release 09/1998
/
®
Lexan profile
contents update
100 kJ/m
2
80
Modulus
60
40
15000 MPa
12500
10000
20
7500
5000
0
2500
0
Lexan
150
100
C
50
0
0
"
40
nt
HB
80
120
V2
160
V1
200 MPa
V0
GE Plastics
®
Lexan profile
release 09/1998
/
EN
a
Lexan Profile 2 Contents
C o n t e n t s
1 Introduction . . . . . . . . . . . . . . . . . . . . 1
2 Markets . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Product Selection . . . . . . . . . . . . . . 8
4 Properties and Design . . . . . . . . . 26
4.1 General properties . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2 Mechanical properties . . . . . . . . . . . . . . . . . . . . . 26
4.3 Thermal properties . . . . . . . . . . . . . . . . . . . . . . . . 33
4.4 Flammability . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.5 Electrical properties . . . . . . . . . . . . . . . . . . . . . . 35
4.6 Aesthetics and optical properties . . . . . . . . . . . . 36
4.7 Environmental resistance . . . . . . . . . . . . . . . . . . . 37
4.8 Processibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.9 Mould shrinkage . . . . . . . . . . . . . . . . . . . . . . . . . 43
5 Processing . . . . . . . . . . . . . . . . . . . . . 44
5.1 Pre-drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.2 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.3 Processing conditions . . . . . . . . . . . . . . . . . . . . . 44
5.4 Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.5 Interruption of production . . . . . . . . . . . . . . . . . . 45
5.6 Purging of the barrel . . . . . . . . . . . . . . . . . . . . . . 45
5.7 Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6 Secondary Operations . . . . . . . . . 46
6.1 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.2 Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.3 Mechanical assembly . . . . . . . . . . . . . . . . . . . . . . 46
6.4 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.5 Metallisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.6 Laser marking . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1
Introduction
®
Lexan Polycarbonate Resins
PC
Lexan polycarbonate is an Lexan resins are tailor-made for a
amorphous engineering range of conversion processes
thermoplastic which is characterized including injection moulding,
by high levels of mechanical, optical, extrusion, blow moulding and foam
electrical and thermal properties. processing. High flow grades have
The Lexan portfolio provides broad been developed which are ideally
design versatility through its wide suited to thin wall, long flow length
range of viscosities and product applications.
options. These options include
halogen-free flame retardancy, impact After their first application life, Lexan
modification, glass-reinforcement, resins can be reground and reused.
optical quality and compliance with As is characteristic of an engineering
stringent FDA and USP requirements. thermoplastic, Lexan resins retain a
high residual value and, in many
The key properties which are cases, they can be recycled into
inherent in Lexan resin include: similar applications within the same
·High impact resistance over a wide industry. Alternatively, they can be
range of temperatures cascaded down for reuse in less
demanding applications.
·Glass clear transparency
·Wide range of colours
·High gloss, quality surface finish
·Excellent optical clarity
·Excellent heat resistance: almost all
grades pass 125°C ball pressure test
·Inherent limited flame retardancy:
all grades pass 850°C glow wire test
at 1.0 mm
Unreinforced Multi Purpose
Unreinforced Lighting
Injection moulding Unreinforced Optical
Glass Reinforced
Specialties
Linear Polymers
1
Extrusion Branched Polymers
Lexan
Flame Retarded CSTB M2
Glass Reinforced
Structural foam
Blowing Agent
2
Markets
Electrical
Lighting
Electrical Lighting
Telecommunications
With its broad portfolio of flame Lexan resin is well-established in
retarded and non-flame retarded the lighting industry, providing
Optical
grades, both unreinforced and glass manufacturers with lightweight,
reinforced, Lexan resin is found in quality parts, fast cycle times through
Automotive lighting
a wide range of electrical products. consistent processibility and
These include meter and fuse box unlimited opportunities for design
Appliances
housings, domestic switches, plugs integration and intricate, snap-fit
and sockets, switchgear, relays and assembly.
Packaging
connectors. Typical applications include linear
fluorescent luminaires, street lamps,
Table- and kitchen-ware
Lexan resin s key properties for the traffic lights, spotlights, reflectors,
electrotechnical industry include its: lamp holders, emergency lights,
Medical
·Halogen-free* flame retarded system, explosion-proof lights, conduits,
with most grades passing the Glow electrical supply track systems and
Optical disc storage
Wire Test at 850°C diffusers where Lexan resin features:
Extrusion
·Excellent thermal properties with all ·Outstanding impact resistance over
grades passing the Ball Pressure Test a wide range of temperatures, from
at 125°C sub-zero to +125°C
·Quality surface finish, high gloss or ·Excellent optical properties
textured, in a wide range of colours
·High heat resistance, with an HDT
under load of 133°C
·High impact resistance
·Good resistance to tracking and ·Excellent dimensional stability and
arcing (CTI >175 volts) low uniform shrinkage
·Constant electrical properties in ·Good resistance to tracking and
aggressive environments arcing (CTI >175 volts)
·Excellent processibility ·Good UV stability
·Compatibility with lasermarking ·Inherent corrosion resistance and
process long-term weatherability; scratch and
chemical resistance can be further
In addition, Lexan 3412R offers a increased through the application of
V0 flammability rating at wall a GE Silicones hardcoat
thicknesses of 0.8 mm according
·Wide range of transparent and
to UL94 to meet the most critical opaque colours
performance requirements of thin
walled connectors. Lexan 900 series
is specified for applications where
extremely low smoke evolution is a
requirement.
2
* in accordance with
DIN VDE472 part 815
Lexan Profile 2 Markets
Telecommunications Optical
Lexan resin is the material of choice The family of Lexan optical quality
·High temperature resistance allowing
for a range of indoor and outdoor (OQ) resins has been specifically the application of various anti-scratch
telecommunications enclosures, developed for the optical industry. coatings
including power supply connection The range includes high impact
·Excellent dimensional stability and
boxes and base-stations, where it grades for safety goggles, optical low water absorption
features: quality clean-room grades for
·High refractive index of 1.586 which
corrective lenses and grades offering allows the production of lenses which
·High temperature resistance
maximum UV screening up to are up to 20% thinner than with
·Good impact strength
400 nm for sunglasses and ski visors. traditional materials
·Good dimensional stability
·Good UV stability ·Low specific gravity compared to
Lexan OQ resins pass internationally traditional materials, producing
·Halogen-free* flame retarded
recognized industry standards lighter lenses
·Quality aesthetics
offering a tailor-made property
·Fast, cost-efficient injection moulding
Lexan structural foam grades are portfolio which includes: cycles and a high degree of precision
an ideal choice for structural
· Water white clarity, achieved ·Unlimited design freedom to create
components where load-bearing through proprietary technology two-and three-dimensional shapes
capability at elevated temperatures
·Light transmission >88%
is a key requirement. They are an
·Built-in UV screen
excellent alternative to metal or
·High impact resistance across
other plastics for the efficient temperatures ranging from
production of large parts such sub-zero to +125°C
as outdoor distribution cabinets.
Here they provide important weight
savings through an inherently high
stiffness to weight ratio. Furthermore,
for optimum UV protection, parts
can be easily painted.
3
* in accordance with
DIN VDE472 part 815
Lexan Profile 2 Markets
Automotive lighting Appliances
Tough, lightweight Lexan LS resins Lexan resin is also ideally suited to Lexan resin is widely used in the
have been specifically developed for the production of bezels which can appliances industry for products such
headlamp lenses. Their unlimited be metallized without the use of a as food mixers and processors, steam
design flexibility and moulding primer or lacquer. Manufacturers can iron water tanks and oven control
precision allows them to be formed produce lightweight, state-of-the-art panels where its key features are its:
into complex shapes. Accurate parts with optimum cost-efficiency
·Exceptional practical impact
refraction planes provide exceptional thanks to Lexan resin s inherent resistance
lighting performance, while design freedom and opportunities
·High heat resistance
integrated fixings reduce for thin wall moulding and part
·Consistent processibility
components and simplify assembly. integration.
·High quality glass-like transparency
GE Silicones proprietary hardcoating and gloss
system provides optimum abrasion
·Wide range of colours, with many
resistance throughout the life of colours having transparent and
the vehicle. As well as providing translucent as well as opaque versions
manufacturers with consistent high
·Inherent design freedom
quality, Lexan resin can considerably
enhance productivity when the lens For products like vacuum cleaner
is designed as part of a total lighting motor end-caps, diffusers and brush
system. holders which require superior
rigidity and stiffness, glass-filled
Lexan polycarbonate offers high
modulus and high impact
performance, combined with ease
of assembly through unlimited
opportunities for design integration
and intricate, snap-fit assembly.
4
Lexan Profile 2 Markets
Packaging
Following market trends for cost The use of Lexan polycarbonate expectancy compared with glass
reduction and product returnable milk bottles is well- products. Tailor-made branched
differentiation, GE Plastics has established as a cost-effective, user- resin, Lexan PKG1643, offers
recently developed in partnership and environment-friendly alternative moulders the ability to produce
with industry two innovative to glass and to one-way disposable a high quality water bottle with a
appliance concepts which cartons and plastic bottles. Popular more uniform wall thickness.
demonstrate the unique advantages with dairy, distributor and consumer
of using Lexan polycarbonate. The alike, the Lexan resin bottle can be In food packaging applications,
first is an oven door which features: washed and refilled up to 50 times Lexan resin can also be used as a top
·Cool-to-the-touch properties which while maintaining excellent taste layer in the coextrusion of multi-layer
are due to the thermal conductivity neutrality and its characteristic high film where it provides:
of Lexan resin being down to four quality, glass-like transparency.
·High mechanical strength
times less than that of glass
·High heat resistance
·Cost-efficient product differentiation The key advantages of Lexan resin ·High gloss
through in-mould finishing which in milk packaging are its:
·Good slip, anti-blocking and film
involves placing a pre-printed, winding properties
·Glass-like transparency and gloss
vacuum formed Lexan film in the
·Excellent taste and aroma protection
door mould prior to injection in compliance with FDA and
moulding European food contact regulations
·Inherent design freedom for cost- ·High impact properties and practical
efficient styling advantages to achieve, toughness for safe handling
for example, fashionable, rounded
·High temperature resistance to
shapes withstand repeated wash cycles
·Enhanced productivity through snap- ·Light weight for ease of handling and
fit assembly cost-effective transportation
·Compatibility with existing materials
The second design concept is an handling systems
injection moulded, circular dryer
·Wide design flexibility for a diversity
door. This single component of bottle shapes, sizes and features
comprises an integrated locking
·Wide range of colours
mechanism, frame, bull s-eye window
·Recyclability for use in other non-
and hinge. Cost-effective variations in food applications
colour and decoration can be easily
achieved through in-mould finishing. Lexan resin is also used in the
production of water bottles where,
as with milk packaging, its key
properties are its taste neutrality,
high temperature resistance for
cleanability and its long life
5
Lexan Profile 2 Markets
Table- and kitchen-ware Medical
Lexan polycarbonate table- and Lexan polycarbonate meets the The key properties of Lexan resin
kitchen-ware is well-established in requirements of the FDA and USP in medical applications are its:
the domestic, commercial and Chapter XXII Class V1 for use in the
·High impact resistance
institutional catering markets. medical industry. It is widely used for
·High temperature resistance
In addition to full compliance with a variety of medical devices and
·Glass-like clarity
FDA and European food legislation, equipment including trocar tubes,
·Good processibility
Lexan resin offers these markets the syringes, dialysis apparatus, blood
·Design versatility
following key benefits: filters and blood oxygenators.
·Inherent high impact strength and Products can be sterilized by all three
practical toughness for products commonly used methods: gamma
which are virtually unbreakable radiation, EtO gas and steam
·Excellent thermal and dimensional (autoclave). Superior colour stability
stability allowing repeated washing at and resistance to yellowing following
high temperatures and reheating of gamma or EtO sterilisation is a key
foodstuffs using hot air, water bath feature of tailor-made Lexan GR
or microwave oven grades.
6
Lexan Profile 2 Markets
Optical disc storage Extrusion
With dedicated manufacturing Specially developed UV-stable Lexan
facilities in the Netherlands, USA extrusion resins can be readily
and Japan, GE Plastics is the only extruded on conventional
global supplier of polycarbonate equipment. The range includes both
resins to optical disc market. Tailor- linear and branched polymers for
made Lexan Optical Quality (OQ) solid, multi- and twin-wall sheet
resins are renowned for their extrusion.
excellent product consistency, both
in terms of purity and processibility. In general, Lexan extrusion grades
Due to their low molecular weight, offer:
these materials have an ultra-high
·Consistent ease of processing
melt flow rate which allows the
·Excellent surface finish and
moulding of discs with very low transparency
birefringence and excellent pit and
·Outstanding impact performance
track replication.
In addition, glass clear UV cap-layer
Working closely with its industry materials have been specifically
partners, GE Plastics continues to developed to improve the UV
push forward with state-of-the-art performance of extruded solid, multi-
materials and process technology and twin-wall polycarbonate sheet.
which will revolutionize the For typical applications such as
production of new optical media. roofing sheets, these unique materials
Included in recent developments is meet critical industry standards for
a further improved flow Lexan OQ outdoor weatherability, while
resin which features lower providing enhanced productivity.
birefringence, enhanced surface
replication and superior flatness
for the DVD format.
