• Polycarbonate structure
• Polymer production
• Manufacturing diagram
• Dr. Hermann Schnell and
his team at “Bayer”
polycarbonate in 1953,
forever changing how we
live our lives.
• PC was introduced in
United States Of America
in 1960 by “general
• As the next 63 years have
shown, polycarbonate has
evolved, finding its way
into a multitude of
products that touch our
lives every day.
What is polycarbonate?
• Polycarbonates received their name because they are polymers
containing carbonate groups (-O-(C=O)-O-).
• Its most popular trade name is LEXAN.
• PC is a good material choice in industry not only due to its
characteristics, but also because its processing is environmentally
friendly, and it can be recycled.
• About 2.7 million tons of polycarbonate are produced annually
• Polycarbonates are long-chain linear polyesters of carbonic acid and
dihydric phenols, such as bisphenol A.
• Take a look at the above diagram. In it, you will see two six-sided
structures. These are called phenyl groups. You will also see two
groups identified by the label CH3. These are methyl groups. The
presence of the phenyl groups on the molecular chain and the two
methyl side groups contribute to molecular stiffness in the
polycarbonate. This stiffness has a large effect on the properties of
polycarbonate. First, attraction between of the phenyl groups
between different molecules contributes to a lack of mobility of the
individual molecules. This results in good thermal resistance but
relatively high viscosity (i.e., low melt flow) during processing. The
inflexibility and the lack of mobility prevent polycarbonate from
developing a significant crystalline structure. This lack of crystalline
structure (the amorphous nature of the polymer) allows for light
• The main polycarbonate material is produced by the reaction of bisphenol A
and phosgene (COCl2). The overall reaction can be written as follows:
Bisphenol A Phosgene PC polymer
• Polycarbonate is transformed from pellets into the desired shape.
The molten PC is passed through a die The PC melt is pressed into a mold with
that gives the material its final shape. the defined shape of the final product.
After this, the melt is cooled rapidly. the melt is then cooled inside the mold.
• excellent physical properties
• excellent toughness
• fair processing
• good electrical insulating properties
• Light weight
• Good scratch resistance
• Excellent thermal properties
• Very durable
• The addition of glass fibers to polycarbonate significantly increases the
tensile strength, and heat deflection temperature . The greater the
amount of glass fiber added to the polycarbonate, the greater the effect on
each property will be.
How do strength
property in PC
compare to other
• ABS: Acrylonitrile butadiene
• PPO: Polyphenylene Oxide
• PBT: Polybutylene
• PET: Polyethylene
• The characteristics of
polycarbonate are quite like
those of polymethyl
methacrylate (PMMA, acrylic),
but polycarbonate is stronger,
usable in a wider temperature
range but more expensive.