46 Plastics Technology HandbookVolume 2

A: iuo:ta:t clcct:ical uct|oc is t|c ucasu:cuc:t oi t|c ciclcct:ic |:ca|cow: oi:t oi a

coati:g. I|c i:st:uuc:ts t|at a:c uscc io: t|is u:osc ca: also |c uscc to cctc:ui:c t|c o:osit,
a:c u:iio:uit, oi a coati:g ;c|atc: !!,.
PROCESS
Overview
lot| Ils a:c I lastics ua, |c uscc as coati:gs. I|c uatc:ials to |c coatcc ua, |c lastic, uctal,
wooc, ac:, ia|:ic, lcat|c:, glass, co:c:ctc, cc:auics, a:c so o:. \ct|ocs oi coati:g a:c va:icc, as
s|ow: i: Ia|lc 10.!1.
TabIe 10.21 CoatIng methods related to performances
Coating 47
Base material
A ~ wovc: a:c :o:wovc: ia|:ic
l ~ ac: a:c ac:|oa:c
~ l,wooc a:c :csscc ii|c:|oa:c
D ~ lastic iilus
l ~ uctal s|cct, st:i, o: ioil
l ~ i::cgula: ilat :ocucts
G ~ i::cgula:l, s|acc :ocucts
Coating composition
Q ~ owcc:cc :csi: couositio:s
k ~ aqucous latcxcs, cuulsio:s, cisc:sio:s
~ o:ga:ic lacquc: solutio:s a:c cisc:sio:s
I ~ lastisol a:c o:ga:osol io:uulatio:s
u ~ :atu:al a:c s,:t|ctic :u||c: couositio:s
V ~ |ot uclt couositio:s
W ~ Il uasscs
X ~ olco:csi:ous couositio:
Y ~ :cacti:g io:uulatio:s ;c.g., cox, a:c ol,cstc:,
Z ~ lastic uo:ouc:s
I|c :occsscs i:clucc cxt:usio: ;lig. 10.+, c|atc: .,, :ollc: coati:g ;lig. 10..,, |:iii:g o:
s:caci:g ;lig. 10.o,, t:a:sic::i:g ;lig. 10.,, cast t:a:sic::i:g ;lig. 10.,, cii:g ;lig. 10.-,,
vacuuui:g ;lig. 10.10,, i: uolc via :cactio: i:|cctio: uolci:g ;lig. 10.11, c|atc: 1!,, clcct:occ
ositio: ;lig. 10.1!,, s:a,i:g ;Ia|lc 10.!!,, iluicizcc |cc, |:us|i:g, ilocci:g, uic:ocasulatio:,
:aciatio:, a:c ua:, ot|c:s ;a icw will |c :cvicwcc,. alc:cc:i:g oi a iilu to a suo:ti:g uatc:ial
is also a io:u oi coati:g t|at tc:cs to |c siuila: to :oll coati:g ;c|atc: -,. l:occsscs a:c also uscc
to coat scciiic :ocucts suc| as iloo: covc:i:g ;lig. 10.1!, a:c ioaucc ca:ct |ac|i:g ;lig. 10.1+,.
u:iacc coati:gs a:c usuall, couoscc oi viscous liquics. I|c, |avc t|c t|:cc |asic couo:c:ts
oi a iilu io:ui:g su|sta:cc o: cou|i:atio: oi su|sta:ccs. a |i:cc:, a iguc:t o: cou|i:atio: oi
iguc:ts, a:c a volatilc liquic. I|c cou|i:atio: oi |i:cc: a:c volatilc liquic is usuall, callcc t|c
vc|iclc. lt ua, |c a solutio: o: a cisc:sio: oi ii:c |i:cc: a:ticlcs i: a :o:solvc:t. :o iguc:ts
a:c i:cluccc ii a clca:, t:a:sa:c:t coati:g is :cqui:cc. I|c couositio: oi t|c volatilc liquic :o
viccs c:oug| viscosit, io: ac|agi:g a:c alicatio:, |ut t|c liquic itscli :a:cl, |ccoucs a:t oi
t|c coati:g.
lilu coati:gs ca: i:volvc c|cuical :cactio:s, ol,uc:izatio:, o: c:oss li:|i:g. ouc iilus
uc:cl, i:volvc coalcscc:cc oi lastic a:ticlcs. I|c va:ious ucc|a:isus i:volvcc i: t|c io:uatio:
oi lastic coati:gs a:c as iollows.
48 Plastics Technology HandbookVolume 2
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Coating 49
FIgure 10.5 Example of roller coatIng processes.
50 Plastics Technology HandbookVolume 2
1. oati:g io:ucc |, c|cuical :cactio:, ol,uc:izatio:, o: c:oss li:|i:g oi cox,, I
ol,cstc:, luk, |c:olic, u:ca, silico:c, a:c so o:
!. Disc:sio:s oi a lastic i: a vc|iclc, aitc: :cuoval oi t|c vc|iclc |, cvao:atio: o:
|a|c, t|c lastic coalcsccs to io:u a iilu oi lastisol, o:ga:osol, watc: |ascc o: latcx
ai:t, iluo:oca:|o:s, a:c so o:
!. llastic cissolvcc i: a solvc:t iollowcc |, solvc:t cvao:atio: to lcavc a lastic iilu oi
vi:,l lacquc:, ac:,lic lacquc:, al|,c, c|lo:i:atcc :u||c:, ccllulosc lacquc:, a:c so o:
+. liguc:ts i: a: oil t|at ol,uc:izcs i: t|c :csc:cc oi ox,gc: a:c c:,i:g agc:ts oi
al|,c, c:aucls, va::is|cs, a:c so o:
.. oati:gs io:ucc |, cii:g i: a |ot uclt oi lastic suc| as ol,ct|,lc:c o: ac:,lic
o. oati:gs io:ucc |, usi:g a owcc:cc lastic a:c uclti:g t|c owcc: to io:u a
coati:g usi:g ua:, ciiic:c:t Ils
FIgure 10.7 Transfer coatIng of PUF (top) and P7C.
FIgure 10.6 KnIfe spread coatIng.
Coating 51
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52 Plastics Technology HandbookVolume 2
FIgure 10. FabrIc dIp coatIng lIne.
Coating 53
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54 Plastics Technology HandbookVolume 2
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Coating 55
lquiuc:t io: coati:g li:cs ca: |c associatcc wit| c:c usc ua:|cts, wit| souc ovc:lai:g.
u|st:atcs o: wc| |a:cli:g c|a:actc:istics cisti:guis| t|c ciiic:c:ccs auo:g t|i: lastic iilu, ac:,
a:c ac:|oa:c cou|i:atio:s. llcxi|lc ac|agi:g cxt:usio: li:cs a:c usi:g :og:cssivcl, t|i::c:
su|st:atcs oi ol,cstc:, o:ic:tcc ol,:o,lc:c, uctallizcc uatc:ials, a:c so o:. I|i: s:ac| iooc
su|st:atcs :cqui:c ui:iuuu tc:sio:s to assu:c t|at :c:i:tcc wc|s a:c :ot cisto:tcc.
lcatu:cs i:clucc D :cgc:c:ativc u:wi:cs a:c i: iccc |olc|ac|s io: :ccisc a:c low lcvcl
tc:sio:, ci:cct o: :cvc:sc g:avu:c io: aqucous lVD a:c ot|c: lastics, coati:g, i:i:a:cc :c|cat
i:g, a:c vacuuu :olls io: wc| co:t:ol. I|c co:cct oi ta:ccu oc:atio:s o: coati:g two siccs oi
a su|st:atc co:ti:ucs to cxa:c to ua:, ilcxi|lc ac|agi:g li:cs t|at :ocucc all |i:cs oi cou|i
:atio:s ;ciiic:c:t lastics, ac:, aluui:uu ioil, wooc, stccl s|cct, ctc., a:c coati:g a lastic io:
|cat scali:g. lig|c: oc:ati:g li:c tc:sio:s a:c uscc i: :ocuci:g st:uctu:cs wit| ac: io: g:a:u
latcc o: owcc:cc uixcs a:c i:cczc: o: suga: w:a uatc:ials. Diiic:c:t lastics, suc| as io:ouc:s,
ac:,lics, :,lo:s, lVls, a:c lVAs, ua, |c a:t oi a co:vc:tc:`s i:vc:to:, oi :csi:s.
I|c cou|i:atio: oi aluui:uu ioil a:c |a::ic: :csi:s cxtc:cs cxisti:g tcc|:ologics to c:catc
li:cs wit| t:ilc o: quac:ulc ;o: uo:c, coati:g s,stcus a:c i:cluccs cocxt:usio: i: o:c o: uo:c
locatio:s.
Film Solidication
W|c: t|c coati:g is alicc to t|c su:iacc, t|c volatilc liquic cvao:atcs, lcavi:g t|c :o:volatilc
|i:cc: iguc:t cou|i:atio: as a :csicual iilu, it ua, o: ua, :ot :cqui:c a c|cuical co:vc:sio: to a:
i:solu|lc co:citio:. uall auou:ts oi accitivcs a:c oitc: i:cluccc to iu:ovc alicatio:, iguc:t
scttli:g, c:,i:g, a:c iilu :oc:tics. \ost |i:cc:s a:c cit|c: |ig| uolccula: wcig|t, :o::cactivc las
tics o: low to ucciuu uolccula: wcig|t, :cactivc lastics caa|lc oi |ci:g iu:t|c: ol,uc:izcc via
c|ai: cxtc:sio: o: c:oss li:|i:g :cactio:s to |ig| uolccula: wcig|t iilus ;c|atc: 1,.
TabIe 10.22 Examples of spray coatIng methods related to transfer efcIency
56 Plastics Technology HandbookVolume 2
\ost coati:gs a:c ua:uiactu:cc a:c alicc as liquics, t|c, a:c co:vc:tcc to solic iilus o:cc
t|c, a:c o: t|c su|st:atc. lowcc: coati:gs a:c alicc as a solic owcc:, co:vc:tcc to a liquic o:
t|c su|st:atc, a:c t|c: io:ucc i:to a solic iilu.
oati:g iilus a:c viscoclastic, so t|ci: ucc|a:ical :oc:tics ccc:c o: t|c tcuc:atu:c a:c
t|c :atc oi st:css alicatio:. I|ci: |c|avio: a:oac|cs t|c clastic uocc wit| i:c:cascc tc:silc
st:c:gt| to iailu:c ;|:ca|agc, o: ccc:cascc clo:gatio: to iailu:c, a:c wit| a uo:c :ca:l, co:sta:t
uoculus as a iu:ctio: oi st:css w|c: t|c tcuc:atu:c ccc:cascs o: w|c: t|c :atc oi alicatio:
oi st:css i:c:cascs ;c|atc: 1-,. I|c s|iits ca: |c cscciall, la:gc ii :csults a:c coua:cc a|ovc
a:c |clow t|c glass t:a:sitio: tcuc:atu:c ;7
J
, c|atc: 1,. lclow 7
J
, t|c coati:gs |avc a: clastic
:cso:sc a:c a:c t|c:cio:c |:ittlc, t|c, |:ca| ii t|c :clativcl, low clo:gatio: to iailu:c is cxcccccc.
A|ovc 7
J
, t|c viscous couo:c:t oi t|c ccio:uatio: :cso:sc is la:gc:, t|c iilus a:c soitc: ;lowc:
uoculus, a:c lcss li|cl, to |:ca| cu:i:g io:ui:g. autio: is :cqui:cc i: co:sicc:i:g t|c :clatio:
s|i oi 7
J
to io:ua|ilit, |ccausc souc uatc:ials, suc| as ac:,lic a:c cscciall, l, a:c cuctilc at
tcuc:atu:cs ia: |clow 7
J
. A|ovc 7
J
, t|c uoculus is :iua:il, co:t:ollcc |, t|c cc:sit, oi t|c
lastic c:oss li:|agcs.
Aitc: a coati:g is alicc, solvc:t cvao:atio: a:c :|cological iacto:s co:t:i|utc to t|c soliciii
catio: o: cu:i:g oi t|c coati:g iilu. olvc:t i:itiall, cvao:atcs i:ou t|c su:iacc oi t|c iilu at a|out
t|c sauc :atc as it woulc i: t|c a|sc:cc oi a |i:cc:. As t|c iilu soliciiics, cvao:atio: slows cow:
|ccausc t|c ciiiusio: :atc to t|c su:iacc is usuall, slowc: t|a: t|c cvao:atio: :atc. lacquc: iilus
co :ot cu:c |, c|cuical :cactio: to ac|icvc t|c :cqui:cc |a:c:css a:c toug|:css. I|c, |ust c:,
|, solvc:t cvao:atio: a:c ccc:c o: t|c |ig| \W oi t|csc Il uatc:ials to :ovicc t|c :cqui:cc
c:io:ua:cc. latcx ai:ts |c|avc i: a siuila: ua::c:.
Coating Methods
\a:, ciiic:c:t uct|ocs a:c uscc to al, lastic coati:gs to su|st:atcs oi all sizcs a:c t,cs, :a:gi:g
i:ou t|c siulc to t|c coulcx. I|c, a:c gc:c:all, couoscc oi o:c o: uo:c lastics, a uixtu:c oi
solvc:ts ;cxcct wit| owcc: coati:gs,, couuo:l, o:c o: uo:c iguc:ts, a:c i:cquc:tl, scvc:al
accitivcs. oati:gs ca: |c classiiicc as Ils o: Is. oati:g uct|ocs a:c catcgo:izcc i: ciiic:c:t
wa,s |, t|c ciiic:c:t i:cust:ics t|at :cqui:c t|cu.
I:acitio:al ai:ts co:tai: a vc|iclc, a solvc:t, a:c a iguc:t. ouc a:c alicc |, s:a,i:g
o: cii:g. t|c: s,stcus i:volvc |cati:g a:ts a:c s:a,i:g t|cu wit| a c:, lastic owcc: t|at
coalcsccs o: t|c |ot a:t to io:u a iilu. I|c ciiic:c:ccs auo:g t|c va:ious coati:g s,stcus a:c
t|c ucc|a:isu oi iilu io:uatio: a:c t|c t,c oi lastic |ci:g alicc. \a:, iuo:ta:t cctails a:c
i:volvcc i: su:iacc :ca:atio: a:c i: alicatio: tcc|:iqucs.
lot| solvc:t |o::c a:c aqucous ai:ts a:c uscc. lai:ts a:c usuall, classiiicc o: t|c |asis
oi t|c |i:cc: ;vc|iclc, uscc. I|c uost oitc: uscc a:c ;1, ac:,lics ;aqucous ac:,lic cuulsio:s,
solvc:t |o::c c:aucls, uclaui:c, a:c ot|c: uociiicc ac:,lic cuulsio:s,, ;!, luks ;aqucous
a:c solvc:t |o::c,, ;!, al|,cs a:c uociiicatio:s, ;+, coxics a:c uociiicatio:s, ;., ol,cstc:s,
Coating 57
;o, vi:,ls a:c uociiicatio:s ;latcx o: solvc:t |o::c,, ;, :it:occlluloscs ;solvc:t |o::c,, a:c
;, ol,auiccs ;solvc:t |o::c,.
