聚碳酸酯PC的注塑成型指南【全中文】
[ 点击下载 ]什么是聚碳酸酯What is Polycarbonate?
Polycarbonate is a transparent amorphous polymer which exhibits outstanding physical properties such as outstanding impact resistance (almost unbreakable), heat resistance up to 125°C and excellent clarity, although opaque and translucent grades are also available.
As attractive as this plastic is, it has demonstrated a seemingly inexhaustible potential for innovation. New applications are developed every year.
Polycarbonate is often used to replace glass or metal in demanding applications when the temperature does not exceed 125°C
All of these highly interesting properties are available in Makrolon®, polycarbonate produced by Bayer.
If you need TRANSPARENCY, TOUGHNESS and HEAT RESISTANCE UP TO 125°C, Makrolon® is the right choice for you!
好处外观Appearance
In order to survive in today
's competitive environment manufacturers increasingly emphasize product differentiation by sophisticated design and eye-catching appearance. It is clear that in some markets design can make or break a product.
Our limit is your creativity!
Easy to color Makrolon® polycarbonate, offers designers infinite possibilities of colors, hues and effects from crystal clear to translucent and opaque. Makrolon® gives designers greater shape, texture and coloration freedom rather than traditional material such as glass.
光学透明Optical Clarity
Due to its excellent clarity and purity combined with its outstanding toughness, Makrolon® can fulfill most needs in applications requiring high transparency. Typical applications are automotive lighting and glazing, corrective lenses, building and construction glazing, safety equipment (glasses), and CD/DVD
's.
Lighter and tougher than glass, Makrolon® stands out as the perfect choice for glass replacement
Figure 1: below shows the Transmittance as a function of wavelength (250900 nm) of Makrolon® 2805 grade
Figure 2: below shows Luminous transmittance as a function of wall thickness of Makrolon® 2805 grade
Makrolon® Optically clear grades
Optical storage media
光学储存介质DP1-1265 Global grade; MFR 73 g/10 min; Low viscosity; Easy release; Injection molding; Available in natural color only; Digital Versatile Disc (DVD)全球级；熔指73g/10min；低粘度，易脱模；适合注塑；只以本色供应；适合作DVD。
CD2005 Global grade; MFR 64 g/10 min; Low viscosity; Easy release; Injection molding; Available in natural color only; Compact Disc (CD) 全球级；熔指64g/10min；低粘度，易脱模；适合注塑；只以本色供应；适合作CD。
Optical lens光学透镜
LQ2647 MFR 13 g/10 min; Medium viscosity; UV stabilized; Easy release; Injection molding; Available in clear tints only; Safety glasses熔指13g/10min；中粘度，紫外光稳定；易脱模；适合注塑；只以透明染色供应；适合作安全眼镜。
LQ3147 Global grade; MFR 6.5 g/10 min; High viscosity; UV stabilized; Easy release; Injection molding; Available in clear tints only; Ophthalmics全球级，熔指6.5g/10min；高粘度，紫外光稳定；易脱模；适合注塑；只以透明染色供应；适合作眼科矫正镜。
LQ3187 Global grade; MFR 6.5 g/10 min; High viscosity; UV stabilized; UV 400 cut off; Easy release; Injection molding; Available in clear tints only; Safety glasses; Sun glasses全球级，熔指6.5g/10min；高粘度，紫外光稳定，能滤去波长400的紫外线；易脱模；适合注塑；只以透明染色供应；适合作安全眼镜和太阳镜。
Automotive lighting
汽车照明AL2447 Global grade; MFR 20 g/10 min; Low viscosity; UV stabilized; Easy release; Injection molding; Available in clear tints only; Headlamp lenses for automotive forward lighting全球级，熔指20g/10min；低粘度，紫外光稳定；易脱模；适合注塑；只以透明染色供应；适合作汽车前灯。
AL2647 Global grade; MFR 13 g/10 min; Medium viscosity; UV stabilized; Easy release; Injection molding; Available in clear tints only; Headlamp lenses for automotive forward lighting全球级，熔指13g/10min；中粘度，紫外光稳定；易脱模；适合注塑；只以透明染色供应；适合作汽车前灯。
Automotive glazing
汽车窗玻璃AG2677 Global grade; MFR 13 g/10 min; Medium viscosity; UV stabilized; Easy release; Injection molding; Available in transparent colors only; Automotive glazing; Roof modules全球级，熔指13g/10min；中粘度，紫外光稳定；易脱模；适合注塑；只以透明颜色供应；适合作汽车窗玻璃；顶窗。
冲击强度Impact Strength
One clear benefit of Makrolon® is its outstanding impact strength
An almost unbreakable Makrolon® out-classes all transparent polymers available in the market with such products as PMMA, Styrenics and PSU. This performance makes it a material of choice in applications needing impact resistance.
Toughness combined with transparency and high temperature resistance make polycarbonate a perfect candidate for demanding transparent applications where safety is critical.
Lighter and tougher than glass, Makrolon® stands out as the perfect choice for glass replacement
If you want to replace glass or metal or to develop an application requiring high impact strength:
Ask for Technical Assistance
Example of applications requiring high toughness需要使用高韧性的应用示例
Figure 1: below compares the toughness of various transparent materials used for glass replacement. (Data compiled by SpecialChem)
耐热Thermal Resistance
Makrolon® is an amorphous polymer with a glass transition around 150°C. This makes Makrolon® suitable for high heat applications up to 125°C including steam sterilization.
Makrolon® stands out as an excellent choice for metal and glass replacement for service temperatures that do not exceed more than 125°C.
For continuous service temperatures up to 150°C, use high heat polycarbonate Apec®.
Typical applications are: Automotive lighting, sterilizable/ reusable bottles, medical equipment and instruments, kitchen utensils, and small appliances.
