How Can Polycarbonate Sheets Be Manufactured In Plants?

Polycarbonate (PC) is a thermoplastic polymer and a strong and tough material. It can be easily moulded and thermoformed and is used in various applications. It is a polymer that contains carbonate groups in its structure and is therefore called polycarbonate.

PC is formed by the reaction of Bisphenol A (BPA) and Phosgene. It can be formed into tubes, rods and sheets depending on the manufacturing method used. The most common method used to make polycarbonate parts is injection moulding. As it is a thermoplastic, it can be easily processed and formed at room temperature using sheet metal techniques.

The material is amorphous and highly transparent to visible light and offers good light transmission. Though it has a low scratch resistance therefore a hard coating is applied to it when used in different applications.

PC is strong and can hold up longer in extreme temperatures. It has a glass transition temperature of 147° C and softens above this.

PC grades with a lower molecular mass are easy to mould but they have less strength. Higher grades have high molecular mass and are tough but they cannot be moulded easily.

Polycarbonate sheet

Manufacturing process

Extrusion

This process is used for making parts with a fixed cross-section. The molten material is forced through the die of the desired cross-section. This process can be used to make parts with complex cross-sections. 

This process can be continuous and produce infinitely long material or semi-continuous and produce many pieces. It can be done with hot or cold material depending on stability. The process creates an excellent surface finish.

The process begins by adding the material to a barrel and heating it. The heated material is then moved to the container in a press. A ram is used to push the material through the die.  The material fuses to create the desired shape. 

This process is used to make tubes, rods and multiwall profiles. To make polycarbonate sheet and films the extrusion process is done using cylinders. A cylinder is a series of hard pressure rollers which are used to smooth out the sheet of material.

Applications

• PC is mainly used in electronic applications because it is a good electrical insulator, heat resistant and has good flame retardant properties. It is used in telecommunications hardware and power systems. 
• The second largest use of PC is in the construction industry. It is used to make dome lights, flat or curved glazing, roofing and sound walls.
• Another main PC market is the data storage market, PC is used to make compact discs, DVDs, and Blu-ray discs. 
• It is used in 3D printing to make durable and strong products that have a high melting point.
• It is commonly used to make moulded drinking bottles, food containers and glasses.