7
3
Product Selection
Lexan 100 Series Lexan HF Series (High Flow)
(Unreinforced, Non-Flame Retarded)
·Formulated using a unique
chemical modification of the base
·Wide viscosity range:
120 series: low viscosity polycarbonate polymer
140 series: low to medium viscosity
·Very low viscosity levels with minimal
160 series: medium viscosity reduction in inherent properties
100 series: high viscosity
·Ideally suited to thin wall, high flow
130 series: very high viscosity length applications
·R grades have easy release ·All grades have easy release
characteristics characteristics
·1x3R grades are UV stabilized ·HF1130R is UV stabilized
·1x4R grades comply with various ·HF1140R is suitable for food and
food contact regulations medical applications
non-flame retarded 1xy series see page 9
·All grades have wide colour
availability
flame retarded UL94V2 2xy series
Unreinforced Multi purpose
flame retarded UL94V0 see page 11
flame retarded CSTB M2
Unreinforced Lighting lens system · optimal clarity
data storage disks
Unreinforced Optical eyewear
see page 13
high reflectivity
Injection moulding
normal glass
Glass Reinforced
short glass
impact modified
Specialties gamma sterilizable
reduced property profile
Lexan
hydrolytic stability
8
Linear Polymers
high melt strength
see page 15
hydrolytic stability
Extrusion Branched Polymers
high melt strength
Flame Retarded CSTB M2
Glass Reinforced 5% normal glass
Structural foam
Blowing Agent chemical concentrate
Lexan Profile 3 Product Selection
" "
lowest 140°C 12 (4) kJ/m2 2300 MPa
ML3729
"
V2/0.80 mm 40 cm3/10min
viscosity
UV stability
" "
140°C 12 (10) kJ/m2 2300 MPa
HF1140R
"
V2/1.09 mm 26 cm3/10min
food, medical & toys
" "
140°C 12 (10) kJ/m2 2300 MPa
HF1130R
"
V2/1.60 mm 26 cm3/10min
UV stability
" "
very low 140°C 12 (10) kJ/m2 2300 MPa
HF1110R
"
V2/1.09 mm 26 cm3/10min
viscosity
" "
141°C 12 (10) kJ/m2 2300 MPa
124R
"
HB/1.14 mm 21 cm3/10min
food, medical & toys
" "
141°C 12 (10) kJ/m2 2300 MPa
123R
"
HB/1.47 mm 21 cm3/10min
UV stability
" "
120 series 141°C 12 (10) kJ/m2 2300 MPa
121 /121R
"
HB/1.14 mm 21 cm3/10min
low viscosity
" "
142°C 25 (10) kJ/m2 2300 MPa
144R
non-flame
"
HB/1.14 mm 12 cm3/10min
retarded
food, medical & toys
1xy series
" "
142°C 25 (10) kJ/m2 2300 MPa
143/143R
"
HB/1.47 mm 12 cm3/10min
UV stability
140 series
" "
142°C 25 (10) kJ/m2 2300 MPa
low to medium
141 /141R
"
HB/1.14 mm 12 cm3/10min
viscosity
" "
145°C 60 (10) kJ/m2 2300 MPa
164R
"
HB/1.14 mm 9 cm3/10min
food, medical & toys
" "
145°C 60 (10) kJ/m2 2300 MPa
163R
"
HB/1.47 mm 9 cm3/10min
UV stability
160 series
" "
145°C 60 (10) kJ/m2 2300 MPa
medium
161R
"
HB/1.14 mm 9 cm3/10min
viscosity
Unreinforced
Multi purpose
" "
145°C 65 (10) kJ/m2 2300 MPa
104R
"
HB/1.14 mm 6 cm3/10min
food, medical & toys
" "
145°C 65 (10) kJ/m2 2300 MPa
103/103R
"
HB/1.47 mm 6 cm3/10min
UV stability
Injection
" "
100 series 145°C 65 (10) kJ/m2 2300 MPa
moulding 101 /101R
"
HB/1.14 mm 6 cm3/10min
high viscosity
130 series
" "
145°C 65 (10) kJ/m2 2300 MPa
highest
134R
"
V2/1.60 mm 3 cm3/10min
viscosity
food, medical & toys
FLOW
9
flame retarded UL94V2 2xy series
flame retarded UL94V0 see page 11
Lexan
flame retarded CSTB M2
Unreinforced Lighting
Unreinforced Optical see page 13
Glass Reinforced
Specialties see page 15
see page 15
Lexan Profile 3 Product Selection
Lexan 200 Series Lexan 900 Series
(Unreinforced, Flame Retarded) (Unreinforced, Flame Retarded)
·Differing levels of viscosity: ·Transparent and opaque UL94 flame
220 series: low viscosity class rated grades
240 series: low to medium viscosity
·Available in different melt viscosities
260 series: medium viscosity
·All products have easy release
200 series: high viscosity characteristics
·R grades have easy release ·9x3 and 9x3A grades are UV
characteristics stabilized
·2x3R grades are UV stabilized ·9xy series are available only in opaque
colours
·All grades have wide colour
availability
·9xyA series are available in opaque
and transparent colours
·All grades are rated UL94 V2
at measured thickness
" "
Heat Impact Modulus
GRADE
"
Flammability Flow
Grade:  R grades show  easy release
10
Heat: Vicat B/120 in °C (ISO 306)
Impact: Izod Notched at 23 (-30)°C
in kJ/m2 (ISO 180/1A)
Modulus: Flexural in MPa (ISO 178)
Flammability: Flame class at mm thickness
(UL94)
Flow: MVR at 300°C/1.2kg
in cm3/10min (ISO1133)
Flow*: MVR at 250°C/1.2kg
in cm3/10min (ISO1133)
n.t.: not tested · NB: not broken
 all colours means  available in transparent,
translucent and opaque colours, unless
otherwise indicated
Lexan Profile 3 Product Selection
non-flame retarded 1xy series see page 9
" "
141°C 12 (10) kJ/m2 2300 MPa
223R
"
V2/1.47 mm 21 cm3/10min
UV stability
" "
220 series 141°C 12 (10) kJ/m2 2300 MPa
221R
"
V2/1.14 mm 21 cm3/10min
low viscosity
" "
142°C 25 (10) kJ/m2 2300 MPa
243R
"
V2/1.47 mm 12 cm3/10min
UV stability
240 series
" "
142°C 25 (10) kJ/m2 2300 MPa
low to medium
241R
"
V2/1.14 mm 12 cm3/10min
viscosity
flame retarded " "
145°C 60 (10) kJ/m2 2300 MPa
263R
"
UL94 V2 2xy series V2/1.47 mm 9 cm3/10min
UV stability
260 series
" "
145°C 60 (10) kJ/m2 2300 MPa
medium
261R
"
V2/1.14 mm 9 cm3/10min
viscosity
" "
145°C 65 (10) kJ/m2 2300 MPa
203R
"
V2/1.47 mm 6 cm3/10min
UV stability
" "
200 series 145°C 65 (10) kJ/m2 2300 MPa
201R
"
V2/1.14 mm 6 cm3/10min
high viscosity
FLOW
" "
141°C 9 (7) kJ/m2 2300 MPa
923
"
V0/1.00 mm 21 cm3/10min
Unreinforced
UV stability
Multi purpose
" "
141°C 9 (7) kJ/m2 2300 MPa
low viscosity
920
"
V0/1.04 mm 21 cm3/10min
" "
142°C 12 (11) kJ/m2 2300 MPa
943
"
V0/1.00 mm 9.5 cm3/10min
UV stability
" "
opaque medium 142°C 12 (11) kJ/m2 2300 MPa
940
"
V0/1.04 mm 9.5 cm3/10min
colours viscosity
" "
145°C 15 (n.t.) kJ/m2 2300 MPa
high viscosity
950
"
V0/1.04 mm 6.5 cm3/10min
FLOW
flame retarded " "
142°C 10 (nt) kJ/m2 2300 MPa
923A
"
UL94 V0 V0/3.20 mm 12 cm3/10min
UV stability
" "
low to medium 142°C 10 (nt) kJ/m2 2300 MPa
920A
"
V0/3.05 mm 12 cm3/10min
viscosity
Injection
all " "
142°C 12 (10) kJ/m2 2300 MPa
943A
moulding
"
colours V0/3.20 mm 9.5 cm3/10min
UV stability
" "
medium 142°C 12 (10) kJ/m2 2300 MPa
940A
"
V0/3.05 mm 9.5 cm3/10min
viscosity
FLOW
" "
145°C 8 (8) kJ/m2 2300 MPa
11
2034
"
V2/1.50 - V0/2.50 mm 8.5 cm3/10min
UV stability
" "
flame retarded medium 145°C 8 (8) kJ/m2 2300 MPa
2014R
Lexan
"
V2/1.47 mm 8.5 cm3/10min
CSTB M2 viscosity
easy release
Unreinforced Lighting
Unreinforced Optical see page 13
Glass Reinforced
Specialties see page 15
see page 15
Lexan Profile 3 Product Selection
Lexan LS Series (Lens System) Lexan Glass Reinforced, Flame
Retarded Series
·Specifically developed for parts
requiring high optical quality,
·UL94 flame class rated grades
i.e. clarity and light transmission
·Range of multi purpose, standard
length glass fibre reinforced grades,
·Range of viscosity levels
complemented by a short glass fibre
·Lexan LS2 meets all global
automotive OEM specifications in grade with superior dimensional
the US, Europe and Asia, including stability
SAE 576, the global standard for
·10% to 40% glass reinforced grades
outdoor weathering
·Excellent rigidity, high heat resistance
and superior impact strength
·All grades have easy release
characteristics compared with other filled resins
·Highly stable mechanical and
Lexan Optical Series electrical properties
·Tailor-made Lexan OQ (Optical ·Lower coefficient of thermal
Quality) resins satisfy stringent purity expansion and reduced mould
requirements of optical data storage shrinkage
discs
·Availability in different viscosity levels
·Grade with ultra-high melt flow rate ·R grades have easy release
and lower birefringence for high characteristics
density DVD market
·Grades for LCD s available with
different melt viscosities
·Special grades for ophthalmic and
safety lenses with superior properties
to acrylic and glass
·Range of transparent colours
complemented by opaque white for
a very high degree of reflectivity
" "
Heat Impact Modulus
GRADE
"
Flammability Flow
Grade:  R grades show  easy release
12
Heat: Vicat B/120 in °C (ISO 306)
Impact: Izod Notched at 23 (-30)°C
in kJ/m2 (ISO 180/1A)
Modulus: Flexural in MPa (ISO 178)
Flammability: Flame class at mm thickness
(UL94)
Flow: MVR at 300°C/1.2kg
in cm3/10min (ISO1133)
Flow*: MVR at 250°C/1.2kg
in cm3/10min (ISO1133)
n.t.: not tested · NB: not broken
 all colours means  available in transparent,
translucent and opaque colours, unless
otherwise indicated
Lexan Profile 3 Product Selection
Unreinforced Multi purpose see page 11
" "
141°C 12 (10) kJ/m2 2300 MPa
low viscosity
LS1
"
HB/1.47 mm 21 cm3/10min
UV Stability
light
" "
Unreinforced lens system transmission low to medium 142°C 25 (11) kJ/m2 2300 MPa
LS2
"
HB/1.47 mm 12 cm3/10min
Lighting optimal clarity transparent viscosity
colours
UV Stability
" "
145°C 60 (10) kJ/m2 2300 MPa
high viscosity
LS3
"
HB/1.47 mm 6 cm3/10min
UV Stability
FLOW
" "
data storage very low 142°C 10 (4) kJ/m2 2300 MPa
OQ1020LN
"
n.t. 11*cm3/10min
disks viscosity
transparent colours
" "
Unreinforced UV cut-off medium 142°C 65 (11) kJ/m2 2300 MPa
eyewear
OQ4320
"
n.t. 12 cm3/10min
Optical 400 nm viscosity
UV Stability
opaque white
" "
145°C 50 (15) kJ/m2 2500 MPa
high
high pigment high viscosity
ML3042
"
n.t. 6 cm3/10min
reflectivity
loading
" "
143°C 8 (8) kJ/m2 3400 MPa
503R
"
V0/1.47 - 5VA/3.05 mm 8 cm3/10min
UV Stability
" "
143°C 8 (8) kJ/m2 3400 MPa
500R
"
V0/1.47 - 5VA/3.05 mm 8 cm3/10min
medium
viscosity
" "
142°C n.t. (n.t.) 3400 MPa
ML3019
"
V0/1.60 mm 8 cm3/10min
10%
low knock-out strength
" "
143°C 6 (6) kJ/m2 3400 MPa
high viscosity
2814R
"
V0/1.47 mm 6 cm3/10min
CSTB M1
" "
low to medium 143°C 8 (8) kJ/m2 4000 MPa
15%
ML3260
"
V1/1.60 mm 11 cm3/10min
viscosity
easy release
Injection
moulding normal glass
" "
low to medium 143°C 8 (8) kJ/m2 5000 MPa
1278R
"
V1/1.57 mm 12 cm3/10min
viscosity
low knock-out strength
20%
" "
145°C 8 (6) kJ/m2 5500 MPa
high viscosity
3412R
"
V0/0.80 mm 6 cm3/10min
Glass 13
" "
145°C 8 (6) kJ/m2 7000 MPa
30% high viscosity
Reinforced 3413R
"
V0/1.47 mm 5 cm3/10min
Lexan
" "
145°C 8 (6) kJ/m2 8500 MPa
40% high viscosity
3414R
"
V0/1.50 mm 4 cm3/10min
" "
150°C 8 (8) kJ/m2 4500 MPa
short glass 30% high viscosity
ML3513
"
V0/1.50 mm 4 cm3/10min
dimensional stability · low warpage
Specialties see page 15
see page 15
Lexan Profile 3 Product Selection
Lexan Specialties Lexan Extrusion and
The Lexan range of specialty Blow Moulding Series
products can be divided into  Impact
·Extrusion, injection blow moulding
Modified ,  Gamma Sterilizable and and extrusion blow moulding grades
 Reduced Properties .
·Linear and branched polymers
·Lexan resins with enhanced impact at ·CSTB M2 rated material available
sub-zero temperatures are available in
·Tailor-made grades meet specific
high and low viscosity grades, offering requirements for UV stability,
increased resistance to chemicals hydrolytic stability and compliance
such as paint systems with food contact regulations
·Lexan GR resins offer gamma
resistance for medical applications. Lexan Structural Foam Moulding
These tailor-made grades provide Series
excellent colour stability and
·Stress-free mouldings particularly
resistance to yellowing after gamma suitable for large parts
radiation
·High heat distortion, combined with
·Lexan resins with reduced properties good flame retardancy and high
are available in both unreinforced electrical resistivity
and glass reinforced grades for
·5% glass filled foam grades
applications with less critical impact
·Tailor-made low pressure chemical
requirements blowing agent for standard and
increased process temperatures
" "
Heat Impact Modulus
GRADE
"
Flammability Flow
Grade:  R grades show  easy release
14
Heat: Vicat B/120 in °C (ISO 306)
Impact: Izod Notched at 23 (-30)°C
in kJ/m2 (ISO 180/1A)
Modulus: Flexural in MPa (ISO 178)
Flammability: Flame class at mm thickness
(UL94)
Flow: MVR at 300°C/1.2kg
in cm3/10min (ISO1133)
Flow*: MVR at 250°C/1.2kg
in cm3/10min (ISO1133)
n.t.: not tested · NB: not broken
 all colours means  available in transparent,
translucent and opaque colours, unless
otherwise indicated
Lexan Profile 3 Product Selection
Unreinforced Multi purpose see page 11
Unreinforced Lighting
Unreinforced Optical see page 13
Glass Reinforced
" "
medium 141°C 58 (17) kJ/m2 2300 MPa
UL94V2
ML3041
"
V2/1.00 mm 10 cm3/10min
viscosity
impact opaque colours
modified
" "
142°C 58 (50) kJ/m2 2150 MPa
Injection
ML3400
"
n.t. 8 cm3/10min
moulding high ductility
medium
opaque colours
at below zero
viscosity
temperatures
" "
140°C 65 (40) kJ/m2 2150 MPa
ML3459
"
n.t. 9 cm3/10min
opaque colours
" "
gamma easy release medium 131°C 11 (8) kJ/m2 2400 MPa
Specialties
GR1210
"
n.t. 14 cm3/10min
sterilizable unreinforced viscosity
limited colours
" "
138°C 15 (10) kJ/m2 2100 MPa
unreinforced low viscosity
ML3562
"
V2/1.00 mm 24 cm3/10min
reduced
property
limited colours
profile
" "
17% glass low to medium n.t. NB (20) kJ/m2 4500 MPa
ML3286
"
n.t. 12 cm3/10min
reinforced viscosity
limited colours
Lexan
" "
hydrolytic UV stability profile 146°C 60 (13) kJ/m2 2300 MPa
ML3021A
"
HB/1.60 mm 4 cm3/10min
stability heat stability extrusion
Linear
transparent colours
Polymers
" "
148°C 65 (13) kJ/m2 2300 MPa
high melt outdoor
solid sheet
ML3403
"
n.t. 5 cm3/10min
strength performance
transparent colours
" "
143°C 60 (10) kJ/m2 2300 MPa
hydrolytic
food contact blow moulding
154
"
n.t. n.t.
stability
limited colours
" "
high melt extrusion blow 143°C 60 (10) kJ/m2 2300 MPa
food contact
PKG1643
"
n.t. n.t.
strength moulding
Branched
transparent colours
Extrusion
Polymers
" "
light twin-wall sheet 143°C 60 (10) kJ/m2 2300 MPa
ML3324
"
HB/1.50 mm n.t.
transmission extrusion
transparent colours
UV stability
" "
flame retarded 135°C 15 (10) kJ/m2 2300 MPa
outdoor
ML3290
"
V0/2.00 mm1) n.t.
extrusion
performance
limited colours
1
)
UL rating V0/2.0 of ML3290 is only valid for clear colours
Flame
" "
148°C 8 (8) kJ/m2 2300 MPa
15
Retarded UV stability
2034E
"
n.t. n.t.
