The common confusion between Lexan and polycarbonate stems from a simple distinction between a brand name and the material itself. Lexan is a specific, trademarked brand of the general-purpose material known as polycarbonate. The material’s unique physical properties led to its widespread adoption, making the brand name Lexan almost synonymous with high-performance, clear plastic.
Clarifying the Relationship: Brand Versus Generic Material
Polycarbonate is the generic name for a group of thermoplastic polymers that contain carbonate groups in their chemical structure. Lexan is a registered trademark currently owned by Polyvantis, which acquired the plastics division of General Electric (GE) in 2007, though the brand has recently moved to Polyvantis in 2024. The material Lexan uses is chemically and structurally polycarbonate, meaning a sheet of Lexan is fundamentally a sheet of polycarbonate.
The history of the material shows that Daniel Fox at General Electric independently invented a version of polycarbonate in 1953, shortly after Hermann Schnell did the same at Bayer in Germany. GE began commercial production of this material under the Lexan name in 1960. This early market presence and association with high-quality engineering plastic cemented Lexan as the leading brand.
Essential Characteristics of Polycarbonate
Polycarbonate’s popularity is due to its combination of superior physical properties, which position it as an engineering thermoplastic. Its most recognized characteristic is its extreme impact resistance; it can be up to 250 times stronger than traditional glass. This toughness comes from its molecular structure, which allows it to absorb and dissipate energy from an impact without shattering.
The material also exhibits excellent optical clarity, often transmitting up to 90% of visible light, a transparency comparable to glass. Unlike glass, polycarbonate is significantly lighter, weighing approximately half as much. This lightweight nature combined with its strength is particularly valuable in applications where reducing mass is important, such as in aerospace or automotive parts.
Another defining feature is its broad temperature stability, making it suitable for use in diverse environments. Polycarbonate maintains its structural integrity and performance across a wide range, often tolerating temperatures between -40°C and 120°C (-40°F and 248°F) for continuous use.
Practical Applications and Quality Considerations
The combination of strength, clarity, and temperature resistance makes polycarbonate a preferred material across various industries, appearing in countless finished products. Common uses include:
- Safety equipment like helmet visors and goggles.
- Construction applications such as security glazing and skylights.
- Automotive parts like headlamp lenses.
- Electronic housings.
- Manufacturing of optical discs like CDs and DVDs.
Branded Consistency
While all polycarbonate shares the same fundamental chemical structure, the choice between the brand-name Lexan and a generic option often comes down to quality and consistency. Branded products like Lexan typically guarantee highly consistent resin quality and tighter tolerances during manufacturing. This consistency is important for applications requiring precise specifications, such as security barriers or specialized optical components.
Proprietary Grades
Lexan also offers proprietary grades that have been chemically engineered for enhanced performance characteristics that generic options may not match. Examples include Lexan MR10, which is specially coated for abrasion resistance, and Lexan SL2, which is UV-stabilized for superior outdoor weatherability. These specialized formulations provide features like enhanced scratch resistance or specific flame retardancy that meet stringent industry standards.
Generic polycarbonate sheets are often more cost-effective and may be perfectly adequate for general-purpose projects. However, the lower price point can sometimes mean less rigorous quality control or the absence of specialized coatings and certifications found in the branded Lexan options. When selecting the material, the buyer must weigh the cost savings of generic polycarbonate against the guaranteed performance, specific certifications, and advanced proprietary features offered by a premium brand like Lexan.