Polyacetal (POM)

The material was produced by the polymerisation of formaldehyde, which was isolated by first Butlerv in
1859 in polymeric form. It was not commercially available until 1952.
The first commercially available acetal resin was marketed by Du Pont in 1952 under the trade name of
Derlin.
The Du Pont monopoly was usually shortlived as Celcon, as acetal copolymer produced by the
Celanese Corporation in 1960. It was commercialized in 1962. In the same year it was also available as
Hoste form from Farb Werke Hoechst Co. Germany.
In 1963, it was also available from Danippon celluloid Co., of Osaka, Japan and Imperial Chemical
industries (ICI), Britan when Celanese joined them. In the early 1970’s ultra form GmBH (A Joint
venture of BASF and Degussa) introduced copolymer under the name of ultra form.
In the early 1970’s Japanese Co., Ashai chemicals introduced the homopolymer under the name Tenal.
By the late 1990’s the main manufacturers where the American based Du Pont, the Japanese based
PolyPlastics and the European based Ticone. Among atleast 8 plants in Asia those of Mitsubishi Gas
and Ashai were significant as was also that of BASF.
 Monomer Ingredients for Polyacetal

Polyacetal is made from formaldehyde (HCHO).

Copolymer of polyacetal is made from trioxane, the cyclic trimer of formaldehyde
 Chemistry of Preparation of Polyacetal

Formaldehyde polymerise in the following ways,

1. The cyclic trimer (trioxane) and tetramer are

obtained by a trace or sulphuric acid on hot
formaldehyde vapor (type i)
2. Linear polymer with degrees of polymerisation of
about 50 and a terminal hydroxy group are
obtained by evaporation of aqueous solution of
formaldehyde (type ii)
3. In the presence of strong acid, the average chain
length may be doubled. Evaporation leads to
products (type iii)
4. In the presence of lime water more complex
reactions occur, leading to the formation of aldose
and hexose (type iv)
 Manufacturing of Polyacetal

heat
Pure Reactor
formaldehyde Cold trap
polymerization
150 - -15 ºc (impurities are
160ºc removed) in presence of Heptane,
Initiator, Stabilizer

1 2 3

Reaction leads to Filter was with

Poly Acetal Dried
20 % solid poly Acetal Heptane and
at 80ºc in vaccum
Acetone

4 5 6
 Relations of Structure and Properties of
POM

Due to structural similarity properties of acetal polymers are compared with those of
polyethylene.

Both polymers are linear with a flexible chain backbone and are thus both thermoplastic.

Both the structures are regular and since there is no question of tacticity arising both polymers
are capable of crystallization.

In the case of both materials polymerization conditions may lead to structures which slightly
impede crystallization; with the polyethylene, this is due to a branching mechanism, whilst with
the polyacetals this may be due to co-polymerization.

The acetal polymer molecules have a shorter backbone (-C-O-) bond and they pack more
closely together than those of polyethylene. The resultant polymer is thus harder and has a
higher melting point.
 Characteristics of POM
(for identification)

The characteristics of POM are,

The material is semicrystalline and maintain high dimensional stability and it is

sensitive to UV light
It is opaque
It is identified by the strong smell of formaldehyde, when burned, faint color flame,
melt and drips
Its melting point is 165-175°C
Its short term and long term service temperatures are respectively 160 - 140°C
and 90 - 100°C
 Characteristics of POM

Good appearance
Homopolymer is resistant to mid acids and bases
Good electrical properties but affected by moisture
Stiff and rigid
Good toughness
Notch sensitive
Excellent fatigue resistance under repeated load
Excellent creep resistance under continuous load
Low coefficient of friction
Good abrasion resistance
Maintains the mechanical, chemical and electrical properties over broad temperature
range and time
 Characteristics of POM

High resistance to thermal and oxidative degradation

Very good resistance to stress relaxation
Excellent dimensional stability
Good processability
Copolymers have better thermal stability
Burn slowly without smoke generation
Susceptible to UV degradation
Attacked by phenol and aniline
Difficult to electroplate
Degradation at high processing temperature and liberate formaldehyde
Structural difference between
homopolymer and copolymer
 Properties of Polyacetals
(special features)

The principal features of acetal resins leading to commercial application may

be summarized as follows.