Figure 1 : below compares the maximum service temperature of various transparent polymers. (Data compiled by SpecialChem)
可接触食品Food Contact
Some specific Makrolon® polycarbonate grades are suitable for food contact applications. They can be used in packaging applications and consumer goods such as water dispenser tanks, sterilizable bottles (orange juice or milk), and kitchen equipment and utensils.
Light, tough, transparent and easy to process, Makrolon® is an excellent alternative to glass in food contact applications
If you want to replace glass or metal or to develop an application requiring food contact:
Ask for Technical Assistance
Makrolon® FDA Grades
阻燃Flame Retardancy
Markets such as Electrical & Electronic and Construction require flame-retardant materials.
As opposed to other transparent polymers, Polycarbonate glazing meet NF P92 510 M1.
Flame-retardant FR materials that comply with Electronic & electrical requirements are also available.
If you want to replace glass, metal or to develop an application requiring a flame retardant material:
Ask for Technical Assistance
Makrolon® FR grades
耐候能力Weatherability
Like most polymers, polycarbonate is sensitive to UV light and tends to haze or to discolour upon exposure. However, with appropriate UV stabilization Makrolon® polycarbonate is perfectly suitable for outdoor conditions.
UV stabilized Makrolon® exhibits excellent weatherability and can be used in demanding applications such as construction and automotive glazing or automotive lighting where durability is critical.
The effect of appropriate UV stabilization is illustrated in Fig. 1 by a reduction in the increase in the yellowness index.
After 10 years of exposure to outdoor weathering, UV-stabilized Makrolon® test samples with a thickness of 4mm can be expected to show a reduction in luminous transmittance of around 8%.
生物相容性Biocompatibility
Some Makrolon® grades are suitable for medical applications. They comply with ISO 10993-1** and the US Pharmacopoeia, Class VI, and Makrolon® can be sterilized by steam at 120°C or by Ethylene oxide gas or by Gamma irradiation.
Makrolon® Biocompatible Grades
好的电气性能Good Electrical Properties
With good electrical properties and the possibility to have flame retardant grades, Makrolon® is suitable for electrical parts such as sockets, plugs, connectors and enclosures.
Makrolon® is UL listed for electrical applications
If you want to replace glass, metal or to develop an application requiring electrical resistance:
Ask for Technical Assistance
Typical Electrical performances
values are listed below.
替代玻璃解决方案Glass Replacement Solutions
Check out our selection of case studies featuring technical and design solutions for glass replacement offered by Makrolon®. All selected solutions have been implemented by designers or product engineers.
透明、易染色的韧性电子壳体材料Transparent, easy to color and tough material for electronic housings
市场Markets: 电子Electronics
聚合物Polymer: 聚碳酸酯Polycarbonate, Makrolon®
主要功用Key performances:
透明Transparency
韧性Toughness
易染色Easy coloration
低收缩Low shrinkage
Bright colors and transparency used for product differentiation
In markets such as electronics, design and differentiation has become essential for commercial success. Manufacturers put a lot of emphasis on appearance and try to move away from traditional black and opaque design. Transparency and bright color is a clear trend initiated a few years ago by a famous computer manufacturer.
For enclosure applications, the material needs to exhibit excellent toughness, good stiffness and easy colorability. Traditional transparent polymers often lack toughness.
Easy to color, tough, Polycarbonate is ideal for modern designs and
"schock proof
"equipments
By selecting Makrolon® 2405 for the housing, in the transparent pop colors of red, yellow, green and blue, users were able to see through to the technology inside - which then became part of the design.
In contrast to other polymers, such as PMMA, SAN or PS, Makrolon® 2405 fulfils the mechanical and electrical requirements without any problems. A further advantage of Makrolon® is its shrinkage
values, which come very close to those of ABS. Housing production was thus continued on the mould designed for ABS without the need for any further measures.
打不破聚合物提高玻璃作镜片和光学器件Unbreakable polymer for glass replacement in lenses and optical applications
市场Markets: 光学Optics
聚合物Polymer:聚碳酸酯 Polycarbonate, Makrolon®
关键功用 Key performances:
光学透明Optical Clarity
韧性Toughness
高断裂强度High fracture strength
省重量Weight savings
New Generation Glass frames require tough and light materials for lenses
For comfort, design and safety reasons, materials used for lenses need to exhibit high optical clarity, low density and outstanding toughness. High fracture resistance is particularly required for specific frameless models due to the necessary holes being drilled through lenses. These holes are generally weak areas concentrating stress and initiating cracks. Superior toughness is also beneficial for childrens and sport models for safety reasons.
For glass replacement, PMMA has been used for a long time, however, toughness is sometimes insufficient to meet new design requirements.
Light and unbreakable, Makrolon® stands out as the perfect choice for glass replacement
The overriding advantage of correction lenses in Makrolon® is their high fracture strength, which means they offer maximum safety. They are thus particularly suitable for children as well as for sportsmen and sportswomen. Lenses in Makrolon® also only weight half as much as lenses in glass, making then particularly comfortable to wear.
Compared with standard grades of Makrolon®, the LQ grades offer even greater purity and light transmission. They also incorporate UV-protection which filters out most of the UV radiation harmful to the eye (up to 380 nm).
Recommended Grades for Lenses
用PC替代玻璃作汽车前灯省重设计灵活Glass replacement by polycarbonate allows weight saving and design flexibility in automotive headlamps.
市场：Markets:汽车照明 Automotive-Lighting
聚合物Polymer: 聚碳酸酯Polycarbonate, Makrolon®
关键功用Key performances:
透明Transparency
韧性Toughness
省重Weight savings
设计灵活Design flexibility
Weight saving and design flexibility drive glass replacement in automotive headlamp lenses
Manufacturing costs and reliability has always been concerns in the automotive industry. More recently fuel consumption reduction has pushed automotive manufacturers to develop lighter and more compact systems driving the replacement of traditional materials such as metal or glass by thermoplastic materials. There are ligher and allow greater design flexibility.
