

The results of the photometric measurements, and the effect of the

various abrasion parameters on the ratio "A", in metres, the performance

parameter, are given in table 1. The results indicate that all six values

of "A" were below the minimum requiroiients listed in the bicycle standard

for the sample abraded for 2000 revolutions while subjected to a load of

9.8 N (2.2 Ibf), Two of the six values were below minimum for the sample

abraded for 1000 revolutions v^ile subjected to a load of 9.8 N (2.2 Ibf).

The two samples abraded using a test load of 4.9 N (1.1 Ibf) met all of the

minimum requirements although the values for A, measured at an entrance

angle of 40*^ and an observation angle of 1.5*^ were marginal. Since it was

not the intent of this study to develop a test procedure and testing

parameters that would result in failure of the reflective tape, three of

the rims were then subjected to somewhat less severe test conditions.

These tests consisted of applying a 3.92 N (0.86 Ibf) load to the

reflective tape for 1000 revolutions, in order to evaluate the

reproducibility of the test procedure. The results of these tests are also

given in table 1

.

Comments on Abrasion Test Parameters

In developing the abrasion test procedures, several selected

parameters were used. These include the type and size of the steel wire

brush, the applied force on the brush, the rotational speed of both the

wire brush and the bicycle rim, and the number of rim revolutions per test.

The selection of these parameters were based on the preliminary studies,

and on some basic concept of the properties of the components comprising

the reflective material under evaluation. Although the chosen test

parameters are arbitrary to a certain extent, they were selected as a means

of at least equaling the severity of abrasion, occurring in the flat panel,

scrub test developed by the manufacturer, which does not, incidentally,

lead to failure. This test was considered by the CPSC to be an adequate

means for evaluating the abrasion resistance of the tape, and for quality

control purposes. In conducting the tests on the bicycle rims, it seemed

reasonable to expect a decrease in reflectivity to occur as the applied

force increased, and as the number of rim rotations increased. These two

variables were the only ones that could be assessed with respect to changes

in reflectivity, at this time. It was hoped that the selected procedures

would subject the material to abrasion ranging from "moderate” to "severe."

The latter was achieved, the former may not have been.

3

One change that will probably have to be made is in the type of wire

brush used. Originally, it had been intended to use a 1.27 cm (0.5 in)

diameter cup brush for these tests. However, during the preliminary work

there was some evidence that an applied test force of 9.8 N (2.2 Ibf) might

result in permanent distortion of the wire bristles before a test were

complete. For this reason, as well as the lack of knowledge as to the

effect of the selected test procedures on the retroreflective properties,

and the limited number of samples, a solid wire brush was used. Beth

brushes were constructed of 0.13 nm (0.005 in) dianeter steel wire.

As a result of the photometric data obtained on the abraded rims, it

seems apparent that the applied force need not exceed 4.9 N (1.1 Ibf).

Under these circumstances, a cup brush should perform satisfactorily.

Subjective observations of both types of brush while in operation, seemed

to indicate that the cup brush conformed better to the rim than did the

solid brush. This may be an important consideration if other reflective

materials of greater width become available. For example, paragraph

1512. l8(o) (2) (i) of the bicycle regulations, permits measurenent of the

retroreflective properties on material between two concentric circles, the

larger of which is no more than 0.02 m (0.79 in) greater in radius than the

smaller

The prototype abrasion test apparatus seems to produce reasonably

consistent results, based on the small sample size. The design is such

that any of the test parameters are easily changed and the approach should

provide a suitable m.ethod for conpliance testing. However, in developing

the apparatus and test procedures, no attempt was made to simulate actual

use conditions.

Peel Resistance

A number of 0.32 cm (0.125 in) wide samples of the reflective tape, in

ready to use form were supplied for the purpose of evaluating the peel

strength. These samples were in the form of cut strips, the useful portion

of which did not exceed 17.8 cm (7 in) in length. Normally, 130® peel

strength tests are conducted using a 30.5 cm (12 in) long specimen, applied

to a test panel in a specified manner. The peel strength is determined by

the average force required to remove 5.1 cm (2 in) of the specimen from a test panel, usually using a testing speed of 30.5 cm (12 in) per minute.

As a general rule, most commonly used pressure-sensitive tapes do not break

under these test conditions. However, the reflective tape under evaluation

was so fragile that it was felt that slower testing speeds should be used

to lessen the initial impact forces on the tape, and to obtain useful data.

The test specimens were prepared by pressure bending approximately

three inches of the strip to a chromium plated steel panel. The specimens

were tested on a Universal Testing Machine at a crosshead speed of 5.1 cm

(2 in) per minute. During the tests some stretching occurred in the

unbonded portion of the specimen. There was virtually no peeling of the

specimen from the test panel. The tape essentially ruptured at the site of

the initial 180® bend. The maximum peel strength, considered to be a more

- 6 -

important parameter for this material than the average peel force, was for

all practical purposes synonymous with the breaking strength. Similar

phenomena occurred during tests conducted at the crosshead speed of 2.54 cm

(1 in) per minute, except that the tape broke at lower load levels. The

average maximum force sustained by the specimens was 0.33 N (1.18 ozf) at

2.54 cm (1 in) per minute, and 0.40 N (1.45 ozf) at 5.1 cm (2 in) per

minute. On the basis of the behavior of the test specimens and the results

obtained, these data do not represent the true peel adhesion strength. The

tests do indicate that the bond between the adhesive and the metal, and

between the adhesive and the support layer (backing) are greater than the

cohesive strength of the support layer, which also contains the reflective

material on its outer surface. This is an extremely desirable property,

with respect to the intended use of this material.

