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Polycarbonate (PC)ThermoplasticTrade Names• Calibre• Karlex• Lexan• Makrolon• Novarex• Panlite• SinvetManufacturerDow ChemicalFerro CorporationGeneral ElectricMiles Inc.Mitsubishi ChemicalTeijin Chem Ltd.Enichem ElastomersGeneral DescriptionIn the polycarbonate resin, carbonate groups are used to link groups ofdihydric or polyhydric phenols. General-purpose polycarbonate isformed by reacting bisphenol A with phosgene, but formulations usingother polyhydric phenols are available. These include specialty resinswhich meet industry codes for flame retardance and smoke density,and resins with increased melt strength for extrusion and blow molding.Polycarbonate is a versatile and popular blend material for polyesterand ABS, and is widely used in the medical device industry as areplacement for glass. Additives and coatings are commonly used andcan greatly improve creep resistance, mold shrinkage, tensile modulus,thermal stability, weatherability, and all strength characteristics ofstandard polycarbonate. In 2004, the price of PC ranged approximatelyfrom $2.00 to $5.00 per pound at truckload quantities.General PropertiesPolycarbonate offers a unique combination of outstanding clarity andhigh impact strength. In addition, it is very dimensionally stable andhas low flammability. These characteristics make polycarbonate wellsuited for light transmission applications, such as automotive tail lighthousings. Due to the low levels of monomers and catalysts used inprocessing polycarbonate, it is generally biocompatible and suited foruse in medical applications where device surfaces may come intocontact with blood or other bodily fluids. PC offers a limited resistanceto chemicals and is soluble in many organic solvents. Solvent weldingor adhesively joining parts makes PC prone to stress cracking. Thiscan be overcome by selecting an adhesive with a rapid curemechanism, an adhesive with a low tendency to induce stresscracking, and/or annealing the part prior to adhesive application.Typical Properties of Polycarbonate (PC)American EngineeringProcessing Temperature 500°F to 575°F 260°C to 302°CLinear Mold Shrinkage 0.003 to 0.007 in./in. 0.003 to 0.007 cm/cmMelting Point – –Density 70.5 to 80.5 lb./ft. 3 1.13 to 1.29 g/cm 3Tensile Strength, Yield 8.4 to 9.6 lb./in. 2 x 10 3 5.9 to 6.7 kg/cm 2 x 10 2Tensile Strength, Break 7.4 to 10.9 lb./in. 2 x 10 3 5.2 to 7.7 kg/cm 2 x 10 2Elongation, Break 97.0 to 136.0% 97.0 to 136.0%Tensile Modulus 3.1 to 3.5 lb./in. 2 x 10 5 2.2 to 2.5 kg/cm 2 x 10 4Flexural Strength, Yield 12.4 to 14.0 lb./in. 2 x 10 3 8.7 to 9.8 kg/cm 2 x 10 2Flexural Modulus 3.2 to 3.5 lb./in. 2 x 10 5 2.2 to 2.5 kg/cm 2 x 10 4Compressive Strength 9.9 to 11.1 lb./in. 2 x 10 3 7.0 to 7.8 kg/cm 2 x 10 2Izod Notched, R.T. 11.3 to 17.0 ft.-lb./in. 60.8 to 91.8 kg cm/cmHardness R120 - R125 Rockwell R120 - R125 RockwellThermal Conductivity 1.3 to 1.6 BTU-in./hr.-ft. 2 -°F 0.19 to 0.23 W/m-°KLinear ThermalExpansionDeflection Temperature@ 264 psiDeflection Temperature@ 66 psiContinuousService Temperature2.9 to 3.9 in./in.