Stiffness
Fatigue endurance
Resistance to creep
Low co-efficient of friction
Good appearance
Properties of Polyacetals
 Properties of Polyacetals

Mechanical Properties
The stress- Strain behaviour of polyacetal is such that it could be used to replace metallic
materials in many precision engineering applications.
Thermal Properties
Acetals have a heat distortion temperature in excess of 110°C and can be used in
applications upto this temperature intermittently.
However, acetal can loose strength and toughness after long exposure to hot
environments.
Homopolymers resist deterioration upto one and a half years at 82°C in air while the
copolymers may be used continuously at temperature upto 104°C in air.
Mouldings of acetal remain dimensionally stable over the recommended use temperature
range.
 Properties of Polyacetals

Electrical Properties
The electrical insulation properties of the acetal resins may be described as good but not
particularly outstanding.
However, application where impact toughness and rigidity are required along with good
electrical insulation characteristics they be used.
Water absorption
The water absorption of polyacetals is low, 15 mg after immersion for 24 hours and 30 mg
after 96 hours at 200° C.
Optical properties
Polyacetal moldings are translucent to white.
The light transmission of 2mm thick injection molded panels is 50%, the refractive index is
1.48.
The gloss of the moldings depends on the surface finish of the mold.
 Properties of Polyacetals

Permeability to gases and vapours

The permeability of polyacetal is very low compared with that of other plastics.
This applies to both aliphatic and halogenated hydrocarbons.
Polyacetal is resistant to fuel gases and is therefore suitable for use in gas fittings and
aerosol containers.
Chemical properties
Polyacetals are resistance to weak acids, weakly alkaline solutions (strongly alkaline
solutions only for copolymers), gasoline, benzene, alcohols, oils, grease, halogenated
hydrocarbons, water, detergents. They are not resistance to strong acids and oxidising
agents.
Polyacetals are not susceptible to stress cracking.
 Properties of Polyacetals

Weathering resistance
Polyacetals are damaged by UV radiation. Resultant changes in properties occur more
rapidly with smaller wall thicknesses. Degradation can be delayed by light stabilizers.
Active carbon black has proved to be the most effective stabilizer. Less effective are
organic light stabilizers used for natural or colored material.
Some pigmented grades exhibit good weathering resistance with added UV absorber.
Resistance to high energy radiation:- polyacetal molding should be used in situation where
the total radiation dosage exceeds approx. 3.104 kg-1 /3mrad. Yellowing and
embrittlement occur at higher dosages.

Flammability
As polymerization products of formaldehyde, polyacetals are flammable.
They burn with a weak bluish flame and drip.
After extinguishing or incomplete combustion there is a choking smell of formaldehyde.
Applications of Polyacetal

Appliances

Agriculture & Irrigation

Consumer Products

Industrial

Electrical

Plumbing & Hardware

 Applications of Polyacetal

Appliances: Housing for business

machine, gears, cams, friction pads,
rollers, pulleys, nuts, chain links and shelf
support brackets, detergent pumps,
refrigerator clips and brackets, bearing,
wear strips and instrument housing in
washers and dryers, spray nozzles and
soap dispensers in dishware's , bowls,
mixing blades and bearings in
counter-top appliance bodies, tops and
cups in water boilers.

