History of DYLARK Engineering Resins

DYLARK styrene Maleic Anhydride (S/MA) copolymers were developed in late sixties. The resins exhibited high heat resistance compared to polystyrene, high-impact polystyrene (HIPS), Acrylonitrile Butadiene Styrene (ABS) and Styrene Acrylonitrile copolymer (SAN). In the early seventies, elastomer-modified reactor and fiberglass reinforced DYLARK grades provided enhanced heat resistance, impact, tensile and flexural strength and flexural modulus properties. These performance characteristics were adapted into a new and growing automotive application - substrates for soft instrument panels (IP’s).

Soft IP’s with injection-molded thermoplastic substrates replaced formed steel substrates. Thermoplastic substrates reduced vehicle weight to meet C.A.F.E. standards, provided overall cost savings and permitted greater flexibility in interior designs and esthetics. In addition, the automobile industry and customers perceived soft IP’s to provide greater passenger safety.

DYLARK resins were evaluated as 20% dry blends, physical mixtures of resin and chopped fiberglass strands. These resins exhibited higher heat and impact resistance and improved cross-car stability compared to existing commercial resins. During this time, vehicle designs increased the windshield slope, which increased the temperature on the IP’s exposed top surface. Due to cross-car thermal expansion, IP’s using competitive substrates buckled and warped along the windshield edge. The thermal stability of DYLARK glass-reinforced resins demonstrated the physical properties required to withstand thermal expansion in the new designs. Glass-reinforced DYLARK also fulfilled U.S. government regulations for improved safety and head impact through greater energy management over a range of temperatures and speeds.

Soft IP’s progressed beyond carriers for polyurethane foam to include more intricate designs for one and two-piece IP constructions. The new designs were more functional, improved cross-car structure and contained additional packaging compartments for radio, heater and speedometer openings.

Additional DYLARK grades were created with increased impact and handling ease to meet expanding industry performance standards. Pre-compounds, pellets with encapsulated glass, replaced dry blends for increased handleablity and processability. S/MA glass reinforced precompound eliminated most in-plant handling and molding problems associated with fiberglass fuzz balls, while providing more consistent and reliable molding operations. At the same time, part weight control and dimensional stability were enhanced. Impact grades provided improved handleablity and enhanced performance, including heat resistance, head impact, chemical resistance, superior urethane foam adhesion and noise, vibration and harshness performance.

Today, several engineering resins designed specifically for IP substrate applications are available, but many designers and suppliers continue to specify DYLARK resins because of the outstanding balance of properties and proven performance. During the past three decades, DYLARK substrates were installed in more than 200 million soft instrument panels worldwide. Numerous automobile manufacturers specify DYLARK worldwide and new applications continue to develop as NOVA Chemicals’ customers expand throughout North America, Europe and Asia.