CSTB M2
limited colours
impact,
" "
n.t. n.t. n.t.
Glass 5% normal
heat & creep
FL900P
"
n.t. 10 cm3/10min
Reinforced glass
resistance
Structural
foam
Blowing chemical
FLC95
Agent concentrate
Lexan Profile 3 Product Selection page 16
Unit Test Method Test Specimen
Typical Properties
MPTS (multi-purpose test speci-
men) as defined in ISO 3167.
Smaller test specimens may be
Typical values only. ISO DIN ASTM machined from MPTS.
Variations within normal tolerances are possible for various colours. IEC* VDE* other* All dimensions in mm.
Mechanical
Tensile stress at yield [at break] at 50 mm/min MPa 527
at break at 5 mm/min MPa 527 MPTS (150 x 20/10 x 4)
Tensile strain at yield [at break] at 50 mm/min % 527
at break at 5 mm/min % 527 MPTS
Tensile modulus at 1 mm/min MPa 527 MPTS
Flexural stress at yield [at break] at 2 mm/min MPa 178 80 x 10 x 4
Flexural modulus at 2 mm/min MPa 178 80 x 10 x 4
Hardness Ball indentation H 358/30 MPa 2039-1 50 x 50 x 4
Abrasion resistance Taber, CS-17, 1 kg per 1000 cycles mg/1000 cy GE*
Impact
Izod notched at +23°C [-30°C] kJ/m2 180-1A
unnotched at +23°C [-30°C] kJ/m2 180-1U 80 x 10 x 4
Thermal
Vicat A/50 10N (method A) at 50°C/h °C 306
B/50 50N (method B) at 50°C/h °C 306 110 x 10 x 4
B/120 50N (method B) at 120°C/h °C 306
HDT/Ae 1.80 MPa edgewise, span 120 mm at 1.80 MPa °C 75/Ae
/Be 0.45 Mpa at 0.45 MPa °C 75/Be 110 x 10 x 4
Ball pressure passes at °C °C 695-10-2
1
Relative Temperature Index RTI Electrical properties °C UL746B* )
Mechanical properties with Impact °C UL746B*
Mechanical properties without Impact °C UL746B*
Thermal conductivity W/m°C 52612 C177
2
)
Coefficient of Thermal Expansion CTE in flow direction 1/°C 53752 D696
Flammability
1
UL94 rating flame class rating at mm thickness class at mm UL94* 125 x 13, thickness as noted )
3
)
3
)
Limited Oxygen Index LOI % 4589 D2863 150/80 x 10 x 4
Glow wire passed at °C at mm thickness °C at mm 695-2-1*
Electrical
Dielectric strength in oil at 0.8 mm / 1.6 mm / 3.2 mm kV/mm 243* D149
Surface resistivity Ohm 93* D257
Volume resistivity Ohm·cm 93* D257
Relative permittivity or Dielectric constant at 50 Hz  250* D150
at 1 MHz  250* D150
Dissipation factor or Loss tangent at 50 Hz  250* D150
at 1 MHz  250* D150
4
)
Comparative Tracking Index CTI 50 drops [M: wetting agent] V 112/3rd* D3638
Physical
Density g/cm3 1183 D792
Water absorption at saturation at 23°C, in water % 62 53495 D570
5
)
Mould shrinkage in flow direction % 527 D955
Optical
Light transmission % D1003
Haze % D1003
Refractive index  489
Rheological
Melt Volume Rate MVR at 300°C / 1.20 kg cm3/10 min 1133 53735 granules
1 4
) as recognized on UL yellow cards; UL recognition may differ with colour ) values may differ with pigmented materials
2 5
) values may differ with glass fibre orientation ) only typical data for material selection purposes - not to be
3
) these ratings are not intended to reflect hazards presented by this or used for part/tool design; for glass reinforced grades: values
other material under actual fire conditions may differ with glass fibre orientation
Lexan Profile 3 Product Selection page 17
Injection moulding page 21
Unreinforced Multi purpose page 19
non-flame retarded 1xy series page 18
lowest
very low viscosity low viscosity low to medium viscosity
viscosity
ML3729 HF1110R HF1130R HF1140R 121/121R 123R 124R 141/141R 143/143R 144R
60 (55) 63 (50) 63 (50) 63 (50) 63 (65) 63 (65) 63 (65) 63 (70) 63 (70) 63 (70)
         
6 (70) 6 (70) 6 (70) 6 (70) 6 (100) 6 (100) 6 (100) 6 (110) 6 (110) 6 (110)
         
2300 2350 2350 2350 2350 2350 2350 2350 2350 2350
85 ( ) 90 ( ) 90 ( ) 90 ( ) 90 ( ) 90 ( ) 90 ( ) 90 ( ) 90 ( ) 90 ( )
2300 2300 2300 2300 2300 2300 2300 2300 2300 2300
95 95 95 95 95 95 95 95 95 95
10 10 10 10 10 10 10 10 10 10
12 (4) 12 (10) 12 (10) 12 (10) 12 (10) 12 (10) 12 (10) 25 (10) 25 (10) 25 (10)
NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB)
145 145 145 145    153 153 153
139 139 139 139 140 140 140 141 141 141
140 140 140 140 141 141 141 142 142 142
121 121 121 121 122 122 122 125 125 125
133 133 133 133 133 133 133 136 136 136
125 125 125 125 125 125 125 125 125 125
n.t. 125 n.t. 125 130 130 130 130 130 130
n.t. 115 n.t. 115 125 125 125 125 125 125
n.t. 125 n.t. 125 125 125 125 125 125 125
0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20
7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5
V2/0.8*) V2/1.09 V2/1.60 V2/1.09 HB/1.14 HB/1.47 HB/1.14 HB/1.14 HB/1.47 HB/1.14
1 1
) )
25 28 25 25 25 25 25 25 25 25
850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0
2 2
) )
35 / 27 / 17 35 / 27 / 17 n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 17
>1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015
>1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015
3 3
) )
2.7 2.7 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0
4 4
) )
2.6 2.6 2.9 2.9 2.9 2.9 2.9 2.9 2.9 2.9
0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001
0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01
n.t. 250 n.t. n.t. n.t. n.t. n.t. 250 250 n.t.
1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.20
0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35
0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70
88 - 90 88 - 90 88 - 90 88 - 90 88 - 90 88 - 90 88 - 90 88 - 90 88 - 90 88 - 90
< 0.8 < 0.8 < 0.8 < 0.8 < 0.8 < 0.8 < 0.8 < 0.8 < 0.8 < 0.8
1.586 1.586 1.586 1.586 1.586 1.586 1.586 1.586 1.586 1.586
40 26 26 26 21 21 21 12 12 12
4
*) UL94 in-house tested ) Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6 NB : not broken ·  : not relevant · n.t.: not tested
1 5
) LOI of 121R, 141R and 101R is 28 ) MVR of OQ1020LN at 250°C/1.20 kg
2 6
) 1141R and 101R is 35 / 27 / 17 ) MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg
3 7
) Relative permittivity at 50 Hz of ) MVR of ML3324 and ML3290 at 300°C/2.16 kg
121R, 141R and 101R is 2.7
Lexan Profile 3 Product Selection page 18
Injection moulding page 21
Unreinforced Multi purpose page 19
Typical Properties
page 17 non-flame retarded 1xy series
Typical values only.
Not to be used for
highest
medium viscosity high viscosity
specification purposes.
viscosity
161R 163R 164R 101/101R 103/103R 104R 134R
Mechanical Unit
Tens. stress y (b) 50 MPa 63 (70) 63 (70) 63 (70) 63 (70) 63 (70) 63 (70) 63 (70)
b 5 MPa       
Tens. strain y (b) 50 % 6 (120) 6 (120) 6 (120) 6 (120) 6 (120) 6 (120) 6 (120)
b 5 %       
Tens. modulus MPa 2350 2350 2350 2350 2350 2350 2400
Flex. stress y (b) MPa 90 ( ) 90 ( ) 90 ( ) 90 ( ) 90 ( ) 90 ( ) 90 ( )
Flex. modulus MPa 2300 2300 2300 2300 2300 2300 2300
Hardness Ball MPa 95 95 95 95 95 95 95
Abrasion Taber mg/1000 cy 10 10 10 10 10 10 10
Impact
Izod notch. 23° (-30°) C kJ/m2 60 (10) 60 (10) 60 (10) 65 (10) 65 (10) 65 (10) 65 (10)
unnotch. 23° (-30°) C kJ/m2 NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB)
Thermal
Vicat A/50 °C       
B/50 °C 143 143 143 144 144 144 144
B/120 °C 145 145 145 145 145 145 145
HDT/ Ae 1.80 MPa °C 127 127 127 127 127 127 131
/ Be 0.45 Mpa °C 138 138 138 138 138 138 140
Ball Pressure °C 125 125 125 125 125 125 125
RTI Electrical °C 130 130 130 130 130 130 n.t.
Mech. with Impact °C 125 125 125 125 125 125 n.t.
without Impact °C 125 125 125 125 125 125 n.t.
Thermal conductivity W/m°C 0.20 0.20 0.20 0.20 0.20 0.20 0.20
CTE flow 1/°C 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5
Flammability
UL94 class at mm HB/1.14 HB/1.47 HB/1.14 HB/1.14 HB/1.47 HB/1.14 V2/1.60*)
1
)
LOI % 28 25 25 25 25 25 25
Glow wire °C at mm 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0
Electrical
2
)
Diel. str. oil 0.8 / 1.6 / 3.2 mm kV/mm 35 / 27 / 17 n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 16
Surface resistivity Ohm >1015 >1015 >1015 >1015 >1015 >1015 >1015
Volume resistivity Ohm·cm >1015 >1015 >1015 >1015 >1015 >1015 >1015
3
)
Rel. permitt. 50 Hz  2.7 3.0 3.0 3.0 3.0 3.0 3.0
4
)
1 MHz  2.6 2.9 2.9 2.9 2.9 2.9 2.9
Dissipation f. 50 Hz  0.001 0.001 0.001 0.001 0.001 0.001 0.001
1 MHz  0.01 0.01 0.01 0.01 0.01 0.01 0.01
CTI V 225 n.t. n.t. n.t. n.t. n.t. n.t.
Physical
Density g/cm3 1.20 1.20 1.20 1.20 1.20 1.20 1.20
Water abs. 23°C % 0.35 0.35 0.35 0.35 0.35 0.35 0.35
Mould shrink. flow % 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70
Optical
Light transmission % 88 - 90 88 - 90 88 - 90 88 - 90 88 - 90 88 - 90 88 - 90
Haze % < 0.8 < 0.8 < 0.8 < 0.8 < 0.8 < 0.8 < 0.8
Refractive index  1.586 1.586 1.586 1.586 1.586 1.586 1.586
Rheological
MVR cm3/10 min 9.5 9.5 9.5 6 6 6 3
4
*) UL94 in-house tested ) Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6 NB : not broken ·  : not relevant · n.t.: not tested
1 5
) LOI of 121R, 141R and 101R is 28 ) MVR of OQ1020LN at 250°C/1.20 kg
2 6
) 1141R and 101R is 35 / 27 / 17 ) MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg
3 7
) Relative permittivity at 50 Hz of ) MVR of ML3324 and ML3290 at 300°C/2.16 kg
121R, 141R and 101R is 2.7
Lexan Profile 3 Product Selection page 19
Injection moulding page 21
page 18 Unreinforced Multi purpose page 20
Typical Properties
flame retarded 2xy series
Typical values only.
Not to be used for
low low to medium medium high
specification purposes.
viscosity viscosity viscosity viscosity
221R 223R 241R 243R 261R 263R 201R 203R
Mechanical
Tens. stress y (b) 50 63 (65) 63 (65) 63 (70) 63 (70) 63 (70) 63 (70) 63 (70) 63 (70)
b 5        
Tens. strain y (b) 50 6 (100) 6 (100) 6 (110) 6 (110) 6 (120) 6 (120) 6 (120) 6 (120)
b 5        
Tens. modulus 2350 2350 2350 2350 2350 2350 2350 2350
Flex. stress y (b) 90 ( ) 90 ( ) 90 ( ) 90 ( ) 90 ( ) 90 ( ) 90 ( ) 90 ( )
Flex. modulus 2300 2300 2300 2300 2300 2300 2300 2300
Hardness Ball 95 95 95 95 95 95 95 95
Abrasion Taber 10 10 10 10 10 10 10 10
Impact
Izod notch. 23° (-30°) C 12 (10) 12 (10) 25 (10) 25 (10) 60 (10) 60 (10) 65 (10) 65 (10)
unnotch. 23° (-30°) C NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB)
Thermal
Vicat A/50   153 153    
B/50 140 140 141 141 143 143 144 144
B/120 141 141 142 142 145 145 145 145
HDT/ Ae 1.80 MPa 122 122 125 125 127 127 127 127
/ Be 0.45 Mpa 133 133 136 136 138 138 138 138
Ball Pressure 125 125 125 125 125 125 125 125
RTI Electrical 130 130 130 130 130 130 130 130
Mech. with Impact 125 125 125 125 125 125 125 125
without Impact 125 125 125 125 125 125 125 125
Thermal conductivity 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20
CTE flow 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5
Flammability
UL94 V2/1.14 V2/1.47 V2/1.14 V2/1.47 V2/1.14 V2/1.47 V2/1.14 V2/1.47
LOI 28 25 28 25 28 25 28 25
Glow wire 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0
Electrical
Diel. str. oil 0.8 / 1.6 / 3.2 mm 35 / 27 / 17 n.t./n.t./ 17 35 / 27 / 17 n.t./n.t./ 17 35 / 27 / 17 n.t./n.t./ 17 35 / 27 / 17 n.t./n.t./ 17
Surface resistivity >1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015
Volume resistivity >1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015
Rel. permitt. 50 Hz 2.7 3.0 2.7 3.0 2.7 3.0 2.7 3.0
1 MHz 2.6 2.9 2.6 2.9 2.6 2.9 2.6 2.9
Dissipation f. 50 Hz 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001
1 MHz 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01
CTI n.t. n.t. n.t. n.t. n.t. n.t. n.t. n.t.
Physical
Density 1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.20
Water abs. 23°C 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35
Mould shrink. flow 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70
Optical
Light transmission 88 - 90 88 - 90 88 - 90 88 - 90 88 - 90 88 - 90 88 - 90 88 - 90
Haze < 0.8 < 0.8 < 0.8 < 0.8 < 0.8 < 0.8 < 0.8 < 0.8
Refractive index 1.586 1.586 1.586 1.586 1.586 1.586 1.586 1.586
Rheological
MVR 21 21 12 12 9 9 6 6
4
*) UL94 in-house tested ) Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6 NB : not broken ·  : not relevant · n.t.: not tested
1 5
) LOI of 121R, 141R and 101R is 28 ) MVR of OQ1020LN at 250°C/1.20 kg
2 6
) 1141R and 101R is 35 / 27 / 17 ) MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg
3 7
) Relative permittivity at 50 Hz of ) MVR of ML3324 and ML3290 at 300°C/2.16 kg
121R, 141R and 101R is 2.7
Lexan Profile 3 Product Selection page 20
Injection moulding page 21
page 19 Unreinforced Multi purpose page 21
Typical Properties
flame retarded UL94V0
Typical values only.