Detergent pumps
 Applications of Polyacetal

Agriculture & Irrigation:

Pop-up sprinklers (nozzles
arms, gears, housing and
water ways),
pumps(housing, impellers,
pistons) metering valves,
tractor components (shift
lever housing, hydraulic
connectors, seed
applicators, bearings and
gears)

Shower
Gears
 Applications of Polyacetal

Automotive:
Fuel level indicators, pump
components, gas caps,
cooling fans, trip clips, color
co-ordinated bucket housings,
window cranks, shift lever
handles, knobs, lever and
mounting brackets,
instrumental cluster gears,
bearings, housing and dials,
exterior door pulls, mirror
housing and brackets

Automotive parts
 Applications of Polyacetal

Consumer Products :
Toys soap dispensers , combs, filter bodies and valves, aerosol containers and valves, pen and pencil
barrels and tips, mascara wands & containers, sprayer pumps, nozzles and pump components for
dental cleaners.

Lip stick holder Gear wheels Air curtain system

 Applications of Polyacetal

Industrial:
Valves, springs,
bearings, cams,
material handling
components such
as conveyors,
chain links gears,
pumps and hose
connectors

Conveyor Gears
 Applications of Polyacetal

Bearings, Bushes, Spools, Cams

 Applications of Polyacetal

Electrical:
Key tops pluggers,
switches, buttons,
cassette tape rollers and
hubs, base plates in
computer keyboards,
springs in telephones and
connectors in modular
components.

Laser mark part HVAC Control

 Applications of Polyacetal

Plumbing & Hardware:

Water –meters, cams, gears, dials and pressure plates, pressure regulator
valves, drapery and venetian blind guide rollers, furniture , casters, slid
plates and locks, tool holders, bearing in adapters, shower heads,
sprayers, garden hoses and nozzles, irrigation gates, impellers, pumps and
hangers.
 Blends of POM

Although unmodified polyacetals already have high inherent

toughness they exhibit a certain notch sensitivity. That is by
virtue of the stress concentration that arises, sharp notches
effect a substantial drop in impact strength.
Blending polyacetal with elastomer brings a noticeable
improvement not only in the notched impact strength, but
also in the ability to bear multiaxial impact loading.
 Blends of POM

Polyacetal/TPU
Among the elastomers, thermoplastic polyurethane have the greatest significance for the impact
modification of polyacetals. Such blends are formulated for extrusion, injection, blow, compression and
transfer moulding.
They show excellent processability, rigidity high impact strength, high fatigue, flexural and tensile
strength, low water absorbency and resistance to chemicals. Mostly contain 10-30 wt of TPU, and have
co continuous morphology for especially good performance.

Polyacetal/ Butadiene
Elastomers based on polybutadiene or poly acrylates are important modifiers.
The essential advantage of modification with polybutadiene is better cold impact strength.

Polyacetal/Acrylate
In the case of modification of polyacetal with polyacrylate the advantages are better heat aging and
better weathering.
 List of Manufacturers/Suppliers
of Polyacetal

Homopolymer

Copolymer
 Polyethylene Terephthalate (PET)

Linear polyesters were studied by Carothers during his classical researches for
development of Polyamides.
But it was Whinfield and Dicson who developed PET at Calico Printers Association,
England I 1941 (As Fibres, Terylene and Dacron and as Film, Melinex and My lar, with
the expiry of the basic ICI patents on PET there was considerable development in
terephthalate polymers in the early 1970’s.
More than a dozen companies introduced PBT as an Engineering Plastics during this
time.
The fiber in the name of Kodel and Film in the name of Kodar was developed by Kodak.
PET was also the basis of glass filled engineering polymer (Rynite) introduced by DuPont
in 1970’s. Towards the end of 1970’s PET was used for the manufacture of biaxial
oriented bottles.
 Monomer Ingredients for PET

The ingredients which are used for PET are ethylene glycol and dimethyl teraphthalate.

HO – CH2 – CH2 – OH Ethylene glycol

Dimetyl terephthalate
 Chemistry of Preparation of PET

The PET polymers is produced by the reaction of ethylene glycol and Terephthalic
acid or Dimethyl terephthalate in the presence of metal acetate catalyst. This process
is called ester exchange process.

