Polycarbonates.pdf synthesis route, application
- 1. POLYCARBONATES PRESENTATION BY: SHIVANSH PANDEY 23SUR116 ARJUN WATVE 23SUR119 POLYCARBONATES 1
- 2. STRUCTURE Polycarbonates are defined as linear polyesters of Carbonic Acid where carbonate groups reoccur in the polymer chain POLYCARBONATES 2
- 3. PRODUCTION OF POLYCARBONATES Main processes: • The two-phase interfacial phosgenation • The melt transesterification (DPC) processes. The spin-off process technologies include • The simple oligomer approach adapted by Asahi Chemical Industries Co. Ltd., Bayer AG., Daicel Chemical Industries Ltd., Idemitsu Petrochemical Co. Ltd., Nippon GE Plastics K.K., Mitsui Petrochemical Industries K.K., and Teijin Ltd. • The "crystalline" oligomer approach (Asahi 10 King Chemical Industries Co. Ltd., Daicel Chemical Industries Ltd., and Teijin Ltd.) • The 'cyclic oligomer" polymerization process (GE Plastics, Bayer AG/ Miles Inc. or Bayer America). POLYCARBONATES 3 Reference 12
- 5. TRANS-ESTERIFICATION With the advent of high-quality, high molecular weight BPA-PC melt resin a commercial reality, current research focus has been directed to catalyst improvement. Catalyst systems other than alkali metal hydroxides (e.g., NaOН) have been investigated; they range from fluoride, carboxylate, and phosphonium salts to neutral amines, phosphite, and guanidine systems. However, except in very special circumstances or applications, alkali metal hydroxides (e.g., NaOH) are still the catalysts of choice. 5 POLYCARBONATES Reference 3
- 7. COMPOUNDING THE POLYMER The compounding system is critically important for all Polycarbonate (PC) based materials. PC ingredients, mostly in powder or chip form, are compounded together with additive components into pellets such as for transparent moulding compounds in the compounding system. In many cases reinforcement agents, flame retardants, dyes or the aforementioned blend partners are also added. Compounding these materials is therefore very demanding and requires customized solutions such as some of the following. Polymer components must be melted as gently as possible, flame retardants have to be perfectly distributed, and reinforcement fibers must be added and processed in such a way as to optimize mechanical properties. 7 POLYCARBONATES Reference 14
- 8. PROCESSING THE POLYMER Injection molding: The most common method to produce polycarbonates and their blends. Polycarbonate is highly viscous. It is usually processed at high temperatures to reduce its viscosity. In this process, the hot polymer melt is pressed through into a mold with high pressure. The mold when cools gives the molten polymer its desired shape and characteristics. This process is generally used to manufacture polycarbonate bottles and plates. Since polycarbonate is a poor-flowing plastic, the wall thickness should not be too thin. 8 POLYCARBONATES Reference 10
- 9. PROCESSING THE POLYMER Extrusion molding: Processing temperatures range from 240 to 300°C. A smooth temperature increase from the feed throat to the tip of the screw, followed by a slightly lower die temperature, has been found most expedient. This favors uniform pressure buildup along the barrel. Provision for cooling the barrel is also desirable in order to dissipate adiabatic heat from the working of the resin and to control temperatures to the desired profile. Thermoforming: Films and sheets of BPA-PC can be subjected to thermoforming. BPA-PC can also be polished to a high gloss, coated, printed, embossed, or vacuum-metallized and bonded with solvents. 9 POLYCARBONATES
- 10. PROPERTIES Physical Properties 1200-1220kg/m^3 Density 1.584- 1.6 Refractive Index 267 °C Melting Temperature 145 °C -150 °C Glass Transition temperature(Tg) 55-75MPa Tensile Strength 10 POLYCARBONATES
- 11. PROPERTIES 1. MECHANICAL PROPERTIES • Light weight • Poor water absorption properties • High tensile strength • Highly recyclable without excessive rigidity • High viscosity in Liquid state due to high rigidity of chain • Excellent transparency due to a very high refractive index • High impact resistance 11 POLYCARBONATES
- 12. PROPERTIES 1. MECHANICAL PROPERTIES • Polycarbonate exhibits scratch resistance and is highly durable. • Good weathering stability. • High dimensional stability • Better creep resistance than most thermoplastics. • Extremely High stiffness and impact toughness. • Good wear resistance 12 POLYCARBONATES