Polycarbonate: The right choice for glass replacement in automotive headlamps lenses
Materials used for head lamps needs to exhibit good optical clarity, good impact resistance and excellent weatherability.
Weight Saving
Makrolon® AL combines all these performances and permits weight savings of some 1.5 kg per car compared with the glass version.
Design flexibility
Makrolon® AL offers design engineers much greater design freedom. At the same time, the plastic headlamp lenses are virtually unbreakable. The lenses are additionally given a scratchresistant coating of special lacquer. It was only this combination of Makrolon® AL and a hard coating (specially developed scratchresistant lacquer) that made it possible for the glass headlamp lenses to be substituted at all.
Reliability
It would not have been possible to produce the dual headlamp (which is designed as a single unit) in conventional materials at a comparable cost. This development contributed towards the breakthrough of further headlamp lenses in plastics, opening up the way for other headlamp producers to develop plastic lenses for various different models of car.
高抗冲透明材料用作防盗包装High impact and transparent material used for theft-proof packaging
市场Markets: 包装Packaging
聚合物Polymer: 聚碳酸酯Polycarbonate, Makrolon®
关键功用Key performances:
透明Transparency
韧性Toughness
挠性Flexibility
易加工Easy processing
Shoplifting can be addressed by using lockable packaging made out of a transparent and tough material
Shoplifting has developed into a national sport in many places, and CDs, DVDs and recorded video cassettes are some of the prime articles favored by thieves. Thanks to their size, these can be readily concealed in jacket pockets and taken out of the store without paying.
This problem can be solved by presenting the objects of desire in a lockable transparent packaging unit containing an RFID that can be removed after payment.
The material needs to exhibit good transparency as well as excellent impact resistance.
Thanks to its excellent transparency and toughness, Polycarbonate, Makrolon is the material of choice.
For this application, Makrolon® 2405 is the perfect material for this application.Thanks to its excellent toughness and ductility, the break-proof packaging withstood 2000 opening/closing cycles during tests without any problems. Its excellent transparency allows a good visualisation of the packaged product.
The reasons for the use of Makrolon® 2405 include its excellent properties such as:
High impact strength
Flexibility
Transparency
Optical purity
Flowability
Ease of processing
头盔材料，高抗冲击、耐刮、防雾Material for Helmet visor combining impact resistance, anticratch and antifog properties
市场Markets: 运输安全物品Transportation safety items
聚合物Polymer: 聚碳酸酯Polycarbonate, Makrolon®
关键功用Key performances:
透明Transparency
高韧性High toughness
挠性Flexibility
耐刮Scratch ressitance
紫外光屏蔽UV screening
Helmet visors require outstanding toughness, antiscrach and antifogging
In summer and winter alike, it is crucial for motorcyclists and those riding on scooters to have a clear view both during the day and at night. Visors easily get scratched and dirty through their daily use in a harsh environment. And it then becomes clear whether the rider
's
"windscreen
" is really up to the job or not.
If the visors are scratched, then light from oncoming cars or the sun appears in the form of a wide halo, which can briefly disorientate the wearer.
It is also important for visors to be protected against fogging on the inside.
The
"helmet windows
" are naturally required to have a high impact resistance so as to reliably prevent stones thrown up by the car in front, from coming into contact with the rider
's eye for example. Material to be used requires high impact resistance in a wide range of temperatures.
Makrolon withstands the impact of steel balls travelling at 420 km/h without suffering any damage
In flying-stone tests, visors in Makrolon® LQ 3187 withstand the impact of steel balls travelling at 420 km/h without suffering any damage.
The Makrolon® visors are fracture-proof and do not splinter. Visors for motorbike helmets are made of Makrolon® LQ 3187 which meets the particularly stringent requirements, such as 100% UV screening (up to 400 nm), with outstanding mechanical strength at the same time.
To improve scratch resistance and antifog, a special scratch-resistant coating is applied to the outside and a special anti-fog coating is applied on the inside to stop the formation of water droplets caused by the visor wearer
's warm, moist breath
玻璃替代材料用作可回用瓶，减轻重量容易操作Glass replacement material for returnable bottles allows weight saving and easier handling
市场 Markets: 包装Packaging
聚合物Polymer: 聚碳酸酯Polycarbonate, Makrolon®
关键功用Key performances:
透明Transparency
高韧性High toughness
省重量Weight savings
替代玻璃Glass replacement
消声Noise dampening
Returnable packaging seeks for glass replacement materials
Glass returnable milk bottle are intensively used in many countries. However, due to environmental concerns for replacement material providing weight saving, noise dampening and high impact strength there is a need to replace glass with a returnable plastic. This trend has been initiated in countries such as The Netherlands.
Makrolon® as the ideal choice for transparent returnable bottles
The Makrolon® bottle brings benefits for all the users involved:
Sound Dampening: Makrolon
's® good damping properties prevent a high level of noise during bottle filling, as well as during delivery and collection.
Weight Saving: The bottle
's extremely low inherent weight of 80 g means that dairies and distributors save on transport and fuel costs.
Design flexibility: The square bottle shape saves space, permitting a larger number of bottles per crate or pallet. Dairies and the retail trade thus save space in their warehouses and refrigerated displays.
Consumers particularly
value the low weight, transparency, fracture-resistance and handy square-shape of the bottle, along with the fact that it can be closed again. The environment ultimately benefits too, since Makrolon® bottles can be filled more than 50 times in the returnable system. Damaged bottles and those at the end of their service life are sent for recycling.