In this process, a low molecular weight diester, known as the monomer is first
produced by reacting 1 mol. or dimethyle terephthalate with about 2.1 – 2.2 mol
ethylene glycol at 150°C in the presence of catalysts, such as antimony trioxide and
cobaltous acetate.
 Chemistry of Preparation of PET

In addition to this diester, di-2-hydroxyethyl terephathalte, some oligomers of following general

structure, are also produced.

HO-(CH2 ) 2 -O[O-C- O -COO-(CH2 ) 2 -O] n-H

When n = 1, 2, 3

Methanol formed during the condensation is removed using a distillation column. The monomer is then
heated to 270° - 280°C with removal of volatiles under reduced pressure down to 1 mm Hg. Heat and
vacuum are employed to increase the molecular weight with concurrent removal of volatile products
such as water /alcohol and glycol.

n CH3OOC - O - COO CH3 + n HO - CH2 - CH2 - OH

O O
- [C - O - C - O -CH2- CH2 - O -] n + 2n CH3 OH
 Manufacturing of PET

PET Polymers are manufactured by a stage-wise melt polymerization process consists

of trans esterification, pre-polymerization and finishing polymerization steps.

Continuous melt poly condensation process for PET manufacture.

 Manufacturing of PET

In the transesterification stage dimethyl temphthalate (DMT) or terephthalic acid (TPA) is converted into
bishydroxy ethyl terephthalate in the presence of metal acetate catalyst.
Ethylene glycol (EG) DMT, and catalyst are fed at a molar ratio of 1.7 to 2.0:1 (with TPA this ratio is 1-3
to 1.5:1) and a temperature of 100-180°C. This stage takes 3-4 hr.
The reaction byproduct methanol (Water When TPA) is used is separated from EG vapors in a reflux
column.
After adding stabilizer and additives, the prepolymer is forced through a superfine fitter to the second
(pre-poly condensation) stage.
The poly condensation reaction is performed under vacuum (15-25 torr) and elevated temperature.
(280 – 300°C).
The resulting EG is removed by a vacuum pump while the prepolycondensation product – a low
molecular weight (DP= 30) relatively non-viscosity material (40 poise) is pumped to the finishing poly
condensation stage after a residence time of about 2 hrs.
 Manufacturing of PET

The finishing polymerization stage, which is operated at 0.5 – 1 torr, requires special wiped film or
extruder type reactor in order to handle the high viscosity of the polymer ((DP = 100), few thousand
poise).
Many manufacturer have devised their own proprietary agitation systems to minimize the build-up of
the solidifying polymer layers.
The EG vapours contaminated with oligomers are drawn off through a special condensing system and
sent to a recovery unit
The polymers melt can be sent to a direct spinning plant or transformed into pellets.
 Relations of Structure and Properties of
PET

There are various classes of linear polyesters.

The concentration of ester groups has predominant effect on the properties of linear
polyesters.
For the aromatic classes of linear polyester, decreasing the concentration of ester groups
apparently leads to a reduction in melting point.
However, in such aromatic linear polyester the decrease in concentration of ester group is
accompanied by the p-phenylene group concentration.
It is found from aliphatic polyester that the ester group concentration has little effect on the
melting point.
In fact a decrease in ester group concentration leads to a slight increase in the melting
point.
 Relations of Structure and Properties of
PET

It is found that in an ester group the in chain ether link –C-O-C- increase the chain
flexibility compared with a polyethylene chain to decrease the heat of fusion.
At the same time there will be some increase in inter chain attraction via the carbonyl
group which will decrease the entropy of fusion.
Since these two effects almost cancel each other out there is almost no change in ester
group concentration.
With all linear series of polyester as the no. of methylene groups in the repeating unit
increases so the polymer becomes more like a linear polyethylene (polymethylene).
 Relations of Structure and Properties of
PET

