This section provides an overview for polycarbonates as well as their applications and principles. Also, please take a look at the list of 40 polycarbonate manufacturers and their company rankings. Here are the top-ranked polycarbonate companies as of September, : 1.Plaskolite, Inc., 2.APSX LLC., 3.Interstate Plastics.
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What Is Polycarbonate?
Polycarbonate is an amorphous plastic with a molecular formula of C15H16O2. It is made from bisphenol A.
It has outstanding impact resistance among resins, making it highly resistant to breakage, possessing high mechanical strength, transparency, non-toxicity, high weather resistance, and self-extinguishing properties. However, it has the drawbacks of low resistance to acids, alkalis, and solvents, and a susceptibility to scratching.
Polycarbonate is classified as a thermoplastic resin that softens when heat is applied.
Figure 1. Polycarbonate Reaction Formula
Uses of Polycarbonate
Polycarbonate is used in a great many applications due to its resistance and processability.
1. Transparency
With transparency equivalent to that of glass, polycarbonate is used in optical applications such as eyeglass lenses, camera lenses, optical fibers, CD and DVD substrates, and fighter aircraft windows. Polycarbonate is the only colorless transparent material among general-purpose engineering plastics.
2. Impact Resistance
With the highest impact resistance of any plastic, polycarbonate is used in bulletproof materials, helmets, windshields, and more, with almost no risk of cracking when used in general environments.
3. Weather Resistance
Because it is resistant to ultraviolet rays and does not deteriorate easily, it maintains its high strength for a long period of time when used outdoors. It is used for outdoor items such as roofing materials and solar panel surface materials, as well as automobile headlights, roof rails, and door handles.
4. Dimensional Stability
Polycarbonate has high dimensional stability due to its low shrinkage and low moisture absorption during molding and is used for smartphone cases and other applications.
Characteristics of Polycarbonate
Figure 2. Five Major General-Purpose Engineering Plastics and Their Physical Properties (Refer to the 5th edition of the Chemical Handbook)
Polycarbonate is one of the five major general-purpose engineering plastics and is characterized by its high impact strength (20 times that of polyamide and polybutylene terephthalate) and resistance to cracking. In addition to its good mechanical strength, it is also used in various places because it has self-extinguishing properties (it does not spread even if it is ignited) since it contains two benzene rings in its main chain.
Polycarbonate is not used alone but is sometimes used in polymer alloys with other polymers. For example, PC-ABS is made by mixing Polycarbonate with ABS resin, which has good chemical resistance, to improve chemical resistance. In addition, polycarbonate can be blended with polyesters such as PET and PBT, or with fillers.
Another feature of Polycarbonate is that it can be used in a wide range of manufacturing processes. In addition to injection molding, polycarbonate can be extruded, vacuum molded, blow molded, and molded using a variety of other methods.
Recently, polycarbonate has also come to be used in 3D printers, which can easily produce complex shapes. However, depending on the manufacturing method, the mechanical strength may be weakened, so caution is required.
Polycarbonate Manufacturing Methods
Polycarbonate can be produced by two methods: polymerization using the reaction formula (interfacial polymerization) and ester exchange.
1. Interfacial Polymerization Method
Polycarbonate is produced by condensation polymerization at the interface between the aqueous and oil phases by adding carbonyl chloride to a suspension solution of bisphenol A in an aqueous sodium hydroxide solution and methylene chloride or chlorobenzene. Since the reaction conditions are milder than those of the transesterification method, polycarbonates with a wide range of molecular weights, from low to high, can be produced.
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After polymerization, the Polycarbonate resin is dissolved in the oil phase, and granular Polycarbonate is obtained through a separation, neutralization, and purification process, as well as a polymer recovery process, and drying process.
2. Ester Exchange Method
Figure 3. Ester Exchange Method Reaction Formula
Polycarbonate is produced by melting and mixing bisphenol A and diphenylcarbonate under the presence of a catalyst and polycondensing while recovering phenol under high temperature and reduced pressure without the use of solvents.
