What Is Polycarbonate Used For?

Polycarbonate is a high-performance thermoplastic used in a wide range of industries for its strength five times greater than ABS, impact resistance, and glass-like transparency. In construction, it is often used to make durable light panels. In electronics, polycarbonate is used in the production of mobile phone housings, laptop housings, and compact discs. It is also widely used in automotive parts, such as headlight covers and instrument panels, due to its heat resistance and malleability. However, polycarbonate is susceptible to scratching and exhibits poor chemical resistance, and the product surface usually requires a protective coating.

Advantages of Polycarbonate

• High Transparency

Polycarbonate has a high transparency close to that of glass, with a light transmittance of 88-91%, making it suitable for use in protective covers, lighting covers, and optical lenses to provide clear visibility.  

• High Impact Resistance

Its impact strength is approximately 200-250 times that of glass, effectively preventing shattering and breakage, so it is widely used in personal protective equipment (PPE), such as safety masks.  

• High Heat Resistance

Polycarbonate can maintain a stable shape at temperatures above 120°C and does not easily soften or deform, making it suitable for use in electrical equipment housings and automotive parts.  

• Lightweight and High Strength

Compared to glass, polycarbonate is about 50% lighter, making it easier to transport and install while maintaining excellent mechanical strength.  

• High Electrical Insulation

Polycarbonate has high dielectric properties to prevent current leakage and is used for relay housings in electronic equipment to ensure safe operation.

Disadvantages of Polycarbonate

• Flammability Limits Application Scenarios

Untreated polycarbonate burns easily at high temperatures or in open flames, and it is difficult to completely prevent combustion even with the addition of flame retardants. Special care is required when using electrical appliances in high-temperature environments. Because of the risk of combustion, polycarbonate is limited in its use as a fire-resistant material in buildings and as an enclosure for electrical equipment.

• Sensitive to chemicals

Polycarbonate is susceptible to corrosion, discoloration, or cracking by certain chemicals, such as alcohol and detergents. In daily life, repeated wiping of PC phone cases with alcohol wipes will lead to fogging. In industrial environments, prolonged exposure to detergents or chemicals may cause material deterioration, which can affect service life. This chemical intolerance limits its application in the chemical industry.

• Higher costs limit large-scale applications

Polycarbonate is more expensive to produce and process than common plastics such as ABS or PVC. Despite its excellent performance, its use is limited in cost-sensitive, high-volume production projects. In areas such as disposable products like single-use cutlery or inexpensive consumer goods like coat hangers, polycarbonate is often not preferred.

• Questionable food contact safety

Some polycarbonates contain bisphenol A (BPA), a chemical that can be released at high temperatures and poses a potential risk to human health. Therefore, this has reduced the use of polycarbonates in food containers, hot water cups, and other products for the food industry.

Applications of Polycarbonate

• Automotive Applications

In automotive manufacturing, polycarbonate is widely used in headlight covers, instrument panels, and windows due to its excellent clarity and durability. Additionally, polycarbonate is used in automotive interiors and windshields to improve fuel efficiency through weight reduction and to enhance the vibration resistance of parts.  

• Electrical & Electronic Components

Polycarbonate's electrical insulation and heat-resistant properties make it an ideal material for use in electrical and electronic applications. It is used in power supply housings, socket panels, and connector shields to prevent current leakage.  

• Consumer Goods

In the consumer goods sector, polycarbonate is favored for its durability and aesthetics. It is used in the production of mobile phone housings and sports water bottles, offering a clear, transparent appearance and scratch resistance. In addition, polycarbonate is used in tool handles, children's toys, and sports equipment to ensure lightweight and impact-resistant products

Plastics Similar to Polycarbonate

• ABS

ABS has impact resistance, good processability, easier injection molding, lower cost, and is suitable for mass production, such as miniature figures, appliance housings for printers, and other consumer electronics. ABS has lower impact strength, especially at low temperatures where it tends to become brittle. Heat resistance and transparency are not as good as PC. The heat distortion temperature of ABS is usually around 90-100°C. The material is typically opaque, while PC is available in highly transparent models.

• PMMA

PMMA, also known as acrylic, is high transparency and weather resistance make it suitable for outdoor applications.It excels in outdoor applications such as billboards and lighting diffusers. PMMA's light transmittance is even higher than glass at 92%. However, PMMA has poor impact resistance and is susceptible to shattering and cracking, making it unsuitable for use in safety guards or applications subject to heavy pressure. In cases where high transparency but not high impact resistance is required, acrylic is usually used, such as display cabinets and billboards.Acrylic is superior to PC in terms of scratch resistance. Additionally, acrylic is less heat resistant, with a heat distortion temperature of about 90°C.  

• PEEK

PEEK is a high-performance engineering plastic that is superior to polycarbonate in terms of heat resistance and mechanical strength. It can withstand up to 260°C continuous working temperature and has excellent chemical resistance and abrasion resistance. Processing is more difficult and requires high-temperature processing equipment, resulting in higher costs. It is mainly used in the oil and gas industry for seals and other high-end industrial applications.