Not to be used for
low medium high low to medium medium
specification purposes.
viscosity viscosity viscosity viscosity viscosity
920 923 940 943 950 920A 923A 940A 943A
Mechanical Unit
Tens. stress y (b) 50 MPa 63 (60) 63 (60) 63 (60) 63 (60) 63 (65) 63 (60) 63 (60) 63 (65) 63 (65)
b 5 MPa         
Tens. strain y (b) 50 % 6 (85) 6 (85) 6 (85) 6 (85) 6 (100) 6 (85) 6 (85) 6 (100) 6 (100)
b 5 %         
Tens. modulus MPa 2350 2350 2350 2350 2350 2350 2350 2350 2350
Flex. stress y (b) MPa  ( )  ( )  ( )  ( )  ( )  ( )  ( )  ( )  ( )
Flex. modulus MPa 2300 2300 2300 2300 2300 2300 2300 2300 2300
Hardness Ball MPa 98 98 98 98 98 98 98 98 98
Abrasion Taber mg/1000 cy 10 10 10 10 10 10 10 10 10
Impact
Izod notch. 23° (-30°) C kJ/m2 9 (7) 9 (7) 12 (11) 12 (11) 15 ( ) 10 ( ) 10 ( ) 12 (10) 12 (10)
unnotch. 23° (-30°) C kJ/m2 NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB)
Thermal
Vicat A/50 °C   150     150 
B/50 °C 140 140 141 141 141 141 141 141 141
B/120 °C 141 141 142 142 145 142 142 142 142
HDT/ Ae 1.80 MPa °C 122 122 125 125 127 124 124 125 125
/ Be 0.45 Mpa °C 133 133 136 136 138 135 135 136 136
Ball Pressure °C 125 125 125 125 125 125 125 125 125
RTI Electrical °C 130 130 130 130 130 130 130 130 130
Mech. with Impact °C 120 120 120 120 120 120 120 120 120
without Impact °C 125 125 125 125 125 125 125 125 125
Thermal conductivity W/m°C 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20
CTE flow 1/°C 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5
Flammability
UL94 class at mm V0/1.04 V0/1.00 V0/1.04 V0/1.00 V0/1.04 V0/3.05 V0/3.20 V0/3.05 V0/3.20
5VA/3.05
LOI % 35 35 35 35 35 38 35 38 35
Glow wire °C at mm 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0
960/1.6 960/1.6 960/1.6 960/1.6 960/1.6 960/1.6 960/1.6 960/1.6 960/1.6
Electrical
Diel. str. oil 0.8 / 1.6 / 3.2 mm kV/mm n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 17 35 / 27 / 17 n.t./n.t./ 17 35 / 27 / 17 n.t./n.t./ 17
Surface resistivity Ohm >1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015
Volume resistivity Ohm·cm >1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015
Rel. permitt. 50 Hz  3.0  3.0 3.0 3.0 2.7  2.7 3.0
1 MHz  2.9 2.9 2.9 2.9 2.9 2.6 2.9 2.6 2.9
Dissipation f. 50 Hz  0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001
1 MHz  0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01
CTI V 225 225 225 225 n.t. n.t. n.t. 225 n.t.
Physical
Density g/cm3 1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.20
Water abs. 23°C % 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35
Mould shrink. flow % 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70
Optical
Light transmission %      88 88 88 88
Haze %      n.t. n.t. n.t. n.t.
Refractive index       1.586 1.586 1.586 1.586
Rheological
MVR cm3/10 min 21 21 9.5 9.5 6.5 12 12 9.5 9.5
4
*) UL94 in-house tested ) Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6 NB : not broken ·  : not relevant · n.t.: not tested
1 5
) LOI of 121R, 141R and 101R is 28 ) MVR of OQ1020LN at 250°C/1.20 kg
2 6
) 1141R and 101R is 35 / 27 / 17 ) MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg
3 7
) Relative permittivity at 50 Hz of ) MVR of ML3324 and ML3290 at 300°C/2.16 kg
121R, 141R and 101R is 2.7
Lexan Profile 3 Product Selection page 21
Injection moulding page 22
page 20 Unreinforced Multi purpose Unreinforced Lighting Unreinforced Optical
Typical Properties
flame retarded CSTB M2 lens system · optimal clarity data storage eyewear high reflectivity
Typical values only.
Not to be used for
medium low low to medium high very low medium high
specification purposes.
viscosity viscosity viscosity viscosity viscosity viscosity viscosity
2014R 2034 LS1 LS2 LS3 OQ1020LN OQ4320 ML3042
Mechanical
Tens. stress y (b) 50 65 (70) 65 (70) 63 (65) 63 (70) 63 (70) 60 (50) 63 (64) 60 (50)
b 5        
Tens. strain y (b) 50 6 (100) 6 (100) 6 (100) 6 (120) 6 (120) 6 (>60) 6 (120) 6 (75)
b 5        
Tens. modulus 2350 2350 2350 2350 2350 2300 2350 2600
Flex. stress y (b) 95 ( ) 95 ( ) 90 ( ) 90 ( ) 90 ( ) 85 ( ) 95 ( ) 90 ( )
Flex. modulus 2300 2300 2300 2300 2300 2300 2300 2500
Hardness Ball 100 100 95 95 95 n.t. 95 n.t.
Abrasion Taber 9 9 10 10 10 n.t. n.t. n.t.
Impact
Izod notch. 23° (-30°) C 8 (8) 8 (8) 12 (10) 25 (10) 60 (10) 10 (5) 25 (11) 50 (15)
unnotch. 23° (-30°) C NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB)
Thermal
Vicat A/50        
B/50 144 144 140 141 144 140 141 143
B/120 145 145 141 142 145 142 142 145
HDT/ Ae 1.80 MPa 129 129 122 125 127 122 124 n.t.
/ Be 0.45 Mpa 139 140 133 136 138 133 136 n.t.
Ball Pressure 125 125 125 125 125 125 125 125
RTI Electrical 125 n.t. 130 130 130 n.t. n.t. n.t.
Mech. with Impact 110 n.t. 125 125 125 n.t. n.t. n.t.
without Impact 125 n.t. 125 125 125 n.t. n.t. n.t.
Thermal conductivity 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20
CTE flow 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 7·10-5 6·10-5
Flammability
UL94 V2/1.47 V0/2.50 HB/1.47 HB/1.47 HB/1.47   
V2/1.50
LOI 40 31 25 25 25 n.t. 25 25
Glow wire 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0
960/3.2 960/3.2
Electrical
Diel. str. oil 0.8 / 1.6 / 3.2 mm 35 / 27 / 17 n.t./n.t./n.t. n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./n.t. n.t./n.t./n.t. 35 / 27 / 17
Surface resistivity >1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015
Volume resistivity >1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015
Rel. permitt. 50 Hz 2.7 3.0 3.0 3.0 3.0 n.t. n.t. 2.7
1 MHz 2.6 2.9 2.9 2.9 2.9 n.t. n.t. 2.6
Dissipation f. 50 Hz 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001
1 MHz 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01
CTI n.t. n.t. n.t. n.t. n.t. n.t. n.t. 250
Physical
Density 1.24 1.24 1.20 1.20 1.20 1.20 1.20 1.33
Water abs. 23°C 0.32 0.32 0.35 0.35 0.35 0.35 0.35 0.35
Mould shrink. flow 0.40 - 0.60 0.40 - 0.60 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70
Optical
Light transmission 88 - 90 88 - 90 88 - 90 88 - 90 88 - 90 >90 88 - 90 
Haze < 0.8 < 0.8 < 0.8 < 0.8 < 0.8 < 0.7 < 0.8 
Refractive index 1.586 1.586 1.586 1.586 1.586 1.586 1.586 
Rheological
5
)
MVR 8.5 8.5 21 12 6 11 12 6
4
*) UL94 in-house tested ) Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6 NB : not broken ·  : not relevant · n.t.: not tested
1 5
) LOI of 121R, 141R and 101R is 28 ) MVR of OQ1020LN at 250°C/1.20 kg
2 6
) 1141R and 101R is 35 / 27 / 17 ) MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg
3 7
) Relative permittivity at 50 Hz of ) MVR of ML3324 and ML3290 at 300°C/2.16 kg
121R, 141R and 101R is 2.7
Lexan Profile 3 Product Selection page 22
page 21 Injection moulding page 23
Glass Reinforced page 23
Typical Properties normal glass
Typical values only.
10% 10% 15% 20% 20% 30% 40%
Not to be used for
medium high low-medium low-medium high high high
specification purposes.
viscosity viscosity viscosity viscosity viscosity viscosity viscosity
500R 503R ML3019 2814R ML3260 1278R 3412R 3413R 3414R
Mechanical Unit
Tens. stress y (b) 50 MPa  ( )  ( )  ( )  ( )  ( )  ( )  ( )  ( )  ( )
b 5 MPa 45 45 45 45 45 80 90 100 100
Tens. strain y (b) 50 %  ( )  ( )  ( )  ( )  ( )  ( )  ( )  ( )  ( )
b 5 % 7 7 5 7 6 2 2 2 2
Tens. modulus MPa 3300 3300 3300 3300 4500 5200 6000 9000 10000
Flex. stress y (b) MPa 95 ( ) 95 ( ) 100 ( )  (95)  (95)  (120)  (120)  (130)  (145)
Flex. modulus MPa 3400 3400 3400 3400 4000 5000 5500 7000 8500
Hardness Ball MPa 115 110 136 131 83 160 125 n.t. 145
Abrasion Taber mg/1000 cy 11 11 11 11 n.t. 17 17 24 32
Impact
Izod notch. 23° (-30°) C kJ/m2 8 (8) 8 (8)  ( ) 6 (6) 8 (8) 8 (8) 8 (6) 8 (6) 8 (6)
unnotch. 23° (-30°) C kJ/m2 NB (NB) NB (NB) 40 ( )  ( ) 80 (80) 40 (40) 30 (30) 30 (30) 30 (30)
Thermal
Vicat A/50 °C  150  150  151 155  155
B/50 °C 141 141 140 141 141 141 147 147 147
B/120 °C 143 143 142 143 143 143 145 145 145
HDT/ Ae 1.80 MPa °C 132 132 135 132 130 134 139 139 139
/ Be 0.45 Mpa °C 140 140 142 140 138 140 144 144 144
Ball Pressure °C 125 125 125 125 125 125 125 125 125
RTI Electrical °C 130 120 115 n.t. n.t. 120 130 130 130
Mech. with Impact °C 125 110 115 n.t. n.t. 120 125 125 125
without Impact °C 125 120 115 n.t. n.t. 120 130 130 130
Thermal conductivity W/m°C 0.21 0.21 0.21 0.18 0.22 0.22 0.22 0.22 0.22
CTE flow 1/°C 4 ·10-5 4 ·10-5 4 ·10-5 4 ·10-5 4 ·10-5 3 ·10-5 3 ·10-5 3 ·10-5 2·10-5
Flammability
UL94 class at mm V0/1.47 V0/1.47 V0/1.60 V0/1.47 V1/1.60 V1/1.57 V0/0.80 V0/1.50 V0/1.50
5VA/3.05 5VA/3.05
LOI % 35 36 34 40 31 34 37 38 38
Glow wire °C at mm 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0
960/1.0 960/1.0 960/3.2 960/1.6 960/3.2 960/3.2 960/1.6 960/1.6 960/1.6
Electrical
Diel. str. oil 0.8 / 1.6 / 3.2 mm kV/mm 33 / 25 / 16 n.t./n.t./ 16 n.t./n.t./ 16 35 / 27 / 17 35 / 27 / 17 n.t./n.t./ 16 33 / 25 / 16 33 / 25 / 16 33 / 25 / 16
Surface resistivity Ohm >1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015
Volume resistivity Ohm·cm >1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015 >1015
Rel. permitt. 50 Hz  3.0 3.1 n.t. 2.7 2.7 n.t. 3.0 3.0 3.0
1 MHz  2.9 3.0 n.t. 2.6 2.6 n.t. 2.9 2.9 2.9
Dissipation f. 50 Hz  0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001
1 MHz  0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01
CTI V 175 175 n.t. 125 175 150 150 n.t. 125
Physical
Density g/cm3 1.25 1.25 1.27 1.25 1.31 1.35 1.35 1.44 1.52
Water abs. 23°C % 0.31 0.31 0.31 0.31 0.30 0.29 0.29 0.26 0.23
Mould shrink. flow % 0.20 - 0.60 0.20 - 0.60 0.20 - 0.55 0.20 - 0.55 0.20 - 0.50 0.20 - 0.50 0.20 - 0.50 0.10 - 0.40 0.10 - 0.30
Optical
Light transmission %         
Haze %         
Refractive index          
Rheological
MVR cm3/10 min 8 8 8 6 11 12 6 5 4
4
*) UL94 in-house tested ) Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6 NB : not broken ·  : not relevant · n.t.: not tested
1 5
) LOI of 121R, 141R and 101R is 28 ) MVR of OQ1020LN at 250°C/1.20 kg
2 6
) 1141R and 101R is 35 / 27 / 17 ) MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg
3 7
) Relative permittivity at 50 Hz of ) MVR of ML3324 and ML3290 at 300°C/2.16 kg
121R, 141R and 101R is 2.7
Lexan Profile 3 Product Selection page 23
page 22 Injection moulding
page 22 Glass Reinforced Specialties
Typical Properties short glass impact gamma reduced property
modified sterilizable profile
Typical values only.
30%
Not to be used for
high medium medium low low to medium
specification purposes.
viscosity viscosity viscosity viscosity viscosity
ML3513 ML3041 ML3400 ML3459 GR1210 ML3562 ML3286
Mechanical
Tens. stress y (b) 50  ( ) 60 (63) 55 (57) 55 (65) 62 (55)  ( )  ( )
b 5 75      50
Tens. strain y (b) 50  ( ) 6 (105) 6 (100) 7 (120) 6 (85)  ( )  ( )
b 5 2      5
Tens. modulus 4500 2350 2100 2100 2300  
Flex. stress y (b)  (120) 88 ( ) 80 ( ) 80 ( ) 92 ( )  ( )  (95)
Flex. modulus 4500 2300 2150 2150 2400 2100 4500
Hardness Ball 142 85 85 n.t. n.t. n.t. n.t.
Abrasion Taber 24 10 10 10 n.t. 10 n.t.
Impact
Izod notch. 23° (-30°) C 8 (8) 58 (17) 58 (50) 65 (40) 11 (8) 15 (10) NB (20)
unnotch. 23° (-30°) C 40 (40) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB)  ( )
Thermal
Vicat A/50 153      
B/50 147 143 140 138   
B/120 150 141 142 140 131 138 
HDT/ Ae 1.80 MPa 140 121 121 122 113 120 120
/ Be 0.45 Mpa 145  133 131 125  
Ball Pressure 125 125 125 125 125 125 125
RTI Electrical n.t. n.t. n.t. n.t. n.t. n.t. n.t.
Mech. with Impact n.t. n.t. n.t. n.t. n.t. n.t. n.t.
without Impact n.t. n.t. n.t. n.t. n.t. n.t. n.t.
Thermal conductivity 0.22 0.20 0.20 0.20 0.15 0.20 0.22
CTE flow 2.8·10-5 7.0·10-5 7.0·10-5 7.0·10-5  7.0·10-5 3.0·10-5
Flammability
UL94 V0/1.50 V2/1.00    V2/1.00 
LOI 33 25 25    
Glow wire 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0
960/3.2
Electrical
Diel. str. oil 0.8 / 1.6 / 3.2 mm n.t./n.t./ 16 35 / 27 / 17 n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 17 n.t./n.t./ 16
Surface resistivity >1015 >1015 >1015 >1015 >1015 >1015 >1015
Volume resistivity >1015 >1015 >1015 >1015 >1015 >1015 >1015
Rel. permitt. 50 Hz 3.3 2.7 3.0 n.t. 2.8 n.t. n.t.