Recommended grades for returnable bottles
玻璃替代材料用作桌上用具，省重设计极度灵活Glass replacement material for Tableware allows weight saving and great design flexibility
市场Markets: 消费品Consumer goods
聚合物Polymer: 聚碳酸酯Polycarbonate, Makrolon®
关键功用Key performances:
透明Transparency
韧性Toughness
省重Weight savings
替代玻璃Glass replacement
可与食品接触Food contact
Glass replacement for weight saving, design flexibility and impact resistance in tableware
Consumer goods, such as kitchen ustensils or tableware follows the same trends as other industries seeking for glass replacement materials. This allows weight saving, greater design flexibility and high impact resistance. Materials used need to exhibit excellent light transmission, high stiffness and high stress cracking resistance.
Light and unbreakable tableware with Makrolon®
To produce these glasses, jugs and bowls of a modern design in transparent plastic is a considerable technical achievement. The wall thickness of these parts ranges from 1.5 to 20 mm (with thick walls at the base of the glasses and very thin walls around the rim). These differences in wall thickness lead to a highly dissimilar light refraction - the so-called crystal effect.
The products do not display any sink marks, entrapped air, internal stresses or flow marks.
The material used for these glass-like products is Makrolon® 2458 , Colour 55/115, which offers unusual properties, including:
High light transmission
High rigidity and strength
High stress cracking resistance
Virtual unbreakability
Makrolon® 2458 is approved for food contact applications by the BgVV, FDA and the French Positive List.
聚碳酸酯用作医用输液组件，透明、韧性而安全Polycarbonate used for medical infusion sets leads to clear, tough and safe products
市场Markets: 医疗Medical
聚合物Polymer: 聚碳酸酯Polycarbonate, Makrolon®
关键功用Key performances:
透明Transparency
韧性Toughness
尺寸℃Dimensional stability
耐消毒Sterilization
生物相容Biocompatibility ISO-10993-1
Intravenous fluids and drugs delivery require safe and transparent materials.
The constant visual monitoring of infusions through transparent connections is one way of contributing towards the safe, optimum care of patients who are receiving intravenous fluids and drugs. High dimensional stability, fracture strength and toughness is also required for safe tube connection points for both patients and medical staff
Makrolon® satisfies the most stringent requirements in infusion sets
To produce infusion sets satisfying the most stringent requirements, Makrolon® Rx1805 is the perfect material to use..
The use of Makrolon® Rx1805 provides the following benefits:
Easy processing: The parts can be readily produced by injection molding
Sterilization: Infusion sets are generally supplied in individually sterilized packs which have been sterilized using ethylene oxide or gamma rays. A special form of stabilization ensures that this latter method leads to just a slight discoloring, which virtually disappears again over time.
The high dimensional stability: guarantee the requisite level of medical safety at the tube connection points for both patients and medical staff.
High fracture strength and toughness: Get robust and reliable products
Biocompatibility: Makrolon® Rx1805 fulfils the requirements of ISO-10993-1 (equivalent to EN 30993-1) in respect of the biocompatibility of plastics for tissue contact of up to 30 days. See disclaimer for medical products.
替代金属Metal Replacement Solutions
Check out our selection of case studies featuring technical and design solutions for metal replacement offered by Makrolon®. All selected solutions have been implemented by designers or product engineers.
电子装置外壳材料有优良的流动性，优异的刚性和高冲击强度，用作电子器件外壳取代玻璃。Material with Excellent Flow, Superior Stiffness and High Impact Resistance for Glass Replacement in Electronic Housings
市场 Markets: 办公设备Office equipment
聚合物Polymer: 聚碳酸酯Polycarbonate, Makrolon
关键功用Key performan, ces:
省重Weight saving
高韧性High toughness
高刚性High rigidity
高尺寸稳定性和公差稳定High dimensional stability and tolerances
取代金属Metal replacement
Office equipment manufacturers seek for weight saving, reliable design and cost savings
In order to improve product reliability, many office equipment manufacturer (printers, fax machine) try to develop new products with simpler design and with a reduced number of parts. This generally leads to more sophisticated parts and systems usually difficult or costly to acheive with traditional materials such as metal. Moreover, as these equipments needs to be moved oftenly, weight is also an important criteria to consider.
For these reasons, there is a clear trend for metal replacement by thermoplastic materials in this industry.
Makrolon® allows weight savings of 55 % through metal substitution.
A leading manufacturer of computer printers, replaced a crossbar which previously comprised 15 separate parts with a single injection moulded part in Makrolon®. This led to a weight reduction of 55% and similar savings on costs.
This precision printer component places stringent requirements on:
Dimensional stability and tolerances,
Strength
Rigidity
Requirements which are all fulfilled by Makrolon® 8025 . The special short glass fibre filling of Makrolon® 8025 ensures a high level of mechanical properties in the material yet, despite this, the material still retains its virtually isotropic behaviour.
This leads to a low shrinkage differential with and across the direction of flow something which is of decisive importance for largely warp-free parts.
Additional elements that contributed towards the success of this printer part were the intensive application-technology advice that was provided, design measures which included the selective use of ribs to provide stiffening, and the rheological layout of the mould with Moldflow calculations.
手机小型化和轻量化要多谢聚碳酸酯Smaller and Ligther Phones are Allowed Thanks to Makrolon® Performances
市场 Markets:电讯 Telecommunication
聚合物Polymer: 聚碳酸酯Polycarbonate, Makrolon
关键功用Key performances:
高流动性（薄壁）High flow (Thin wall)
高韧性High toughness
高刚性High stiffness
重量轻Low weight
Smaller and ligther mobile phones require material with excellent flow, high stiffness and high impact resistance.
No doubt! Mobile phone still continue to grow significantly. To differentiate they products and they services, phone operators propose new media services with sophisticated phones. Design is a key element for success and phone manufacturers develop smaller and lighter models. Materials to be used needs to demonstrate very high stiffness, high impact resistance and excellent flow to allow thin wall thickness of less than 1 mm.
Stringent mobile phone industry requirements are meet with Makrolon®
These are the demands that Motorola has successfully satisfied with its new Star Tac mobile phone. The housing - scarcely bigger than a cigarette pack - is lightweight and provides highly effective protection for the electronics that it accommodates. It is also of a very appealing design. And it
's not just the size that makes it a lightweight housing but also its low wall thickness of less than 1 mm.