It is also observed that Tm (melting point) of a polymer with an odd no. of methylene
groups in the aliphatic portion of the repeat unit is lower than for the polymer with one
more but an even no. of methylene groups.
Generally, the highest melting points are obtained where the in-chain aromatic ring is of
the p-phenylene type.
The materials have a disadvantage of sensitivity to water and alkaline solution.
These materials are crystalline and only proton donors that are capable of inter action with
the ester groups are effective solvents.
 Characteristics of PET (For
Identification)

The PET is a semicrystalline material, normally amorphous with low crystallinity and high
transparency.
It is identified by sweet smell, when burns, orange flame, soot forming and melt drips.
It is scratch resistant
Melting point is 220°C
It is having short and long term thermal limit temperature respectively 135°C and 100°C
 Characteristics of PET

Outstanding chemical resistance to organic and inorganic liquids

Water repellent
Sterilizable by ethylene oxide and X-rays
Inherent good electrical property
Ability to orient
Good tensile strength
Superior strength and stiffness
Excellent dimensional stability
Excellent melt strength with slower crystallization rate
Good impact strength even at low temperature
High tear strength
Heat resistant
Flame retardant
Outstanding clarity
High gloss
OSDP Properties of PET

Properties Units Values

Specific gravity ---- 1.40
Tensile strength MPa 51
Tensile modulus MPa 175
Flexural modulus Mpa 204
Elongation at break % 7
Impact strength izod, Notched, kg.cm/cm 9.25
Hardness R 105
0
Deflection temperature under load C 205-210
(1.82 Mpa)
Vicat softening point °C 75
0
Coefficient of linear expansion mm/mm/ C 6.0 x 10-5
Water absorption, 24hrs % < 0.1
Refractive index 1.62
Dielectric strength KV/mm 26
Dielectric constant 10-6 Hz 3.3
Power factor 0.03
Volume resistivity Ohm.m 1013
0
Melting point C 265
Glass transition temperature °C 67
OSDP Properties of PET

Mechanical Properties
PET exhibits a high modulus up to 75°C, when it is crystalline and 40°C, when it is amorphous even when
they are mechanically stressed for a long period.

Thermal Properties
PET has excellent dimensional stability.

Electrical Properties
PET has high dielectric strength and high volume resistivity. The dielectric properties are adequate for
many electronics applications.

Water Absorption
PET is hygroscopic and in its melt states the resin hydrolyses.

Optical Properties
The light transmission of PET differs greatly according to chemical composition.
 Properties of PET

Permeability to water vapour and Gases

PET is less permeable than PVC-U.
The permeability of film is 40µm/1.58 mil.
The permeability to water vapour is higher than that of the polyolefins but lower than that of PC, PA,
POM. PET films are largely odor-proof which leads to their frequent use in packaging materials in
combination with PE films.

Chemical Properties
PET is resistant to weak acids and alkaline solutions, oils, fats, aliphatic and aromatic hyrocarbons,
carbon tetrachloride.
It is not resistant to strong acids and alkaline solutions, phenol, long exposure to hot water.
The crystalline polyalkyle terephthalates are susceptible to hydrolysis which precludes their use in
aqueous solution temperatures above 70°C for in steam.
PET does not show any pronounced tendency to stress cracking.
 Properties of PET

Weathering Resistance
The relatively high resistance to weathering can be increased by the use of carbon black to protect against
UV.

Resistance to High energy Radiation

PET is relatively resistant to high energy radiation. It is degraded more strongly only at absorbed energies of
more than 100 KJ/ Kg. After 7 to 8 MJ/Kg it decomposes into powder.

Flammability
PET burns with a sooty orange-yellow flame, it drips and smells sweetly aromatic. Flame retardant grades
donot drip and meet the requirements of UL 94 V-0.

Toxicity
PET is suitable for applications involving contact with food stuffs and is physiologically inert.