Tensile Tests

Tensile breaking strength tests were also conducted at a crosshead

speed of 2.54 cm (1 in) per minute. The average breaking force was 0.38 N

(1.38 ozf) for the 0.32 cm (0.125 in) tape, or approximately 1.20 N per

centimeter of width (0.69 Ibf per inch of width). Elongation to break was

112% on specimens tested with a 2.54 cm (1 in) gage length. It should be

noted that the tensile strength is not significantly different than the

force values obtained at break during the peel tests.

Manual Tape Removal

Attaifipts to lift the tape from the rim, e.g., by scraping off a section and then trying to lift the exposed end with the fingernails, were

not successful. It was possible to ranove the tape with a sharp edged

device such as a razor blade, but when the lifted section was grasped with

the fingers, the tape broke immediately.

Comments on Peel Resistance

The results of the tensile and peel strength tests obviously indicated

that the reflective tape evaluated in this program would be essentially

resistant to all but abnormal abuse. Consequently, the development of a generic test for resistance to peeling, using this particular pressuresensitive tape as a model, was virtually precluded.

One possible means of compliance testing for the peel resistance would

be to lift a portion of the material, attach a specified weight to this

portion in such a manner as to induce a 90^ peel angle, and limit the

amount of material that could be peeled off over a specified period of

time. Such a procedure, however, would be suspect, since even microscopic

damage encurred in removing the material from the rim, could result in

premature failure. In the case of this particular application, premature

failure would be an asset, since a damaged section of material might be

expected to break more readily than an undamaged section and therefore pass

a requirement for peel resistance.
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Summary

A prototype testing apparatus was designed and built for use in

conducting abrasion tests on reflective materials applied to bicycle wheel

rims. Data were obtained to determine the effects of various arbitrarily ' selected test parameters on the retroreflective material used as a model.

These results, although preliminary in nature and based on a small sample,

indicate that the apparatus and procedure are suitable for compliance

testing.

It was not the purpose of this program to attempt to simulate use

conditions, nor to recommend specific test parameters. The design of the

apparatus is sufficiently flexible to allow a rather broad range in test

parameter options. These options involve the type and size of the abrader

brush, speed of rotation of both the brush and the bicycle wheel, the force

applied to the abrader, and the number of wheel rotations.

Attempts to establish some bases for measuring the adhesive peel

resistance were not successful. The cohesive strength of the tape matrix

was less than the adhesive strength of the pressure sensitive adhesive used

in this system. As a result, the tape tended to break before a measurable

amount of peel could be achieved.
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The

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Abrasion

on

Bicycle

Wheel

Rim

Reflective

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9.8 N

(2.2

Ibf) 0

2000

revolutions

3.92 N

(0.86

Ibf) 0

1000

revolutions -

average

of

three

samples



V.





U.S. DEPT. OF COMM.

BIBLIOGRAPHIC DATA

SHEET

1. PUBLICATION OR REPORT NO. NBSIR80-20352.Gov*L Accession No. 5. RecifJtBttt' 4 Accession No. ..

.

' - •^ /

4. TITLE AND SUBTITLE

BICYCLE WHEEL RIM REFLECTIVE MATERIALS

TEST METHOD DEVELOPMENT

5. Publication Date April 1980

6. Performing Organization Code

7. AUTHOR(S)

Samuel D. Toner, Stanley K. Wakamiya

8. Performing Organ. Report No.

9. PERFORMING ORGANIZATION NAME AND ADDRESS

NATIONAL BUREAU OF STANDARDS

DEPARTMENT OF COMMERCE

WASHINGTON, DC 20234

10* Pfo|eq^ask/Work Unit No.

11. Contract/Grant No.

12. SPONSORING ORGANIZATION NAME AND COMPLETE ADDRESS rs(ree<. City, state, ziP)

Consumer Product Safety Commission

5401 Westbard Avenue

Bethesda, Maryland 20016

13. Type of Report & Period Covered

14. ^ionsofing Agency Code

15. SUPPLEMENTARY NOTES

I I Document describes a computer program; SF-185, FIPS' Software Summary, is attached.

16. ABSTRACT (A 200-word or less factual summary of most significant information. If document includes a significant bibliography or

literature survey, mention it here.)

A prototype testing apparatus was designed and built for use in conducting

abrasion tests on reflective materials applied to bicycle wheel rims. Data

obtained on the effects of various arbitrarily selected test parameters on a pressure sensitive reflective tape, used as a model, indicate that the abrader

and test procedures are suitable for use in compliance testing of rim-applied

retroreflective materials. Materials of this type, intended for use in lieu of

spoke reflectors or retrorefl ective tires, are not included in the current

bicycle safety regulations promulgated by the Consumer Product Safety Commission.

17, KEY WORDS ('s/x to twelve entries; alphabetical order; capitalize only the first letter of the first key word unless a proper name;

separated by semicolons)

Abrasion test development; bicycle compliance tests; bicycle safety; reflective

materials for bicycles; safety of bicycles; safety standards.

18. AVAILABILITY OUnlimited 19. SECURITY CLASS 21. NO. OF

(THIS REPORT) PRINTED PAGFS

Q ] For Official Distribution. Do Not Release to NTIS UNCLASSIFIED

1 1 Order From Sup. of Doc., U.S. Government Printing Office, Washington, DC

20402, SD Stock No. SN003-003-

20. SECURITY CLASS

(THIS PAGE)

22. Price

1 1 Order From National Technical Information Service (NTIS), Springfield,

VA. 22161 UNCLASSIFIED

USCOMM- DC