Polycarbonate is obtained in a pure molten state, not in solution, and can be pelletized into products, making this method a simpler synthesis process than the interfacial polymerization method.
Polycarbonate is a type of plastic that many everyday items are made from and it is also used in products like eyewear lenses. It can be found in numerous everyday items, such as glasses, cameras and windows. It is the best for being hard and durable that people only its working because of it. They have a hard coating to make them more scratch-resistant and harder, though all polycarbonates are softer than tempered glass. That hard coating helps protect the polycarbonate and make it more durable. In today's post, we are going to focus only on the top 10 manufacturers of Erpei hard coated polycarbonate products.
Covestro - The company is a global manufacturer of Hard Coated Acrylic Sheet and hard coated polycarbonate films. They make such films for a variety of purposes, including in the interior of cars or electronic devices. They have high quality and strength products.
SABIC - SABIC is also a major role-player in the plastic manufacturing industry. Zeipol Plastic Sheets is a factory that produces hard coated polycarbonate sheets for windows, signs and other accessories. The sheets that they manufacture are high quality and built to last.
Evonik - EVONIK IS A LEADING PRODUCER OF SPECIALTY CHEMICALS, AND ONE OF THEIR MAIN PRODUCTS ARE HARD COATED POLYCARBONATE FILMS. These are the types of films that allow our electronic devices screens to stay clear and scratch free.
Mitsubishi Chemical - Mitsubishi Chemical is one of the largest manufacturers in hard-coated polycarbonate films. Its products play a critical role in the automotive, aerospace and construction industries where strong material properties are required.
Teijin - Teijin is a Japanese company that produces hardcoated polycarbonate films. Their films are frequently used in touch screen devices, as well as automotive interiors for protection and functionality.
Bayer MaterialScience - Bayer MaterialScience, now Covestro produced many hard coated polycarbonate films and sheets These products are made for a multitude of applications; hence, the adaptability it has created in this industry.
Sumitomo Chemical - Sumitomo Chemical is also a complex manufacturing company in Japan which is famous for their hard coated polycarbonate films and sheets. Their applications include automotive glazing, light fixtures and security windows to ensure the safety of people.
Is an enterprise formed by the firm Lisa Plastics, a company established in China specializing in manufacture of polycarbonate sheets with hard coat. Their sheets have several applications, e.g., in roofing and electrical components that indicates how common they are.
Plazit-Polygal - PlazitPolymersLtd produces processed hard coated polycarbonate sheets for a broad range of application areas. Their products include salt-laden lights, secure windows and noise barriers ensuring quality and safety.
Astra Polymers- Astra polymers is another firm aggravating in preparing hard coated polycarbonate sheets. They manufacture sheets, which are further used in automotive interiors, machine shields and protective screens require for various businesses.
These businesses are also known to be at the top, producing hard coated polycarbonate products. They are also reputed to be very effective in negotiation and customer interaction. They supply various kinds of coatings and solutions, made specifically to integrate the special interests of their consumers. With such companies, it is their effort to satisfy the customers with service output.
This is why you will have new hard coated polycarbonate products being released by these companies every now and then, in an effort to keep up with the high demand for their goods. Their products are of the highest quality, but their prices always remain reasonable and easily affordable to most customers. They are always innovating and making their offers better.
The most suitable agents to be the best maker of single side hard coated polycarbonate and hard coated polycarbonate are easily available in a lot of places around the global village. The companies cater to all types of businesses ranging from large corporations to small enterprises across their services in Asia, Europe and the Americas. These products are utilized in different applications, which might demonstrate why hard coated polycarbonate is so critical to us.
So, all in one and finally if you tend to get your hands on high quality hard coated polycarbonate products then these are the top 10 companies where from making a kickoff with. With years of experience, and expertise they are producing industry-grade polycarbonate solutions for many industries so that you will find what you want with confidence.
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