- 14. PROPERTIES 2. ELECTRICAL PROPERTIES • Polycarbonate has excellent insulating properties • The value of dielectric constant is 2.9 which is higher than PTFE and Polyolefins. • Polycarbonate has very high surface and volume resistivity which helps it withstand high voltage without breaking down. • The dielectric strength of polycarbonate is roughly around 16 to 35 kV/mm. 14 POLYCARBONATES
- 15. PROPERTIES 3. CHEMICAL PROPERTIES • Resistant to dilute mineral acids and alcohols but susceptible to aromatic compounds, alkalis, ketones, and chlorinated hydrocarbons. • Has decent resistance to greases and oils so it can be easily coated in the form of a film. • However, its UV resistance is limited, causing it to yellow relatively quickly under prolonged exposure. 15 POLYCARBONATES
- 16. PROPERTIES 4. THERMAL PROPERTIES • Good Heat resistance and Thermal Stability. • Exhibits Flame retardant behaviour and High ignition temperature. • High Heat Distortion temperature generally around 270- 280℉ • Exhibits self-extinguishing property. • Relatively low thermal Conductivity. 16 POLYCARBONATES
- 17. COPOLYMERS AND BLENDS • Most important and commercially established blends are those with ASA, ABS graft polymers or those with PBT/PET in combination with impact-resistance modifiers such as ABS. • More than 20% of produced polycarbonates is used in polycarbonate blends. Impact Property Blended with Better than ABS Heat Resistance ABS Better than ABS Light Stability ABS Better than BPA-PC Processability ABS Better than BPA-PC Gasoline Resistance PET/PBT Higher than BPA-PC Heat distortion resistance PET/PBT Better than BPA-PC Low Temperature Toughness PET/PBT 17 POLYCARBONATES
- 18. GRADES 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. 1. Standard Grade: General-purpose applications (Basic durability and impact resistance are sufficient, cost effective, clarity and weatherability maintained). Example: Protective glazing. 2. Glass Filled Grades: Glass fibers may be added in various amounts (10%, 20%, 30% and 40%). It offers high impact strength, excellent strength retention at elevated temperatures, high tensile, shear, and flexural strength, high modulus of elasticity, low deformation under load, excellent creep and cold flow resistance, low coefficient of thermal expansion, good electrical insulation properties, easy processability. 18 POLYCARBONATES
- 19. GRADES 1. Stand 2. lass Filled Grades 3. UV-Protected Grade: These sheets feature added UV stabilizers and inhibitors, providing enhanced protection against UV radiation without yellowing or decaying. Example: Greenhouse panels. 4. Flame Retardant Grade: Engineered to meet stringent fire safety regulations, making them suitable for applications where fire resistance is paramount. Example: electrical enclosures, and transportation applications where compliance with fire codes is mandatory. 5. High-Impact Grade: These sheets exhibit exceptional strength and toughness, resisting breakage and deformation even under severe stress. Example: Security Glazing. 6. Optical Grade: Optical-grade polycarbonate sheets are engineered for applications requiring exceptional clarity, precision optics, and light transmission properties. Example: Display Screens. 19 POLYCARBONATES
- 20. TRADE NAMES Trade Name Polymer Grade Company Makrolon Flame Retardant (Can be UV stabilised) Covestro Bayblend PC/ABS Bayer MaterialScience Lexan Optical, Flame retardant, UV stable SABIC Xenoy PC/PET SABIC Tarflon Siloxane copolymer Idemitsu Kosan Calibre UV stable, colorability, toughness Trinseo (Styron formerly Dow) Lupoy PC/ABS LG Chemicals (Dow) 20 POLYCARBONATES
- 21. APPLICATION OF POLYCARBONATES Polycarbonates are widely used due to their exceptional properties and versatility. 21 POLYCARBONATES
- 22. APPLICATION OF POLYCARBONATES 1. AUTOMOTIVE INDUSTRY • Polycarbonate is widely utilized in the headlamp lenses, dashboard components, door trims, and window glazing, thanks to its excellent impact resistance, transparency, and heat tolerance. • Additionally, its lightweight nature enhances fuel efficiency.. • Polycarbonate is also used in sunroofs and safety shields, providing enhanced protection and design flexibility. 22 POLYCARBONATES