I|c cisti:ctio: |ctwcc: ai:ts a:c c:aucls is :ot st:aig|tio:wa:c. lowcvc:, c:aucls gc:c:
all, co:tai: |ig|c: \W |i:cc:s a:c a:c io:uulatcc wit| lowc: solics co:cc:t:atio:. I|c, a:c also
io:uulatcc at lowc: iguc:t |i:cc: :atios to c:catc a suc:io: gloss.
lacquc:s ciiic: i:ou ai:ts a:c c:aucls |ccausc t|c, a:c couou:ccc wit| Ils, w|ic| a:c
solu|lc lastics oi uuc| |ig|c: \W a:c low c|cuical :cactivit,. lilu io:uatio: occu:s |, solvc:t
cvao:atio:. o:vc:tio:al lacquc:s a:c :o:uall, solvc:t |o::c. Disc:sio:s oi lastics i: watc:,
latcxcs, o: o:ga:ic vi:,l liquics ;o:ga:osols, ,iclc solu|lc iilus oi Il, t|c, also qualii, as lacquc:s.
llastisols a:c cisc:sio:s oi ii:cl, civiccc vi:,l i: lasticizc:s t|at a:c :o:solvc:t at :oou tcuc:a
tu:c |ut a:c gooc solvc:ts at |ig| tcuc:atu:cs. I|c, a:c sta|lc u:cc: :o:ual sto:agc co:citio:s
a:c ca: |c coalcsccc i:to iilus at clcvatcc tcuc:atu:cs.
ouc lastic :ocucts t|at :cqui:c ai:ti:g ua, :ccc sccial co:sicc:atio:s |ccausc oi t|ci:
su:iacc co:citio:s. ouc lastics ua, |c sc:sitivc to cc:tai: solvc:ts, so ta|c ca:c to u:cc:sta:c
t|c situatio:.
llastic coati:g su|st:atcs :c:csc:t a |ig |usi:css. I|c su|st:atcs ua, |c ;1, iilus suc| as
lastics a:c aluui:uu ioils, ;!, ac:s, ;!, ia|:ics t|at a:c wovc: o: :o:wovc: o: |ot|, ;+, co:
c:ctc, sto:c, a:c ot|c: t,cs oi uaso::,, ;., a:cls oi wooc, stccl, a:c so o:, ;o, :oiilc s|acs
uacc i:ou ciiic:c:t uatc:ials, ;, ta:|s a:c sto:agc |i:s, a:c so o:. I|c coati:g uatc:ial :oviccs
ua:, :oc:tics :cqui:cc to ua|c t|c su|st:atcs uo:c usciul i: couuc:cial a:c i:cust:ial alica
tio:s. o:sicc:atio:s i: sclccti:g t|c lastic coati:g i:clucc suc| iacto:s as c|cuical c:vi:o:uc:t,
ucc|a:ical :oc:tics, :occssi:g c|a:actc:istics, a:c costs.
lilus a:c coatcc to cxtc:c t|c utilit, oi t|c su|st:atc |, iu:ovi:g cxisti:g :oc:tics o:
acci:g :cw a:c u:iquc :oc:tics. I|c coati:gs ca: :ovicc |cat scala|ilit,, iuc:uca|ilit, to
uoistu:c, watc:, vao:, c:iuucs, a:c ot|c: gascs, |cat a:c ult:aviolct |a::ic:s, uociiicc otical o:
clcct:ical :oc:tics, altc:cc cociiicic:ts oi i:ictio:, a:c a tc:cc:c, towa:c |loc|i:g.
oati:gs a:c ciiic:c:t i:ou laui:atio:s oi two o: uo:c iilus. laui:atcs va:, i: co:st:uctio:.
lastic iilu to aluui:uu ioil, two o: uo:c lastic iilus cou|i:cc, lastic iilu to ac: to lastic
iilu, ac: to lastic iilu to ac:, a:c so o:. Wit| lastic iilus, t|c coati:gs a:c usuall, t|i::c:
t|a: t|c |asc iilu. oati:gs a:c gc:c:all, 0.0. to 0.! uil ;1.! to ..1 u, t|ic|. l: laui:atio:s uost
iilus a:c at lcast 0.!. uil ;o.+ u, t|ic|, a:c uo:c couuo:l, 0.. to ! uil ;1! to .1 u, t|ic|.
Diiic:c:t ccsi:a|lc :oc:tics oi a ia|:ic ca: |c sulcuc:tcc |, lastic coati:g. I|c ia|:ics
:ovicc at lcast tc:silc a:c s|ca: st:c:gt|s wit| clo:gatio: co:t:ol. oati:gs ca: :otcct t|c ia|
:ic, :ccucc o:osit,, :ovicc ccco:ativc ciiccts, a:c ot|c: |c:ciits. oatcc ia|:ics a:c ccsig:cc io:
scciiic alicatio:s. I|c t|:cc ua|o: co:sicc:atio:s a:c t|c |,sical c:vi:o:uc:t, t|c c|cuical
c:vi:o:uc:t ;watc:, acic, solvc:ts, a:c so o:,, a:c cost. lu:cg:atio: is t|c :occss oi t|o:oug|l,
soa|i:g a:c iilli:g t|c voics a:c i:tc:sticcs oi t|c su|st:atc ;as wcll as wooc a:c ac:, wit| t|c
lastic coati:g. I|c o:ous uatc:ials gc:c:all, sc:vc as :ci:io:ccuc:ts io: t|c lastic aitc: t|c coat
i:g t:catuc:t.
58 Plastics Technology HandbookVolume 2
l:occssi:g is cictatcc |, t|c :oc:tics oi t|c su|st:atc a:c t|c coati:g. I|c viscosit, oi t|c
coati:g uust c:uit ilow a:ou:c t|c ,a:: o: ii|c: su:iacc. l: cxt:usio: a:c calc:cc:i:g, :cssu:c
a:c |cat iluicizc t|c coati:g. l: ot|c: :occsscs, solutio: o: cisc:sio: ca: :ccucc viscosit,.
Wall covc:i:gs, u|olstc:,, a:c aa:cl a:c cxaulcs oi ccco:ativc coatcc ia|:ics. l:|s a:c
alicc wit| o:c o: uo:c g:avu:c :i:tc:s to co::cct t|c colo: o: to acc a attc::. kclici attc::s
a:c o|tai:cc |, al,i:g |cat a:c :cssu:c wit| cu|ossi:g :olls.
I|c:c a:c lcat|c: su|stitutcs t|at a:c ccsig:cc to iuitatc t|c aca:a:cc oi lcat|c: wit| its su:
iacc g:ai:. I|is is accoulis|cc |, coati:g su|sta:ccs t|at a:c caa|lc oi io:ui:g a u:iio:u iilu.
llasticizcc lV ii:st uct t|is :cqui:cuc:t cu:i:g t|c 1-+0s. W|c: lasticizcc lV ;solic o: ioau,
is coatcc o:to a su|st:atc, it :ocuccs a lcat|c: li|c uatc:ial callcc vi:,l coatcc ia|:ic. lt cx|i|its
|ig| cc:sit,, vc:, low watc: vao: c:uca|ilit,, colc touc|, oo: ilcx c:cu:a:cc, a:c oo: las
ticizc: uig:atio:. lut it |as gooc sc:atc| :csista:cc a:c colo:a|ilit, as wcll as |ci:g i:cxc:sivc.
luk coatcc ia|:ics, ccvclocc i: t|c 1-o0s, wc:c a: iu:ovcuc:t. luk is coatcc o: wovc:
o: |:ittcc ia|:ics. Wit| a 7
J
|clow !!l ;0,, luk is vc:, ilcxi|lc at :oou tcuc:atu:c wit|out
a lasticizc:. A:ot|c: iuo:ta:t c|a:actc:istic is t|at its uolccula: st:uctu:c allows watc: vao:
c:uca|ilit,. l: accitio:, t|c solvc:ts :o:uall, uscc io: a luk will c:uit coagulatio: |, a :o:
solvc:t wit| io:uatio: oi a o:ous st:uctu:c. I|c :csult is i:c:cascc ilcxi|ilit, a:c watc: vao:
c:uca|ilit,.
D:,i:g a cast luk solutio: to io:u a iilu t|at is laui:atcc o:to t|c su|st:atc will :ocucc
o:ci:a:, luk coatcc ia|:ics. ig:iiica:t iu:ovcuc:ts i: aca:a:cc, iccl, a:c g:ai: a:c accou
lis|cc |, usi:g a |:us|cc ia|:ic as t|c su|st:atc. lt is laui:atcc wit| a cast luk iilu. Altc::ativcl,,
a: o:ga:ic solvc:t solutio: oi luk is alicc to a |:us|cc, wovc: ia|:ic iuuc:scc i: a :o:solvc:t
|at| io: coagulatio:.
I|c o:ouc:ics a:c also callcc s,:t|ctic lcat|c:. I|c, wc:c ccvclocc cu:i:g t|c 1-o0s as a:
iu:ovcuc:t ovc: ia|:ics coatcc wit| lcat|c: li|c coati:gs, w|osc alicatio:s wc:c liuitcc |, t|c
:oc:tics oi t|c |:ittcc o: wovc: su|st:atc. lo:ouc:ics usc a :o:wovc: ia|:ic iu:cg:atcc wit|
lastic, w|ic| t|c:c|, c:catcs a su|st:atc :cscu|li:g lcat|c:. li:c ii|c: co:st:uctio: :oviccs t|c
ccsi:cc soit:css. l:ca:cc wit| luk, t|c o:ouc:ic coati:g la,c: co::cso:cs to t|c g:ai: oi t|c
lcat|c:.
listo:icall,, suo|c a:c t|c :csulti:g toxic iuucs causcc |, t|c |u::i:g oi a ilauua|lc su|
st:atc wc:c a:t oi a:, ii:c, :cga:clcss oi w|ct|c: a ii:c :cta:ca:t t:catuc:t was alicc. W|at was
:ccccc was to suot|c: t|c ii:c a:c t|us sto t|c gc:c:atio: oi toxic suo|c a:c :cvc:t iu:t|c:
cauagc to t|c su|st:atc. l:tuucscc:cc coati:gs wc:c ccvclocc ovc: a |ali cc:tu:, ago |, t|c u
:av, io: usc o: s|is. l:cust:, :o|ccts ccvclocc ciiic:c:t t,cs oi watc: :csista:t i:tuucscc:t
coati:gs. I|csc i:tuucscc:t coati:gs, w|c: su||cctcc to ii:c, io:u a c|a: |ctwcc: t|c su|st:atc
a:c t|c ii:c sou:cc. I|c |asic :ocuct |ccoucs ilauc:ooi.
l:tuucscc:cc coati:gs :ovicc t|c uost ciicctivc ii:c :csista:t s,stcu availa|lc, |ut o:igi
:all, t|c, wc:c cciicic:t i: ai:t colo: :oc:tics. i:cc, |isto:icall,, t|c i:tuucscc:cc :ocuci:g
c|cuicals wc:c quitc solu|lc i: watc:, coati:gs |ascc o: t|osc c|cuicals cic :ot ucct t|c s|ii:g
Coating 59
ca: sta|ilit,, casc oi alicatio:, c:vi:o:uc:tal :csista:cc, o: acst|ctic acal :cqui:cc oi a gooc
:otcctivc coati:g.
Coating Equipment
I|c:c a:c ciiic:c:t uct|ocs uscc, cxaulcs a:c s|ow: i: ligu:c. !.+ a:c ligu:c !... lac| |as its
c:io:ua:cc acva:tagcs a:c cost |c:ciits. oati:g cquiuc:t is uscc to al, a su:iacc coati:g, a
laui:ati:g ac|csivc, a:c a:, couou:cs io: satu:atio: o: iu:cg:atio: ;o: |ot|, oi a ia|:ic. I|c
cquiuc:t |as t|:cc |asic couo:c:ts. t|c coati:g |cac, a c:,c: o: ot|c: coati:g soliciiicatio:
u:it, a:c wc| |a:cli:g |a:cwa:c ;c:ivcs, wi:cc:s, ccgc guiccs, co:t:ols, ctc.,. lt ca: gc:c:all,
coat va:ious su|st:atcs i: :oll o: s|cct io:u.
oati:gs ca: |c alicc ci:cctl, to t|c su|st:atc o: t:a:sic::cc to t|c su|st:atc i:ou a:ot|c:
su:iacc, suc| as a :oll. I:a:sic: i:ou a:ot|c: su:iacc is uscc w|c: t|c su|st:atc is sc:sitivc to t|c
coati:g uatc:ial, w|c: it ua, |c cauagcc |, cxosu:c to ovc: tcuc:atu:cs, io: sccial scco:ca:,
oc:atio:s suc| as al,i:g :cssu:c sc:sitivc la|cls, a:c so o:.
Du:i:g its alicatio:, t|c coati:g uust |c suiiicic:tl, iluic to |c s:cac i:to a u:iio:ul, t|i:
la,c: ac:oss a wc|. oati:gs ca: |c alicc as solutio:s i: o:ga:ic solvc:ts, as aqucous solutio:s o:
cuulsio:s, o: as uoltc: o: soitc:cc solics. olutio:s a:c cuulsio:s :cqui:c c:,i:g to o|tai: solic
coati:gs. ooli:g soliciiics |ot uclts. ouc coati:gs ua, |c alicc as :cactivc liquics a:c t|c:
ol,uc:izcc |, i:i:a:cc o: |cat.
lcat a:c uass t:a:sic: ta|c lacc siuulta:cousl, cu:i:g t|c c:,i:g :occss. I|c |cat is t:a:s
ic::cc |, co:vcctio: i: ai: c:,c:s, |, :aciatio: i: i:i:a:cc c:,c:s, a:c |, co:cuctio: i: co:tact c:uu
c:,c:s. I|c c:,i:g cquiuc:t usuall, |as a uca:s to :cuovc a:c :cci:culatc t|c vao: wit| |cat
cxc|a:gc cquiuc:t to co:sc:vc c:c:g,.
I|c coati:g |cac accoulis|cs two iu:ctio:s. lt alics t|c coati:g to t|c su|st:atc, cist:i|uti:g
it u:iio:ul, i: uctc:cc auou:ts ovc: t|c su:iacc. \ost coatc:s iall i:to t|c iollowi:g catcgo:ics.
:oll, |:iic, |lacc, o: |a:. I|c:c a:c also cxt:usio: o: slot o:iiicc coatc:s.
koll coatc:s, t|c uost wiccl, uscc |i:c oi coatc:, a:c su|civiccc |, t|ci: co:st:uctio:, suc|
as ci:cct, :cvc:sc, g:avu:c, o: calc:cc:. lxaulcs oi coati:g cquiuc:t i:clucc t|c iollowi:g.