Sterilization
PET can be sterilized in an ethylene oxide atmosphere or by irradiation.
 Applications of PET

Appliances

Automotive

Electrical/Electronics

Films

Furniture

Packaging

Miscellaneous
 Applications of PET

Appliances :
Oven and appliance handles, coil forms for microwave oven transformers,
small appliance structural framers, panels, chassis and housing and
instrument covers.
 Applications of PET

Automotive:
Structural parts such as luggage racks and grills, fuctional housing such
as windshield, wiper motor housing , fuel filters, blade supports and bells,
sensor, lamp sockets, relays, switches and solenoids

Grill opening retainer

Door module
 Applications of PET

Electrical/Electronics:
Lamps sockets , coil forms for audio/video transformers, terminal blocks,
electrical. Electronic connectors and thrust washers.

Electricals Connectors
 Applications of PET

Films:
X-ray films, photographic films, magnetic tapes and printing sheets.

Food packaging
 Applications of PET

Furniture:
Pedestal bases, sent pans, chair arms and castes.
 Applications of PET

Packaging :
Carbonated soft drink containers, distilled spirits, toiletries, food products,
mustard, pickle foods, peanut butter, spices, edible oil cocktail mixer and
syrups.

Containers
 Applications of PET

Miscellaneous:
General purpose pumps housing , mirror housings three dimensional circuit boards and
structural components in office automation equipment, computer housing and structural
components, containers, trays, blisters and drinking cups.

Automobile engine cover Heat shield Door washers

Gear box
 POLYCARBONATE (PC)

Polycarbonates are polyesters of carbonic acid.

Although carbonic acid itself is not a stable compound, its derivatives (phosgene, urea,
carbonates) are commonly available.
The reaction of gaseous phosgene with bisphenol A gives rise the formulation of
commercial polycarbonate.

Repeat unit of Polycarbonate

 History of development

PC was first prepared by Einhorn in 1898 by reacting the hyroxy benzenes, hydroquinone
and resorcinol separately with phosgene in pyridine solution.
In 1920 similar kind of product was prepared by Bischoff and Von Heden storm with the
use of diphenyl carbonate.
In 1930 Carothers and Natta prepared a number of aliphatic polycarbonates using ester
inter change reaction.
In 1956 Herman Schnell of Farben Fabriken Bayer and D.W. Fox of GE independently
produced PC from Bisphenol A and Phosgene.
In 1958 production of Bisphenol, a polycarbonate was started simultaneously by GE Co.
both in Germany and USA from Bisphenol A and phosgene.
Today about 75% of the market is held by General Electric and Bayer.
Other manufacturers are ANIC (Italy), Taifin Chemical Co.,Mitsubishi Edogawa and
Idemitsu Kasei in Japan and since in 1985, DOW (USA) do Polycarbonates in Brazil.
 Monomer Ingredients for PC

The PC is made from Bisphenol A and Phosgene (COCl2).

Phosgene is prepared commercially from carbonmonoxide and chlorine.
Bisphenol A can be produced by the condensation of phenol with acetone under acidic
conditions.

COCl2
Phosgene
 Chemistry of Preparation of PC

Poly (bisphenol – A-carbonate) or PC, is a condensation product of bisphenol A, a

carbonate precursor such as phosgene or diphenyl carbonate and a monophenol chain
terminator such as phenol [11] or 6-butyl phenol. The structure of PC is given below :

Normally the following reaction takes

place in the base medium.
OSDP Manufacturing of PC

Poly carbonates are commercially produced by either interfacial polymerization or melt

polymerization.
The solution process, which was once a major commercial process is no longer used in
industry because of its inferior economics.

Interfacial Polymerization

Transesterification Processes
(melt polymerization)
 Interfacial Polymerization

The interfacial polymerization of polycarbonates involves a reaction of BPA (Bisphenol A) with

phosgene at the interface between an inert organic methylene chloride solution and an aqueous caustic
solution.
The reaction takes place in two steps. First, phosgene reacts with BPA to form monochloroformates.
Then the poly condensation takes place between BPA hydroxyl groups and chloroformates in the
presence of triethylamine as a catalyst, yielding the polymer that remains dissolved in the organic
phase.
During the polymerization, the by-product (hydrochloric acid) reacts with aqueous caustic phase to form
sodium chloride.
After the polymerization, the organic polymer solution is separated from the aqueous phase and
purified.
The polymer is recovered from the purified polymer solution by precipitation or evaporation.
The solid polymer is crushed and extruded into pellets.
The interfacial polymerization can be conducted by batch or continuous reactors.
 Batch polycarbonate polymerization
process

Schematic of a typical batch polycarbonate polymerization process is given below.