All this was made possible by the specially developed, impactmodified Makrolon® DP 11456 , which offers very good flowability.
Filling studies and calculations based on the geometry of the parts provided assistance in determining the necessary filling pressures and pressure losses in the mould and runner system, the flow fronts that form, the expected temperature acting on the melt during the filling stage and the solidification behaviour that prevails during the cooling phase. These same studies and calculations were additionally used to establish the optimum design for the moulds and injection moulding machines.
用作轻量的大容量行李箱包Makrolon® Utilized for Light and Optimized Used of Space Luggages.
市场 Market: 行李箱包Luggage
聚合物Polymer:聚碳酸酯 Polycarbonate, Makrolon®
关键功用Key performances:
省重Weight saving
韧性Toughness
刚性Stiffness
尺寸稳定Dimensional stability
Light luggages with optimized use of space require tough materials with good rigidity and good dimensional stability.
As many other markets, luggage manufacturers are looking for weight reduction while maintaining toughness. This can be acheived by replacing metallicparts (flame...) by thermoplastics. For optimized use of space, inner ribs should be avoided and compensated by using materials which demonstrate superior stiffness and toughness.
Weight reduction and space saving allowed by using Thermoformed Makrolon® Sheet.
Samsonite recently introduced a new range of cases under the name D
'Light 500. This new lightweight baggage collection is designed so as to make optimum use of the space inside - there are no inner ribs. The aluminum frame has also been dispensed.
Nevertheless, the case retains its shape completely, even when subjected to very rough handling. It is all down to the high rigidity and impact strength of the plastic material and its outstanding dimensional stability. The case is produced by thermoforming extruded Makrolon® 3103 sheet.
Through the use of 2 to 2.5 mm thick Makrolon® sheets made by the Makroform company and by dispensing entirely with the aluminum frame, the weight of the suitcase itself has been reduced considerably (2.6 kg for the 55 cm case). This is why the new range has been called D
'Light 500. The cases are available in four sizes: 55 cm, 63 cm, 72 cm and 81 cm.
Another special feature of this range is that the cases have a sewn-in inner lining
探照灯外壳，易制造，省时省力省成本Makrolon® Floodlights Casing for Easier Manufacturing, Labor and Cost Savings
市场Market:照明 Lighting
聚合物Polymer: 聚碳酸酯Polycarbonate, Makrolon®
主要功用Key performances:
省重Weight saving
韧性Toughness
刚性Stiffness
可循环Recyclable
设计灵活Design flexibility
Producing the die-cast housings is a highly complex task and therefore a very costly one too.
Floodlights are used to illuminate monuments, churches and other works of architecture at night, as well as to light up hotel, restaurant and supermarket facades. The illuminant employed is generally a sodium-vapor lamp, equipped with a reflector.Since they are exposed to the elements, these floodlights need to be correspondingly robust.The latest generation of outdoor floodlights are generally produced in die-cast aluminum in sizes up to 430 x 450 mm.
Metal replacement by Makrolon provides design flexibility, part integration and ultimately weight and cost savings.
A Moldflow calculation showed that housings in Makrolon® 2607 from Bayer AG can be produced with the requisite degree of stiffness and the desired surface finish.
The Elba company in Romania has taken up this recommendation and is making housings in Makrolon® 2607 colored black. The housings are now being produced more efficiently by injection molding. They offer:
Low weight,
A smooth surface
High heat resistance,
Superior toughness including at low temperatures,
Good weathering and aging properties.
The amount of assembly work has been reduced through the integration of a number of components.
Makrolon® also offers advantages in environmental terms, since it can be recycled
市场汽车照明和窗玻璃Automotive Lighting and Glazing
The automotive industry requires materials that permit lightweight construction and are absolutely reliable in continuous service. Materials should also offer a high potential for integrating different functions in order to permit all-in components or systems to be produced. Freedom of design is also of major importance.
Thanks to excellent transparency, high impact strength, good heat resistance, good durability, Makrolon® is intensively used as glass replacement in applications such as headlamps or glazing.
If you want to replace glass or to develop an automotive application with Makrolon®:
Ask for Technical Assistance
Benefits of Makrolon® in automotive
Superior toughness even at low temperatures
The toughness (unnotched) of Makrolon® at -30 °C is comparable to that at room temperature.
Transparency/coloring
Makrolon® is crystal clear, allowing it to be colored easily in any desired shade. Standard colors are available for virtually all traffic signal types (e.g. indicator lenses and car tail lights).
Weather resistance
The colors used for light signals must not undergo any change even when used outdoors. UV-stabilized Makrolon® grades have demonstrated excellent mechanical strength and colorfastness over a period of many years. The surface can be additionally stabilized by coating it with a suitable light stabilizer system for particularly critical applications.
High dimensional stability in heat
Non-reinforced Makrolon® has a Vicat-B softening temperature of 145-150°C. This outstanding property makes Makrolon® suitable for automotive headlamps.
Recommended Makrolon® grades for automotive applications
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光学Optics
Thanks to its excellent optical clarity and toughness, polycarbonate is an excellent and safe alternative for glass in optical applications.
Polycarbonate exhibits a unique set of physical properties including high toughness, superior heat resistance, good flow, easy coloration, and UV filtering.
If you want to replace glass or to develop applications requiring optical clarity with Makrolon®:
Ask for Technical Assistance
Benefits of Makrolon® in optical applications are:
Weight saving for comfort
Almost unbreakable for high safety and reliability
Possibility to have UV filtering (up 400 nm) for eye protection
Design flexibility allowing great product differentiation and complexity
Good dimensional tolerances
Good detail duplication
Makrolon® Optical grades
Comments
医疗Medical
Equipment such as blood oxygenators, dialysers and infusion units require visual monitoring in order to check for air bubbles and contamination, and only a transparent material will permit this. The non-toxicity of the material employed is a further criterion needed in many medical and laboratory applications.