:oll coatc:s, |:iic |a: coatc:s, cu:tai: coatc:s, a:c cquiuc:t io: coil coati:g, vacuuu coati:g,
s:a, coati:g, iloc coati:g, clcct:occositio: coati:g, owcc: coati:g, iluicizcc |cc coati:g, clcc
t:ostatic coati:g, clcct:ostatic iluicizcc coati:g, ilooc coati:g, uic:oc:casulatio: coati:g,
i:|olc i:cc t|i: coati:g, a:c :aciatio: cu:i:g ;1,.
Roll- Coat Finish
kcic::cc to as :oll coat ii:is|cs |ccausc t|c, a:c alicc to coilcc uctal |, t|c :csc:vc :ollc:
coati:g tcc|:iquc ;siuila: to oiisct :i:ti:g,, t|csc ii:is|cs |avc g:ow: i:to a so|isticatcc g:ou
oi uatc:ials si:cc t|ci: i:cctio: a|out 0 ,ca:s ago a:c a:c :ow oiic:cc i: a wicc va:ict,. I|ci:
:iua:, acva:tagc is t|at t|c, ca: wit|sta:c uctalwo:|i:g oc:atio:s wit|out a:, :csulti:g su:iacc
60 Plastics Technology HandbookVolume 2
cauagc. I|us t|c, ca: |c alicc |cio:c :ocuct ia|:icatio:, w|ic| cliui:atcs ii:is|i:g stcs aitc:
wa:c a:c ca: t|c:c|, cut costs.
Wit| t|c wicc :a:gc oi :csi:s, t|c:c a:c t,cs oi :oll coat ii:is|cs t|at a:c cxt:cucl, ilcxi|lc,
caa|lc oi ta|i:g vc:, scvc:c io:ui:g oc:atio:s wit| :o c:ac|i:g o: loss oi ac|csio:. o:sc
quc:tl,, t|c, a:c |ci:g uscc io: alicatio:s i:volvi:g :igo:ous |c:cs, w|ic| |cio:c :o|i|itcc t|c
usc oi :ccoatcc uctal io: lac| oi ii:is|cs wit| c:oug| io:ua|ilit,. :c suc| uatc:ial is a vi:,l
coati:g. lt ca: satisiacto:il, wit|sta:c o:c oi t|c uost t:ou|lcsouc |c:cs, t|c zc:o :acius o: |ac|
to |ac| |c:c. I|c:c a:c also ilcxi|lc ac:,lics a:c ol,cstc:s.
A:ot|c: acva:tagc oiic:cc |, t|csc uatc:ials is t|c |:oac :a:gc oi ccco:ativc ciiccts t|c, ca:
ac|icvc, w|ic| also |as |cc: |oostcc |, t|c wicc: va:ict, oi :csi:s availa|lc.
lccausc :ollc: coati:g is a |ig| sccc oc:atio:, t|csc :oll coat ii:is|cs |avc to cu:c quic|l,.
I|c:cio:c, uociiicatio:s |avc |cc: uacc to ug:acc t|c c:io:ua:cc oi lastic :csi:s i: t|is a:ca.
A: avc:agc |a|i:g c,clc toca, is o0 scco:cs at .00l ;!o0,, i: w|ic| tiuc ovc: !00 it oi coil is
coatcc. Wit| coil coatc:s oc:ati:g at cvc: g:catc: scccs, t|c :csi:s |avc to cu:c i: s|o:tc: |a|cs.
t|c: :oc:tics oi t|c :oll coat ii:is|cs t|at |avc |cc: co:ti:uall, iu:ovcc a g:cat ccal a:c t|ci:
cxtc:io: cu:a|ilit,, c|cuical :csista:cc, a:c colo: :ctc:tio:.
Spread Coating
l: s:cac coati:g, t|c uatc:ial to |c coatcc asscs ovc: a :ollc: a:c u:cc: a lo:g |lacc o: |:iic. I|c
lastic coati:g couou:c is laccc o: t|c uatc:ial |ust i: i:o:t oi t|c |:iic a:c is s:cac out ovc:
t|c uatc:ial. I|c t|ic|:css oi t|c coati:g is |asicall, :cgulatcc |, t|c sccc at w|ic| t|c uatc:ial
is c:aw: u:cc: t|c |:iic a:c t|c ositio: oi t|c |:iic. l: :ollc: coati:g, two |o:izo:tal :ollc:s a:c
uscc. :c :ollc: ic|s u t|c lastic coati:g solutio: o: its su:iacc a:c ccosits it o: t|c scco:c
:ollc: t|at, i: tu::, ccosits t|c coati:g solutio: o: t|c suo:ti:g uatc:ial. I|c usual coati:g
uatc:ial is a lastic uclt |ut lastics i: t|c io:u oi ii:c owcc:s a:c also uscc.
Floating Knife Coater
I|is coati:g uac|i:c alics a u:iio:ul, co:t:ollcc auou:t oi io:ui:g, sizi:g, o: ot|c: ccsi:a|lc
uatc:ial to a wc| o: a s|cct oi su|st:atc. I|c c|oicc oi coatc: ;s:cac, s:a,, :oll, ci, a:c ai: |:iic,
ccc:cs o: t|c t,c oi coati:g a:c t|c su|st:atc. t|c: iacto:s suc| as solvc:t :cuoval, c:,i:g, a:c
:ocuctio: :atc uust |c co:sicc:cc.
:cac coatc:s i:clucc t|c |:iic o: |a: coatc:s t|at sc:ac oii a |cav, la,c: oi coati:g liquic to
t|c ccsi:cc t|ic|:css. I|c iloati:g |lacc coatc: ccc:cs o: wc| tc:sio: a:c |lacc co:tou: to co:
t:ol t|ic|:css, w|c:cas t|c |:iic ovc: :oll co:iigu:atio: ;lig. 10.., allows ,ou to sct t|c |:iic at a
iixcc cista:cc i:ou t|c :oll. \ociiicatio:s oi |:iic co:tou: co:t:ol coati:gs oi va:ious viscositics
a:c :|cologics cxist.
A u:iquc io:u oi s:cac coatc: oc:atcs |, al,i:g a: cxccss oi coati:g a:c t|c: uctc:i:g
wit| a t:a:svc:sc :oc |clicall, w:acc wit| a wi:c ;o: :oc,. I|c gaugc oi t|c wi:c govc::s t|c
Coating 61
t|ic|:css oi t|c :cuai:i:g coati:g ;at co:sta:t solics co:tc:t,. A coa:sc wi:c givcs |cavic: coat
i:gs, w|ilc a ii:c o:c lcavcs t|i::c: iilus. I|c :oc is uost oitc: uscc io: t|ixot:oic solutio:s a:c
cisc:sio:s, cilata:t liquics co :ot c:io:u wcll wit| t|is uct|oc.
Alicatio: oi iluic coati:gs to a wc| |, s:a,i:g is usuall, accoulis|cc wit| uultilc s:a,
|cacs uou:tcc o: a: oscillati:g ca::ic:. \ou:t t|c s:a, |cacs so t|c attc::s ovc:la, a:c uovc
t|cu ac:oss t|c wc| to la, cow: a u:iio:u coati:g.
I|c:c a:c ua:, t,cs oi :oll coatc:s availa|lc, c:|as t|c uost succcssiul is souc vc:sio: oi
t|c :cvc:sc :oll a::a:gcuc:t. I|c :cvc:sc :oll is so callcc |ccausc t|c :oll :otatcs cou:tc: to t|c
su|st:atc t:avcl. I|is allows ,ou to co:t:ol coati:g t|ic|:css |, ac|usti:g t|c ga |ctwcc: cit|c:
t|c uctc:i:g :oll o: alicato: :oll o: |ot|. I|c :cvc:sc :oll coatc: wo:|s |cst at al,i:g coati:gs
t|at a:c t|ixot:oic o: at lcast :cwto:ia: ;c|atc: 1,. oati:gs oi a cilata:t :atu:c gc:c:all, :u: at
lowc: scccs |ccausc oi t|c |ig| s|ca: |ctwcc: t|c alicato: :oll a:c t|c su|st:atc.
l: souc i:sta:ccs, w|c:c |ot| siccs oi a su|st:atc uust |c coatcc, it is |cst to ci t|c su|st:atc
ci:cctl, i:to t|c coati:g a:c :cuovc t|c cxccss to lcavc t|c ccsi:cc t|ic|:css. I|is is ac|icvcc |,
assi:g t|c coatcc su|st:atc |ctwcc: two :olls o: two wi:c wou:c :ocs. lusi:g two siccc coati:gs
oi stic|, su|sta:ccs is gc:c:all, ciiiicult, a:c :ocuctio: scccs a:c usuall, vc:, low.
Ai: |:iic coati:g uac|i:cs a:c uscc io: al,i:g watc: cisc:sio:s o: a: cuulsio:, w|c:c sol
vc:t loss a:c :csulta:t su:iacc s|i::i:g is :ot a :o|lcu. l, usi:g a: a::a:gcuc:t siuila: to t|c o:c
ccictcc i: ligu:c 1!.!-, ,ou ca: al, a suoot|, u:iio:u coati:g.
Fluidized Bed Coating
l: iluicizcc |cc coati:g, t|c o||cct to |c coatcc is |catcc a:c t|c: iuuc:scc i: a cc:sc |asc ai:
iluicizcc |cc oi owcc:cc lastic, t|c lastic ac|c:cs to t|c |catcc o||cct a:c su|scquc:t |cati:g
:oviccs a suoot|, i:|olc i:cc coati:g.
Spray Coating
:a, coati:g is uscc |cio:c a:c aitc: asscu|l,, t|c lattc: a:ticula:l, ii t|c :ocuct is al:cac,
asscu|lcc a:c |as a coulcx s|acc a:c cu:vcc su:iaccs. \a:, ciiic:c:t t,cs oi s:a, cquiuc:t
a:c i: usc to |a:clc t|c ciiic:c:t io:us oi ai:ts. I|c, a:c classiiicc |, t|ci: uct|oc oi atouizatio:
;ai:lcss, ai:, :ota:,, clcct:ostatic, ctc., a:c |, t|ci: ccositio: tcc|:iquc ;clcct:ostatic o: :o:clcc
t:ostatic, ilauc s:a,, ctc.,. :a,i:g tcc|:iqucs ua, iall i:to scvc:al oi t|csc catcgo:ics. I|c,
:a:gc i:ou siulc s,stcus wit| o:c ua:ual alicato: to |ig|l, coulcx, couutc: co:t:ollcc,
autouatic s,stcus. I|c, ca: i:co:o:atc |u:c:ccs oi s:a, u:its. Autouatic s,stcus ua, |avc t|ci:
alicato:s uou:tcc o: iixcc sta:cs, o: :cci:ocati:g o: :otati:g uac|i:cs, o: :o|ots, a:c so o:.
Flame spray coating
llauc s:a, coati:g co:sists oi |lowi:g a owcc: t|:oug| a ilauc t|at a:tiall, uclts t|c owcc:
a:c iuscs it as it co:tacts t|c su|st:atc. I|c a:t`s su:iacc is :c|catcc wit| t|c ilauc, usuall, to
62 Plastics Technology HandbookVolume 2
a|out +00l ;!0+, w|c: usi:g ol,ct|,lc:c. I|c usual a:oac| is to coat o:l, a icw squa:c
uctc:s at a tiuc so t|c tcuc:atu:c ca: |c co:t:ollcc. I|c ilauc is t|c: ac|ustcc. W|c: coati:g is
coulctcc, t|c owcc: is s|ut oii a:c t|c coati:g is ost|catcc wit| t|c ilauc. llauc s:a,i:g is
a:ticula:l, usciul io: coati:g :ocucts wit| su:iacc a:cas too la:gc io: |cati:g i: a: ovc:. Disac
va:tagcs a:c t|c :o|lcus associatcc wit| a: oc: ilauc a:c t|c :ccc io: s|illcc oc:ato:s to al,
t|c coati:g.
Powder Coating
lowcc: coati:g is a solvc:tlcss s,stcu, it cocs :ot ccc:c o: a sac:iiicial ucciuu suc| as a solvc:t,
|ut is |ascc o: t|c c:io:ua:cc co:stituc:ts oi solic Il o: I uatc:ials. lt ca: |c a |ouogc:cous
|lc:c oi t|c lastic wit| iillc:s a:c accitivcs i: t|c io:u oi c:,, ii:c a:ticlcs oi a couou:c siuila:
to ilou:.
Acva:tagcs oi owcc: coati:g i:clucc ui:iuuu ai: ollutio: a:c watc: co:taui:atio:,
i:c:cascc c:io:ua:cc wit| coati:g, a:c co:scquc:t cost savi:gs. lt |as ua:, oi t|c sauc :o|lcus
as solutio: ai:ti:g. li :ot :oc:l, io:uulatcc, t|c coati:g ua, sag ;a:ticula:l, ii it is t|ic|,, s|ow
oo: c:io:ua:cc w|c: :ot coulctcl, cu:cc, s|ow iuc:icctio:s suc| as c:atc:s a:c i:|olcs,
a:c |avc oo: |ici:g wit| low iilu t|ic|:css. Va:ious uct|ocs a:c uscc to al, owcc: coati:gs.
Electrostatic Spraying
llcct:ostatic s:a,i:g is |ascc o: t|c iact t|at uost lastic owcc:s a:c i:sulato:s wit| :clativcl,
|ig| voluuc :csistivit, valucs. I|c:cio:c, t|c, accct a c|a:gc ;ositivc o: :cgativc ola:it,, a:c
a:c att:actcc to a g:ou:ccc o: oositcl, c|a:gcc o||cct ;w|ic| is t|c o:c |ci:g coatcc,.
Coil Coating (Metal Coating)
oil coati:g :occsscs i:volvc |ig| sccc ;at lcast .00 itui:, a:c co:ti:uous ucc|a:izcc :occ
cu:cs io: ai:t coati:g o:c o: |ot| siccs oi a coil oi s|cct uctal. oati:g cquiuc:t, uctal clca:i:g,
a:c :cw ai:t io:uulatio:s :ovicc casc oi io:ua|ilit, wit| c:vi:o:uc:tal cu:a|ilit,. I|c |asic
oc:atio:s i: t|c :occss i:volvc u:wi:ci:g stccl coil, c|cuicall, :ct:cati:g stccl, :cvc:sc :oll
coati:g ai:t, |a|i:g ai:t, al,i:g accitio:al coati:gs i: cc:tai: :occsscs, cooli:g coatcc uctal,
i:scctio:, a:c :cwi:c coil.
I|c :atio:al oil oati:g Associatio: i: lcvcla:c, o:ga:izcc i: 1-o!, |as al:cac, |cc: vc:,
activc i: suc| oc:atio:s as ccvcloi:g i:cust:, sta:ca:cs, cxc|a:gi:g tcc|:ical i:io:uatio:, :c
a:i:g tcc|:ical ua:uals, a:c |cci:g :cco:cs oi salcs g:owt|.