1 MHz 3.3 2.6 2.9 n.t. 2.7 n.t. n.t.
Dissipation f. 50 Hz 0.001 0.001 0.001 0.001 0.001 0.001 0.001
1 MHz 0.01 0.01 0.01 0.01 0.01 0.01 0.01
CTI 150 n.t. n.t. 175 275 n.t. n.t.
Physical
Density 1.42 1.20 1.20 1.20 1.20 1.20 1.33
Water abs. 23°C 0.26 0.35 0.35 0.35 0.35 0.35 0.30
Mould shrink. flow 0.20 - 0.40 0.50 - 0.70 0.60 - 0.80 0.60 - 0.80 0.50 - 0.70 0.50 - 0.70 0.20 - 0.55
Optical
Light transmission     80  
Haze     1.0  
Refractive index     n.t.  
Rheological
MVR 4 10 8 9 14 24 12
4
*) UL94 in-house tested ) Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6 NB : not broken ·  : not relevant · n.t.: not tested
1 5
) LOI of 121R, 141R and 101R is 28 ) MVR of OQ1020LN at 250°C/1.20 kg
2 6
) 1141R and 101R is 35 / 27 / 17 ) MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg
3 7
) Relative permittivity at 50 Hz of ) MVR of ML3324 and ML3290 at 300°C/2.16 kg
121R, 141R and 101R is 2.7
Lexan Profile 3 Product Selection page 24
Extrusion
Linear Polymers Branched Polymers Flame
Retarded
CSTB M2
Typical Properties hydrolytic high melt hydrolytic high melt
stability strength stability strength
Typical values only.
Not to be used for
profile solid blow extrusion twin-wall flame retarded
specification purposes.
extrusion sheet moulding blow moulding sheet extrusion extrusion
ML3021A ML3403 154 PKG1643 ML3324 ML3290 2034E
Mechanical Unit
Tens. stress y (b) 50 MPa 60 (65) 60 (65) 60 (65) 60 (65) 60 (65) 60 (65) 65 (70)
b 5 MPa       
Tens. strain y (b) 50 % 6 (100) 7 (120) 7 (120) 7 (120) 7 (120) 6 (100) 6 (100)
b 5 %       
Tens. modulus MPa 2400 2350 2350 2300 2300 2350 2350
Flex. stress y (b) MPa 85 ( ) 85 ( ) 100 ( ) 100 ( ) 100 ( ) 95 ( ) 90 ( )
Flex. modulus MPa 2300 2300 2300 2500 2300 2300 2300
Hardness Ball MPa 93 n.t. 95 95 95 95 n.t.
Abrasion Taber mg/1000 cy 10 10 10 10 10 10 9
Impact
Izod notch. 23° (-30°) C kJ/m2 60 (13) 65 (13) 60 (10) 60 (10) 60 (10) 15 (10) 8 (8)
unnotch. 23° (-30°) C kJ/m2 NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB) NB (NB)
Thermal
Vicat A/50 °C 150   148 148 148 
B/50 °C 143 146 146 146 146 146 144
B/120 °C 146 148 143 143 143 135 148
HDT/ Ae 1.80 MPa °C 131 127 124 124 124 124 129
/ Be 0.45 Mpa °C 140 142  136 136 136 
Ball Pressure °C 125 125 125 125 125 125 125
RTI Electrical °C n.t. n.t. n.t. n.t. n.t. n.t. n.t.
Mech. with Impact °C n.t. n.t. n.t. n.t. n.t. n.t. n.t.
without Impact °C n.t. n.t. n.t. n.t. n.t. n.t. n.t.
Thermal conductivity W/m°C 0.17 0.20 0.20 0.20 0.20 0.20 0.20
CTE flow 1/°C 6.7·10-5 7.0·10-5 7.0·10-5 7.0·10-5 7.0·10-5 7.0·10-5 7.0·10-5
Flammability
UL94 class at mm HB/1.60 n.t. n.t. n.t. HB/1.50 V0/2.00 n.t.
LOI % 28 n.t. 25 n.t. n.t. 25 n.t.
Glow wire °C at mm 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0 850/1.0
960/3.2 n.t. n.t. n.t. n.t. 960/3.2 n.t.
Electrical
Diel. str. oil 0.8 / 1.6 / 3.2 mm kV/mm 35 / 27 / 17 n.t./n.t./n.t. n.t./n.t./n.t. n.t./n.t./n.t. n.t./n.t./n.t. 35 / 27 / 17 n.t./n.t./n.t.
Surface resistivity Ohm >1015 >1015 >1015 >1015 >1015 >1015 >1015
Volume resistivity Ohm·cm >1015 >1015 >1015 >1015 >1015 >1015 >1015
Rel. permitt. 50 Hz  2.7 2.7 3.0 n.t. n.t. 2.7 n.t.
1 MHz  2.6 2.7 2.9 n.t. n.t. 2.6 n.t.
Dissipation f. 50 Hz  0.001 0.001 0.001 0.001 0.001 0.001 0.001
1 MHz  0.01 0.01 0.01 0.01 0.01 0.01 0.01
CTI V 225 n.t. n.t. n.t. n.t. n.t. n.t.
Physical
Density g/cm3 1.20 1.20 1.20 1.20 1.20 1.20 1.24
Water abs. 23°C % 0.35 0.35 0.35 0.35 0.35 0.35 0.32
Mould shrink. flow % 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.50 - 0.70 0.40 - 0.60
Optical
Light transmission % 88 - 90 88 - 90 88 - 90 88 - 90 88 - 90 88 - 90 88 - 90
Haze % < 0.8 < 0.8 < 0.8 < 0.8 < 0.8 < 0.8 < 0.8
Refractive index  1.586 1.586 1.586 1.586 1.586 1.586 1.586
Rheological
6 6 7 7 6
) ) ) ) )
MVR cm3/10 min 4 5 2 2 5 8 2
4
*) UL94 in-house tested ) Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6 NB : not broken ·  : not relevant · n.t.: not tested
1 5
) LOI of 121R, 141R and 101R is 28 ) MVR of OQ1020LN at 250°C/1.20 kg
2 6
) 1141R and 101R is 35 / 27 / 17 ) MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg
3 7
) Relative permittivity at 50 Hz of ) MVR of ML3324 and ML3290 at 300°C/2.16 kg
121R, 141R and 101R is 2.7
Lexan Profile 3 Product Selection page 25
Structural foam
Glass Blowing
Reinforced Agent
Typical Properties
Typical values only.
5% normal chemical
Not to be used for
glass concentrate
specification purposes.
FL900P FLC95
Mechanical
Tens. stress y (b) 50 n.t. (n.t.)  ( )
b 5 n.t. 
Tens. strain y (b) 50 n.t. (n.t.)  ( )
b 5 n.t. 
Tens. modulus n.t. 
Flex. stress y (b) n.t. (n.t.)  ( )
Flex. modulus n.t. 
Hardness Ball n.t. 
Abrasion Taber n.t. 
Impact
Izod notch. 23° (-30°) C n.t. (n.t.)  ( )
unnotch. 23° (-30°) C n.t. (n.t.)  ( )
Thermal
Vicat A/50 n.t. 
B/50 n.t. 
B/120 n.t. 
HDT/ Ae 1.80 MPa n.t. 
/ Be 0.45 Mpa n.t. 
Ball Pressure 125 
RTI Electrical n.t. 
Mech. with Impact n.t. 
without Impact n.t. 
Thermal conductivity 0.15 
CTE flow 3.5·10-5 
Flammability
UL94 n.t. 
n.t. 
LOI n.t. 
Glow wire n.t. 
n.t. 
Electrical
Diel. str. oil 0.8 / 1.6 / 3.2 mm n.t./n.t./n.t.  / /
Surface resistivity n.t. 
Volume resistivity n.t. 
Rel. permitt. 50 Hz n.t. 
1 MHz 2.3 
Dissipation f. 50 Hz n.t. 
1 MHz 0.01 
CTI n.t. 
Physical
Density 0.95 
Water abs. 23°C 0.35 
Mould shrink. flow 0.50 - 0.70 
Optical
Light transmission  
Haze  
Refractive index  
Rheological
MVR 10 
4
*) UL94 in-house tested ) Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6 NB : not broken ·  : not relevant · n.t.: not tested
1 5
) LOI of 121R, 141R and 101R is 28 ) MVR of OQ1020LN at 250°C/1.20 kg
2 6
) 1141R and 101R is 35 / 27 / 17 ) MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg
3 7
) Relative permittivity at 50 Hz of ) MVR of ML3324 and ML3290 at 300°C/2.16 kg
121R, 141R and 101R is 2.7
4
Properties and Design
4.1 General properties 4.2 Mechanical properties
Lexan resin s exceptional impact
Lexan polycarbonate is an strength and practical toughness In general, Lexan resin exhibits
amorphous engineering establish it as a first choice material excellent mechanical property
thermoplastic which displays high for many very demanding retention over a wide temperature
levels of mechanical, optical, applications across diverse industries. range.
electrical and thermal properties. As illustrated in FIGURES 1 and 2,
Its unique property profile includes Design calculations for Lexan resin Lexan resin s tensile strength and
outstanding impact strength over a are no different than for any other flexural modulus decrease slightly as
wide range of temperatures, from material. Physical properties of plastic temperature increases. However, the
subzero to over 80°C. are dependent on the expected effect of temperature on impact
temperature and stress levels. Once resistance is the reverse: as the
A characteristic Lexan resin offers: this dependency is understood, and temperature decreases, Lexan resin
the end-use environment has been becomes slightly stiffer and slightly
·High transparency
defined for an application, standard more brittle.
·Extreme toughness
engineering calculations can be used
·Low uniform shrinkage
to accurately predict part
·Dimensional stability
performance. However, in designing
·Consistent processibility
for Lexan it is important to take
·UV stability
into account the notch sensitivity
·Flame retardancy
and lower hydrolytic stability of
·Heat resistance
polycarbonate resins.
·Wide colour availability
140
Lexan
FIGURE 1
3414R
120
3412R
Tensile strength
500R
as a function
100
141R
of temperature
80
60
40
20
0
-40 -20 0 20 40 60 80 100
Temperature (°C)
8000
Lexan
FIGURE 2
3414R
7000
26
3412R
Flexural modulus
500R
of Lexan 3414R,
6000
141R
3412R, 500R and
5000
141R as a function
of temperature
4000
3000
2000
1000
0
-40 -20 0 20 40 60 80 100 120
Temperature (°C)
Tensile strength (MPa)
Flexural modulus (MPa)
Lexan Profile 4 Properties and Design
4.2.1 Impact strength
At very low temperatures, impact There are several factors which
Lexan resin s exceptional impact resistance can be further improved determine the ability of a plastic part
strength and practical toughness by blending with other resins such to absorb impact energy.
make parts virtually shatter-proof, as ABS, as in Cycoloy® PC/ABS alloy, In addition to the type of material
providing a high degree of safety and or by blending with impact modifiers. these factors include:
durability in service in the toughest of FIGURE 4, for example, compares
·Wall thickness
environments. The superior impact the Izod impact strength of impact
·Geometric shape and size
resistance of Lexan polycarbonate modified Lexan ML3400 resin with
·Operating temperature and
versus glass can be seen in FIGURE 3. a standard unmodified Lexan grade. environment
Lexan ML3459 resin offers superior
·Rate of loading
impact retention after painting with
·Stress state induced by loading
various paint systems.
80
Lexan
FIGURE 3
glass
70
Tensile impact
of Lexan and glass
60
as a function of
50
temperature
40
30
20
10
0
20 40 60 80 100 120
Temperature (°C)
100
Lexan
FIGURE 4
impact
27
modified
Izod impact
80
standard
strength of Lexan
as a function
of temperature 60
40
20
0
-40 -30 -20 -10 0 10 20 30
Temperature (°C)
2
Tensile impact (KJ/m )
2
Izod notched impact (KJ/m )
Lexan Profile 4 Properties and Design
4.2.2 Stiffness
For ductile polymers such as Lexan A change from 3 to 4 mm thickness
resin, the load at which yield occurs can even provide a transition of the The Lexan resin family offers
in a part is affected by the last three failure mode from ductile to brittle designers a great deal of choice as
factors. Of even more significance behaviour at a given temperature, far as stiffness is concerned.
to design is the fact that, under the through the influence of molecular While stiffness values can vary greatly
appropriate circumstances, the weight and specimen thickness on from one grade to another, the
impact behaviour of a ductile Izod notched impact. This is stiffness properties for an individual
polymer will undergo a transition illustrated in FIGURE 6. Materials grade will remain constant over a
from a ductile and forgiving response which already exhibit a brittle wide temperature range from subzero
to a brittle and catastrophic one. fracture mode at 3 mm, such as to 120°C. In accordance with ISO 178,
Usually this change in behaviour is mineral and glass-reinforced grades, the flexural modulus values range
described in terms of a transition will not be affected. Impact modified from 2300 MPa for unreinforced
temperature above which the failure grades will also not be affected as they grades to up to 3400 MPa for 10%
is more ductile by nature, and below still exhibit a ductile failure mode at glass-reinforced grades, 5500 MPa for
which it is more brittle, as illustrated greater than 4 mm. 20% glass-reinforced, 7000 MPa for
in FIGURE 5. 30% glass-reinforced and 8500 MPa
Therefore, ISO and ASTM impact for 40% glass-reinforced grades.
Interpretation of ISO & ASTM impact values may be radically different for
values exactly the same material. However,
Impact properties can be very the ductile brittle transition described
sensitive to test specimen thickness rarely plays a role in real life as almost
and molecular orientation. The all parts are designed with less than
differences in specimen thickness as 3 mm wall sections.
used in ASTM and ISO may have an
important effect on impact values.
FIGURE 5
Graph illustrating
effect of
ductile behaviour
temperature upon
impact response
ductile/brittle transition
brittle behaviour
Temperature
ASTM ISO
3.2 mm 4.0 mm
Lexan
FIGURE 6
101
121
Influence of
28 141
specimen
161
thickness and
molecular weight
on Izod notched
impact properties
of Lexan
0 1 2 3 4 5 6
Specimen thickness (mm)
Impact value
Izod notched impact
Lexan Profile 4 Properties and Design
The stiffness of a part is defined as FIGURE 7 compares the tensile stress A further important consideration
the relationship between the load and strain, showing modulus of in the calculation of part stiffness
and the deflection of a part. The unreinforced Lexan 141R with 10% is the temperature at which the
most important material property glass-reinforced Lexan 500R and 20% load is applied. As can be seen in
for stiffness is the stress/strain curve. glass-reinforced Lexan 3412R. Lexan FIGURES 8 and 9, the stress/strain
In general, the Young s modulus, 500R shows an excellent combination curves of thermoplastics are strongly
(ISO 527), which is determined from of energy absorption and modulus, influenced by temperature.
the stress/strain curve, is the best while Lexan 3412R has an ideal fit in
parameter to be used when high modulus applications.
comparing the stiffness of materials.