Makrolon®is used for the production of high-grade medical appliances. The main reasons for the choice of Makrolon® include its glass-like transparency, toughness, resistance-to-fracture, reliable sterilizability and good compatibility with body fluids and tissues for contact times of up to 30 days.
If you want to replace glass or to develop applications requiring biocompatibility or sterilization resistance with Makrolon®:
Ask for Technical Assistance
Benefits of Makrolon® in medical applications.
Biological compatibility (see Disclaimer on biocompatibility)
All applications that involve direct or indirect contact with blood or tissue must comply with the appropriate provisions of the relevant authorities.
In the case of medical products within the validity area of ISO 10 993-1, only Makrolon® grades that comply with the test criteria specified in this standard may be employed. The biocompatibility tests conducted on the basis of this standard, however, do not cover the following areas of use:
long-term use over 30 days, particularly when used as an implant
long-term contact over 30 days with endogenous substances (blood, tissue, dentine and other body fluids)
multiple use in medical applications
Sterilizability
It is essential for medical equipment to be capable of reliable sterilization.
Makrolon
's® dimensional stability at high temperatures, permits steam sterilization at 121 °C. The range of special medical grades is rounded off by Makrolon® grades for gamma radiation sterilization. All Makrolon® grades can additionally be sterilized through exposure to ethylene oxide gas (ETO).
When even higher temperatures are required. Apec® can be used for hot-steam sterilization and for treatment in autoclaves at temperatures up to 134 °C.
Makrolon® Medical Grades
Comments
** see Disclaimer for medical products
建筑窗户Construction Glazing
Makrolon® roofs offer reliable protection from wind, hail, snow and vandalism. They make you feel safe, and they are also highly transparent.
Makrolon® is ideal for roofs that need to let plenty of light through and create a friendly, bright and cheerful atmosphere
If you want to replace glass or to develop applications for construction glazing with Makrolon®:
Ask for Technical Assistance
Benefits of Makrolon® in construction glazing
Excellent resistance to breakage over a broad range of temperatures
Makrolon
's® excellent impact strength and resistance to breakage are exploited for glazing wherever people and property have to be protected from injury and damage.
High light transmission of over 80 % depending on panel type and thickness.
A non-distorted view is possible through solid sheets.
Good weather resistance
Special Makrolon® UV-absorber concentrates can be co-extruded during the sheet extrusion process to enhance weatherability
Low inherent weight
Makrolon® sheet is used, among other things, for glazing on lightweight, transparent hall and stadium roofs. Its low inherent weight compared to glass means that Makrolon® sheet offers considerable advantages in the design and static-equilibrium layout of the support structure.
Freedom in design
Makrolon® sheet offers a high level of freedom in design on account of its suitability for hot and cold forming.
Recommended Makrolon® grades for construction glazing
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包装Packaging (Bottles)
Lightweight and break-resistant bottles and containers simplify many everyday tasks and reduce the danger of injury and also transport costs.
Molded parts in Makrolon® are virtually indestructible and weigh less than glass containers. Molding flexibility using Makrolon® allows for square bottles take up 30% less space than round ones.
If you want to replace glass or to develop applications for packaging with Makrolon®:
Ask for Technical Assistance
Benefits of Makrolon® in packaging applications
Non-toxic and tasteless for contact with food
Makrolon® food-contact grades fulfill all the requirements placed on plastics for this application in the different countries - such as the FDA provisions and EU Directive 90/128/EEC and its supplements; some grades (mostly FBL = colorless) are also listed in NSF Standard 51.
Transparency
Makrolon® is clear and transparent and its high light transmission of almost 90% permits an unimpeded view. Transparent dark color shades (to protect against light) are available to protect the vitamin content of foods.
High impact strength and fracture resistance
Bottles and jars produced from Makrolon® are made to last and are virtually unbreakable. A further positive factor is that these bottles have an extremely low noise emission during loading and sorting.
Cleanability
The smooth, closed surface permits impeccable cleaning in standard-type machines and a large number of standard commercial cleaning agents. A check should be conducted on the compatibility of the cleaning agents. Containers in Makrolon® can also be sterilized by the standard methods.
Recommended Makrolon® grades for Packaging applications
Comments
体育运动和休闲设施Sports and Leisure
Applications in sports are high-tech in character, calling for mechanical strength and toughness, as well as weather resistance and precision moldings.
Makrolon® is exceptionally break-resistant and virtually splinter-proof. This is why it is always the first choice for practitioners of dangerous sports. Snowboarders, motor cyclists, inline skaters, ice-hockey players, skiers, racing drivers and cyclists all rely on lightweight yet rugged products made of high-tech Makrolon® plastic.
Shatter-proof and virtually splinter-free: helmets, sports goggles and visors of Makrolon®
If you want to develop applications for Sports and Leisure with Makrolon®:
Ask for Technical Assistance
Benefits of Makrolon® in Sports and Leisure
Weather resistance
Materials used for outdoor applications must be highly resistant to weathering. The UV-stabilized grades of Makrolon® have proved particularly successful.
Outstanding mechanical strength
Unnotched Makrolon® is just as tough at -30 °C as at room temperature - a very important feature for winter sports equipment.
Excellent dimensional accuracy
Its low shrinkage
values, very low coefficient of thermal expansion and high softening temperature mean that Makrolon® retains its dimensional accuracy even under extreme conditions.
安全设施Safety Equipment
Virtually unbreakable, polycarbonate finds many uses in safety equipment. From transparent to opaque application, Makrolon® offers many benefits such as weight saving, design flexibility and can easily replace metal or glass.