 Batch polycarbonate polymerization
process

Gaseous or liquid phosgene is pumped into a well – stirred reactor containing BPA in an
organic aqueous dispersion.
Aqueous sodium hydroxide is added during reaction to maintain an alkaline PH.
A molecular weight regulator, most often para-tert –butyl phenol or phenol is added to the
reactor to inactivate some of the end groups in the oligomer carbonates.
At the end of polymerization, the polymer containing organic phase is separated and
washed to remove the catalyst and impurities such as sodium chloride.
The washed solution is then concentrated by flashing and is passed through a
devolatilizing extruder to produce a molten ribbon, which is then cooled and chopped into
pellets.
In the continuous process, multiple tubular reactors in series or a cascade of stirred tank
reactor is used.
In this process, oligomeric chloroformates are produced by the phosgenation of BPA prior
to polycondensation in the presence of a catalyst.
Polymerization condition for batch /
continuous processes
 Trans esterification Processes

Conventionally, the polymer is produced by, transterifying diphenyl carbonate with BPA
in the presence of a catalyst such as a sodium salt of BPA. Monophenyl carbonate of
BPA is formed first.
It reacts further to produce oligomers having phenoxy and hydroxy end groups. The
oligomers are then poly condensed to give poly carbonate.
During the polymerization, the reaction temperature is kept above the melting point of
the reaction mass, initially about 150°C.
It is increased in steps to a final temperature of 30°C. Meanwhile, the pressure is
reduced also in steps from an initial 760 torr to less than 1 torr at the final stage of the
polymerization.
During the high temperature low pressure polymerization, the viscosity of
polycarbonates increases dramaticallyand specially designed extruder type reactors are
required to finish the poly condensation.
 Schematic process flow diagram of a continuous
melt polycarbonate polymerization process

Continuous melt polymerization process of polycarbonate.

 Relations of Structure and Properties of PC

A study of the molecular structure of bis-phenol A polycarbonates enables one to make

fairly accurate prediction of the bulk properties of the polymer.
The relevant factors to be considered are:

a) The molecule has a symmetrical structure and therefore questions of stereo

specificity do not arise.
b) The carbonate groups are polar but separated by aromatic hydro carbon groups.
c) The presence of benzene rings in the chain restricts flexibility of the molecule.
d) The repeating unit of the molecule is quite long.

Because of its regularity it would be expected that the polymer would be capable of
crystallization.
In practice, however, the x-ray pattern characteristics of crystalline polymer is absent in
conventionally fabricated samples.
 Characteristics of PC
(For identification)

The characteristics of PC are,

The PC is amorphous material

It is having good impact resistance and it is sensitive to stress cracking
Its glass transition temperature is 145°C
Short term and long term service temperatures are 135°C and 100°C
respectively
It is identified by transparency, orange yellow flame, soot forming, self
extinguishing, melts but chars
It smells phenolic during burning (ink smell)
 Characteristics of PC

High clarity
Good stain resistance
Low haze
Easy colourability
Transmission rate is between 86 to 89%
Good bio-compatibility
High heat deflection temperature
Chemically resistant to organic and inorganic liquids
Flame resistance
Non-toxic
Self extinguishing in nature
Good insulator
Limited scratch resistance
Dielectric constant is independent of temperature
Notch sensitive
High corrosion resistant
Hygroscopic in nature
High creep resistance over board temperature range
Turns yellow when exposed to UV light for
Excellent toughness
a long period of time
Dimensionally stable
Crazing occurs when exposed to water at
Very good impact resistance at small thickness
elevated temperature
Good property retention upto-20°C
Properties of Polycarbonate
Mechanical Properties Thermal Properties

