Luxus’ composite achieves accelerated material performance requirements

An advanced range of lightweight, scratch resistant thermoplastics has passed accelerated materials performance trials with a Tier 1 moulder, giving it potential for commercial use.

Hycolene PP, engineered by technical compounder Luxus, has recently concluded the latest in a series of trials with IAC, bringing to an end the material validation process required for Hycolene as part of the €1.4m Eco-innovation funded Recyclite commercialisation project .

The aim was to provide a theoretical equivalent of real-time ‘vehicle life’ for Hycolene (grade 16818), to satisfy fellow project member, Jaguar Land Rover’s engineering standard. The materials trials followed previous positive performance, delivering high scratch-resistance; lightweight benefits and a rapid cycle time in the spring of this year.

The chosen ‘A’ class interior test component for these latest trials was a current Jaguar Land Rover instrument panel (IP), which was exposed to in-market service temperatures expected for IP assemblies for several weeks ending in June 2016. IAC’s laboratory and an independent test house, which compared the results against an industry standard thermoplastics grade, managed the tests.

Accelerated material tests were completed as auto manufacturers require all interior plastics components to be more resistant to sunlight and heat as part of an overall goal of achieving a 10-year vehicle life. Weathering requirements have also become more severe as larger, aerodynamic windshield designs for example, have increased the sunlight exposure of many vehicle interiors today.

Luxus’ Technical Director, Dr Christel Croft, explained: “Firstly, we took panel gap measurements both pre and post-tests to determine if there was any degree of component movement. UV resistance was also critical, with only minor fade allowed and no other colour tone change. A non-uniform colour change was unacceptable in these trials – Hycolene 16818 passed all the agreed criteria.

“Any occurrence of tackiness; grain loss; blistering; distortion; cracking; crazing; fibre deterioration; wrinkling; waviness; milking or spotting would have led to a rejection. We along with our Recyclite project partners are satisfied that Hycolene has once again exceeded expectations.”           

Peter Middleton, CBU director at IAC, added: “We are pleased that Hycolene has proved to be a fully developed and durable composite able to meet the requirements of this trial. We believe this composite now has the potential to be successful at full commercial scale for auto manufacturers that demand advanced lightweight and scratch performance in either sustainable recycle content or virgin grades for the vehicle’s life.”