80
Lexan
FIGURE 7
3412R
72
500R
Stress-strain
64
141R
curve of Lexan
56
3412R, 500R
and 141R (23°C) 48
40
32
24
16
8
0
0 2 4 6 8 10 12 14 16
Strain (%)
80
-30°C
FIGURE 8
72 0°C
Stress-strain 23°C
64
60°C
curve of
56 90°C
Lexan 141R
48
40
32
24
16
8
0
0 6 12 18 24 30 36 42 48 54
Strain (%)
100
-30°C
FIGURE 9
90 0°C
Stress-strain 23°C
80
29
60°C
curve of
70 90°C
Lexan 3412R
60
50
40
30
20
10
0
0 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4
Strain (%)
Tensile stress (MPa)
Tensile stress (MPa)
Stress (MPa)
Lexan Profile 4 Properties and Design
4.2.3 Strength 4.2.4 Behaviour over time
Lexan grades subjected to small
The strength of a part is defined as strains, the stress increases There are two types of phenomena
the maximum load that can be proportionally with the strain. which should be considered. Static
applied to a part without causing part However,early in the test non-linearity time dependent phenomena such
failure under given conditions. will occur. In fact a close observation as creep are caused by the single,
In order to be able to determine the of the stress/strain curve shows that a long-term loading of an application.
strength of a part, failure has to be proportional part does not exist. With Dynamic time dependent
first defined. The right definition of larger strains, yield will occur and the phenomena such as fatigue, on the
failure depends on the application maximum stress is reached. If the other hand, are produced by the
and how much deformation is strain is further increased, necking cyclic loading of an application.
allowed. will occur. The neck will propagate Both types of behaviour are heavily
through the structure until the influenced by the operating
Material strength is a stress/strain material fails. environment and component design.
related property which is inherent
in the material. The tensile test The speed of deformation in the
provides the most useful information application is vital. The differences
for engineering design. For unfilled are shown for Lexan 500R in
FIGURE 10.
70
10 %/sec
FIGURE 10
63 1 %/sec
Stress-strain 0.1 %/sec
56
0.01 %/sec
curve of
49
Lexan 500R (23°C)
42
35
28
21
14
7
0
0 2 4 6 8 10 12
Strain (%)
30
Stress (MPa)
Lexan Profile 4 Properties and Design
4.2.4.1 Creep behaviour 4.2.4.2 Fatigue endurance
FIGURE 11 shows that a key property
Creep is defined as the increasing of Lexan resin is its predictable, low Fatigue is an important design
rate of deformation of a geometrical creep behaviour even at higher loads. consideration for parts subjected to
shape when subjected to a constant This is due to the amorphous cyclic loading or vibration. Structural
long-term load. With plastics, structure and its inherent high heat components subjected to vibration,
the creep rate is dependent on resistance. At higher temperatures, components subjected to repeated
temperature, load and time. At a the creep behaviour is increased as impacts, reciprocating mechanical
certain stress level, creep becomes can be seen in FIGURE 12. components, plastic snap-fit latches
minimal and can be disregarded and moulded-in plastic hinges are all
in long-term, continuous-load examples where fatigue can play an
applications. important role. Cyclic loading can
result in mechanical deterioration
and fracture propagation through the
material, leading to ultimate failure.
When parts are subjected to cyclic
loading, fatigue failure can occur,
often at a stress level considerably
below the yield point of the material.
3.6
40 MPa
FIGURE 11
35 MPa
3.2
Deformation at 30 MPa
2.8
25 MPa
constant load
20 MPa
(creep) of Lexan
2.4
15 MPa
141R (23°C)
2.0
1.6
1.2
0.8
0.4
0
100 101 102 103
Time (hrs)
1.8
23°C
FIGURE 12
60°C
Deformation at 1.6 90°C
constant load
(creep) of Lexan
1.4
141R (15 MPa)
1.2
1.0
0.8
31
0.6
10-4 10-3 10-2 10-1 100 101 102 103
Time (hrs)
Strain (%)
Strain (%)
Lexan Profile 4 Properties and Design
In such applications, an uniaxial Fatigue tests are usually conducted regarded as  ideal . However,
fatigue diagram could be used to under flexural conditions, though practical conditions usually
predict product life. These curves tensile and torsional testing is also necessitate the use of a modified
can be used to determine the fatigue possible. A specimen of material is fatigue limit, as other factors may
endurance limit, or the maximum repeatedly subjected to a constant affect performance, including most
cycle stress that a material can deformation at a constant frequency, notably the type of loading, the size
withstand without failure. and the number of cycles to failure of the component and the loading
FIGURES 13 and 14 compare the is recorded. The procedure is then frequency.
fatigue behaviour of an unfilled and repeated over a range of deflections
a filled Lexan grade. or applied stresses. The test data are However, fatigue testing can only
usually presented as a plot of log provide an indication as to a given
stress versus log cycles; this is material s relative ability to survive
commonly referred to as an S-N fatigue. It is therefore essential that
curve, as shown in FIGURES 13 tests are performed on actual
and 14. S-N curves obtained under moulded components, under actual
laboratory conditions may be end-use operating conditions.
70
FIGURE 13
Uniaxial fatigue 60
test of Lexan 141
(frequency 5 Hz,
50
23°C)
40
30
20
10
102 103 104 105 106 107
Cycles to failure
70
FIGURE 14
Uniaxial fatigue
60
test of Lexan 500R
(frequency 5 Hz,
23°C) 50
40
30
20
101 102 103 104 105 106
32
Cycles to failure
Stress (MPa)
Stress (MPa)
Lexan Profile 4 Properties and Design
4.3 Thermal properties
In accordance with UL746B, Lexan According to UL Subject 94, the
The property profile of Lexan resins have been granted a Relative Lexan 900 series has been rated V0 at
resin includes very good thermal Thermal Index (RTI) of between low thicknesses (e.g. 943 is UL94 V0
properties. 80°C and 130°C. There can be up to at 1.04 mm), Lexan 3412R is rated V0
However, all thermoplastics will three independent RTI ratings at 0.8 mm, while the Lexan 500 series
soften at elevated temperatures. assigned to a material: electrical, has been rated V0 at 1.5 mm and 5VA
The most common thermal test is mechanical with impact and at 3 mm. A complete overview of the
the Vicat Softening Temperature, mechanical without impact. UL 94 classifications for Lexan is
as shown in FIGURE 15, which given in TABLE 1. It should be noted
measures the temperature at which that each Lexan resin tested may
4.4 Flammability
a plastic starts to soften rapidly. receive several ratings depending on
Non-flame retarded standard Lexan colour and/or thickness.
A second commonly used thermal test resins in addition to the flame
is the Heat Deflection Temperature, retarded Lexan 500 and 900 series all In addition, Glow Wire Test results,
which in amorphous materials such as offer halogen-free flame retardancy according to IEC 695-2-1, are
Lexan resin is strongly related to the according to DIN VDE 472, part 815. dependent on the thickness of the
glass transition temperature (Tg). material sample and the actual test
The most widely accepted temperature. Almost all Lexan grades
Other thermal tests include the Ball flammability performance standards pass the 850°C test at 1 mm, while
Pressure Test, IEC 695-10-2, for plastics are UL ratings which most of the flame retarded grades will
according to which almost all Lexan identify a material s ability to pass the 960°C test at 1.6 mm. Special
resins pass at 125°C. extinguish a flame once ignited. grades are available which pass the
960°C test at 1 mm.
1.2
FIGURE 15
1.0
Vicat indentation
vs. temperature
0.8
of Lexan 161R
(ISO 179; Shear
0.6
rate: 120°C/hr;
weight: 50 N)
0.4
0.2
0
-0.2
0 20 40 60 80 100 120 140 160
Temperature (°C)
TABLE 1
UL recognition for flammability
UL rating Thickness Lexan grades
UL94 HB < 1.5 mm 103R, 123R, 143R, 163R, LS1, LS2, LS3, ML3322
1.5 - 3.0 mm 1xy series, ML3021A, ML3324
UL94 V2 < 1.5 mm 201R, 221R, 261R, HF1110R, HF1140R,
ML3021A, ML3041
1.5 - 3.0 mm 2014R, 2034, 2xy series, 910A, 920A, 940A,
33
950A, 923A, 943A, 953A, ML3290, ML3485
UL94 V1 1.5 - 3.0 mm 1278R, ML3260
UL94 V0 < 1.5 mm 3412, 923, 940, 943
1.5 - 2.5 mm 2814R, 3413R, 500R, 503R, 920, 950,
ML3290, ML3513
> 2.5 mm 2014R, 2034, 910A, 920A, 940A, 943A, 950A,
953A, ML3260
> 4.0 mm FL900P
UL94 5VA > 3.0 mm 500R, 503R, 950
Indentation (mm)
Lexan Profile 4 Properties and Design
4.4.1 Transportation industry
In accordance with ISO 4589, Lexan In aircraft applications, Lexan resin s
regulations
general purpose grades have a limited compliance with the requirements of
oxygen index (LOI) of 25-28%, while Lexan resin is widely used in a variety Airbus standard ABD0031 for smoke
Lexan 900A grades have an LOI of of transportation applications. evolution and toxicity is detailed in
38%. This means that all Lexan resins Stringent flammability requirements TABLE 4.
are self-extinguishing. FIGURE 16 are enforced depending on the
compares the LOI of various GE industry and the country. According to the federal motor
Plastics resins. vehicle safety standard FMVSS302,
In railway industry applications in all Lexan grades pass at thicknesses
This combination of properties makes France, for example, the I, F, M >1.5 mm, while flame retarded
Lexan resin an ideal material for a classification according to grades even pass at thicknesses below
variety of electrotechnical NF F 16-101 is important, while in 1.5 mm.
applications. Germany applications are subject to
DIN 5510. Typical values for Lexan
for both regulations are given in
TABLES 2 and 3, with the
understanding that these values
can be thickness and/or colour
dependent.
Ultem *
FIGURE 16
Lexan
Limited oxygen
Noryl
index (ISO 4589)
Valox
Cycoloy
TABLE 2
Noryl GTX
Typical values for Lexan according to
Cycolac
transportation industry regulation NF F 16-101
Noryl Xtra
Xenoy
I-class F-class M-class
Lexan 2034 I2 F2 M2
% 10 20 30 40 50 60
Lexan 2814R I2 F2 M2
inherent flame redardancy
*
Lexan 500R I3 F1 
burns extinguishes
Lexan 943 I3 F1 
21 % O2 in air
Lexan 943A I2 F1 
TABLE 3
Typical values for Lexan according to
transportation industry regulation DIN5510
Fire Smoke Dripping
Lexan 503R S3 SR2 ST2
Lexan 923 S3 SR2 ST2
34
TABLE 4
Typical values for Lexan according to
Airbus standard ABD0031
FAR25853 Smoke D4min Toxicity
Lexan 500R b < 200 pass
Lexan 940 b < 200 pass
Lexan 950 b < 200 pass
Lexan 950A b < 200 pass
Lexan ML3290 b < 200 pass
Lexan Profile 4 Properties and Design
4.5 Electrical properties 4.5.2 Relative permittivity 4.5.3 Dissipation factor
As an organic material, Lexan resin FIGURE 18 shows that the relative As can be seen in FIGURE 19, the
is an excellent electrical insulator. permittivity values of Lexan resins are electrical dissipation factor of Lexan
intermediate to high when compared resins over a wide range of
with other polymers. The higher frequencies varies from intermediate
4.5.1 Dielectric strength
values indicate a greater insulating to high when compared with other
As can be seen in FIGURE 17, the quality. polymers; the smaller values for the
dielectric strength is non-linear with dissipation factor correspond to a
the thickness. Standard Lexan resin better dielectric material. In addition
typically exhibits a dielectric strength to frequency, temperature and
of 17 kV/mm at 3.2 mm, 27 kV/mm at contaminants such as moisture affect
1.5 mm, 35 kV/mm at 1 mm and the dissipation factor.
67 kV/mm at 0.25 mm thickness.
70
FIGURE 17
Dielectric 60
strength of
unfilled Lexan
50
as a function
of thickness
40
30
20
10
0 0.5 1 1.5 2 2.5 3 3.5
Thickness (mm)
5.0
Valox
FIGURE 18
Ultem
Relative 4.5 Lexan
Noryl
permittivity at
60Hz and 50%
4.0
RH of unfilled
materials
3.5
3.0
2.5
2.0
0 20 40 60 80 100 120 140 160 180
Temperature (°C)
10-1
Valox
FIGURE 19
Ultem
35
Dissipation factor Lexan
Noryl
at 23°C of unfilled
materials
10-2
10-3
10-4
102 103 104 105 106
Frequency (Hz)
Dielectric strength (kV/mm)
Dielectric constant
Dissipation factor
Lexan Profile 4 Properties and Design
4.6 Aesthetics and optical
Lexan resin has excellent light FIGURE 21 shows the excellent light
properties
transparency which is close to that of transmission of standard natural
Lexan resin is a naturally transparent, glass, and a very high refractive index colour Lexan 141R resin at different
 water white material with excellent of 1.586. Its highest transmission rate thicknesses. The light transmission
aesthetic properties. It is available in is in the visible light and infrared of transparent Lexan resins can be
a wide choice of colours, many of region, as shown in FIGURE 20. changed if required. Grades such as
which have transparent, translucent, Lexan 143R-111 and Lexan LS2-111
opalescent and opaque versions. have a built-in UV screen to filter out
In addition, Lexan resin consistently UV radiation up to 380 nm. Modified
reproduces mould surface finish grades such as Lexan OQ4320 will
with great accuracy. This provides even reach 400 nm, thereby providing
designers with top quality, high gloss additional sun protection without
or textured surface finishes. affecting the transmission in the
UV visible infra red
100
280 - 315 nm
FIGURE 20
UV-B middle UV region
315 - 280 nm
Light transmission
80
UV-A middle UV region
of UV stabilized
380 - 780 nm
Lexan
visible light region
60 780 - 1400 nm
near infra red region
1400 - 3000 nm
middle infra red region
40
20
0
0 800 1600 2400 3200
Wavelength (nm)
92
FIGURE 21
Light transmission
of Lexan 141R
as a function
90
of thickness for
standard natural
colour
88
36
86
1 mm 2 mm 3 mm 4 mm 5 mm 6 mm
Light transmission (%)
Transmission (%)
Lexan Profile 4 Properties and Design
4.7 Environmental resistance
visible region. Special colours provide While Lexan generally displays good
a high light transmission in the property retention when exposed to
4.7.1 Chemical resistance
infrared region only, which blocks all water, mineral acids and organic
light in the visible light region for Lexan resin can be adversely affected acids, crazing and/or embrittlement
applications such as remote control by certain combinations of chemical may occur if the Lexan resin part is
panels, as illustrated in FIGURE 22. environment, temperature and stress. highly stressed and exposed to hot
For this reason, lubricants, gaskets, water or a humid environment.
Opalescent colours provide partial O-rings, cleaning solvents or any
light diffusion for the Lighting material which may come into contact Lexan resin is insoluble in aliphatic
Industry. The transmission at a given with the finished part should be hydrocarbons, ethers and alcohols.
thickness is critical. Lexan resins can carefully evaluated for compatibility. It is partly soluble in aromatic
be produced in a wide range of hydrocarbons, soluble in chlorinated
opalescent colours with different In all cases extensive testing of the hydrocarbons and will slowly
transmission values, as shown in finished part under actual service decompose in strong alkaline
FIGURE 23. conditions is strongly recommended. solutions. TABLE 5 (see next page)
The performance and interpretation provides a comprehensive overview of
of the results of end-use testing are the chemical compatibility of Lexan
the end-producer s responsibility. resin according to the specified
GE Plastics test conditions.
