Microcellular Polycarbonate with Improved Notched Impact Strength Produced by Injection Moulding with Physical Blowing Agent

Polycarbonate has the reputation of having a tough breaking behaviour, but it is often unknown that this applies only to special conditions. The impact strength of polycarbonate depends on the temperature, the thickness (with a tough brittle transition at thickness increases), contribution of notch tip radius, impact speed, physical blowing agent, molecular weight of the polymer and the processing parameters. Research results indicated that microcellular foams produced by injection moulding with physical blowing agent (MuCell™ Technology by Trexel) shows significant higher notched impact strength than compact polycarbonate, if the compact material is brittle under the same test parameters. However, if the compact polycarbonate breaks toughly, the notched impact strength of the foamed material is always lower. Therefore, it is highly important to pay attention to the test parameters and conditions when comparing the toughness of the foamed with the compact material. The toughness of microcellular foams shows similar properties to PC/ABS and PC/PP blend systems, which provides the possibility to combine the higher impact strength with the advantages of microcellular foaming like weight reduction, lower shrinkage, shorter cycle times, lower clamp forces and reduced melt viscosity. In order to use technologies and conditions which are applied in the polymer industry, all materials were produced by an injection moulding process. Special processing technologies like gas counter pressure and precision mould opening were used in order to reach microcellular foam structures with cell diameters around 10 μm. These technologies yield exactly adjustable foam morphologies. Special morphologies are required to improve the notched impact strength of the foamed material. Two different equivalent models were extracted from the analyses, which indicate significant higher notched impact strength than the compact material under the same test conditions. The knowledge of the ideal foam morphologies enables the industry to produce foamed materials with improved mechanical properties.