I|c ii:st cxtc:sivc ua:|ct io: t|is :ocuct was io: vc:ctia: |li:cs, iollowcc |, uctal aw:i:gs,
uctal sici:gs, autouo|ilc t:ius, lig|t :cilccto:s, luggagc, uctal coo:s, a:c ot|c: siuila: :ocucts.
Coating 63
FIgure 10.16 7acuum ultravIolet radIatIon effects on stabIlIzed organIc coatIngs.
FIgure 10.15 7acuum ultravIolet radIatIon effects on organIc coatIngs.
PROPERTY
llastic coati:g uatc:ials |avc |cc: cxoscc to all |i:cs oi c:io:ua:cc tcsts a:c c:vi:o:uc:ts to
ucct t|c ua:, ciiic:c:t :cqui:cuc:ts t|at cxist i: t|c ua:, ciiic:c:t alicatio:s. ligu:cs 10.1. to
10.!0 s|ow a icw :oc:tics oi coati:gs w|c: i: scvc:c c:vi:o:uc:ts. W|at iollows is i:io:uatio:
t|at |ig|lig|ts souc oi t|c :oc:tics a:c tcsts t|at i:iluc:cc t|c c:io:ua:cc oi coati:gs sta:ti:g
wit| Ia|lc 10.!! ;c|atc: !!,.
64 Plastics Technology HandbookVolume 2
FIgure 10.18 FelatIonshIp between solar absorbance and pIgment ratIos.
FIgure 10.17 FelatIonshIp between solar absorbance, total hemIspherIcal emIttance, and pIgment
ratIos.
Corrosion and Chemical Resistance
o::osio: a:c c|cuical :csista:t ai:ts a:c uscc to :otcct i:cust:ial :ocucts a:c st:uctu:cs
i:ou attac| |, t|c wcat|c: a:c co::osivc uatc:ials. A wicc :a:gc oi :otcctivc coati:gs |as |cc:
ccvclocc to ucct va:ious ciiic:c:t sc:vicc co:citio:s, uct|ocs oi alicatio:, c:,i:g sc|cculcs,
a:c ot|c: c:io:ua:cc a:c cco:ouic :cqui:cuc:ts. ouc oi t|csc coati:gs a:c uscc wit|out
Coating 65
FIgure 10.20 Effects of vacuum ultravIolet radIatIon on pIgments.
FIgure 10.1 7acuum ultravIolet radIatIon effects on InorganIc coatIngs.
iguc:t a:c a:c |ascc o: s,:t|ctic :csi:s a:c :u||c:s. t|c:s co:tai: sccial co::osio: i:|i|iti:g
iguc:ts, t|ci: |i:cc:s a:c uatc:ials suc| as c:,i:g oils, va::is|cs, al|,cs, a:c coxics.
A:ot|c: g:ou oi t|csc coati:gs is |ascc o: |ituui:ous uatc:ials. Alt|oug| t|c, a:c ccsig:cc
to :ovicc a :otcctivc |a::ic: |ctwcc: t|c su:iacc to |c :otcctcc a:c t|c co::oci:g clcuc:ts
o: uatc:ials, t|c, utilizc two ciiic:c:t uct|ocs oi :otcctio:. lo: cxaulc, clca: coati:gs a:c
t|osc |ascc o: |ituui:ous uatc:ials :otcct cssc:tiall, |, :ovici:g a |a::ic: t|at is oi suiiicic:t
t|ic|:css o: :csista:cc ;o: |ot|, to sc:vicc co:citio:s to :cvc:t t|c co::oci:g c:vi:o:uc:t i:ou
:cac|i:g t|c :otcctcc su:iacc.
lowcvc:, co::osio: :csista:t coati:gs |ascc o: c:,i:g oils, va::is|cs, a:c ot|c: :ocucts a:c
quitc c:uca|lc to watc: a:c ox,gc:. I|csc coati:gs ccc:c aluost c:ti:cl, o: t|ci: i:|i|iti:g
66 Plastics Technology HandbookVolume 2
iguc:t to co:t:ol co::osio:. l: accitio:, t|c clcct:ol,tic :csista:cc oi coati:gs is a: iuo:ta:t
iacto: i: t|ci: a|ilit, to i:|i|it co::osio:.
\a:, ciiic:c:t iacto:s uust |c co:sicc:cc i: t|c ccvclouc:t oi a suita|lc coati:g s,stcu.
l: ua:, cascs, cou|i:atio:s oi co::osio: i:|i|iti:g :iuc:s o|tai: t|c |cst :csults a:c :ocucc
|ig|l, :csista:t ii:is|cc coats. lowcvc:, i: all cascs it |as |cc: ccuo:st:atcc quitc clca:l, t|at t|c
ai:t s,stcu uust |avc suiiicic:t t|ic|:css to o|tai: accquatc :otcctio:. lt is gc:c:all, |clicvcc
t|at t|c ui:iuuu t|ic|:css oi t|c ai:t s,stcu s|oulc |c . uils.
Fire Retardant
I|c ua|o:itics oi ai:t |i:cc:s a:c o:ga:ic i: :atu:c a:c |c:cc a:c i:ilauua|lc. l:co:o:ati:g
accitivcs suc| as c|lo:i:c, |:oui:c, :it:ogc: ;|ou:c i: a:ticula: wa,s,, |os|o:us, o: silica ca:
TabIe 10.23 PlastIc coatIng property guIde
Coating 67
:ccucc t|c i:ilauua|ilit, oi o:ga:ic uatc:ial. oati:gs |ascc o: :o:i:ilauua|lc |i:cc:s i:clucc
liuc was|c:s, ccuc:t ai:ts, a:c silica ai:ts.
l:o:ga:ic iguc:ts a:c gc:c:all, :o:i:ilauua|lc. A:tiuo:, t:ioxiccs a:c zi:c |o:atcs a:c
a:ticula:l, ciicctivc. ou|i:atio:s oi o:ga:ic a:c t|csc i:o:ga:ic iguc:ts :ovicc ii:c :cta:ca:t
c|a:actc:istics.
Vc:, icw clca: ii:c :cta:ca:t coati:gs a:c availa|lc. I|c, a:c gc:c:all, two a:t s,stcus usi:g
cox, o: u:ct|a:c :csi:. I|c:c is a t:a:sa:c:t luk t,c io: usc o: wooc a:c uctal a:ts suc| as
walls, ccili:gs, |uilci:g iixtu:cs, a:c iu::itu:c. W|c: su||cctcc to ii:c, it swclls, c:cati:g a: i:sulati:g
su:iacc oi c|a::cc ioau t|at :cvc:ts iu:t|c: |u::i:g. I|is is iu:cauc:tall, a :actical alicatio: io:
w|at was ccvclocc cu:i:g t|c lo:ca: Wa: as ii:c walls io: usc i: ciiic:c:t uilita:, vc|iclcs.
I|csc coati:g a:c :ot sc:sitivc to uoistu:c, as wc:c t|c :cvious t,cs. A c:, coati:g ca:
cxa:c 1oo tiucs, o: go i:ou o uils t|ic|:css to 1 i:. I|is s,stcu :oviccs a ua|o: stc io:wa:c
i: savi:g livcs a:c :oc:t, i:ou ii:c.
l: t|c uca:tiuc, t|is i:cust:, co:ti:ucs to ta:gct t|c ccvclouc:t oi a ii:c :cta:ca:t coati:g
t|at cocs :ot causc t|c usual loss i: ot|c: :oc:tics a:c cocs :ot sig:iiica:tl, i:c:casc cost. i
cou:sc t|c :cal us| io: t|csc coati:gs will occu: ii statc a:c local govc::uc:ts acot uo:c st:i:
gc:t |uilci:g coccs.
Intumescent Coating
l:tuucscc:t coati:gs, o: coati:gs t|at |u||lc a:c ioau to io:u a t|c:ual i:sulatio:, |avc |cc:
uscc io: ua:, ,ca:s. uc| coati:gs ca::ot ot|c:wisc |c ciiic:c:tiatcc i:ou co:vc:tio:al :ocucts.
I|c:cuo:, |owcvc:, t|c, cccouosc to io:u a t|ic|, :o:ilauua|lc, uulticcllula:, a:c i:sulativc
|a::ic: ovc: t|c su:iacc o: w|ic| t|c, a:c alicc. I|is i:sulativc ioau is a vc:, ciicctivc i:sulatio:
t|at uai:tai:s t|c tcuc:atu:c oi a ilauua|lc o: |cat cisto:ta|lc su|st:atc |clow its ig:itio: o:
cisto:tio: oi:t. lt also :cst:icts t|c ilow oi ai: ;ox,gc:, i:ou t|c su|st:atc iucl.
lt is cstiuatcc t|at uillio:s oi gallo:s oi al|,c a:c latcx cuulsio: i:tuucscc:t ai:ts a:c uscc
a::uall,. I|csc coati:gs :ovicc t|c uost ciicctivc ii:c :csista:t s,stcu availa|lc, |ut o:igi:all,
t|c, wc:c cciicic:t i: ai:t :oc:tics. i:cc, |isto:icall,, t|c i:tuucscc:cc :ocuci:g c|cuicals
wc:c quitc solu|lc i: watc:, coati:gs |ascc o: t|osc c|cuicals cic :ot ucct t|c ca: sta|ilit,, casc
oi alicatio:, c:vi:o:uc:tal :csista:cc, o: acst|ctic acal :cqui:cc oi a gooc :otcctivc coati:g.
l: tiuc to ucct ua:|ct :cqui:cuc:ts, \o:sa:to oua:, ccvclocc a :cw watc: :csista:t,
|os|o:us |ascc i:tuucscc:cc catal,st. I|is :cw couuc:ciall, availa|lc :ocuct, l|os |c| l!0,
ca: |c i:co:o:atcc ;wit| ot|c: watc: i:solu|lc :cagc:ts, i:to watc: :csista:t i:tuucscc:t coati:gs
oi cit|c: t|c al|,c o: latcx cuulsio: t,c. I|csc i:tuucscc:t coati:gs, io:uulatcc acco:ci:g to t|c
ua:uiactu:c:`s :ccouuc:catio:s, a:c ccsc:i|cc as cquivalc:t to co:vc:tio:al :ocucts i: coati:g
:oc:tics. I|c, also :ovicc c:ua:c:t ii:c :csista:cc to t|c su|st:atc o: w|ic| t|c, a:c alicc.
68 Plastics Technology HandbookVolume 2
Heat Resistant
Diiic:c:t t,cs oi coati:gs a:c availa|lc to ucct t|c ciiic:c:t |cat :csista:t c:vi:o:uc:ts. I|c:c a:c
coati:gs t|at ca: |c cxoscc to |ig| tcuc:atu:c i:tc:uittc:tl,. I|c iilu is su||cctcc to ucc|a:i
cal io:ccs |, ciiic:c:tial cxa:sio: a:c co:t:actio:. liuiti:g iacto:s i:volvc |:ca|i:g t|c |o:c to
t|c su|st:atc a:c t|c ciicct at clcvatcc tcuc:atu:cs oi ox,gc: attac| o: t|c coati:gs ;w|c: i: a:
ox,gc: :ic| atuos|c:c,.
l:o:ga:ic ol,uc:s a:c scuio:ga:ic ol,uc:s a:c t|c |i:cc:s t|at s|ow t|c |cst |cat :csis
ta:cc. lxtc:sivc :csca:c| a:c ccvclouc:t |avc |cc: u:cc:ta|c: to stuc, ol,uc:s co:tai:i:g
|o:o:, :it:ogc:, |os|o:us, silico:, a:c so o:. I|c cstc:s oi silico:, tita:iuu a:c t|c silico:cs a:c
cxaulcs oi |i:cc:s t|at a:c suita|lc io: co:ti:uous usc at tcuc:atu:cs a|ovc 1.0l ;oo,. lo:
t|c |cst :actical :csults, t|c, a:c iguc:tcc wit| lcaii:g aluui:uu. I|is couositc :otccts t|c
o:ga:ic a:t oi t|c |i:cc: i:ou ox,gc: attac| a:c also io:us a uctal cc:auic coulcx.
lo: tcuc:atu:cs u to 1.0l, ua:, |i:cc:s ua, |c uscc to o|tai: a usciul liic. |o:t oil |c
:olic va::is|cs, oxicizcc :u||c:, a:c uclaui:cal|,c :csi: stovi:g ii:is|cs ;w|c:c t|c al|,c is a
satu:atcc iatt, aciciso|t|alic acic t,c, |avc |cc: uscc i: va:ious coati:g s,stcus.
Thermal Control
i:cc 1-o0, assivc t|c:ual co:t:ol oi sacc vc|iclcs a:c t|ci: couo:c:ts |as cuc:gcc as a: a:ca
oi i:c:casi:g iuo:ta:cc auo:g t|c sacc scic:ccs. I|is a:ca is ccsti:cc to ac|icvc g:catc: statu:c
as ou: vc:tu:cs i:to sacc |ccouc lo:gc: i: cu:atio: a:c coulcxit,. l:cicativc oi t|is iuo:ta:cc
is t|c :csca:c| :ow |ci:g ccvotcc to sacc cxlo:atio:.
l: co:t:ast to activc t|c:ual co:t:ol, assivc t|c:ual co:t:ol oiic:cc t|c acva:tagcs oi :o
uovi:g a:ts, |c:cc t|c a|sc:cc oi ucc|a:ical iailu:c, a:c a co:sicc:a|lc wcig|t savi:gs. I|c iu:
cauc:tal a:auctc:s i: co:t:olli:g t|c sacc vc|iclc`s tcuc:atu:c |, assivc uca:s a:c t|c otical
c|a:actc:istics oi t|c su:iacc oi t|c saccc:ait, t|at is, t|c sola: a|so:ta:cc a:c t|c cuitta:cc.
lowcvc:, i: o:cc: to iu:ctio: as a t|c:ual co:t:ol su:iacc, a coati:g uust |c oticall, sta|lc i:
t|c sacc c:vi:o:uc:t, cscciall, wit| :cscct to ult:aviolct :aciatio:, a:ticulatc :aciatio:, |ig|
vacuuu, a:c tcuc:atu:c. l: accitio:, t|c :oc:tics oi t|c coati:g, suc| as ilcxi|ilit,, ac|csio:,
casc oi alicatio: a:c a|ilit, to ai: cu:c coulc :ot |c ovc:loo|cc.