PC is distinguished by its high deflection

The material has temperature.
high strength, 135°C for unreinforced and
high stiffness, over the 145°C for reinforced plastics.
high hardness and range from
–150 to
high toughness
+ 135°C
 Optical Properties

The refractive indices of PC lies in the range of 1.56 to 1.65, which is high for
transparent plastics.
The refractive index of Bisphenol A based PC falls from 1.53 at - 20°C to 1.56 at +200°
C.
In the region of the glass transition temperature of about 145 °C a sharp bend occurs.
Transparency at 85 to 90% is reached in the region of visible light.
 Weathering Resistance

Weather resistant and light stabilized grades are suitable for

many years of outdoor use.
The highest UV protection is provided by surface treatment.
 Applications of PC

Appliances
Automotive
Electrical & Electronics
Food contact articles
Medical
Optical
Miscellaneous
 Applications of PC in appliances

Coffee filters, shaver housings, chocolate moulds, blenders, tablewares, kitchen mixer
bowls, grinder bowls, housing for ball point and fountain pens, rim heater grills, motor
bracket and housing, camera, binocular casings, housings for hair dryers and coffee
makers, water tank for steam iron, films for labels and memory switches, fruits juicer
parts, high impact vacuum sweeper housing, mixers and power tools, bobbins for
textile industries, baby feeding bottles and cutlery

Hair dryer housing Business machine covers

 Applications of PC in Automotive

Wind screen wiper brackets, car interior moulded trims, instruments glazing, indicator
lamps, wind shields for two wheelers, door handles, tail and side marker lights, PC
blends in instruments, panels as well as bumpers, wheel cover and body panels
protective hoods, fan wheels, components for sewing machines, chaises, levers,
valves, control cams, directional signs, heating grill, ventilators and radiator grills,
overrides, fuse box & covers and housing for automobile & aerial motors.

Cover for Tail lamps

List of Manufacturers/Suppliers
of PC
 Thermoplastic Polyurethane
Elastomers (TPU)

Polyurethanes are characterized by the presence of urethane linkages

- CO-NH-(R)-NH-CO-O- (R’)-O-
Urethanes are reaction product of a diisocyanate and diols
Abrasion resistance of the urethane is outstanding among elastomers
 TPU-Structure and properties

Polyurethane consist of hard and soft segments

The hard segments control the rigidity and strength - Diisocyantes- MDI,
HMDI
The soft segment controls low temperature properties solvent
resistance and weathering - polyesters, polyethers
 TPU-Additives

Mold release agents are the most commonly employed additives

Polyester based TPUs are stabilized by aromatic carbodiimides
Sterically hindered phenols, amines are used against degradation by
light, oxidation
Friction can be reduced by the addition of graphite's, silicone oil,
fluorinated hydrocarbons
Calcium carbonate, organic fibers and glass fibers are used as
reinforcing fillers
 TPU-Synthesis

Thermoplastic polyurethanes are made by mixing the isocyantes and

alcohols at temperatures above 80 C. for optimum results, the ratio of
isocyanate groups and alcohol's ,should be close to one.
 TPU-General characteristics

High tensile strength Good chemical resistance

Excellent tear resistance
Excellent flex life
Excellent abrasion resistance
High scratch resistance
Easy printability
Good thermal properties
Low gas permeability
Excellent low temperature resistance
Good migration resistance
good ozone resistance
 TPU applications

Automotive- exterior body parts, automobile interiors, body side

mouldings, fender extensions etc.,
Electrical/electronics - wire and cable jacketing, hose jackets, sheets,
cable cores & seals etc.,
films and sheets- adhesive film fro garment labels, conveyor belts,
gaskets etc.,
Tubings - air instrument tubing, blood tubing, dental tubing, fuel hose
jackets etc.,
TPU-availability