- 24. APPLICATION OF POLYCARBONATES 2. ARCHITECHTURAL GLAZING • Polycarbonate sheets serve as a superior alternative to glass, offering excellent transparency, thermal insulation, lightweight construction, and high impact resistance. • These versatile sheets are widely used in greenhouses, skylights, roof domes, and building facades. • Additionally, they provide UV protection, weather resistance, and enhanced durability, making them ideal for outdoor structures and noise-reducing panels in urban environments. 24 POLYCARBONATES
- 25. APPLICATION OF POLYCARBONATES 3. ELECTRICALAND ELECTRONIC • Polycarbonate's excellent electrical insulation, and dimensional stability make it an ideal material for a wide range of electrical and electronic applications. • It is commonly used in connectors, sockets, switches, and LED lighting components. • Its durability, heat resistance, and lightweight contribute to its use in circuit breakers, battery casings, and enclosures for electrical equipment. 25 POLYCARBONATES
- 26. APPLICATION OF POLYCARBONATES 4. MEDICALAND PHARMACEUTICAL EQUIPMENT AND PACKAGING • Polycarbonate's exceptional transparency, resistance to chemicals, and ability to withstand sterilization make it an ideal material for a wide range of medical and laboratory applications. • Its clarity allows for easy visual inspection of contents, making it particularly valuable for medical devices such as syringes, IV components, and implantable devices. 26 POLYCARBONATES
- 27. APPLICATION OF POLYCARBONATES 4. MEDICALAND PHARMACEUTICAL EQUIPMENT AND PACKAGING • Its durability and resistance to harsh chemicals ensure the safe storage of pharmaceuticals, making it a preferred choice for pharmaceutical packaging. • In laboratory settings, polycarbonate is widely used in the manufacturing of equipment such as petri dishes, centrifuge tubes, and safety goggles, where its strength and sterilizability contribute to maintaining hygienic and reliable testing conditions. 27 POLYCARBONATES
- 28. RECYCLING At the end of a product's life cycle, polycarbonate (PC) remains a valuable resource that can be recovered through various recycling methods: • Mechanical Recycling – Regains PC as a secondary raw material. Common in recovering PC from items like CDs through processes such as sandblasting, milling, and chemical washing. • Feedstock Recycling – Breaks down PC chemically to retrieve monomers like BPA using methods like hydrolysis, alcoholysis, or aminolysis. Research is ongoing into solvent-free degradation methods using supercritical fluids or mild catalysts. • Thermal Decomposition (Pyrolysis) – Converts PC into synthesis gas or liquid fuels. Challenges include improving efficiency and reducing byproducts through catalyst innovation. Recycling success depends heavily on the quality and quantity of waste PC, which is influenced by local waste management systems. Post-industrial waste is easier to recycle, while post-consumer waste presents challenges due to contamination and mixed materials. 28 POLYCARBONATES
- 29. REFERENCES 1. Polycarbonates by William F. Christopher, Daniel Wayne Fox 2. Ullmann's Encyclopedia of Industrial Chemistry 3. Chemistry And Physics of Polycarbonates by Hermann Schnell 4. Handbook of Polycarbonate Science and Technology by Donald E. Hudgin 5. Advances in Polycarbonates by Daniel J. Brunelle and Michael R. Korn 6. JACI Textbook, Introduction to GSC No.2, Novel Non-phosgene Polycarbonate Production Process Using By-product CO2 as Starting Material 7. Morphological, thermal, and mechanical properties of polypropylene/polycarbonate blend from Journal of Applied Polymer Science 8. https://laminatedplastics.com/polycarbonate.pdf 9. https://www.bpf.co.uk/plastipedia/polymers/Polycarbonate.aspx#grades 10. https://omnexus.specialchem.com/selection-guide/polycarbonate-pc-plastic 11. https://www.tridentplastics.com/a-quick-guide-to-polycarbonates-all-you-need-to-know/ 12. https://cdn.intratec.us/docs/reports/previews/pc-e11a-b.pdf 13. https://pslc.ws/macrog/pcsyn.htm 14. https://busscorp.com/industries/polycarbonate-compounds/ 15. https://www.americhem.com/pages/polycarbonate 29 POLYCARBONATES