CHEM - LEC - Polycarbonate

John Leree Coralde 1–3 11/14/18
I. Identity of Polymer
POLYCARBONATE
Chemical Name
Polycarbonate (PC) plastics are a naturally transparent amorphous thermoplastic.

Polycarbonate of bisphenol A or typically just polycarbonate is most commonly formed with the
reaction of bisphenol A with carbonyl chloride (phosgene) in an interfacial process hence gets it
name from the presence of carbonate groups in its backbone chain.
Physical and Chemical Properties
Polycarbonates are strong, stiff, hard, tough, transparent engineering thermoplastics that
can maintain rigidity up to 140°C and toughness down to -20°C or special grades even lower.
The material is amorphous (thereby displaying excellent mechanical properties and high
dimensional stability), is thermally resistant up to 135°C and rated as slow burning. Constraints
to the use of PC include limited chemical and scratch resistance and its tendency to yellow upon
long term exposure to UV light.
Unlike most thermoplastics, polycarbonate can undergo large plastic deformations

without cracking or breaking. As a result, it can be processed and formed at room temperature
using sheet metal techniques, such as bending on a brake. Even for sharp angle bends with a tight
radius, heating may not be necessary. This makes it valuable in prototyping applications where
transparent or electrically non-conductive parts are needed, which cannot be made from sheet
metal. PMMA/Acrylic, which is similar in appearance to polycarbonate, is brittle and cannot be
bent at room temperature
Here are specific quantities:
Tensile Strength: 70 - 80 N/mm²

Notched Impact Strength: 60 - 80 Kj/m²
Thermal Coefficient of expansion: 65 x 10-6
Max Cont. Use Temp: 125 °C
Density: 1.20 g/cm3
Glass transition temperature: 145oC.
Melting temperature: 225oC.
Amorphous density at 25oC: 1.20 g/cm3.
Molecular weight of repeating unit: 254.3 g/mol.
RESISTANCE TO CHEMICALS
Dilute Acid Good
Dilute Alkalis Poor
Oils and Greases Moderate
Aliphatic Hydrocarbons Good
Aromatic Hydrocarbons Poor
Halogenated Hydrocarbons Poor
Alcohols Good
Processing and Manufacturing
A condensation polymerization is used to synthesize Polycarbonate (PC) from phosgene

and bisphenol A in which elimination of Cl- ions are done every time the monomers react.
Firstly, bisphenol A groups are made to react with proton acceptors like NaOH to result in
polymerization functional groups.
At a temperature range between 25 and 35°C, phosgene and a catalyst react with the
deprotonated Bisphenol A. This forms a PC monomer and the catalyst mostly pyridine is
removed with the chloride anion
PC is then converted from pellets to the desired shape by melting it and forcing it into a
die or mold to provide the needed shape based on the application. This process is done
repeatedly. In the extrusion process, the molten PC is passed through a die giving the material its
final shape. The melt is rapidly cooled after this. Using this process, long pipes and sheets are
formed.
Applications
A. Electrical & Electronics (E&E)
The largest application for PC is in the optical media market (i.e. usage in computer and
audio compact discs). This is followed by an assortment of sheeting and glazing applications.
The rest of the market consists of electrical and electronics (hosting applications in the business
machine and telecommunications market), followed by transportation (including automotive),
appliances, packaging, and other miscellaneous uses.
Miniaturization fast product cycles make the E&E market one of the most demanding for
Engineering Plastics. Demands include high service temperature, spike temperature resistance,
ductility and toughness in thin sections, and flammability. All of this must be delivered
consistently throughout the world, with coordinated engineering, market development, and
technical service. In the E&E market our materials are well suited to internal components and
current carrying devices.
Typical examples of applications of technology are within:
o power distribution (covers and housings)

o connectors
o electrical household appliances
o mobile phones
o electrical chargers
o lighting
o battery boxes
B. Automotive
The use of Engineering Plastics in automotive applications is nearing its fiftieth

anniversary. PC has been part of this history and continues to bring innovation, which allows
automakers to produce lighter, stronger, and more durable components.
Typical PC and PC-blend applications include:

o automotive lighting
o head lamp lenses
o dashboards
o interior cladding
o exterior parts (bumpers, body panels)
C. General Industries / Packaging
While automotive and E&E markets tend to drive the technological breakthroughs in
materials, other industries develop their own unique uses for Engineering Plastics. In most of
these industries durability, cost effectiveness, and appearance are the driving factors in material
selection. The largest of these markets include:
o power tools
o baby bottles
o water dispensers
o garden equipment
o furniture (office & institutional)
o sporting goods
o medical applications
Why Polycarbonate?
Polycarbonate is a tough and stable clear plastic offering unique advantages. Namely
outstanding levels of light transmission, incredible high strength (whilst being incredibly light in
weight) and resistant to stresses both accidental and intentional. Due to its incredible tensile
strength which is 250x stronger than glass, it is also used in protective eyewear since it is also
quite light compared to regular glass. Due to it being a thermoplastic, has the property of being
recyclable, it can be molded easy at room temperature just like sheet metal. It is because of that
property that it comes are various shapes and sizes in the market (bottles, tools, automotive
accessories, electrical components, etc.).
Due to its high strength and light weight are valued for making CDs, DVDs, mobile
phones and laptops; using polycarbonate to manufacture these products means they can be
incredibly light yet virtually impossible to break. Polycarbonate is an excellent choice for
applications where sheet metal lacks viability, namely when transparency is needed and when a
non- conductive material with good electrical insulation is a requirement. Polycarbonate makes
an excellent material for tackling DIY jobs such as secure glazing and replacing greenhouse
glass to make greenhouses virtually unbreakable year after year.
polycarbonate glazing makes greenhouses virtually

unbreakable
II. Quiz on Polymers
Multiple Choice:
1. The repeating sub – unit of Teflon, a polymer used in coating non – stick pans, is ______
a. Tetraflouron b. Trifluronthylene c. Tetrafluoroethylene d. Trifluoroethylene
2. Polystyrene is used in food packaging and containers, what is its number in the Plastics
Recycling Code/Resin Identification System?
a. 3 / Three b. 5 / Five c. 8 / Eight d. 6 / Six
3. It was the first synthetic polymer ever created by industrial means.

a. Nylon b. Acrylic c. Bakelite d. Coke
4. It is a polyethylene terephthalate plastic that is used in fibers and films which was formed by
condensation polymerization.
a. Polyester b. Dacron c. Nylon d. Elastomers
5. It is a process of forming cross – links between polymer chains which improves the
mechanical properties of the rubber.
a. Vulcanization b. Sulfurization c. Crystallization d. Polymerization
Identification:
1. He synthesized nitrocellulose, an artificial polymer from the natural polymer of commonly

found in plants. (Christian Schnobein)
2. It is formed by the addition polymerization of butadiene to styrene and is usually used for tires
and gum. (Styrene-Butadiene Rubber / SBR)
3. It is a natural polymer that plays a key role in nearly all biological processes. (Protein)
4. It is a type nucleic acid that is considered to be one of the largest known molecules.
(Deoxyribonucleic Acid / DNA)
5. It is type of plastic can be recycled: can be softened when heated and becomes firm when
cooled. (Thermoplastics)

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John Leree Coralde 1–3 11/14/18

Polycarbonate (PC) plastics are a naturally transparent amorphous thermoplastic.

Physical and Chemical Properties

Unlike most thermoplastics, polycarbonate can undergo large plastic deformations

Tensile Strength: 70 - 80 N/mm²

Processing and Manufacturing

A condensation polymerization is used to synthesize Polycarbonate (PC) from phosgene

A. Electrical & Electronics (E&E)

Typical examples of applications of technology are within:

o power distribution (covers and housings)

The use of Engineering Plastics in automotive applications is nearing its fiftieth

Typical PC and PC-blend applications include:

C. General Industries / Packaging

polycarbonate glazing makes greenhouses virtually

3. It was the first synthetic polymer ever created by industrial means.

1. He synthesized nitrocellulose, an artificial polymer from the natural polymer of commonly

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