I|c ua|o: ciio:t ovc: t|c ast scvc:al ,ca:s |as t|us |cc: ci:cctcc towa:c t|c :ca:atio: oi
o:ga:ic a:c i:o:ga:ic coati:gs wit| ccsi:a|lc tcuc:atu:c co:t:ol :oc:tics. At t|c sauc tiuc,
:csca:c|c:s u:succ a c:itical cvaluatio: oi t|c iacto:s oi t|c sacc c:vi:o:uc:t a:c c:io:ucc
la|o:ato:, :csca:c| i:volvi:g t|c ciiccts oi t|csc iacto:s o: t|c otical a:c |,sical :oc:tics o:
coati:gs a:c coati:g uatc:ials.
l: a: attcut to siuulatc t|c c:vi:o:uc:t oi outc: sacc, t|c :csca:c| wo:|c: was iaccc wit|
ua:, u:|:ow: iacto:s. I|c ccii:itio: oi t|c sacc c:vi:o:uc:t |as |cc: a:c is :csc:tl, a ua|o:
a:ca oi scic:tiiic :csca:c| i: itscli. I|is lac| oi ovc:all |:owlccgc, i: accitio: to t|c cco:ouics
i:volvcc i: siuulati:g t|c sacc c:vi:o:uc:t i: its c:ti:ct,, t:a:slatcc i:to cou:ouiscs i: t|c
cxosu:c c|au|c:s.
Coating 69
Alt|oug| w|itc o:ga:ic coati:gs |avc |cc: s|ow: to ccg:acc, :iua:il, |, ult:aviolct :aciatio:,
t|ci: ilcxi|ilit,, ac|csio:, casc oi alicatio:, ai: c:,i:g c|a:actc:istics, a:c |ig| cuitta:cc |avc
c:suaccc :csca:c|c:s to sc:c co:sicc:a|lc tiuc a:c ciio:t stuc,i:g t|cu. l:o:ga:ic coati:gs,
|owcvc:, oiic:cc t|c :ouisc oi sta|ilit, to ult:aviolct :aciatio: a:c |ig| vacuuu, |ut :csc:tcc
:o|lcus i: ac|csio: a:c ilcxi|ilit, a:c i:volvcc |cat cu:cs. I|c ciiccts oi a:ticulatc :aciatio:,
alt|oug| :ot io:gottc:, :cuai:cc soucw|at i: t|c |ac|g:ou:c.
:ga:ic io:uulatio:s |avc |cc: ccvclocc wit| ai: cu:c :oc:tics a:c otical :oc:tics. lig
u:c 10.1. s|ows t,ical coati:gs. liguc:t :csca:c|, wit| :cga:cs to sta|ilit,, couati|ilit,, i:ccx
oi :ci:actio:, a:ticlc sizc, u:it,, a:c ot|c: :oc:tics, |as s|ow: Z:, Ii, a:c Z: to oiic: t|c
uost :ouisc. I|c uost sta|lc vc|iclcs i: cou|i:atio: wit| t|csc iguc:ts i:volvcc t|c silico:cs
a:c t|ci: va:iatio:s, ac:,lics, silico:c al|,cs, a:c cc:tai: iluo:oca:|o: ol,uc:s.
Wit| t|c s,:t|csis oi colo:lcss ult:aviolct :aciatio: a|so:|c:s, suc| as t|c cc:ivativcs oi
osuocc:c a:c :ut|c:occ:c, it |as |cc: ossi|lc to c:|a:cc t|c sta|ilit, oi ot|c:wisc |o:cc:li:c
acccta|lc t|c:ual co:t:ol coati:gs to t|c oi:t w|c:c t|csc coati:gs |ccouc ca:cicatc uatc:ials
;lig. 10.1o,. I|c cc:ivativcs oi ic::occ:c, alt|oug| c:|a:ci:g t|c sta|ilit, oi cc:tai: w|itc coat
i:gs, gavc a |ig| i:itial c:io:ua:cc cuc to its i:|c:c:t :cc colo:atio:. I|c cc:ivativcs oi osuocc:c
a:c :ut|c:occ:c, |owcvc:, wc:c w|itc to lig|t ,cllow.
I|c co:t:ollcc accitio: oi iguc:t to |ot| |asic w|itc a:c |lac| io:uulatio:s |as :oviccc
ccsig: c:gi:cc:s wit| a sc:ics oi coati:gs wit| a wicc :a:gc oi c:io:ua:ccs io: scciiic alica
tio:s. I|csc io:uulatio:s a:c s|ow: i: ligu:cs 10.1 a:c 10.1.
Electrical Insulating
A :cw a:c :cvolutio:a:, icca |as |cc: cxlo:cc io: t|c alicatio: oi c:aucls to coc: ;o: alu
ui:uu, ctc., uag:ct wi:c ;lig. 10.1!,. lt is clcct:occositio:, a :occss oi coati:g coc: wi:c i:
a: aqucous solutio: |, a: clcct:ic cu::c:t. l: t|is uct|oc, a: o:ga:ic :csi: a:ticlc is cisc:scc i:
watc: i: suc| a ua::c: t|at it |as a: clcct:ical c|a:gc. I|c:, u:cc: t|c i:iluc:cc oi a: clcct:ical
iiclc, it is att:actcc to a ositivc clcct:occ, t|c coc: wi:c a:occ, a:c ccositcc o:to it.
I|is uct|oc |as |cc: uscc io: ,ca:s i: t|c clcct:olati:g oi uctals. lt was :ot u:til t|c :csi:
c|cuist was a|lc to io:uulatc suc:io: watc: solu|lc, o: watc: cisc:si|lc, :csi:s, t|at t|csc |asic
:i:cilcs coulc |c alicc to t|c coati:g i:cust:,.
I|c :occss oi clcct:occositio: :ocuccs a: u:usual |c:ouc:o:. I|c :csi: la,s a cual :olc
i: t|c :occss. I|c uatc:ial is a co:cucto: at o:c oi:t, a:c a icw ui:utcs latc: it is a: i:sulato:.
I|c o||cctivc oi t|c :og:au was to :csolvc t|csc two a:acoxical :occsscs. lc:|as it uig|t
aca: t|at wit| t|is a:oac|, i: w|ic| t|c i:sulato: is watc: solu|lc cu:i:g its :occssi:g, t|c
coati:g woulc still |avc a: aiii:it, io: watc:. lowcvc:, t|c coatcc c:aucl |as lost its watc: solu|il
it, t|:oug| t|c |a|i:g c,clc cu:i:g w|ic| it |as |ccouc a: i:solu|lc, I :csi:. o::cct io:uulati:g
:i:cilcs c:uit t|c :csi: to c:io:u t|is cual :olc.
I|c :i:cial acva:tagcs oi clcct:occositio: ovc: co:vc:tio:al uct|ocs a:c as iollows.
70 Plastics Technology HandbookVolume 2
1. lastc: :ocuctio: :atcs. l:ocuctio: oi coatcc wi:c ca: |c i:c:cascc iou: to six tiucs
c: |ou:. :l, o:c assagc oi t|c wi:c t|:oug| t|c ci ta:| is :cqui:cc. lo: cxaulc,
a :occssi:g wi:c uill will |avc to :u: 41 AWG coc: uag:ct wi:c t|:oug| t|c
ci ta:| o:l, o:c tiuc :at|c: t|a: iou: to six tiucs to o|tai: |cav, |uilc.
!. uc:io: :oc:tics t|:oug| io:uulatio: oi |ig|c: \W uatc:ials. I|c :csi: c|cuist will
|c a|lc to ccvclo u:usuall, lo:g c|ai: ol,uc:s |ccausc watc: is uscc i: t|c s,stcu.
!. lliui:atio: oi oiic:sivc oco:s, cscciall, c:cs,lic acic iuucs t|at a:c couuo: i:
citics.
+. oulctc a:c u:iio:u covc:agc. l: clcct:occositio:, t|c c|a:gcc :cgativc a:ticlcs
a:c att:actcc to ositivc uctal su:iaccs. I|is att:actio: will co:ti:uc u:til t|c c:ti:c
uctal su:iacc is covc:cc.
I|c |c:ouc:a oi clcct:occositio:, as alicc to a :otcctivc coati:g alicatio: uct|oc, a:c
coulcx. Alt|oug| t|c uct|oc culo,s t|co:ics csta|lis|cc ua:, ,ca:s ago, t|c :actical ali
catio: oi t|csc :i:cilcs |as i:t:ocuccc va:ia|lcs t|at coulicatc t|c ccositio:. Io accoulis|
ccositio: |, t|is uct|oc, it is :cccssa:, to |avc a watc: solu|lc :csi: ;o: watc: cisc:si|lc :csi:
o: cuulsio:, a:c a ci ta:| wit| two clcct:occs. W|c: t|c cu::c:t is tu::cc o:, t|c iollowi:g :cac
tio:s occu:. clcct:o,sis, clcct:o|o:csis, clcct:ocoagulatio:, a:c clcct:oosuosis. All iou: oi t|csc
:cactio:s usuall, occu: siuulta:cousl, cu:i:g t|c ccositio: oi a :csi:. I|c, la, a: iuo:ta:t :olc
i: t|c co::cct alicatio: oi t|c :csi: to t|c wi:c.
SIMULATED SERVICE TESTS
\a:, ciiic:c:t sc:vicc tcsts |avc |cc: uscc t|:oug|out t|c cc:tu:ics, a:c uo:c tcsts will |c ccvcl
occ i: t|c iutu:c. I|is wa, oi liic is ci:cctl, :clatcc to :og:css. i cou:sc t|c :cal tcst is w|c:
a:ts a:c i: usc. \a:, oi t|c la|o:ato:, tcsts ccsc:i|cc t|:oug|out t|is c|atc: a:c |oo| will
:ovicc usciul iccas io: co:cucti:g siuulatcc sc:vicc tcsts. I|is scctio: :csc:ts a :cvicw o: |ow
to cvaluatc coatcc ia|:ics. Diiic:c:t tcsts ca: |c uscc to cvaluatc clastouc: coatcc ia|:ics. I|c iol
lowi:g t,ical tcsts :ovicc |:ici a:c liuitcc cxaulcs oi i:io:uatio: o: tcsti:g :occcu:cs.
Abrasion Resistance
A|:asio: is oi :iua:, iuo:ta:cc wit| uatc:ials t|at a:c cxoscc to uuc| a|:asio:, suc| as t:uc|
covc:s. Icsts s|oulc |c co:cuctcc aitc: cxosu:c to t|c liquic i: w|ic| it will oc:atc. Icst valucs
|avc o:l, :clativc uc:it, :o|cctio: oi :csults to sc:vicc ca: |c ciiiicult wit|out cxc:ic:cc, si:cc
ua:, iacto:s aiicct c:io:ua:cc. lxaulcs oi tcsts iollow.
l: t|c Ia|c: A|:asio: Icst, a|:asio: w|ccls a:c wcig|ts a:c uscc i: va:ious cou|i:atio:s to
a|:acc o:c o: |ot| siccs oi a ia|:ic. Valucs a:c :co:tcc i: :uu|c:s oi c,clcs :ccccc to ac|icvc
cit|c: ii:st cxosu:c oi t|c |asc ia|:ic o: to causc i:itial tca:i:g. l: a:ot|c: uct|oc, t|c a|:acc:
Coating 71
is :u: io: a :uu|c: oi givc: c,clcs, a:c t|c: t|c coati:g`s wcig|t loss is ucasu:cc. A lcss accu:atc
uct|oc i:volvcs |ucgi:g t|c aca:a:cc oi ia|:ic aitc: a givc: :uu|c: oi c,clcs.
l: t|c Dulo:t c:u| Icst, a scciuc: is vigo:ousl, sc:u||cc agai:st itscli |ctwcc: two uov
i:g |aws. I|c :uu|c: oi c,clcs :ccccc to ii:st cxosc t|c |asc ia|:ic is :co:tcc. Valucs a:c usuall,
cctc:ui:cc io: cac| sicc a:c io: wa: a:c iilli:g ci:cctio:. Visual i:scctio: aitc: a givc: :uu|c:
oi c,clcs is :ot as accu:atc.
l: t|c W,sc:|ac| Icst, also callcc t|c oscillato:, c,li:cc: tcst, t|c ia|:ic is su||cctcc to u:ici
:cctio:al :u||i:g actio: u:cc: |:ow: co:citio:s oi :cssu:c, tc:sio:, a:c a|:asivc actio:. Io tcst
scciuc:s, t|c, a:c laccc i: co:tact wit| a: oscillati:g c,li:cc: covc:cc wit| a: a|:asivc uatc:ial.
Valucs a:c :co:tcc io: loss oi |:ca|i:g st:c:gt| aitc: !.0 c,clcs oi co:ti:uous a|:asio: u:cc: a !
l| loac ;AI\ D11.,.
Adhesion
Ac|csio: is a:ticula:l, iuo:ta:t i: alicatio:s w|c:c a ia|:ic is cxoscc to a g:cat auou:t oi
ilcxi:g, :cssu:c, a:c st:ctc|i:g. lo: ia|:ics wit| scvc:al lics, ac|csio: |ctwcc: lics s|oulc |c
tcstcc. lt is a a:ticula:l, c:itical :oc:t, i: suc| :ocucts as liic :aits, liic vcsts, a:c ot|c: |o:ccc
i:ilata|lcs. A tcsti:g cxaulc is t|c cott tcst uct|oc, i: w|ic| ac|csio: is tcstcc |, ccli:g coat
i:g i:ou t|c |asc ia|:ic, o: |, ccli:g two lics aa:t. A ! i: wicc saulc is i:sc:tcc i: |aws t|at
sca:atc at a givc: sccc, uost i:cquc:tl, ! iu o: 1! iu. kcsults a:c cx:csscc i: l|i: oi wict|
:cqui:cc to ccl coati:g a:c ia|:ic o: two lics aa:t ;AI\ D.1,.
Accelerated Aging in Hot Air
I|is is a usciul ucasu:c oi sc:vicc liic at atuos|c:ic tcuc:atu:cs, a:c is a:ticula:l, iuo:ta:t
io: ia|:ics t|at uust c:io:u at clcvatcc tcuc:atu:cs, suc| as autouotivc a:c |cati:g cquiuc:t.
I|c iollowi:g a:ag:a|s ccsc:i|c cxaulcs oi t|c tcsts uscc.
Hot- air aging
aulcs a:c laccc i: a t|c:uostaticall, co:t:ollcc ai: ci:culati:g ovc: a:c agcc io: scciiicc tcu
c:atu:cs a:c tiucs. la|:ics t|at a:c :ot cxcctcc to c:io:u i: clcvatcc tcuc:atu:cs a:c usuall,
agcc io: ! |ou:s at 1o0l ;1,. la|:ics uscc i: autouotivc alicatio:s a:c agcc io: ! |ou:s
at !00l to !00l ;-! to 1+-,. li ia|:ics will |c cxoscc to oils o: ot|c: iluics cu:i:g actual
sc:vicc, saulcs a:c iuuc:scc i: suita|lc tcst iluics.
Aging in stop- and- go applications
Agi:g tcsts a:c i:tc::utcc a:c ia|:ics a:c allowcc to c:, |ctwcc: |ot ai: tcsts. Aitc: agi:g, :oc:
tics a:c coua:cc wit| t|osc ta|c: |cio:c agi:g ;AI\ D.!,.
