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Polycarbonate in Military Applications

Polycarbonate in Military Applications. Mahima Kishore Chelsea Korth Vedang Kothari Madeleine Oxley. TOPICS. History Cost Polymerization Structure Processing Material Properties Military Applications. History of Polycarbonate (PC).

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Polycarbonate in Military Applications

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  1. Polycarbonate in Military Applications Mahima Kishore Chelsea Korth Vedang Kothari Madeleine Oxley

  2. TOPICS • History • Cost • Polymerization • Structure • Processing • Material Properties • Military Applications

  3. History of Polycarbonate (PC) • 1953 Independently discovered by Dr. H. Schnell with Bayer in Germany and D.W. Fox with GE in the USA both using BPA • 1957USA began commercial production, 1958Germany • 1960’s Apollo 11 helmet visors made of PC • 1982 CD's and DVD's made of PC Apollo Lunar Surface Journal http://www.hq.nasa.gov/alsj/alsj-LEVA.html Nexant Inc. http://www.chemsystems.com/reports/search/docs/abstracts/0203-S8-abs.pdf http://www.bisphenol-a.org

  4. History Cont’d 1993GE launched “melt” (non-phosgene) method of polymerization (~15% of capacity) 2002launch of CO2 non-phosgene production of PC by Asahi Kasei Corp. in Japan 2008BPA free campaign began Green Chemistry http://www.chemsystems.com/reports/search/docs/abstracts/0203-S8-abs.pdf Health and Wellness: Gordon Edlin, pages 541-542

  5. Markets and Regions GPA Insight, October 2011 http://cde.cerosmedia.com/1G4e8429568c0d1012.cde/page/5 • Pre-Economic Downturn (pre-2007): • Optical Media • Electrical • Construction • Post-Economic Downturn (post 2011): • Automotive • Electrical • Construction • Medical

  6. Cost $1.63-1.78 per lb of general purpose molding and extrusion (bulk quantities) as of March 2012 *up $0.13 from January due to rising costs of feedstocks benzene and propylene. • Demand was 3.5 Million tons in 2011 • Growth is expected to 4.2 Million by 2016 Wesley Busch, ICIS http://www.icis.com/Articles/2012/03/14/9541737/us-polycarbonate-producers-largely-successful-with-price-hikes.html GPA Insight, October 2011 http://cde.cerosmedia.com/1G4e8429568c0d1012.cde/page/5

  7. Cost PolyOne, Polymer Comparison Charthttp://www.polyone.com/en-us/docs/Documents/Geon%20Rigid%20Polymer%20Comparison%20Chart_Technical_Bulletin.pdf

  8. Polymerization of Polycarbonate • Condensation Reaction • Bisphenol A with Phosgene • (HOC6H4)2CMe2 + 2 NaOH → (NaOC6H4)2CMe2 + 2 H2O • (NaOC6H4)2CMe2 + COCl2 → 1/n [OC(OC6H4)2CMe2]n + 2 NaCl • (HOC6H4)2CMe2 + (C6H5O)2CO → 1/n [OC(OC6H4)2CMe2]n + 2 C6H5OH http://i00.i.aliimg.com/photo/v0/246214738/multilayer_polycarbonate_sheets.jpg http://en.wikipedia.org/wiki/Polycarbonate

  9. Polymerization of Polycarbonates in Blends • Polycarbonate is blended with other polymers such as • PP – Miscible at low PP, and Immiscible at high PP • PET – Miscible after trans esterification • ABS – PC/SAN miscible and PC/PB immiscible • PS - Miscible • PBT- Miscible in melt and solid states • Improves properties such as: • Impact Strength • Toughness • Dimensional Stability • Heat Resistance • Die Swell During Extrusion http://www.sciencedirect.com/science/article/pii/025405848790023X http://onlinelibrary.wiley.com/doi/10.1002/app.11518/abstract http://www.sciencedirect.com/science/article/pii/004060319187193Z http://onlinelibrary.wiley.com/doi/10.1002/pen.760241708/abstract http://www.meplab.fudan.edu.cn/uploadfiles/2011311225613190435.pdf http://www.omnexus.com/tc/makroblend/index.aspx

  10. Processing Polycarbonate • Many different grades of PC for many different applications • Flame retardant, film, stress crack resistant … etc. • Main methods for processing • Injection Molding • Structural Foam Molding • Extrusion • Vacuum Forming • Blow Molding • Sheet Metal Techniques http://2.bp.blogspot.com/-KYtg618aUK8/ToHxYR4IpSI/AAAAAAAAAgc/UsvOdnz1CTE/s1600/Polycarbonate_extruder_drive.jpg http://www.isplc2006.org/b2b/pics/Corrugated_Polycarbonate_and_PC_Wave_Sheet.jpg www.kpolymers.com/polycarbonate.asp

  11. Processing Polycarbonate http://www.sporteyes.com/bugzsight.jpg http://www.gearculture.com/wp-content/uploads/2009/11/poc-synapsis-xp-ski-helmet.jpg

  12. Military Applications • Fighter planes • Sunglasses • Laptops • F-86 Sabre • 1st plane to have PC encased canopy • Superior strength • UN air superiority in Korean war

  13. American Fighter Aircraft • F-22 Raptor • 1st military grade fighter to have a monolith PC canopy • F-16 Fighting Falcon • Clear PC canopy give 360 degree view • Bird proof

  14. Beyond Aircraft – Field use laptops • Bullet proof rugged laptops- Dell and Panasonic • Fiberglass injected polycarbonate in screens • Polycarbonate casing

  15. Field Tactical Gear

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