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Polymer Coatings: Coating Process

• PVC (Polyvinylchloride) • PVDC (Polyvinylidenechloride) • PVA (Polyvinylacetate) and acetate copolymer • Acrylics • PU (Polyurethane)

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163 views3 pages

Polymer Coatings: Coating Process

• PVC (Polyvinylchloride) • PVDC (Polyvinylidenechloride) • PVA (Polyvinylacetate) and acetate copolymer • Acrylics • PU (Polyurethane)

Uploaded by

waqas
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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POLYMER COATINGS

Introduction:
Polymer-coated textiles are flexible composite materials comprising the coat (the polymer) and the
substrate (textile layer(s)) adhered together through a specific coating process to provide additional
properties for the system.
A military tent can be made of a material that combines Nylon fabric with a Neoprene coat, whereas a
urethane coated polyester cloth can be used to make the inflatable chutes installed at the emergency exits
on aircrafts. Other examples include protective clothing for firemen,
Waterproof jackets, and seat upholstery for cars.

Combination of various properties of each layer determines the overall properties of the system.
That is, the textile substrate contributes to the strength (tear and tensile), elongational and dimensional
properties of the system in general, whereas the polymer coat helps to introduce resistance to penetration
and impermeability (to liquids, gases and dust particles), as well as improve fabric abrasion.
The layers (of the textile and the coating) are bonded to each other in situ (typically means "in the
reaction mixture.") by the adhesive properties of the layers leading to the ‘coated fabric’, or by the use
of an added adhesive leading to the ‘laminated fabric’.

COATING PROCESS:
The first step in the production of a coated textile fabric is ‘direct spreading’ of the (thickened liquid or
paste) polymer in liquid form over the textile surface. The thickened liquid is allowed to evaporate,
leaving the polymer on the fabric (if solvent based) or allowed to transform into a coat (if plastisol- or
dispersion-based); both of these processes are carried out in special ovens. During this process,
appropriate crosslinking (‘curing’) of the polymer coat is achieved to improve durability to abrasion and
resistance to solvents (and water). This type of processing has the advantage of producing coats without
mechanical or thermal stresses; however, it has the disadvantage of removal of large amounts of solvent
or dispersion medium, which is energy-intensive.

The combination possibilities of the textile and coating are almost infinite, and are dependent upon final
use. The polymer coat can be on one (or both) side(s) of the substrate (with identical or different types of
polymers on each side), whereas the substrate can be a woven, knitted or even non-woven textile material.

FACTORS OF COATING:
The overall properties of a polymer-coated textile are mainly dependent upon the:
 Characteristics of Textile substrate.
 Characteristics of the coat applied.
 Coating method selected and employed

Polymeric Materials Commonly Used for Textiles Coating:


Most of the properties of thermoplastics are useful for coating because they can be used as hot-melt
adhesives and can be welded by heat. The polymer to be selected is expected to have certain properties, in
addition to appropriate molecular weights to provide the requisite mechanical properties with appropriate
values of Tm and Tg.

The most commonly used thermoplastic polymers applied for textiles coatings are as follows:
 PVC (Polyvinylchloride)
 PVDC (Polyvinylidenechloride)
 PVA (Polyvinylacetate) and acetate copolymer
 Acrylics
 PU (Polyurethane)
 others

In addition, for several special applications, other thermoplastics (e.g., polyimide and PTFE) can also be
used. In more sophisticated applications (e.g., those leading to inherently electrically conducting textile-
coated systems), other selected polymers (e.g., polypyrrole) can also be employed.

PVC (Polyvinylchloride):
PVC and PVDC are also known as ‘vinyl’s’ or ‘vinyl resins’. PVC is one of the most widely used
commodity polymers. It is a white, water-insoluble thermoplastic resin mainly used for coatings,
insulation and piping.

The advantages of using PVC as a coat are:


 PVC is a versatile and economical polymer
 PVC has good resistance against oil, solvent and abrasion
 It can be readily compounded with a series of different additives(including plasticizer)
 It has inherent good fire retardant resistance

The disadvantages of using PVC as a coat are:


 PVC tends to crack when cold
 PVC has moderately low heat resistance
 It has low ageing resistance

PVDC Polyvinylidene Chloride:


Along with PVC, PVDC is a member of the ‘chloropolymers’ family. It is a thermoplastic vinyl polymer.
Its emulsions are used to impregnate mainly fabrics, leather and paper.

The advantages of using PVDC as a coat are:


 Exceptional fire retardancy property
 Very low permeability to gases
 Transparent with high gloss
 No effect of sunlight on PVDC
 Resistant to strong acids and bases

The disadvantages of using PVDC as a coat are:


 More brittle than PVC and easily crack if coldec
 Soluble in most organic solvents
 The monomer, VDC, is an irritant and genotoxic.

Acrylics (Acrylic Polymers):


Acrylic polymers are very common, and have a range of properties and prices. They are mainly used as
back coatings for upholstery (fabric and carpets), as adhesives for laminates, and as lacquers for tarpaulin.
The polymer itself is used as an adhesive.
The products of the latter solution and emulsion polymerization are preferably used for coatings. Acrylic
resin coats, as waterproof coatings, are successfully applied on woven Nylon or polyester substrates with
‘crushed foam coatings for curtains. Modern car seats are usually back-coated with acrylics to increase
abrasion resistance and to improve fire resistance.

The advantages of using acrylic polymers as a coat are:


 Have good clarity
 High UV resistance
 Good resistance to ozone aging
 Resistant to various chemicals and water
 Economical

The disadvantages of using acrylics as a coat are:


 Fire retardance resistance of acrylic is very poor
 The monomer, MMA, is toxic

Polyurethane:
The PU become much more light-resistant and are extensively used for coatings. PU coatings of
polyurethane have very good resistance to abrasion and solvent attack, and have good flexibilities and
impact resistances. PU coatings are mainly prepared by conventional solution-based techniques, which
use one- or two-component systems. They can be applied by dip, spray or brush techniques and adhere
very well to various materials. PU coatings are specifically preferred if unusual impact and abrasion
resistances are required (e.g., floors in public buildings), as well as for various outdoor and marine uses
(due to their good weather ability). PU coatings are used to produce tents of different sizes (in general,
smaller ones of PU and the larger ones of PVC or Neoprene coated polyester/Nylon woven fabrics), in
upholstery (mainly transfer coated PU with expanded grades for a soft touch) and in waterproof protective
clothing (i.e., mainly with PU transfer coated items.

The advantages of using PU as a coat are:


 PU coatings are extremely tough with very high tensile/tear/impact resistance and very good abrasion
resistance.
 good weather ability
 flexible at low temperature with leather like properties
 no curing is needed
 can be dry cleaned (plasticizers are not used)
 good adhesion to fabric substrates, have good elongation and excellent flexibilities

The disadvantages of using PU as a coat are:


 In case of fire, PU can generate toxic fumes of carbon monoxide and cyanic acid
 The monomer, isocynates are highly toxic

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