Polycarbonate (PC)
3.5-10 usd/kgPolycarbonate (PC) is an important engineering plastic. It offers excellent transparency, toughness, thermal stability and dimensional stability. These properties are utilised in safety-critical applications, such as helmets, visors, lighting and aircraft and ballistic glazing. Its superior moulding characteristics and incredible impact strength make it the go-to material for many automotive, consumer electronic and small appliance housings, too.
The compatibility of PC with other plastics is utilised in alloys (blends), which combine the benefits of the mixed polymers to better fit the performance and productivity requirements of the application. PC is combined with acrylonitrile butadiene styrene (PC/ABS), which is an upgrade on ABS but less expensive than pure PC. It is combined with acrylonitrile styrene acrylate (PC/ASA) for enhanced resistance to weathering and UV light, ensuring colour retention over time. And it is combined with polyester – polyethylene terephthalate (PC/PET) and polybutadiene terephthalate (PC/PBT) – to produce a material with enhanced chemical resistance.
In the past, PC was commonly used in drinks bottles, babies bottles and other food contact applications. Its transparency and impact properties make it a tough and lightweight alternative to glass. However, the downside of PC is its chemistry: it is most commonly formed with the reaction of bisphenol A (produced through the condensation of phenol with acetone under acidic conditions) with carbonyl chloride. Bisphenol A (BPA) has been at the centre of numerous studies, because it poses a risk to people and the environment (it is an endocrine disruptor and oestrogen-mimicker). The concern is that small amounts of the chemicals present in food packaging materials migrate into the contents. The US Food and Drug Administration (FDA) and the European Food Safety Authority (EFSA) consider BPA to be safe at current levels occurring in foods. In other words, they currently approve the use of PC in food containers and packaging (BPA is found in the epoxy-based coatings used to line the inside of metal cans as well as PC). Whether it is dangerous or not, public opinion resulted in a shift away from PC in applications where a ‘safer’ alternative existed.
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Polycarbonate (PC) is an amorphous engineering plastic with good dimensional stability up to around 135 degC, making it suitable for structural applications and parts that demand reliability and guaranteed performance. However, similar to other members of the polyester family – polyethylene terephthalate (PET) and polybutadiene terephthalate (PBT) – PC cannot tolerate continuous exposure to warm water. After prolonged exposure to water at 60 degC its mechanical properties start to breakdown.
It has very good transparency and is used in many of the same applications as polymethyl methacrylate (PMMA), acrylic. These plastics have replaced glass in many cases, because they offer a tougher and lighter alternative that can be injection moulded in a broad colour spectrum. However, neither has the hardness of glass, and will scratch relatively easily. Compared to acrylic, PC is not as hard, but it has superior impact properties. In applications where scratches will be determinate to use or perceived quality, such as where transparency or surface finish are important, a clear hardcoat or in-mould labelling (IML) film is added to improve resistance to scratching and abrasion. These surface barriers also help to protect PC from damage from exposure to chemicals. While it has good resistance to many acids and alcohols, PC is negatively affected by some cleaning products, fruit juice and soft drink, insect repellent, brake fluid and fuels.
Its transparency and toughness are utilised in things like protective sports equipment, safety helmets, headlamp lenses, glazing and car headlights. Another advantage of transparent PC is that it filters out UVA and UVB radiation from the sun, which makes it a popular choice for roof glazing. It can be inherently tinted, or coloured, too. However, if exposed to the elements, it will need added UV protection to ensure longevity.
Its insulating properties, combined with toughness and inherent resistance to fire (which is improved with additives), make it a good choice for electrical components and housings. Examples include things like plugs, sockets, power tools and electrical vehicle parts. It is combined with glass fibre for improved strength and stiffness.
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