UV visible infra red
100
Lexan
FIGURE 22
141R
non-UV stabilized
Light transmission
80
LS2
of transparent
UV stabilized
Lexan OQ4320
UV stabilized with
60
400 nm cut-off
121R
 infra red colour
40
20
0
300 400 500 600 700 800 900 1000 1100
Wavelength (nm)
85
82025
FIGURE 23
82027
Transmission of 82046
82052
Lexan opalescent
70
82062
colours as a
82082
function of
82103
thickness
82227
55
82253
82268
40
37
25
1.5 1.8 2.1 2.4 2.7 3.0 3.3
Thickness (mm)
Transmission (%)
Transmission (%)
Lexan Profile 4 Properties and Design
TABLE 5
Chemical compatibility of Lexan polycarbonate
Key to performance
This overview shows the chemical resistancy of Lexan polycarbonate  poor, not recommended; will result in
sheet. Chemical compatibility of thermoplastics e.g. Lexan is dependent failure or severe degradation
on contact time, temperature and stress (external stress to which the
application is subjected). Chemical exposure can result in discolouration, 0 fair, found marginal; only for short
softening, swelling, crazing, cracking or loss of properties of the exposures at lower temperatures or when
thermoplastic. The chemicals listed have been evaluated for Lexan loss of properties is not critical
according to a very stringent GE Plastics test method. This test
incorporates exposure to the chemical under defined conditions including + good; found unaffected in its performance
temperature (20°C and 80°C) and stress (0.5% and 1% strain) for a time when exposed with regards to time,
period of seven days. temperature and stress according
This information should be used as indicative only. The true chemical the GE Plastics test method
compatibility can only be determined under conditions as in the final
application. Please contact your local representative in case additional
information is required.
Acid, mineral Glycerine + Ester
Boric acid + Hepthyl alcohol  Benzyl benzoate 
Hydrogen chloride 20% + Isobutanol 0 Buthyl cellosolve acetate 
Hydrogen chloride 25%  Nonyl alcohol  Buthyl stearate 
Hydrogen fluoride 25% + Octyl alcohol + Cello acetobutyrate 
Nitric acid 70%  Oxydiethanol 2.2 + Cellulose acetate 
Perchloric acid  Phenetyl alcohol  Cellulose proprionate 
Phosphorus pentoxide dry + Polyalkylene glycol  Dibuthyl phthalate 
Phosphoric acid 1% + Polyethylene glycol + Didecyl carbonate 
Phosphoric acid 10%  Propylene glycol  Disodecyl phthalate 
Phosphorus pentachloride + Sorbitol + Disononyl phthalate +
Sulphuric acid 50% + Thiodiglycol 5%  Dioctyl phtalate 
Sulphuric acid 70%  Triethylene glycol + Dioctyl sebacate 
Sulphurous acid 5%  Tripropylene glycol  Ditridecyl carbonate 
Ditridecyl phthalate 
Acid, organic Aldehide Ethyl bromoacetate +
Acetic anhydride  Acetaldehyde  Ethyl butyrate 
Formic acid concentrate  Butyraldehyde  Ethyl cellusolve 5% 
Gallic acid + Formaldehyde solvent 37% + Ethyl chloracetate 
Malelc acid + Formalin + Ethyl cyanoacetate 
Mercapto acetic acid  Propionaldehyde  Ethyl lactate 
Murstic acid 20% + Ethyl salicilate 
Muristic acid 25%  Amide Isopropyl myristrate 
Olelc acid + Dimethylformamide  Methyl acetate +
Palmitic acid + Methyl calicylate 
Phenol sulphonic acid  Amine Methylbenzoate 
Phenoxyacetic acid + Aniline  Triacetine 
Phthallic anhydride + Diphenylamine  Tributoxethyl phosphate 
Salycilate acid + Methylaniline N  Tributyl cello phosphate 
Tannic acid + Methylene dianiline  2 dodecyl phenyl carbonate +
Tannic acid 20%  Phenylhydrazine 
Thiodiacetic acid + Pyridine  Ether
Trichlor acetic acid  Triethanolamine + Ether 
Sulphamine acid 5% 0 Hydroxylamine + Ethyl cellosolve 5% 
Methyl cellosolve 
38
Alcohol Base Polyalkylene glycol 
Allyl alcohol  Aluminium hydroxine powder + Polyethylene glycol +
Amyl alcohol  Ammonia concentrate  Polyethylene sulfide 
Butoxyethanol  Ammonium hydroxide 0.13%  Propylene oxide 
Chlorethanol 2  Calcium hydroxide 
Decyl alcohol  Potassium hydroxide 10%  Gaseous
Dodecyl alcohol  Sodium hydroxide dry + Ammonia concentrate 
Ethanol  Sodium hydroxide 10%  Bromine 
Ethyl glycol 100%  Sodium thotalamate + Chloracetophenone 
Ethyl glycol 60% + Chlorine 
Furfuryl alcohol  Iodine 
Lexan Profile 4 Properties and Design
Isobutane  Salt, inorganic Potassium iodide +
Methane  Aluminium ammonium sulphate  Potassium nitrate +
Oxygen + Aluminium chloride  Potassium permaganate 
Ozone 2%  Aluminium floride + Potassium persulphate +
Propylene + Aliminium potassium sulphate  Potassium sulphate +
Sulphur dioxide  Aluminium sodium sulphate + Silver chloride saturated 
Sulphur hexafluoride  Ammonium bicarbonate + Silver nitrate +
Ammonium bromide + Sodium bicarbonate saturated 0
Halogenated HC Ammonium carbonate  Sodium bicarbonate 13% 
Acetylene dibromo  Ammonium dichromate + Sodium bisulphate +
Acetylene tetrabromide  Ammonium persulfate + Sodium bromate +
Bromochloromethane  Arsenic trioxide  Sodium bromide +
Carbon tetrachloride  Barium carbonate + Sodium carbonate +
Chlorethanol 2  Barium chloride + Sodium carbonate solvent 
Chlorobenzene  Barium sulphate + Sodium chlorate +
Chlorobutane  Calcium carbonate paste  Sodium etherlaurysulphate 0
Chloroform  Calcium chloride + Sodium ferrycyanide +
Dibromomethane  Calcium sulphate + Sodium fluoride +
Dichloroethane  Cesium bromide + Sodium hypochlorite 6% +
Dichlorohydroxybenzene + Copper (II) chloride 5% + Sodium hypochlorite 15% 
Dichloromethane  Iron (II) chloride  Sodium nitrate 10% 
Ethyl bromoacetate + Iron (III) ammonium sulphate + Sodium perborate +
Iron (III) chloride saturated + Sodium phosphate +
Ketone Iron (III) nitrate  Sodium sillicate +
Methyl ethyl ketone  Iron (III) sulphate + Sodium sulphide 
Lithium bromide + Sodium sulphite +
Metal & metal oxide Lithium hydroxide powder + Strontium bromide +
Aluminium oxide + Magnesium bromide + Tin (II) chloride +
Arsenic trioxide  Magnesium chloride + Tin (IV) chloride +
Calcium oxide paste  Magnesium nitrate + Titanium tetrachloride +
Cuprous oxide + Magnesium sulphate + Trisodium phosphate 5% 
Mercury metallic  Mercury (I) nitrate + Zinc bromide +
Mercury (II) chloride  Zinc carbonate +
Phenol Mono ammonium phosphate + Zinc chloride 
Allyl 4 methoxyphenol  Nickel nitrate + Zinc oxyde 
39
Cresol  Potassium bicarbonate dry + Zinc sulphate +
P-Phenylphenol  Potassium bisulphate +
Pentachlorophenol  Potassium bromate + Salt, organic
Phenol sulphonic acid  Potassium bromide + Alluminium acetate +
Phenol 5%  Potassium carbonate + Ammonium acetate 
Phenoxyacetic + Potassium chlorate + Ammonium oxalate +
Potassium chloride saturated  Aniline sulphate +
Potassium chloride 15% + Potassium acetate 30% 
Potassium chormium sulphate  Qulnine sulphate 
Potassium cyanide powder + Sodium acetate 30% 
Potassiun dichromate + Valine bromide dl +
Lexan Profile 4 Properties and Design
4.7.2 Sterilization 4.7.3 Cleaning and degreasing 4.7.4 Ultraviolet exposure
Lexan polycarbonate meets the Cleaning or degreasing of Lexan Lexan resin may be sensitive to long-
requirements of the FDA and USP resin finished parts can be performed term exposure to ultraviolet light and
Chapter XXII Class V1 for use in the using methyl or isopropyl alcohol, weathering. The degree of sensitivity
medical industry where it is used for a mild soap solutions, heptane or is very much dependent on the
wide range of equipment which must hexane. The parts should not be specific grade, the specified colour
be sterilized. This can be achieved by cleaned with partially hydrogenated and the weathering conditions.
all three commonly used methods: hydrocarbons, with ketones such as
gamma radiation, EtO gas and steam MEK, with strong acids or with Lexan resins are ideally suited to a
(autoclave). Tailor-made Lexan GR alkalines such as sodium hydroxide. range of both indoor and outdoor
grades provide superior colour applications. FIGURES 24 and 25
stability and resistance to yellowing show that UV stabilized Lexan grades
following gamma or EtO sterilisation. maintain high light transmission after
prolonged UV exposure and offer a
good resistance to yellowing after
prolonged exposure to harsh climatic
conditions.
90
Lexan
FIGURE 24
UV stabilized
non stabilized
Transmittance
of transparent
80
Lexan after
natural exposure
acc. ASTM G7,
70
at Florida (USA)
60
50
012345
Exposure (years)
40
Lexan
FIGURE 25
UV stabilized
non stabilized
Yellowness index
of transparent
30
Lexan after
natural exposure
acc. ASTM G7,
20
at Florida (USA)
10
40
0
012345
Exposure (years)
Transmittance (%)
Yellowness index
Lexan Profile 4 Properties and Design
For applications which are exposed enhanced resistance to haze and materials are given as calculated disk
to critical environments of intense yellowing which can be obtained flow lengths, where the injection
sunlight and high humidity, Lexan through the application of a silicone pressure is plotted against the radial
resin can be additionally protected in hardcoat. flow length. Determination of the
various ways. Tailor-made glass clear calculated disk flow length is
UV cap-layers further improve the important when trying to predict
4.8 Processibility
weathering resistance of extruded whether or not a part can be filled.
Lexan sheet, while for injection To obtain extruded sheet, blow As an example, FIGURE 28 shows
moulded parts a variety of coatings, moulded or injection moulded parts, the calculated disk flow lengths of
including a range of GE Silicone the material s flow properties are Lexan 141R.
hardcoats, enhance weathering, critical. These are measured based on The melt flow length of a material is a
scratch and abrasion resistance. melt flow length and melt tempera- function of viscosity, shear properties
FIGURES 26 and 27 illustrate the ture. The flow lengths of GE Plastics and thermal properties.
15
Lexan
FIGURE 26
uncoated
coated
Haze of transparent
Lexan, coated and
uncoated, after
10
accelerated outdoor
exposure
5
0
0 500 1000 1500 2000
Exposure (hours)
15
Lexan
FIGURE 27
uncoated
coated
Yellowness Index
of transparent
Lexan, coated and
10
uncoated, after
accelerated outdoor
exposure
5
0
0 500 1000 1500 2000
Exposure (hours)
500 5
3 mm
FIGURE 28
2 mm
41
Calculated flow 1 mm
400 4
length indication
of Lexan 141R
300 3
200 2
100 1
0 0
20 40 60 80 100 120
Gate pressure (MPa)
Haze (%)
Yellowness index
Injection time (s)
Flow length (mm)
Lexan Profile 4 Properties and Design
4.8.1 Viscosity
FIGURE 31 relates specifically to FIGURE 32, Lexan resin exhibits
Lexan resin is available in a wide selected flame-retarded grades. a very low degree of shear thinning
range of viscosities which are Common viscosity tests include melt when compared with other
obtained by producing polycarbonate viscosity, MV, and melt volume rate, thermoplastics. Unlike most
with different molecular weights: MVR, measurements. thermoplastic materials,
higher molecular weight grades polycarbonate shows an almost
have a higher viscosity. Newtonian behaviour, which means
4.8.2 Shear properties
The portfolio ranges from ultra-low that the viscosity is hardly influenced
viscosity Lexan OQ grades for the MV tests are carried out over a large by the shear rate.
DVD format, to very high viscosity range of shear rates. As materials
grades for multiple wall extrusion, as show significantly different MV Shear curves showing the relationship
depicted in FIGURE 29. FIGURE 30 curves, comparisons should be made between shear rate and viscosity at
shows the range of melt viscosities for according to the MV curves rather different temperatures are required
various glass-filled grades, while than on the MVR. As can be seen in for accurate injection moulding
simulation.
104
Lexan
FIGURE 29
ML3021A
201R
Capillary melt
261R
viscosity of Lexan
241R
showing a wide
103
221R
range of available
HF1110R
viscosities
ML3729
(300°C) OQ1020LN
102
101
102 103 104 105
Shear rate (sec-1)
103
Lexan
FIGURE 30
3414R
40% glass filled
Capillary melt
500R
viscosity of
10% glass filled
standard glass 3412R
20% glass filled
filled Lexan
(300°C)
102
102 103 104
Shear rate (sec-1)
103
Lexan
FIGURE 31
950
42
950A
Capillary melt
940
viscosity of
940A
standard flame
920
retarded Lexan
920A
grades (300°C)
102
102 103 104
Shear rate (sec-1)
Viscosity (Pa·sec)
Viscosity (Pa·sec)
Viscosity (Pa·sec)
Lexan Profile 4 Properties and Design
4.9 Mould shrinkage
As an amorphous material, Lexan relationship. This relationship is
Mould shrinkage refers to the resin exhibits lower shrinkage than illustrated for both unreinforced and
shrinkage that a moulded part semi-crystalline materials. The levels glass-fibre reinforced Lexan grades in
undergoes when it is removed of shrinkage in both cross-flow and FIGURE 33.
from a mould and cooled at room flow direction are also closer to each
temperature. Expressed as an average other for amorphous materials, which The packing or holding pressure
percentage, mould shrinkage can makes it easier to produce precise phase in the injection moulding
vary considerably depending on the parts. The addition of glass process also has a significant effect on
mould geometry, the processing reinforcement increases the degree shrinkage. In general, the higher the
conditions and the type of resin. of orientation but lowers shrinkage. holding pressure and the longer it is
The influence of the material on effective, the smaller the shrinkage.
shrinkage is usually expressed by the This is illustrated in FIGURE 34.
PVT (Pressure-Volume-Temperature)
polycarbonate
FIGURE 32
most thermoplastics
Melt viscosity
of polycarbonate
and most other
thermoplastics
Shear rate
1.00
Lexan
FIGURE 33
141
500
PVT relationship 0.95
3412R
for unreinforced
and glass
0.90
reinforced Lexan
(80MPa)
0.85
0.80
0.75
0.70
0 40 80 120 160 200 240 280 320 360
Temperature (°C)
0 MPa
FIGURE 34
50 MPa
43
Typical PVT 100 MPa
150 MPa
relationship
for Lexan PC.