72 Plastics Technology HandbookVolume 2
Accelerated aging in oxygen
I|is tcsti:g csta|lis|cs t|c |c|avio: oi ia|:ics t|at a:c cxoscc to ai: a:c su:s|i:c i: c:itical ali
catio:s, suc| as liic :aits, ta:auli:s, a:c :acouc covc:s. l: t|c ox,gc: |ou| tcst, saulcs a:c
laccc i: a |ou| io: a scciiicc c:ioc oi tiuc at a tcuc:atu:c oi 1o0l a:c !00 si ;! \la, oi
ox,gc: :cssu:c. Aitc: agi:g, uost iuo:ta:t |,sical :oc:tics a:c tcstcc a:c c|cc|cc agai:st
valucs o|tai:cc |cio:c agi:g ;AI\ D.!,.
Blocking
I|is tcsti:g s|ows t|c tc:cc:c, oi cc:tai: clastouc:s, i:cluci:g :atu:al :u||c:, to ac|c:c to t|cu
sclvcs. l: a |loc|i:g tcst, a saulc is iolccc a:c ut u:cc: a + l| wcig|t i: a: ovc: at 10l ;!,
io: !- ui:. Aitc: cooli:g, t|c saulc is u:iolccc a:c cxaui:cc io: ac|c:c:cc o: ccli:g oi t|c
coati:g ;AI\ D 1-!,.
Burst Strength
I|is is a: iuo:ta:t guicc i: alicatio:s i: w|ic| a ia|:ic is cxoscc to |ig| a:c succc: :cssu:cs,
suc| as i: gas :cgulato:s a:c co:t:ols. l: t|c \ullc: tcst, a saulc is claucc ac:oss t|c o:iiicc oi a
\ullc: tcstc: wit| a :u||c: cia|:agu. lowc: is alicc, a:c t|c :cssu:c at w|ic| :utu:c occu:s
is :cco:ccc i: g:oss a:c :ct si valucs ;AI\ D .1,.
Compression Set
I|is ucasu:c oi t|c c:ua:c:t ccio:uatio: oi a ia|:ic cxoscc to co:sta:t :cssu:c o: ccilcc
tio: ca: |c iuo:ta:t, a:ticula:l, wit| coatcc ia|:ic cia|:agu asscu|lics i: u:its wit| |olts o:
c:ius. I|c:c a:c t|c tcst uct|ocs i: w|ic| a saulc is |clc u:cc: cit|c: co:sta:t loac ;uct|oc
A, o: co:sta:t ccilcctio: ;uct|oc l, io: a scciiicc lc:gt| oi tiuc i: a scciiicc co:sta:t tcuc:a
tu:c. I|c :csicual ccc:casc i: t|ic|:css, cit|c: a c:cc:tagc oi o:igi:al t|ic|:css ;uct|oc A, o: a
c:cc:tagc oi ccilcctio: u:cc: loac ;uct|oc l,, is :co:tcc as t|c cou:cssio: sct. A: i:tc:val oi
at lcast o:c wcc| |ctwcc: :cuovi:g t|c loac a:c ucasu:i:g t|c :csicual ccc:casc i: t|ic|:css o:
ccilcctio: is :cccssa:, to cvaluatc t|c c:ua:c:t sct ;AI\ D !-.,.
Curl
u:l is a: i:co:vc:ic:cc i: asscu|l,, cscciall, w|c: usi:g autouatic asscu|l, cquiuc:t. la|:ics
t|at :o:uall, |avc t|c sauc coati:g o: |ot| siccs s|oulc :ot cu:l, |owcvc:, uatc:ials coatcc o:
o:c sicc aluost alwa,s cu:l. I|c:c is a tcst uct|oc w|c:c a cisc wit| a ciauctc: oi ! i: is allowcc
to :cst io: !+ |ou:s at 0l ;!1, wit| t|c sicc t|at s|ows t|c tc:cc:c, to cu:l iaci:g u. I|c
cista:cc i:ou ta|lcto to t|c |ig|cst oi:t oi cu:l is :co:tcc as cu:l valuc. A cu:l oi i: o: uo:c
is usuall, co:sicc:cc cxccssivc io: a cia|:agu asscu|l,.
Coating 73
Elongation
llo:gatio: wit|out :utu:c is ccsi:a|lc i: cia|:agus t|at ulsc wit| a lo:g st:o|c. l: ot|c: ccviccs
i: w|ic| ciuc:sio:al sta|ilit, is oi utuost iuo:ta:cc, suc| as uctc:i:g ccviccs, clo:gatio: oi a
ia|:ic is u:ccsi:a|lc. Icst uct|oc saulcs a:c st:ctc|cc i: a cott tcstc: u:til t|c, :utu:c. I|c
auou:t oi st:ctc|i:g t|at occu:s |ctwcc: |c:c|ua:|s at t|c tiuc oi :utu:c is t|c ultiuatc clo:
gatio: oi t|c ia|:ic. Valucs a:c cx:csscc as c:cc:tagcs oi t|c o:igi:al cista:cc |ctwcc: t|c ua:|s
;AI\ D .1,.
Flame Resistance, Vertical
A guicc to ilauc :csista:cc is iuo:ta:t wit| a:, coatcc ia|:ic uscc w|c:c a ii:c |aza:c cxists. cv
c:al ilauc tcsts ;ul, a:c availa|lc oi w|ic| t|c scvc:cst a:c uost wiccl, uscc is vc:tical ilauc tcst.
l: t|is tcst, a saulc ucasu:i:g ! i: 1! i: is claucc |ctwcc: uctal ila:gcs a:c susc:ccc i:
a uctal ca|i:ct to s|iclc it i:ou c:aits. A ilauc oi a sta:ca:c sizc a:c a sta:ca:c i:tc:sit, is laccc
u:cc: t|c saulc io: 1! scco:cs. I|c |u::c: is t|c: :cuovcc wit|out oc:i:g t|c ca|i:ct. I|:cc
valucs a:c usuall, ucasu:cc. ;1, t|c lc:gt| oi tiuc t|c ilauc co:ti:ucs to |u:: aitc: t|c :cuoval oi
t|c |u::c:, ;!, t|c lc:gt| oi tiuc t|c glow co:ti:ucs, a:c ;!, t|c c|a: lc:gt|, cx:csscc as cista:cc
to w|ic| a c|a::cc saulc will tca: w|c: su||cctcc to a scciiicc loac.
Flexibility
I|is :oc:t, is iuo:ta:t i: ua:, lig|twcig|t ia|:ic cia|:agus uscc i: cclicatc sc:si:g ccviccs.
A tcsti:g uac|i:c ta|cs o:c c:c oi 1 ! i: saulc a:c laccs it i: a clau t|at will :otatc t|c
saulc u to -0. I|c ot|c: c:c oi t|c saulc actuatcs a |ala:ccc a:u t|at givcs :caci:gs u to
100 u:its. I|c stiiicst saulcs givc t|c |ig|cst :caci:gs, wcig|ts ca: |c acccc to |ala:cc vc:, stiii
saulcs. Valucs ;cx:csscc i: wcig|ts lus u:its, ca: |c :cac at va:ious ccg:ccs oi :otatio: oi t|c
saulc. \ost couuo:l,, t|c valuc at !0 :otatio: is :cac.
I|c:c is also a tcst i: w|ic| a st:i ucasu:i:g 1 i: wicc is laccc |ctwcc: two :ollc:s wit| 1
i: ciauctc:s |clc togct|c: |, s:i:g :cssu:c. :c oi t|c :ollc:s is slowl, :otatcc. I|c ovc:|a:gi:g
saulc is ac|ustcc u:til it ialls ovc: i: |ot| ci:cctio:s oi :otatio: w|c: t|c i:aucwo:| is :otatcc cloc|
wisc a:c cou:tc:cloc|wisc. I|c lc:gt| oi t|c ovc:|a:gi:g o:tio:, i: uu, is t|c ilcxi|ilit, valuc.
Hardness
A ucasu:c oi |a:c:css is iuo:ta:t i: suc| :ocucts as :u||c: oiisct |la:|cts. I|c |a:c:css oi a
coati:g is usuall, ucasu:cc |cio:c t|c coati:g uatc:ial is alicc to t|c |asc ia|:ic. I|c oula:
|o:c cu:ouctc: is o:c uct|oc oi tcsti:g. lt usuall, givcs valic :caci:gs o:l, wit| u:suo:tcc
clastouc:s oi at lcast i: t|ic|:css. : coatcc ia|:ics it cocs :ot :ocucc :clia|lc, a|solutc valucs
|ccausc i:st:uuc:t :cgistc:s souc oi t|c |a:c:css oi t|c |asc ia|:ic.
74 Plastics Technology HandbookVolume 2
A |o:c cu:ouctc: ucasu:cs :csista:cc oi t|c saulc to c:ct:atio: |, a: i:cc:tc: at t|c
oi:t oi a: i:st:uuc:t, w|ic| cxtc:cs 0.1 i: |c,o:c t|c su:iacc oi t|c :cssc: ioot. I|c cu:ou
ctc: :cacs 0 w|c: t|c i:cc:tc: is iull, cxtc:ccc a:c 100 w|c: it is :csscc to a ilat iccc oi latc
glass, t|us a |ig| valuc i:cicatcs a |a:c saulc. oatcc ia|:ic, to |c |a:c, s|oulc givc a :caci:g
oi a|out 0.
Hydrostatic Resistance
A ucasu:c oi t|is c|a:actc:istic is usciul io: coatcc ia|:ic i:tc:ccc io: :ai::ooi alicatio:s. I|c
\ullc: tcst is io: |ig| watc: :cssu:c :csista:cc. A saulc is claucc |ctwcc: |aws wit| ci:cula:
oc:i:gs a:c watc: :cssu:c is :aiscc u:til t|c ii:st c:o oi watc: asscs t|:oug| saulc. l:cssu:c
at t|is oi:t is cx:csscc i: \la ;si, AI\ D .1,.
I|c utc: tcst is uscc io: ucciuu o: low watc: :cssu:c :csista:cc ;u to 1+ |la ! si,, it
culo,s a :isi:g watc: coluu: laccc ovc: a tcst saulc. kcsista:cc is :co:tcc as t|c |cig|t, i:
cu, oi t|c coluu: at w|ic| :cssu:c causcs t|c ii:st c:o oi watc: to c:ct:atc t|c saulc.
I|c:c is a: iuact s:a, tcst io: low watc: :cssu:c :csista:cc. A ia|:ic saulc is |ou|a:ccc
wit| a s:a, oi watc: i:ou a scciiicc |cig|t, usuall, a coluu: ucasu:i:g 0.- u ;! it,. I|c watc: t|at
asscs t|:oug| a saulc oi a sta:ca:c a:ca wit|i: a scciiicc tiuc is accuuulatcc i: a o o i: |lottc:
uou:tcc |c|i:c ia|:ic. I|c i:c:casc oi wcig|t, i: ug, oi t|c |lottc: is t|c s:a, c:ct:atio: valuc.
Low Temperature Cracking
I|is guicc is iuo:ta:t wit| ia|:ics t|at uust c:io:u outcoo:s i: colc cliuatcs, suc| as gas uctc:
a:c :cgulato: cia|:agus. Icst tcuc:atu:cs oi +0l a:c ol ; +0 a:c 1-, a:c couuo:l,
uscc. l: t|c |c:t loo a:c |auuc: tcst, a wcig|t is c:occ o: a |c:t saulc u:til it c:ac|s. I|c
tcst ucasu:c is givc: as t|c :uu|c: oi c,clcs to iailu:c.
l: t|c |a: tcst, two saulcs ucasu:i:g 1 i: wicc a:c t|:caccc u:cc: a |a: wit| i: ciauctc:
t|at io:us t|c |i:gc |ctwcc: a cc:tc: latc a:c a lo:gc: latc o: cac| c:c. I|c c:c latcs a:c liitcc
a:c t|c: allowcc to c:o o: t|c cc:tc: latc, ilcxi:g t|c ia|:ic saulcs a:ou:c t|c |a: u:til t|c,
c:ac|. I|c ucasu:c oi :csista:cc is t|c :uu|c: oi c,clcs to iailu:c.
l: iolc a:c :oll tcsts, a 10 l| ;+.. |g, :ollc: is :ollcc ovc: a saulc t|at is ii:st iolccc i: o:c
ci:cctio: a:c t|c: iolccc i: t|c oositc ci:cctio:. I|c tcst is co:ti:ucc u:til t|c saulc c:ac|s,
a:c t|c :uu|c: oi c,clcs to iailu:c is uscc as t|c ucasu:c oi :csista:cc. t|c: tcsts i:clucc AI\
D !o, AI\ D +o, AI\ D -, a:c AI\ D 10.!.
Modulus
A coati:g wit| a low uoculus oi clasticit, is ccsi:a|lc i: |ig|l, ilcxi|lc coatcc ia|:ic alicatio:s,
suc| as :aicl, ulsati:g cia|:agus. A uoculus ca: |c ucasu:cc satisiacto:il, o:l, |cio:c t|c
clastouc: is alicc to t|c |asc ia|:ic. lt is usuall, ucasu:cc |, t|c st:css i: \la ;si, at a:, givc:
clo:gatio:, uost couuo:l, uscc valucs a:c o|tai:cc at !00 clo:gatio:.
Coating 75
Gas Permeability
lc:uca|ilit, ucasu:cuc:ts oi gascs a:c iuo:ta:t io: coatcc ia|:ics uscc i: liic vcsts a:c ot|c:
i:ilata|lc :ocucts. I|c, a:c also vital io: gas uctc: a:c :cgulato: cia|:agus. l: t|c au|:icgc
c:ucauctc: tcst,saulcs a:c tcstcc i: a: aa:atus usi:g |,c:ogc: gas. Icsts a:c usuall, co:
cuctcc io: ! ui:utcs, a:c t|c i:st:uuc:t co:vc:ts :caci:gs i:to valucs cx:csscc i: 1u
!
!+ |.
lo: liic vcsts a:c :aits, a :caci:g oi .1u
!
!+ | is acccta|lc. kcsults ca: |c co:vc:tcc i:to cquiva
lc:t valucs io: |cliuu, ca:|o: cioxicc, o: ot|c: gascs |, usi:g iacto:s :ccouuc:ccc |, t|c lu:cau
oi ta:ca:cs ;AI\ D 1.,.
Liquid Permeability
liquic c:uca|ilit, ucasu:cuc:ts a:c sig:iiica:t io: ia|:ics uscc as iucl co:tai:c:s o: vao: t:as,
suc| as |:cat|c: |alloo:s. l: a tcst, a scciiicc auou:t oi tcst liquic is laccc i: a cu o: |a: oi scciiicc
ciuc:sio:s, t|c ia|:ic saulc is t|c: laccc ovc: t|c cu o: |a: a:c scalcc. Aitc: allowi:g t|c saulc
to :cac| cquili|:iuu, t|c cu o: |a: is wcig|cc accu:atcl, a:c t|c: i:vc:tcc a:c allowcc to sta:c io:
a scciiicc c:ioc, aitc: w|ic| it is wcig|cc agai:. Wcig|t loss is calculatcc gc:c:all, i: il ozit
!
