Overview
Polycarbonate (PC) is an engineering thermoplastic prized for its unique combination of transparency, durability, and heat resistance. Developed in the 1950s, it revolutionized industries requiring shatterproof alternatives to glass. Its molecular structure features carbonate groups linked to aromatic rings, granting exceptional mechanical properties. As a raw material, PC is typically supplied as pellets or sheets for injection molding, extrusion, or thermoforming. Major manufacturers like Covestro, SABIC, and Mitsubishi Chemical produce specialized grades for optical, medical, and flame-retardant applications. Global demand exceeds 5 million tons annually, driven by sustainability initiatives (e.g., recyclable PC) and lightweighting trends.
Physical and Chemical Properties
PC exhibits a glass transition temperature of ~147°C, maintaining dimensional stability between -40°C to 120°C. Its light transmittance reaches 90%, rivaling glass, while being 250x more impact-resistant. The material’s Rockwell M hardness ranges from 70–90, and its tensile strength is ~70 MPa. Chemically, PC resists dilute acids, alcohols, and hydrocarbons but is susceptible to alkalis and chlorinated solvents. UV exposure can cause yellowing unless stabilized with additives. Unlike acrylic (PMMA), PC withstands repeated sterilization, making it suitable for medical devices. Its dielectric properties are stable across frequencies, ideal for electrical insulators.
Main Applications
In automotive sectors, PC glazing reduces weight by 50% compared to glass, used in headlamp lenses and panoramic roofs. Electronics leverage PC’s flame retardancy (UL94 V-0 ratings) for smartphone casings and LED diffusers. Construction applications include soundproof windows and riot shields. Medical-grade PC meets ISO 10993 standards for surgical instruments and dialysis membranes. Emerging uses include 5G antenna housings (low dielectric loss) and transparent PPE visors. Blends with ABS (PC/ABS) enhance ductility for tool housings, while glass-filled grades improve stiffness for industrial parts.
Safety and Storage
PC pellets are non-hazardous under normal conditions but require dust control during handling to prevent respiratory irritation. Processing above 300°C may emit trace BPA, necessitating fume extraction. Storage should avoid moisture absorption (max 0.02% water content) to prevent hydrolysis during molding. Sheets must be stacked horizontally to prevent stress whitening. OEMs often mandate compliance with FDA 21 CFR or EU 10/2011 for food-contact applications. Disposal follows polymer recycling codes (#7), though industrial scrap is commonly regranulated for closed-loop reuse.
B2B Procurement Guide
Specify optical clarity (e.g., haze <1%), Izod impact strength (≥600 J/m), and regulatory certifications (REACH, RoHS) when sourcing. For extrusion grades, melt flow rate (MFR) of 10–25 g/10min (300°C/1.2kg) ensures optimal processing. Bulk orders (20+ tons) often secure 8–12% discounts. Audit suppliers for post-industrial recycled (PIR) content availability, which reduces costs by 15–20%. Just-in-time delivery is preferable to minimize storage degradation. Key Asian suppliers include Teijin (Japan) and Chi Mei (Taiwan), while regional distributors provide quicker lead times for small batches.
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