In the plastics industry, Polycarbonate sheet is one of the most popular materials on the market. What makes them a favorite among builders and product manufacturers? What are the advantages and disadvantages of polycarbonate sheets?
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First, Polycarbonate is a thermoplastic that comes in a transparent sheet. It the incredibly tough and absorbs minimal moisture making its high impact resistance, flame-retardant, chemical resistant, and is also resistant to water damage.
As to polycarbonate sheet applications, the specific benefits make it effective in many different applications: skylights, window glazing, sign faces, riot shields, enclosures, food processing, medical equipment, aerospace, exhibits, and displays.
Polycarbonate sheet is widely used in industries because of its strength combined with design flexibility. Polycarbonate solid sheet is 30 times stronger than acrylic and 200 times stronger than glass with a much lighter weight.
Polycarbonate is to work with. Transporting, cutting, drilling and construction. The polycarbonate sheet is lightweight and flexible. When all these benefits come to a single material, it undoubtedly becomes the best choice.
Another advantage of polycarbonate sheets is UV protection. There is a layer of UV resistance on one side of the sheet, which blocks the UV ray of the sun to protect the sheet structure.
Polycarbonate sheet is B1 level of flame resistance. It has a unique fire-resistant property. So polycarbonate is the best choice for buildings built in fire-prone areas.
I am afraid the only disadvantage of the polycarbonate sheet is the cost. It is a little more expensive than other similar build materials. But the amount of the benefits have made up for the cost.
Polycarbonate sheets have unique benefits, which make them replace the glass. Polycarbonate sheets are widely used in construction, agriculture, electronics, etc. the followings are the most popular applications being used.
Polycarbonate sheets are greatly used in greenhouses and nurseries, the sheets are UV coated the UV layer blocks almost all of the sun’s light. The harmful UV radiations are also blocked. So the plants are protected well within. If you choose twinwall or multiwall anti-fog polycarbonate sheets, thermal insulation is assured. Also, the sheets provide light diffusion and better protection. If you choose single polycarbonate sheets, it gives both light diffusion and warmth maintenance ability.
Polycarbonate solid sheets are strong impact resistance to be used for riot shields, prison windows, and protective visors. The main concern of the usage of these sheets in the police force is the use and abuse of these objects, which results in the damage of this equipment and making them useless, but if an anti-scratch coating layer is added. These tools become scratch-resistant.
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Another common use for polycarbonate sheets is to divide a room. The sheets are lightweight, it is easy to transport and install. Some are customized styles so you can open and close as you needed, and even some are made on wheels for easier movement.
Polycarbonate roofing panels are over 200 times stronger than glass. Which makes it a perfect replacement option for glass when available. Polycarbonate solid sheet is durable for skylights and glazing security lights in buildings. The insulation is much better than glass and it is lower cost when used in place of glass for building purposes.
1 History of Polycarbonate
2 Properties
3 Grades Available
4 Physical Properties
5 Resistance to Chemicals
6 Applications
6.1 Electrical & Electronics (E&E)
6.2 Automotive
6.3 General Industries / Packaging
7 Case Studies
7.1 Automotive
7.2 Traffic Lights
7.3 Cash Dispenser
7.4 Baby Bottle
7.5 Mobile
8 Looking to source PC or another polymer?
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. Special flame retardant grades exist which pass several severe flammability tests.
Constraints to the use of PC include limited chemical and scratch resistance and it's tendency to yellow upon long term exposure to UV light. However these constraints can be readily overcome by adding the right additives to the compound or processing through a co-extrusion process.
Polycarbonate is available in a number of different grades dependent on the application and chosen processing method. The material is available in a variety of grades such as film, flame retardant, reinforced and stress crack resistant, branched (for applications requiring high melt strength) and other speciality grades. Also blends of PC are available with e.g. ABS or Polyesters, widely used in automotive industry. Processing of PC generally falls into:
Note that these ratings are generalised. The resistance against specific substances can deviate and are dependent on temperature, applied stresses, exposure time etc.
In recent years Polycarbonate blends have become increasingly commercially important. PC is widely used in blends due to its excellent compatibility with a range of polymers. Typical blends include rubber modified PC, improving impact properties, PC/PBT blends, which allow toughness to be retained at lower temperatures and having improved fuel and weather resistance. Amongst the most significant are those incorporating ABS (Acrylonitrile Butadiene Styrene). PC/ABS blends exhibit high melt flow, very high toughness at low temperatures and improved stresscrack resistance compared to PC.
All Blends are produced using a compounding step to blend the polymers. This compounding technology is very important for creating the optimal morphology and interaction between the two phases. In combination with the right additive know-how (flame retardant, stabilisation, reinforcement) blends are obtained with an optimally balanced set of properties.
PC finds usage in a host of markets, notably in the automotive, glazing, electronic, business machine, optical media, medical, lighting and appliance markets
6.1 Electrical & Electronics (E&E)
The largest UK 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.
Miniaturisation 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 co-ordinated 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:
6.2 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.
6.3 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:
The British Plastics Federation have over 500 members many of which supply polycarbonate and other major polymers. The BPF offer a free 'source a supplier' service - simply complete the form below and we will send you enquiry direct to companies who can supply you with the product you are looking for.
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