Makrolon® - a plastic that ensures safety
If you want to develop applications for safety equipment with Makrolon®:
Ask for Technical Assistance
Benefits of Makrolon® in Safety Equipment
Outstanding mechanical strength
Unnotched Makrolon® is just as tough at -30 °C as it is at room temperature - a very important feature for winter sports equipment.
Weather resistance
Materials used for outdoor applications must be highly resistant to weathering. The UV-stabilized grades of Makrolon® have proved particularly successful.
消费产品Consumer Goods
Consumer goods articles are frequently subject to high mechanical and thermal stressing and are required to satisfy stringent aesthetic demands. Articles that come into contact with food must also comply with the international regulations.
Makrolon® fulfills the many different requirements and is used in a wide range of consumer goods applications.
If you want to develop applications for Consumer Goods with Makrolon®:
Ask for Technical Assistance
Benefits of Makrolon® in Consumer Goods
Good electrical insulation
values
Good dielectric properties of Makrolon® ensure reliable protective insulation.
Contact with food (see also packaging)
Bayer produces special grades of Makrolon® for this demanding field of application which comply with the Directives issued by the EU Commission as well as with the American FDA provisions for plastics that come into contact with foods. Makrolon® has no taste and does not suffer pronounced staining through fruit and vegetable juices.
High dimensional stability in heat
Contact with boiling hot foodstuffs must not result in vessels becoming deformed.
Makrolon® retains its dimensional stability at long-term service temperatures of up to 125 °C. Depending on the load acting on the component, non-reinforced grades of Makrolon® will remain dimensionally stable up to 135 °C.
Outstanding impact strength
Makrolon
's® high impact strength is retained over a prolonged period of time even when in contact with hot water (< 60 °C).
Transparency
Makrolon® is crystal clear and permits an unimpaired view.
电子电气 E&E
The plastics used in the electronics and electrical engineering sectors are required to offer reliable insulation properties, safe operation, and 100% protection against electric shock. The material must naturally have a high mechanical property profile as well.
Makrolon® combines a range of completely different material properties and is therefore ideally suited to products in the electrical sector.
If you want to develop applications for Electrical and Electronic with Makrolon®:
Ask for Technical Assistance
Benefits of Makrolon® in Electrical and Electronic applications
Transparency/light transmission
Makrolon® is crystal clear and has a light transmission of up to 89 % depending on the wall thickness. Since Makrolon® does not have a very pronounced natural color; it can be colored in all transparent, translucent and opaque color shades. Special color shades are available for signal effects and infrared signal technology, as well as opal white colors with optimum light scatter.
High impact strength
The toughness and resilience of Makrolon® are not affected by temperature, making it the ideal material for safety covers and housings.
High heat resistance
Makrolon® parts, subjected to low mechanical stresses, will withstand a temperature of 134 °C for brief periods, and glass fiber reinforced grades a temperature of 145 °C. Heat resistance in the ball pressure test to IEC 60335-1 is in excess of 135 °C: The maximum service temperature where long-term exposure to heat is involved will depend on the molding and the demands made upon it. The temperature indices to UL 746 B and IEC 216, for example, provide a rough guide.
Good weather resistance
UV radiation constitutes a critical type of stressing and UV-stabilized grades of Makrolon® are ideal for outdoor applications. Additional surface treatment may be required for applications in countries closer to the equator, in high mountain regions, or when high-pressure mercury lamps are used.
High insulation resistance
Makrolon® is ideal for low-voltage applications. The power density on the carriers of live parts, the necessary protection against electric shock and the mutual isolation of electrical components requires a plastic which offers a correspondingly high insulation resistance.
Makrolon® offers an excellent surface resistance, dielectric strength and volume resistivity. It has a relative permittivity of approx. 3 at 100 Hz (IEC 250). These
values are largely independent of temperature and relative humidity.
Fire performance
With standardized
values to UL 94, Makrolon® achieves a UL 94 HB or UL 94V-2 fire rating. A number of flame retardant grades attain a UL 94V-0 or UL94-5VA rating.
Recommended Makrolon® FR grades for Electrical and Electronic
Comments
玩具Toys
Applications in the toy market are high-tech in character, calling for mechanical strength and toughness as well as low-toxicity and precision molding.
Tough, transparent, easy-to-color and non-toxic, Makrolon® allows for aesthetically pleasing and safe toys
If you want to develop applications for Toys with Makrolon®:
Ask for Technical Assistance
Benefits of Makrolon® in Electrical and Electronic
Non-toxicity
A whole series of Makrolon® grades complies with all the relevant ordinances and standards governing toys in all the key industrial countries.
Outstanding mechanical strength
Unnotched Makrolon® is just as tough at -30 °C as at room temperature.
Easy coloration
Makrolon® is available in an infinite set of colors, hues and effects from crystal clear, translucent and opaque. Makrolon® allows designers greater shape, texture and colorability freedom to provide modern and attractive toys.
工程Engineering
Due to corrosion, weight saving and noise reduction there is also a clear trend to replace metal, ceramics or glass in engineering applications.
Thanks to its unique set of properties combining outstanding impact strength, and heat resistance up to 125°C and transparency, Makrolon® can be used in demanding applications.
If you want to develop applications for Engineering with Makrolon®:
Ask for Technical Assistance
Benefits of Makrolon® in Engineering applications
Good electrical insulation
values
The good dielectric properties of Makrolon® ensure reliable protective insulation.
High dimensional stability in heat
Contact with boiling hot foodstuffs must not result in parts becoming deformed.
Makrolon® retains its dimensional stability at a long-term service temperature of up to 125 °C. Depending on the load acting on the component, non-reinforced grades of Makrolon® will remain dimensionally stable up to 135 °C.
Weather resistance
UV-stabilized Makrolon® grades have demonstrated excellent mechanical strength and colorfastness over a period of many years. The surface can be additionally stabilized by coating it with a suitable light stabilizer system for particularly critical applications.