-°F x 10 -5 2.2 to 7.0 cm/cm-°C x10 -5Typical Applications• Packaging – Reusable bottles, frozen foods, large water bottles• Food Service – Beverage pitchers, mugs, food processor bowls,tableware, microwave cookware• Automotive – Lamp housings and lenses, parts,electrical components, instrument panels• Medical – Filter housings, tubing connectors,surgical staplers, eyewear• Miscellaneous – Bulletproofing, computer housings,aircraft interiorsSI200°F to 350°F 98°C to 177°C280°F to 350°F 138°C to 177°C240°F to 275°F 116°C to 135°CDielectric Strength 375 to 500 V/10 -3 in. 1.5 to 2.0 V/mm x 10 4Dielectric Constant@ 1 MHzDissipation Factor@ 1 MHzWater Absorption,24 hr.2.7 to 3.2 2.7 to 3.20.009 to 0.010 0.009 to 0.0100.1 to 0.3% 0.1 to 0.3%40The Loctite ® Design Guide for Bonding Plastics, Volume 4
ADHESIVE SHEAR STRENGTH(psi)(MPa)PolycarbonateUNFILLED RESIN4 rmsROUGHENED18 rmsANTIOXIDANT0.1% Irgafos 1680.1% Irgafos 1076UV STABILIZER0.4% Tinuvin 234FLAME RETARDANT2% BT-931% Antimony OxideIMPACT MODIFIER5% Paraloid EXL3607LUBRICANT0.3% Mold WizINT-33UDKGLASS FILLER23% Type 3090Glass FillerCOLORANT4% CPCO7327Loctite ® 380 Black Max ® Instant Adhesive,Rubber Toughened7505.2160011.07505.27505.213009.010006.913009.011507.9165011.4Loctite ® 401 Prism ® Instant Adhesive,Surface InsensitiveMEDICAL: Loctite ® 4011 Prism ®Instant Adhesive, Surface Insensitive385026.6450031.0385026.6385026.6>4100 3850>28.3 26.6385026.6385026.6385026.6Loctite ® 401 Prism ®Loctite ® 770 Prism ® PrimerMEDICAL: Loctite ® 4011 Prism ® /Loctite ® 7701 Prism ® Primer200013.8340023.5200013.8200013.8>3800 2000>26.2 13.8200013.86004.15003.5Loctite ® 414 Super Bonder ®Instant Adhesive, General Purpose160011.0395027.2395027.2160011.0>3400 >4500 3850>23.5 >31.0 26.6270018.8395027.2Loctite ® 330 Depend ® Adhesive,Two-Part No-Mix Acrylic11007.611007.65503.84503.13002.15003.511007.611007.611007.6Loctite ® 3105 Light Cure Adhesive,MEDICAL: Loctite ® 3311 Light Cure Adhesive370025.5455031.4370025.5370025.5370025.5370025.5370025.5485033.5370025.5Loctite ® 3340 Light Cure Adhesive,UV Cationic Epoxy8005.5Adhesive PerformanceCalibre 300-4 produced by Dow ChemicalLoctite ® 4305 Flashcure ® Light Cure AdhesiveFLUORESCENT: Loctite ® 4307 Flashcure ®Light Cure AdhesiveLoctite ® H3000 Speedbonder Structural Adhesive, General PurposeLoctite ® H4500 Speedbonder Structural Adhesive, Metal BonderLoctite ® 3030 Adhesive, Polyolefin BonderLoctite ® E-00CL Hysol ® Epoxy Adhesive,Low OdorLoctite ® E-90FL Hysol ® Epoxy Adhesive,FlexibleLoctite ® E-30CL Hysol ® Epoxy Adhesive,Glass BonderMEDICAL: Loctite ® M-31CL Hysol ®Epoxy Adhesive, Glass BonderLoctite ® E-20HP Hysol ® Epoxy Adhesive,Fast SettingMEDICAL: Loctite ® M-21HP Hysol ®Epoxy Adhesive, Fast SettingLoctite ® E-214HP Hysol ® Epoxy Adhesive,High Strength>4250 >29.3 12508.611007.68505.99006.211507.9265018.312008.312008.3Loctite ® 4305 Flashcure ® Light Cure Adhesive achieved bond strengths which were higher than the grade ofunfilled polycarbonate tested. Loctite ® 401 Prism ® and 414 Super Bonder ® Instant Adhesives, Loctite ®3105 Light Cure Adhesive, and Loctite ® E-30CL Hysol ® Epoxy Adhesive, Loctite ® 3631 Hysol ® Hot MeltAdhesive, and Loctite ® Fixmaster ® High Performance Epoxy all achieved the very high bond strengths on PC.Loctite ® 3651 and 7804 Hysol ® Hot Melt Adhesives achieved the lowest bond strengths.Surface TreatmentsSurface roughening either caused no effect or a statistically significant increase in the bondability of PC. Theuse of Loctite ® 770 Prism ® Primer in conjunction with Loctite ® 401 