!+ |.
pH Value
I|c l valuc oi a coati:g is usciul to |:ow i: alicatio:s w|c:c t|c coati:g coucs i: co:tact
wit| uctal a:ts. :o:uall,, t|c coati:g s|oulc |avc a :cut:al l. I|c tcst uct|oc uscs t|c ia|:ic
o: coati:g cut i:to suall icccs a:c laccc i: cistillcc watc: io: ! |ou:s. I|c l is t|c: ucasu:cc
wit| a sta:ca:c uctc:. A :caci:g oi :c:csc:ts :cut:alit,, s|ows acicit,, ~ s|ows al|ali:it,
;Ia|lcs 10.!+ a:c 10.!.,.
Resiliency
kcsilic:c, ca: |c a: iuo:ta:t i:ccx i: ua:, alicatio:s, suc| as :u||c: coatcc oiisct :i:t
i:g |la:|cts. I|c las|o:c :csiliouctc: tcst |as a |o| c:occ vc:ticall, o:to a ia|:ic saulc at
t|c |asc oi a: i:st:uuc:t. I|c cista:cc t|at t|c |o| |ou:ccs |ac| aitc: iuact is :co:tcc as a
c:cc:tagc oi t|c o:igi:al |cig|t i:ou w|ic| it was c:occ. lt s|oulc |c :cucu|c:cc t|at t|c
:csiliouctc: :cco:cs t|c cou|i:cc :csilic:c, oi t|c coati:g a:c |asc ia|:ic. li a :caci:g oi t|c
clastouc: coati:g alo:c is wa:tcc, t|c: a iai:l, t|ic| saulc oi clastouc: coati:g uatc:ial uust
|c tcstcc |cio:c t|c coati:g alicatio:.
Stretch
Icuo:a:, st:ctc| a:c c:ua:c:t :csicual st:ctc| a:c u:ccsi:a|lc i: a coatcc ia|:ic t|at :cqui:cs
g:cat accu:ac,, suc| as a uctc:i:g cia|:agu o: a: oiisct :i:ti:g |la:|ct. I|c tcst uct|oc uscs a
10 i: lc:gt| ;accu:atc to t|c :ca:cst 0.01 i:., t|at is ua:|cc oii o: a 1 1! i: saulc. A clau is
76 Plastics Technology HandbookVolume 2
TabIe 10.24 Examples of acIds and bases pH
Coating 77
TabIe 10.25 Color IndIcators of acIds and bases pH
78 Plastics Technology HandbookVolume 2
alicc to cac| c:c, a:c a .0 l| ;!!.. |g, wcig|t is susc:ccc i:ou o:c c:c io: 10 ui:utcs. I|c
auou:t t|at t|c ia|:ic st:ctc|cs cu:i:g tcsti:g is :co:tcc as tcuo:a:, st:ctc| a:c is cx:csscc
i: a c:cc:tagc oi t|c o:igi:al 10 i: lc:gt|. li a st:ctc| :cuai:s aitc: :cuovi:g t|c wcig|t, it is
:co:tcc as c:ua:c:t :csicual st:css.
Swelling
A tcst io: swclli:g is :cqui:cc io: a:, coatcc ia|:ic t|at ua, couc i: co:tact wit| oils, solvc:ts, o:
ot|c: liquics cu:i:g usc. I|c:c is a tcst uct|oc w|c:c o|lo:g saulcs a:c iuuc:scc i: a g:acuatcc
c,li:cc: co:tai:i:g alco|ol to ucasu:c t|ci: voluuc. I|c saulcs a:c t|c: c:icc a:c iuuc:scc
i: t|c tcst ucciuu io: a scciiicc c:ioc u:cc: a scciiic tcuc:atu:c. lollowi:g cxosu:c, t|c
saulcs a:c :cuovcc a:c t|ci: voluuc is ucasu:cc agai:. I|c i:c:casc i: voluuc i:ou swclli:g is
:cco:ccc as c:cc:tagc oi t|c o:igi:al voluuc.
Alco|ol is uscc to ucasu:c t|c ia|:ic voluuc |ccausc it is clca:, cocs :ot causc swclli:g, a:c
c:uits t|c saulc to si:|. Ioluol is t|c uost i:cquc:tl, uscc swclli:g ucciuu |ccausc its swclli:g
:oc:tics uatc| t|osc oi ua:, uccia. lowcvc:, scvc:al ot|c: iluics a:c availa|lc io: cctc:ui:i:g
swclli:g c|a:actc:istics.
\a:, |:a:cs oi gasoli:cs, oils, a:c ot|c: iluics |avc :o:icta:, io:uula i:g:ccic:ts. Dust,
iuucs, a:c tcuc:atu:c, auo:g ot|c: iacto:s, ua, aiicct t|c couositio: oi t|c iluics. I|c:cio:c,
i: c:itical alicatio:s suc| as iucl a:c |:a|c s,stcus, cxtc:sivc liic tcsts s|oulc |c co:cuctcc wit|
ia|:ics u:cc: t|c cxcctcc oc:ati:g co:citio:s.
li t|c coatcc ia|:ic |as to c:io:u at clcvatcc tcuc:atu:cs, t|c: swclli:g tcsts a:c :u: at t|c
cxcctcc tcuc:atu:cs. l: souc cascs, t|c c:cc:tagc i:c:casc i: gaugc o: wcig|t, :at|c: t|a: t|c
c|a:gc i: voluuc, is ucasu:cc.
Tear Strength
la|:ic t|at will |c st:csscc s|oulc |c tcstcc io: tca: st:c:gt|. I|c lc:culuu uct|oc ;lluc:co:i,
tcst uscs a !.. + i: ia|:ic saulc |clc |ctwcc: two claus at t|c |asc oi a: lluc:co:i i:st:uuc:t.
I|c saulc is :ic|cc wit| a |:iic attac|uc:t, a:c t|c: a c:culuu is :clcascc a:c ialls t|:oug| t|c
saulc. I|c c:culuu ca::ics a ci:cuuic:c:tial scalc t|at i:cicatcs t|c io:cc :cqui:cc to tca: t|c
scciuc:. calc :caci:gs ca: |c uultilicc |, a:o:iatc iacto:s to givc :csults i: ou:cs o: g:aus.
Valucs a:c cctc:ui:cc io: |ot| t|c wa: a:c iilli:g ci:cctio: oi t|c ia|:ic ;AI\ .1,.
l: t|c Io:guc uct|oc ;st:i,, a cut is uacc at t|c cc:tc: oi t|c ! i: ccgc oi a ! i: saulc.
I|c two 1 i: c:cs a:c t|c: laccc i: two |aws oi a tcstc:. I|c |aws a:c sca:atcc at a sccc oi 1!
iu. A :cco:cc: :cco:cs tca: as a |ig| oi:t o: a c|a:t. I|c avc:agc oi iivc tcsts is :co:tcc as tca:
st:c:gt| i: l| o: \la. Valucs a:c cctc:ui:cc io: |ot| wa: a:c iilli:g ci:cctio:.
l: t|c I:aczoic uct|oc, a t:aczoical saulc, o i: lo:g o: o:c sicc a:c ! i: lo:g o: t|c
oositc a:allcl ccgc, is givc: a suall cut at t|c cc:tc: oi t|c ! i: ccgc. I|c :o:a:allcl ccgcs
Coating 79
a:c claucc i:to t|c |aws oi a tcstc:, a:c t|c saulc is to:: aa:t at a sccc oi 1! iu. usi:g t|c
:cco:cc:, a :csca:c|c: :otcs t|c avc:agc oi iivc |ig| oi:ts as tca: st:c:gt| i: \la ;l|,.
Tensile Strength
I|c coatcc ia|:ic ua:uiactu:c: :o:uall, sulics a sta:ca:c tc:silc st:c:gt| valuc |, t|c g:a|
uct|oc i: |ot| wa: a:c iilli:g ci:cctio:s. I|c G:a| uct|oc uscs + o i: ia|:ic saulcs t|at a:c
i:sc:tcc i: 1 1 i: |aws oi a tcstc:. I|c |aws, ! i: aa:t at t|c sta:t, a:c sca:atcc at 1! iu. Valucs
a:c :co:tcc i: ou:cs c: i:c|. Io o|tai: accu:atc :csults, cxt:cuc ca:c uust |c uscc to o|tai:
:oc: alig:uc:t oi t|c ,a::s i: t|c |aws ;AI\ D .1,.
l: a cut st:i uct|oc, st:is ucasu:i:g 1 o i: a:c cut i: |ot| t|c wa: a:c iill ci:cctio:s. l:
tu:: t|c ,a::s a:c ca:ciull, alig:cc i: t|c cics. aulcs a:c :utu:cc i: a tcstc:, valucs a:c :cco:ccc
i: l| i: ;AI\ D .1,.
Thickness
l: ua:, alicatio:s, it is cssc:tial to |avc u:iio:u t|ic|:css ovc: t|c c:ti:c su:iacc oi a coatcc
ia|:ic. Icst uct|ocs usi:g a gaugc wit| 0.001 i: g:acuatio:s ca: |c culo,cc io: t|ic|:css uca
su:cuc:ts. i:cc t|c gaugc uscs a ccacwcig|t :at|c: t|a: a s:i:g gaugc, g:cat ca:c uust |c ta|c:
to al, a: a|solutcl, st:aig|t loac to o|tai: accu:atc :caci:gs.
Wicking
l: souc c:itical alicatio:s, it is cssc:tial to ucasu:c t|c ai: o: gas lca|agc t|:oug| i:|olcs o:
t|:oug| i:tc::all, cxoscc ccgcs oi vc:t |olcs i:to t|c ia|:ic i:ou w|c:c it |lcccs to ia|:ic ccgcs.
oatcc ia|:ic cia|:agus c:io:ui:g i: c:itical alicatio:s, suc| as ai: co:t:ols, uust |c :ooicc
agai:st wic|i:g. l: a wic|i:g tcst, a coatcc ia|:ic saulc is claucc i:to a tcst |ig iuuc:scc i:
watc:. lla:gc claui:g :cssu:c uust |c suiiicic:t to :cvc:t loss oi gas |ctwcc: t|c saulc a:c
t|c ila:gcs, |ut :ot so |ig| as to iuccc t|c ilow oi gas t|:oug| t|c ccgcs.
Aitc: iuuc:si:g t|c |ig i: watc:, gas :cssu:c is alicc to t|c |ig, a:c :cssu:c is g:acuall,
:aiscc u:til |u||lcs a:c visi|lc at t|c outc: ccgc oi t|c saulc. l:cssu:cs a:c usuall, :aiscc at
i:c:cuc:ts oi 10 si u to a uaxiuuu oi 100 si. I|c :cssu:c at w|ic| i:itial lca|agc occu:s is
:cco:ccc, a:c t|c :cxt lowcst :cssu:c is ccii:cc as t|c a:tiwic|i:g valuc, o: t|c :cssu:c u to
w|ic| t|c ia|:ic will c:io:u wit|out wic|i:g.
Weathering
Wit| a:, coatcc ia|:ic t|at is to |c uscc outcoo:s, it is vc:, usciul to |avc a guicc to wcat|c:
i:g :oc:tics |cio:c t|c ia|:ic is laccc i: sc:vicc. Io o|tai: accclc:atcc :csults, wcat|c:ouctc:
cquiuc:t ca: |c uscc to siuulatc :ai: a:c su:s|i:c |, usc oi watc: s:a, a:c ca:|o: a:c. lot|
|,sical tcsts a:c visual cxaui:atio: ca: |c uscc to i:cicatc t|c cctc:io:atio: t|at occu:s aitc: a
80 Plastics Technology HandbookVolume 2
scciiicc c:ioc oi tiuc. \ilita:, scciiicatio:s i:cquc:tl, stiulatc t|c ui:iuuu |,sical tcst
valucs t|at uust |c uct aitc: a scciiicc tiuc oi cxosu:c. oua:ativc cvaluatio:s ca: :ovicc a:
i:cicatio: oi t|c wcat|c: :csista:cc oi ciiic:c:t ia|:ics ;AI\ D.0,.
SOLVENT AND COATING
Solvent Composition in Coating
I|c usual ccii:itio: oi solvc:ts ccsc:i|cs t|cu as iluics |avi:g a uaxiuuu |oili:g oi:t oi +!l
;!.0, a:c a|lc to cissolvc ot|c: couo:c:ts oi coati:gs, cscciall, |i:cc:s. I|c, cvao:atc u:cc:
c:,i:g co:citio:s w|c: ai:t iilus a:c io:ucc. olvc:ts uust :ot :cact wit| t|c coatcc :ocuct. I|c
couositio: oi coati:gs ;ai:ts, va::is|cs, ctc., is cctc:ui:cc |, alicatio: :cqui:cuc:ts, c:,i:g
tcuc:atu:c, a:c c:,i:g tiuc. Dcc:ci:g o: t|c :oc:tics oi ai:ts a:c va::is|cs, ciiic:c:t uix
tu:cs oi solvc:ts a:c acccc. Ia|lc 10.!o :oviccs classiiicatio:s a:c ccii:itio:s oi solvc:ts ;!+,.
I|c iu:ctio:s a:c :oc:tics oi solvc:ts i: coati:gs a:c as iollows.
1. Dissolvc scvc:al couo:c:ts, cscciall, |i:cc:s.
!. l:iluc:cc a:c co:t:ol ai:t viscosit,.
!. Wct iguc:ts, t|us i:iluc:ci:g solu|ilit,, c:a|li:g |,c:ogc: |o:ci:g |, solvc:ts,
a:c :cvc:ti:g t|c sca:atio: oi iguc:ts.
+. l:iluc:cc a:c co:t:ol ilow :oc:tics ;c.g., |ut,l acctatc, |uta:ol, a:c gl,col ct|c:s,.
.. l:iluc:cc s|i: io:uatio:. I|c aiu is to :ocucc a |ouogc:cous cu:c w|c:, io:
cxaulc, t|c ai:t o: va::is| iilu |a:cc:s wit|out t|c io:uatio: oi a sta|lc su:iacc
iilu cu:i:g t|c c:,i:g c:ioc. I|c co::cct couositio: oi t|c solvc:t will avoic
t:ai:g solvc:ts u:cc: t|c su:iacc iilu.
o. l:iluc:cc t|c c:,i:g :occss, t|us i:iluc:ci:g t|c accclc:atio: |, low |oilc:s o: t|c
:ocuctio: oi a ilawlcss su:iacc |, ucciuu a:c |ig| |oilc:s ;c.g., t|c c|cuical a:c
|,sical c:,i:g :occsscs,.
. l:iluc:cc su:iacc tc:sio: ;c.g., i:c:casc |, :aic cvao:atio: oi solvc:ts,.
. l:iluc:cc ucc|a:ical :oc:tics oi ai:ts ;c.g., ac|csio: :oc:tics,.
-. l:iluc:cc |lus|i:g o: |looui:g oi ai:ts |, :cvc:ti:g t|c a|so:tio: oi co:cc:scc
watc: |, va:ious solvc:ts ;c.g., ct|a:ol a:c gl,col ct|c:,.