Outstanding impact strength
Makrolon
's® high impact strength is retained over a prolonged period of time even when in contact with hot water (< 60 °C).
Transparency
Makrolon® is crystal clear and permits an unimpaired view.
加工要点干燥Drying
The chief prerequisite for achieving high-grade molded parts and semi-finished products in Makrolon® is careful drying of the pellets immediately prior to processing.
Moisture inside and on the surface of the pellets will lead to reject parts being produced when the Makrolon® is processed.
Makrolon® can be dried at 120 °C in the appropriate dryers.
Preliminary drying can be dispensed with if use is made of injection molding machines with vented plasticization units or vented extruders.
The dryness of non-reinforced Makrolon® can be established with a TVI test unit immediately prior to processing.
More information for drying Makrolon®
注塑Injection Molding
Makrolon® can be processed on all modern injection molding machines. Shut-off nozzles can be used if the heating is adequate and uniform. Heating systems and control instruments must be designed for at least 350 °C.
Wear and corrosion resistant plasticizing units have proved successful for processing Makrolon® grades that contain flame retardants and/or a large amount of filler. The use of steels with a high chromium content is also worthwhile for general-purpose grades in terms of boundary layer formation.
If you want advice for injection molding of Polycarbonate:
Ask for Technical Assistance
Processing parameters
Melt temperatures
The standard melt temperatures for processing are between 280 and 320 °C. Lower melt temperatures lead to surface defects - particularly in the case of glass fiber reinforced grades. The cylinder temperature should be reduced to between 160 and 180 °C during production breaks, but the heating should not be switched off.
Mold temperatures
It should be possible to heat the mold intensively and uniformly, and the mold temperature should be between 80 and 130 °C. High mold temperatures reduce the level of stress and improve the surface quality of the moldings for filled grades in particular. The holding pressure should also be set at a low level in order to obtain stress-free moldings.
Processing pressures
The pressures required to produce injection moldings (injection pressure and holding pressure) depend on the molded part in question and must thus be established in tests. The back pressure should generally be set at 50 to 150 bar (hydraulic pressure).
Screw speed
The screw speed should be selected in such a way that the circumferential velocity of the screw is between 0.05 and 0.2 m/s. A speed of 0.3 m/s should not be exceeded.
Shot weight and metering
To produce molded parts with a defined shot weight, it is best to use screws of just one particular size range (diameter range). This then makes it possible to achieve a favorable metering stroke of between 1 x D and 3 x D (D = screw diameter). It is a good idea for a screw of defined diameter to be used exclusively for molded parts in the appropriate weight or shot volume range. Outside this range, quality impairments may occur in the form of surface defects, molecular weight reductions or entrapped air.
挤吹Extrusion Blow Molding
Makrolon® 1239 has been developed specially for extrusion blow molding. This is a high-viscosity, branched grade which, if correctly processed, complies with the FDA regulations for food contact applications. Makrolon® 1239 is produced in colorless-transparent and transparent, colored versions. Makrolon® 1239 is used to produce hollow articles with a capacity of up to 20 l and more by the extrusion blow molding process.
If you want advice for extrusion blow molding of Polycarbonate:
Ask for Technical Assistance
Machinery
Makrolon® 1239 is generally processed on extruders with a smooth feed section. Grooved feed sections are also possible, providing that the grooved section is not too long (< approx. 3.5 D), the grooves are not too deep and the feed section is heated to approximately 150 °C or more. The universal three-section screws normally used for processing engineering plastics are appropriate here. Shearing sections frequently heat the melt quite considerably, which means that the melt may not be rigid enough. Mixing sections have a positive impact on melt homogeneity, but experience has shown that they are not necessarily required. A screw diameter of 50 to 60 mm is recommended for the production of 1-l bottles, and plants for the production of 20-l containers have screws with a diameter of between 70 and 100 mm.
Providing that the flow channels do not have any dead spots in which the melt can stagnate and suffer thermal degradation, Makrolon® 1239 can be processed with the following types of blowing heads: center-fed, mandrel and spiral mandrel.
For smaller articles of up to approximately 5-l capacity, side-fed dies are employed, and for larger articles, an accumulator head is needed. Machines with a reciprocating screw-plasticizing unit are also suitable.
Processing parameters
Vented extruders are not usually employed with blow molding machines, and hence the material must be dried prior to processing. Polycarbonate can absorb moisture from the air very rapidly. For this reason, any parison waste that is produced must be re-dried.
The standard melt temperature employed for processing Makrolon® 1239 is 230 to 260 °C. The higher the melt temperature, the more brilliant the bottle surface but the lower the rigidity of the melt. The optimum melt temperature must be established empirically for the blow molded part in question. The molds should be heated to around 55 to 80 °C. Separate heating/cooling circuits are recommended for the base, body and neck section. Production output for 20-l bottles can total 100 bottles/hour and more.
The very nature of the process means that extrusion blow-molded hollow articles display high inherent stresses at the pinch-off welds. These can lead to stress cracking as soon as polycarbonate bottles are cleaned in hot alkaline washing solutions at industrial plants. These stresses should therefore be eliminated by annealing as far as possible, before the bottles are brought into service. This can be done through heating in hot air in appropriate ovens or by means of infrared radiation. Further details are given in ATI 1054 and ATI 8002.
消毒Sterilization
Due to its high temperature resistance, Apec® parts are ideal for steam sterilization from 134°C to 143°C. This allows for very short sterilization cycle times compared to standard polycarbonate. Approximately 100 sterilization cycles are possible (depending on processing conditions, cleanness of the part and cleaning agent).
Apec® parts can be steam sterilized from 134°C to 143°C
Specific Apec® grades are suitable for medical application and comply with United States Pharmacopeia (USP) XXII Class VI and Tripartite test ISO 10993.1 see disclaimer for medical products
Recommended Apec® grade for steam sterilization in medical applications.
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