Prism ® Instant Adhesive, or Loctite ®4011 Prism ® Medical Device Instant Adhesive with Loctite ® 7701 Prism ® Primer, caused a statisticallysignificant decrease in the bond strengths achieved on PC for most of the formulations evaluated.Other Important Information• Polycarbonate is generally compatible with acrylic and cyanoacrylate adhesives, but thereis a potential for stress cracking. In addition, polycarbonate can be attacked by the activatorsfor two-part, no-mix acrylic adhesives before the adhesive has cured. Any excess activatorshould be removed from the surface of the polycarbonate immediately.Loctite ® Fixmaster ® High Performance EpoxyLoctite ® 1942 Hysol ® Hot Melt Adhesive,EVA Based245016.93502.4• Polycarbonate is incompatible with anaerobic adhesives.• Surface cleaners: isopropyl alcohol, Loctite ® ODC-Free Cleaner & Degreaser.Loctite ® 3651 Hysol ® Hot Melt Adhesive,Polyolefin1000.7Loctite ® 7804 Hysol ® Hot Melt Adhesive1000.7Loctite ® 3631 Hysol ® Hot Melt Adhesive,UrethaneLoctite ® U-05FL Hysol ® Urethane Adhesive,High StrengthLoctite ® Fixmaster ® Rapid Rubber RepairOEM: Loctite ® U-04FL Hysol ®Urethane Adhesive, Fast SettingLoctite ® 5900 ® Flange Sealant,Heavy Body RTV Silicone320022.18505.96004.12001.4NOTES: The force applied to the tests specimens exceededthe strength of the material resulting in substrate failurebefore the actual bond strength achieved by the adhesivecould be determined.The addition of the indicated additive (or surfaceroughening) caused a statistically significant decrease inthe bond strength within 95% confidence limits.The addition of the indicated additive (or surfaceroughening) caused a statistically significant increase inthe bond strength within 95% confidence limits.The Loctite ® Design Guide for Bonding Plastics, Volume 4 41
Page 5 and 6: How To Use The Plastic Bonding Guid
Page 8: Cyanoacrylate AdhesivesGeneral Desc
Page 11 and 12: Light Curing Acrylic AdhesivesGener
Page 13 and 14: Silicone AdhesivesGeneral Descripti
Page 15 and 16: Why Bond Plastics With Loctite ® B
Page 17 and 18: ADHESIVE SHEAR STRENGTH(psi)(MPa)Ac
Page 25 and 26: ADHESIVE SHEAR STRENGTH(psi)(MPa)Di
Page 27 and 28: ADHESIVE SHEAR STRENGTH(psi)(MPa)Ce
Page 29 and 30: ADHESIVE SHEAR STRENGTH(psi)(MPa)Ep
Page 31 and 32: ADHESIVE SHEAR STRENGTH(psi)(MPa)Po
Page 33 and 34: ADHESIVE SHEAR STRENGTH(psi)(MPa)Io
Page 35 and 36: ADHESIVE SHEAR STRENGTH(psi)(MPa)Li
Page 37 and 38: ADHESIVE SHEAR STRENGTH(psi)(MPa)Ph
Page 41: ADHESIVE SHEAR STRENGTH(psi)(MPa)Po
Page 53 and 54: ADHESIVE SHEAR STRENGTH(psi)(MPa)Lo
Page 73 and 74: ADHESIVE SHEAR STRENGTH(psi)(MPa)St
Page 75 and 76: ADHESIVE SHEAR STRENGTH(psi)(MPa)Vi
Page 77 and 78: Surface TreatmentsAdhesive Abrading
Page 79 and 80: Adhesive Joint DesignIntroductionIn
Page 81 and 82: TitleDesign GuidelinesEngineers mus
Page 83 and 84: Shortening bond overlaps reduces bo
Page 85 and 86: Softening and weakening of the surf
Page 87 and 88: Determining The Test MethodThe lap
Page 89 and 90: Block Shear Test Method1. Assemblie
Page 91 and 92: ViscosityViscosity is a product pro
Page 93 and 94:
Index of Trade NamesTrade Name Plas
Page 95 and 96:
Trade Name Plastic Type Manufacture
Page 97 and 98:
AcknowledgmentsThis manual would no
Page 99:
For more information, please call 1
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