Higher holding
pressure reduces
volumetric
V50
shrinkage
V150
Troom Tfreeze
Temperature
Viscosity
3
Specific volume (cm /g)
3
Specific volume (m /kg)
5
Processing
Lexan polycarbonate can be Back pressure
successfully processed by injection
·Conventional construction materials A machine back pressure of 5-10 bar
moulding, structural foam moulding, for screw and barrel are acceptable is recommended in order to improve
extrusion, injection (stretch) blow for the processing of Lexan resin. melt quality and maintain a consistent
moulding and extrusion blow However, screws and cylinders of a shot size. For glass-reinforced grades,
moulding. Extruded sheet from bimetallic type with high abrasion careful monitoring of back pressure is
Lexan polycarbonate resin can be and corrosion resistance are advisable in order to minimize fibre
thermoformed. Standard equipment preferred, especially for glass-filled damage.
can be used and the processing range grades.
is very broad. Fast cycle times are Screw rotation speed
·A vented barrel and screw is not a
possible and any rejects can be satisfactory alternative to pre-drying Screw surface speeds should not
ground and reused, providing and is therefore not recommended exceed 250-300 mm/s.
contamination has not occurred for Lexan resin. If a vented barrel is For reinforced grades a screw
during processing. used, then the level of moisture which speedat the lower end of the range
is present in the material, and the is recommended.
percentage of the shot capacity,
5.1 Pre-drying
will have a considerable influence Suck back
Most thermoplastic materials absorb on whether any degradation is The suck back stroke should be just
atmospheric moisture which, at encountered as a result of hydrolysis. enough to keep the resin in and the
normal processing temperatures,
·A free-flowing nozzle with its own air out, to avoid melt degradation
can cause polymer degradation. heater band and control is and subsequent moulding problems.
This consequently lowers property recommended. Nozzle openings
levels, in particular impact strength. have to be as large as possible. Screw cushion
Lexan polycarbonate therefore must
·It is possible to mould with as little as A screw cushion of 3-10 mm is
be thoroughly dried before moulding 35 N/mm2 clamping force but more recommended, depending on the
to ensure optimum part performance commonly pressures are between screw diameter. Without a cushion it
and appearance. The recommended 40 and 50 N/mm2. For complex thin is not possible for the after pressure
drying temperature is 120°C; the time wall components requiring fast to have an effect.
required to achieve sufficient drying injection speeds combined with high
is dependent on the type of dryer injection pressures, a clamping force Injection speed
and varies from 2 to 4 hours. Target of up to 80 N/mm2 is required. The fastest possible injection speed is
moisture content should be a desirable due to Lexan resin s fast set-
maximum of 0.02%. Excessive drying Careful attention to the right tool/ up times, especially when using glass-
times of over 24 hours will not affect equipment combination is critical for reinforced grades. Adequate venting
the properties of the polymer but complex thin wall components which is essential when selecting a fast
they might decrease release require fast processing and high injection speed.
performance during processing. injection pressures.
Mould temperature
Lexan resin should always be
5.2 Equipment 5.3 Processing conditions
moulded in temperature-controlled
Melt temperature moulds. High mould temperatures
·High compression ratio screws
or those with a short compression It is important not to create long are desirable for optimum flow,
44
zone should not be used. residence times which can result minimum moulded-in stress and
It is recommended to use a in material degradation. For Lexan optimal surface appearance.
conventional 3-zone screw with a resin, the ideal maximum residence
L:D ratio of 20:1-25:1 and a time is between 6 and 12 minutes,
5.4 Venting
compression ratio of 2:1-2.5:1. depending on the selected melt
temperature. When processing Good mould venting is essential to
Lexan on the upper limit of the prevent blistering or burning and
melt temperature range, it is to aid cavity filling. Ideally the vents
recommended that the shot size should be located at the end of the
is 60%-80% of the barrel capacity material flow paths. Inadequate or
to minimize residence time. poorly located venting can result in
Lexan Profile 5 Processing
incomplete filling, poor weld line
strength, uneven shrinkage, warping
and the need for excessive injection
Melt temperature 280 - 310 °C
pressure to fill the cavity.
FIGURE 35
Mould °C Nozzle Zone 3 Zone 2 Zone 1 Hopper
Typical moulding
350
5.5 Interruption of production
temperatures
for Lexan general
300
Keeping Lexan resin in the cylinder
purpose: 141R
overnight or over a weekend is
250
generally not recommended. If
production delays are unavoidable, 200
the following precautions are
150
recommended.
·Reduce cylinder temperature to
100
170°C-180°C
·Leave heaters on 50
·Ensure that the temperature never
drops below 160°C. This is to prevent 0
the resin from adhering to the
cylinder walls which may pull off
metal particles and degraded resin
as it cools and contracts, causing
black specks in the mouldings when
production is restarted
Melt temperature 280 - 300 °C
·During production delays, empty the
FIGURE 36
screw to prevent overheating
Mould °C Nozzle Zone 3 Zone 2 Zone 1 Hopper
Typical moulding
350
temperatures
5.6 Purging of the barrel
for Lexan flame
300
retarded: 940
Thorough purging of the barrel is
250
required when changing materials.
The best purging material for Lexan
200
resin is PMMA. PA or ABS should not
be used as a purging material directly
150
after Lexan resin. The cylinder
temperature should be lowered if the 100
resins to be moulded afterwards are
50
POM, ABS or PA.
0
5.7 Recycling
Sprues and faulty mouldings can all
be reground with minimal reduction
in resin properties. Care must be
taken to ensure that the regrind is
free from impurities and that proper
Melt temperature 290 - 320 °C
pre-drying of the regrind has been
FIGURE 37
Mould °C Nozzle Zone 3 Zone 2 Zone 1 Hopper
carried out. Blends of regrind and
Typical moulding
350
virgin material are possible in the
temperatures
ratio of 20:80. Regrind should not
for Lexan flame
300
®be used in applications where
retarded, glass
45
impact performance and/or agency
filled: 500R
250
compliance are required.
200
150
Note
Further information on the
100
processing of engineering
thermoplastics can be found
50
in GE Plastics brochures:
0
·Injection Moulding Mini Guide
·Engineering Thermoplastics in
the Extrusion Industry
6
Secondary Operations
Although most Lexan parts are
6.2 Adhesives 6.3 Mechanical assembly
moulded as finished components,
the design and ultimate use of Lexan resin parts can be bonded to Mechanical assembly techniques are
certain parts may require machining, other plastics, glass, aluminium, brass, widely used with Lexan parts. To
assembly or finishing operations. steel, wood and other materials. achieve optimum results, mechanical
Lexan resin makes a wide variety of A wide variety of adhesives can be fasteners should be kept free from oil
secondary operations available to the used, sometimes with the addition of and grease. Depending on the type of
design engineer. a suitable primer. In general, Lexan fastener, a permanent stress or
parts can be easily solvent bonded to deformation is applied locally. Clamp
parts made from Lexan, Cycolac® ABS forces should be controlled or
6.1 Welding
or Cycoloy® PC/ABS alloy with Methyl distributed over a large surface area.
Welding is a commonly used Ethyl Ketone (MEK) or in mixtures This is in order to decrease local
permanent assembly technique for of MEK with Cyclohexanone, ideally stresses in the part after assembly and
engineering thermoplastics. Lexan 50:50. to minimize the risk of loosening the
parts can be welded using different fasteners through creep and
processes. Selecting the right process Cleaning parts relaxation. Notches in the design as
depends on the size, shape and Thorough cleaning of Lexan parts well as notches resulting from
function of the part: before bonding is essential in order mechanical fasteners should also be
·Hot Plate welding allows excellent to avoid part failure. All oil, grease, avoided.
weld strengths to be achieved at paint, mould releases, rust oxides,
temperatures of 260°C-300°C etc., must be removed by washing Recommended assembly techniques:
with solvents which are compatible
·Friction welding can be applied, ·Thread-forming screws rather
using either the vibration, orbital with Lexan resin. These solvents than thread cutting screws are
or rotation method include isopropyl alcohol, heptane recommended. Screws with a
or a light solution of non-alkaline maximum flank angle of 30° are
·Ultrasonic welding is commonly
used, in particular for mobile detergents. Bond strength is further preferred for minimal radial stresses
telephone components. Welding improved by sanding, sand blasting or
·Inserts which leave low residual
amplitudes with 20 kHz ultrasonic vapour blasting the bonding surfaces. stresses can be used. Installation by
processes should be in the range heat or ultrasound are the preferred
of 25-40 µm (0-peak) techniques. Press and expansion
inserts produce high hoop stresses in
·Induction Welding
bosses and should therefore be used
with caution
·Snap fit assembly
·Rivets
·Staking
Note
General information on Secondary
Operations like welding, mechanical
assembly and bonding of engineering
46
thermoplastics can be found in the
following GE Plastics brochures:
·Assembly Guide
·Design Guide
TABLE 6
Compatibility of adhesives with Lexan resin
Epoxy PUR PUR PUR hot MS Silicone Silicone Acrylic Cyano-
2K 1K 2K melt reactive polymer 1K 2K 2K acrylate
primer no yes no no no yes/no no no no
aggressive at high t° no no no no alkoxy no yes yes
Lexan Profile 6 Secondary Operations
6.4 Painting 6.5 Metallisation
·Coatings can be used to help
A wide variety of colours and textures minimize colour degradation Properties usually associated with
can be applied to Lexan using
·Conductive coatings offer shielding metals such as reflectivity, abrasion
commercially available organic paints against radio frequency interference resistance, electrical conductivity
and conventional application (RFI) or electromagnetic and decorative surfaces can be
processes. Painting is an economical interference (EMI) added to plastics through
means of enhancing aesthetics and metallisation. Three of the more
providing colour uniformity. Paint solvents commonly applied metallisation
It is important that solvent techniques are discussed here.
Pre-treatment formulations are carefully considered
Vacuum metallisation
·Handwashing the part with cleaning when selecting a paint for use with
agents based on alcohol or aliphatic amorphous resins such as Lexan. Vacuum metallisation through
hydrocarbons It should be stressed that it can be Physical Vapour Deposition involves
or: difficult to achieve an ideal match the depositing of an evaporated
metal, mostly aluminium, on a
·Powerwashing the part with cleaning between solvent and substrate.
agents based on detergents dissolved substrate. To achieve evaporation,
in water. These detergents can be Although it is generally difficult the pure metal is heated in a deep
either acidic by nature, (pH 3-4), to give rules for balancing solvent vacuum. To ensure a good result
or neutral, (pH 8-9). Alkaline-based mixtures, there are some basic when using this method with Lexan
detergents (pH >11) should be guidelines. For example, strong resin, a glow discharge pre-treatment
avoided. solvent action can be balanced with is highly recommended.
a non-dissolving liquid like butanol
Paint selection or dipentene. Solvents with strong After vacuum metallisation, the
Paint selection is determined by the embrittlement effects, on the other aluminium must be protected
desired decorative effect, specific hand, can be balanced by adding against environmental influences.
functional needs and the application stronger dissolving solvents. It should This is because of the ultra-thin
technique to be applied. A variety of be noted that lower boiling point layer thickness combined with the
conventional and waterborne paints solvents cause embrittlement effects reactive nature of aluminium to
can be successfully applied to Lexan more quickly. humidity. Most commonly this
resin. Generic types include: protection is provided through the
The occurrence of stress cracking is application of a Plasil/Glipoxan top
·Acrylic
a result of solvent action on the one layer, (a silicone-based monomer
·Epoxy
hand and stresses in the part on the layer which is applied in the vacuum),
·Polyester
other. The level of stress in the part or a clear coat top layer.
·Polysiloxane
should be ideally below 5 MPa.
·Polyurethane
This is achieved through optimal part In general, unreinforced Lexan
Special coatings and tool design and proper moulding resin does not require a basecoat
·A range of siloxane-based coatings procedures. In general, if stress levels or lacquer primer layer before
with inherent glass-like optical are above 10 MPa, painting will metallisation because of the good
properties has been developed to become critical. In case of doubt, surface quality of Lexan parts after
provide Lexan resin transparent parts Lexan resin parts should be tested moulding. However, in certain cases,
47
with optimum chemical and scratch using a mixture of Toluene and application of a basecoat is
resistance and UV protection. These n-Propanol or propylene-carbonate. recommended to enhance reflectivity,
special coatings can be easily applied in particular where a glass-filled
by dip coating, flow coating or by Lexan material has been specified.
spraying
·Acrylic-based coatings can be used in
applications such as compact discs
where only UV protection and
moderate scratch resistance is
required
Lexan Profile 6 Secondary Operations
6.6 Laser marking
In most cases a surface activation
pre-treatment is required. The laser marking of thermoplastics
is a complex process. The differing
·Glow discharge takes place in a
vacuum vessel in the presence of a low demands of applications, together
pressure gas such as air. This method with a diverse range of materials,
gives an increased surface energy and pigments and additives, as well as
micro porosity to the Lexan part. the equipment itself, provide a large
·Cleaning with a cloth or solvents is number of variables. Through its
not recommended because of the advanced research and development
sensitivity to scratches that can be programme, GE Plastics has gained
seen after metallisation. The best valuable insight into the thermal,
method is to keep the mouldings optical, mechanical and chemical
clean and to metallise the parts as processes which take place during
soon as possible after moulding, or laser marking. An important result of
to store them in clean containers. this has been the development of a
broad tailor-made range of materials
Plating using proprietary combinations of
This can be done by two methods. pigments and additives. These
In the first, electro plating, current include Lexan grades 121R, 141R
is used to effect an electrolytic and ML3432 which provide light on
deposition of metals derived from a dark contrast laser marking.
dissolved metal salt. Most frequently
used metals include chrome, nickel
or gold. Note
General information on Secondary
The second method, electroless Operations like painting and
plating, is executed without the metallisation of engineering
addition of current to the galvanic thermoplastics can be found in the
process. Electroless plating can be following GE Plastics brochures:
further divided into non-selective
·Painting Guide
(double-sided) and selective (single-
·Metallization Guide
sided) plating.
·For non-selective or all-over
electroless plating, a pre-etch is
generally required with Lexan resin.
·Selective electroless plating starts with
the masking of those areas of the part
which must remain metal-free.
A catalytic lacquer is then applied to
seed the exposed surface to initiate
the deposition of metal after
immersion in the metal salt solution.
·If only EMI shielding is required, an
electroless copper layer of 1-2 µm is
applied with a finish of electroless
nickel.
Hot foil stamping
In this dry metallisation technique,
the metal foil is impressed on the
plastic surface with a heated die or
48
rubber roll. Standard foils are
available for use with Lexan resin
parts, but it is recommended to test
each grade and new application for
compatibility and melting point.
GE Plastics
®
Lexan profile
Impact
100 kJ/m
2
80
Modulus
60
40
15000 MPa
12500
10000
20
7500
Heat
5000
0
2500
0
Lexan
200°C
150
100
50
0
0
"
40
nt
HB
80
120
V2
160
V1
200 MPa
V0
Str
ength
5VB
5V
A
Flammability
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RESULTING FROM ANY USE OF ITS MATERIALS OR PRODUCTS DESCRIBED
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HEREIN. Each user bears full responsibility for making its own determination as to
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the suitability of GEP s materials, products, recommendations, or advice for its own
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particular use. Each user must identify and perform all tests and analyses necessary to
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assure that its finished parts incorporating GEP materials or products will be safe and
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suitable for use under end-use conditions. Nothing in this or any other document, nor
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any oral recommendation or advice, shall be deemed to alter, vary, supersede, or waive
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any provision of GEP s Standard Conditions of Sale or this Disclaimer, unless any such
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modification is specifically agreed to in a writing signed by GEP. No statement contained
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herein concerning a possible or suggested use of any material, product or design is
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intended, or should be construed, to grant any license under any patent or other
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intellectual property right of General Electric Company or any of its subsidiaries or
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affiliates covering such use or design, or as a recommendation for the use of such
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material, product or design in the infringement of any patent or other intellectual
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property right.
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* Company not connected with the English company of a similar name.
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® ® ® ® ® ® ® ® ® ®
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®
and Enduran are Registered Trademarks of General Electric Co., USA.
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Gelon"! is a Trademark of General Electric Co., USA.
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Tel. (90) [phone]
Fax (90) [phone] Lexan Eng/4M/0998
300°C
25
For your convenience, the preference
for ÔMax ÒFit VisibleÓ MagnificationÕ
!
should be changed from 800% to 150%.
set preference continue