In-Depth Guide to Polycarbonate Solid Sheet

1. Core Material & Manufacturing Advantages

Key Material Properties

• Outstanding impact resistance (inherent to PC, no extra structural modifications needed).
• Excellent thermal stability (maintains rigidity at high temperatures and flexibility at low temperatures).
• Natural transparency (raw PC resin is water-clear, with minimal light scattering).

Precision Manufacturing Process

1. Resin Melting: PC resin pellets are fed into an extruder, heated to 250–300°C (482–572°F) to form a molten polymer.
2. Extrusion: The molten PC is forced through a flat die (customized for sheet thickness, e.g., 1mm–20mm) to create a continuous sheet.
3. Calibration & Cooling: The extruded sheet passes through precision rollers to set its thickness and surface finish (e.g., glossy, matte), then is cooled rapidly with controlled air or water to lock in shape and prevent warping.
4. Surface Treatment: Optional post-processing includes co-extruding a UV-protective layer (critical for outdoor use) or applying anti-scratch, anti-fog, or anti-glare coatings to enhance functionality.

2. Standout Performance Traits

(1) Unmatched Impact Resistance

• Their impact strength is 250–300 times that of ordinary float glass and 30 times that of acrylic (PMMA) sheets of the same thickness.
• They can withstand high-force impacts (e.g., a 1kg steel ball dropped from 2 meters) without shattering—instead, they may flex slightly and retain structural integrity.
• Unlike glass, which breaks into sharp shards, PC solid sheets either remain intact or split into large, blunt pieces—minimizing safety risks. This makes them ideal for safety-critical applications (e.g., machine guards, protective barriers).

(2) Exceptional Optical Clarity

• Transparency: Clear PC solid sheets offer 88–90% light transmittance—nearly identical to glass—with minimal color distortion. This makes them suitable for applications where unobstructed visibility is key (e.g., display cases, storefront windows).
• Optical Stability: Unlike acrylic, which yellows over time due to UV exposure, PC solid sheets with a co-extruded UV layer retain their clarity for 10–15 years outdoors. Even uncoated sheets resist yellowing better than acrylic in indoor or shaded environments.
• Customizable Optics: They are available in matte, frosted, or textured finishes to reduce glare, enhance privacy, or diffuse light (e.g., frosted sheets for bathroom partitions, matte sheets for LED light diffusers).

(3) Wide Temperature Tolerance

• PC solid sheets perform reliably across an extreme temperature range: -40°C to 120°C (-40°F to 248°F).
• At low temperatures (e.g., -40°C), they remain flexible and non-brittle—unlike glass, which becomes prone to cracking in freezing conditions.
• At high temperatures (e.g., 100°C), they retain their shape and rigidity—making them suitable for applications like oven windows (up to 120°C) or outdoor signage in hot climates.

(4) Chemical & Weather Resistance

• Chemical Resistance: They resist most common chemicals, including weak acids (e.g., vinegar), weak alkalis (e.g., soapy water), and oils—making them easy to clean and suitable for industrial settings (e.g., laboratory work surfaces). Note: They are not resistant to strong solvents or concentrated acids/alkalis, which can cause surface damage.
• Weather Resistance (with UV Coating): When equipped with a co-extruded UV layer (typically 5–10μm thick), they block 99% of UVA/UVB rays, preventing photo-oxidation (brittleness, yellowing) and extending outdoor lifespan to 15+ years. Uncoated sheets are best for indoor use (e.g., office partitions, display shelves).

(5) Lightweight & Easy Processing

• Weight: PC solid sheets weigh 50% less than glass (density: 1.2g/cm³ vs. glass’s 2.5g/cm³) and 10–15% less than acrylic. This reduces structural load on buildings or frames, lowers transportation costs, and simplifies installation (no heavy lifting equipment needed).
• Processability: They can be easily cut (with circular saws or utility knives), drilled (with standard metal drill bits), bent (via cold bending or heat forming), and bonded (with PC-compatible adhesives). Cold bending is particularly useful—sheets can be formed into gentle curves (minimum bending radius = 175× sheet thickness) for architectural designs (e.g., curved storefronts).

3. Common Applications by Industry