10. l:iluc:cc gloss ;c.g., iu:ovcuc:t wit| |ig| |oilc:s,.
11. l:cvc:t cciccts a:ticula:l, i: va::is| coati:g ;c.g., |ac|g:ou:c wctti:g,.
1!. l:iluc:cc clcct:ostatic :oc:tics ;c.g., s:a, ai:ti:g,.
1!. l:iluc:cc ccii:cc su:iacc :oc:tics ;c.g., c:catc st:uctu:al c|a:gcs,.
1+. l:iluc:cc cu:a|ilit, oi ai:ts a:c va::is|cs.
1.. l:iluc:cc :ocuct suita|ilit, ;c.g., s:a,i:g a:c cii:g lacquc:s t|at :ccc to c:, at
:oou tcuc:atu:c,.
Coating 81
TabIe 10.26 ClassIcatIons and denItIons of solvents
82 Plastics Technology HandbookVolume 2
TabIe 10.26 ClassIcatIons and denItIons of solvents FRQWLQXHG
Coating 83
l: accitio: to t|ci: ciicct o: c:io:ua:cc a:c :oc:tics solvc:ts i:tc:act wit| ot|c: couo
:c:ts i: ai:ts a:c va::is|cs i: sig:iiica:t wa,s. l:tc:actio:s |ctwcc: |i:cc:s a:c solvc:ts i: ai:ts
a:c va::is|cs a:c vc:, iuo:ta:t. Wit| t|c aic oi solu|ilit, a:auctc:s, solvc:ts o: uixtu:cs oi sol
vc:ts t|at :ocucc t|c :cqui:cc :oc:tics ua, |c sclcctcc. I|c i:iluc:cc cxtc:cs to t|c cissolvi:g
oi |i:cc:s, t|c :ccuctio: oi ai:t viscosit,, iguc:t wctti:g, a:c so o:.
tiuizcc cissolvi:g oi |i:cc:s ca: |c ac|icvcc |, sclccti:g t|c a:o:iatc solvc:t uixtu:cs,
i: w|ic| t|c cc:sit, a:oac|cs t|at oi t|c |i:cc: solu|ilit, :a:gc. :cvc:t|clcss, t|c sclcctio: oi a:
otiuizcc solvc:t uixtu:c is ciiiicult |ccausc t|c:c a:c co:ilicti:g :cqui:cuc:ts a:c outcoucs. l:
o:c ascct, t|c c|cuical :atu:c oi t|c solvc:ts s|oulc |c siuila: to t|osc oi t|c |i:cc: to iu:ovc t|c
ilow. l: a:ot|c: ascct, t|c solu|ilit, a:c |,c:ogc: |o:ci:g a|ilitics oi t|c solvc:ts s|oulc |c at t|c
ccgc oi t|c |i:cc: solu|ilit, :a:gc, |ccausc t|is :csults i: :aic c:,i:g wit| a low :ctc:tio: oi solvc:ts.
Solvent and Solvent- Free Coatings
olvc:t couositio: is a: iuo:ta:t ascct i: classii,i:g ai:ts a:c va::is|cs. A list oi t|c uai:
g:ous oi t|csc coati:gs iollows.
1. 6ROYHQW SURGXFWV. I|csc :ocucts co:tai: solvc:ts oi va:ious uixtu:cs, t,cs, a:c
co:cc:t:atio:s ccc:ci:g o: t|c :oc:tics ccsi:cc ;c.g., alicatio: uct|oc, su:iacc
iilu, o: s|i: io:uatio:,. olvc:ts a:c :o:uall, t|c uai: couo:c:ts oi t|csc :ocucts.
TabIe 10.26 ClassIcatIons and denItIons of solvents FRQWLQXHG
84 Plastics Technology HandbookVolume 2
!. 6ROYHQW UHGXFHGSURGXFWV. I|csc co:tai: solvc:ts i: lowc: co:cc:t:atio:s coua:cc
to co:vc:tio:al :ocucts a:c t|us a |ig|c: co:tc:t oi solics. I|c uai: g:ous oi
solvc:t :ccuccc ai:ts a:c ucciuu solic co:tc:ts ;.. to o. solics, a:c |ig| solic
co:tc:ts ;o0 to 0 solics,.
!. :DWHUERUQH FRDWLQJV. I|is g:ou co:tai:s ccio:izcc watc: as a cisc:si:g agc:t.
:o:uall, cosolvc:ts a:c acccc ;u to !.,. I|c tc:u watc:|o::c coati:gs is
uai:l, alicc to i:cust:ial coati:g uatc:ials, w|ic| ciiic: i:ou silicatc colo:s,
wooc :csc:vativc va::is|cs, a:c cuulsio: ai:ts.
+. 6ROYHQW IUHHSURGXFWV. I|c :ocucts oi t|is g:ou a:c :ocuccc a:c alicc wit|out
o:ga:ic solvc:ts. I|c, i:clucc owcc: coati:gs, :aciatio: cu:i:g s,stcus, a:c
solvc:t i:cc watc: coati:g ;wit|out cosolvc:ts,.
I|c usc oi ai:ts a:c va::is|cs co:tai:i:g |ig| solvc:t co:cc:t:atio:s is |ccoui:g lcss cou
uo:, solvc:t :ccuccc :ocucts, watc:|o::c coati:gs, a:c solvc:t i:cc :ocucts a:c alicc uo:c
oitc:. W|c:cas c:vi:o:uc:tal a:c |calt| :clatcc co:cc::s call io: t|c :ccuctio: oi solvc:ts i:
ai:ts a:c va::is| :ocucts, qualitativc asccts still ccua:c t|c usc oi solvc:ts i: souc iiclcs oi
alicatio:.
olvc:t :ccuccc :ocucts |avc ac|icvcc t|c sauc qualitativc :oc:tics as solvc:t co:tai:i:g
:ocucts ;c.g., alicatio: :oc:tics, c:iocs oi gua:a:tcc, liuitcc costs, loaci:g caacitics, su:
iacc :oc:tics,. olvc:t :ccuccc o: solvc:t i:cc va::is| :ocucts |avc |cc: :ocuccc wit| |ig|
qualit, ;c.g., cu:a|lc, gooc alicatio: :oc:tics, a:c liuitcc costs. l: souc iiclcs oi alicatio:,
suc| as watc:|o::c coati:gs, |ig| solics i: va::is| coati:gs oi vc|iclcs, a lot oi ccvclouc:tal wo:|
|as |cc: co:c.
Accitio:all,, ot|c: couo:c:ts i: va::is|cs aa:t i:ou solvc:ts o: uociiicatio:s oi ali
catio: tcc|:iqucs ca: iu:ovc t|c :oc:tics oi solvc:t :ccuccc ai:t a:c va::is| :ocucts.
:cvc:t|clcss, a wicc :agc oi qualit, cxists i: ai:ts a:c va::is| :ocucts t|at a:c oiic:cc cou
uc:ciall, a:c, i: souc cascs ;c.g., iilu io:ui:g :occsscs, :occssa|ilit,, co::osio: :otcctio:,
u:iiicatio:, sccial alicatio:s, o: wooc :csc:vatio:,, solvc:t |ascc :ocucts a:c still :c
ic::cc. l: t|c iiclc oi wooc :csc:vatio: cscciall,, solvc:t |ascc :ocucts ;al|,c :csi:s, a:c
uscc |ccausc oi souc tcc|:ical acva:tagcs ;c.g., uo:c solic su:iaccs,, |ut altc::ativc |ig| solic
s,stcus a:c availa|lc.
Emission
olvc:ts a:c usuall, t|c uost sig:iiica:t cuissio: :ocucts coui:g i:ou |uilci:g uatc:ials a:c
i:tc:io: iu::is|i:gs. All ai:tcc :ocucts a:c otc:tial sou:ccs oi cuissio:. lvc: t|c so callcc
|io ai:ts o: :atu:al ai:ts cuit va:ious su|sta:ccs. lxaulcs oi t|csc i:clucc ui:c:al va::is|cs,
:atu:al oils, a:c cvc: s,:t|ctic tc:c:c li|c couou:cs. Dcc:ci:g o: t|c :ocucts a:c t|c cou
o:c:ts t|at ua|c t|cu u, t|c iollowi:g va:ious a:auctc:s ca: cctc:ui:c t|c cuissio:s a:c
|c|avio: oi solvc:ts i: au|ic:t ai: i:ou ai:ts a:c va::is|cs ;!+,.
Coating 85
1. luissio: oi solvc:ts cu:i:g t|c iilu io:uatio: stagc. I|c cuissio: :atc is ci:cctl,
:oo:tio:al to t|c V co:cc:t:atio:s i: t|c :ocuct a:c i:vc:scl, :oo:tio:al to
t|c iilu t|ic|:css ;ii:st o:cc: oi |i:ctics,. W|c: t|c iilu |as coulctcl, io:ucc, t|c
cuissio: is co:t:ollcc |, a ciiiusio: :occss, a:c t|c cuissio: :atc is :ow i:vc:scl,
:oo:tio:al to t|c squa:c oi t|c iilu t|ic|:css.
!. Alicatio: oi t|c ai:ts a:c va::is|cs, uct|ocs oi alicatio: oi t|c ai:t o: va::is|
;c.g., sccc oi alicatio: oi t|c ai:t,.
!. |a:actc:istics oi solvc:ts i: ai:ts a:c va::is|cs ;c.g., volatilit, o: t|c |oili:g
oi:t, c,:auic c|a:actc:istics oi cvao:atio: a:c co:cc:t:atio:s,. u|sta:ccs
t|at |avc a low |oili:g oi:t cvao:atc iast, uostl, cu:i:g alicatio:, a:c causc
a :aic s|i: io:uatio:. I|us t|c :is| oi cxosu:c is uai:l, wit| t|c ai:tc:s.
\cciuu |oilc:s allow t|c su:iacc to :cuai: oc: io: a w|ilc ;cvao:atio: oi
volatilc :ocucts,. I|c cvao:atio: oi su|sta:ccs wit| a |ig| |oili:g oi:t is slow,
ta|i:g scvc:al wcc|s o: uo:t|s aitc: alicatio:, as a :csult, a |uilci:g`s occua:ts
ua, |c cxoscc to t|c su|sta:ccs.
+. |a:actc:istics oi ot|c: couou:cs i: ai:ts a:c va::is|cs ;c.g., :clatio:s|i oi
|i:cc:s to solvc:ts, ossi|lc :cactio:s |ctwcc: solvc:ts a:c ot|c: couou:cs,.
.. |a:actc:istics oi su:iaccs t|at |avc |cc: ai:tcc ;c.g., a:ca, st:uctu:c oi su:iacc,.
o. |a:actc:istics oi cuissio: :occsscs ;c.g., ciiiusio:,, c,:auics oi cuissio:s
;co:sta:t oi cvao:atio:,, i:tc::clatio:s ;c.g., ciiiusio: a:c |ac| ciiiusio:,.
I|c qua:titativc asscssuc:t oi cuissio: :occsscs ca: |c ccsc:i|cc wit| va:ious uoccls. I|c
usciul:css oi t|csc uoccls ciiic:s. ouc uoccls ccsc:i|c t|csc :occsscs vc:, wcll, as :ovc: |,
va:ious cxc:iuc:ts o: ucasu:cuc:ts ;c.g., tcst c|au|c:s,. lasic cquatio:s t|at ccsc:i|c cuissio:
:occsscs a:c s|ow: i: Ia|lc 10.!. A: cuissio: oi solvc:ts i:ou a va::is| s,stcu occu:s i: t|c
cou:sc oi a va::is|`s liic c,clc i: scvc:al ciiic:c:t locatio:s, as s|ow: i: ligu:c 10.!1.
I|c cuissio: :occsscs oi solvc:ts i:ou ai:ts a:c va::is|cs ca: |c civiccc i:to two |ascs.
1. luissio:s cu:i:g alicatio: oi ai:ts, w|ic| ccals wit| coulcx i:tc::clatio:s
ccc:cc:t o: va:ious a:auctc:s
!. luissio:s aitc: t|c alicatio: :occss, t|c cou:sc oi w|ic| is govc::cc |, coulcx
cuissio: :occsscs t|at a:c ccc:cc:t o: va:ious a:auctc:s ;c.g., iilu io:uatio:,
su:iacc a:ca,
\ost solvc:t :ocucts, cscciall, o:ga:ic solvc:ts a:c souc accitivcs, cuittcc i:ou ai:ts
a:c va::is|cs a:c Vs. I|c la:gcst couo:c:ts oi Vs a:c solvc:ts ;c.g., ali|atic a:c a:ouatic
|,c:oca:|o:s, alco|ols, aui:cs, acics, alcc|,ccs, cstc:s, |cto:cs, a:c tc:c:cs,. I|c ccii:itio:
oi Vs va:ics. A sta:ca:c ccii:itio: is u|lis|cc |, lu:oca: ouuittcc io: ta:ca:cizatio:
;l:,. Vs a:c a:, o:ga:ic liquics a:co: solics t|at cvao:atc so:ta:cousl, at t|c :cvaili:g
86 Plastics Technology HandbookVolume 2
TabIe 10.27 Examples of basIc calculatIons of 7DC emIssIons durIng applIcatIons of emulsIon paInts
Coating 87
tcuc:atu:c a:c :cssu:c oi t|c atuos|c:c. V co:tc:t ;V, is ccii:cc as t|c uass oi t|c
Vs i: a coati:g uatc:ial, as cctc:ui:cc u:cc: scciiic co:citio:s.
Clean Air Act
Aluost all solvc:ts a:c Vs a:c |aza:cous ai: olluta:ts ;lAls,, a:c t|ci: cvao:atio: c:catcs
c:vi:o:uc:tal :o|lcus t|at |avc |ccouc t|c iocus oi ua:, coucstic a:c i:tc::atio:al :cgula
tio:s a:c i:itiativcs. A V solvc:t is ccii:cc |, t|c l:vi:o:uc:tal l:otcctio: Agc:c, ;llA, as a:,
couou:c oi ca:|o:, cxcluci:g ca:|o: uo:oxicc, ca:|o: cioxicc, ca:|o:ic acic, uctallic ca:|iccs
o: ca:|o:atcs, a:c auuo:iuu ca:|o:atc, w|ic| is cuittcc o: cvao:atcc i:to t|c atuos|c:c.
l: :ccc:t ,ca:s, t|c u o:g:css a:c t|c llA |avc :ccog:izcc t|c :ccc to acc:css c:vi:o:uc:
tal :o|lcus i:ou a uo:c |olistic a:oac|, co:sicc:i:g uultiuccia a:c i::ovativc c:vi:o:uc:tal
ua:agcuc:t st:atcgics. I|us va:ious lca: Ai: Act :og:aus a:c :o|cct i:itiativcs, w|ic| |avc
:ovc: to |c cxt:cucl, succcssiul, |avc cuc:gcc. \a:, oi t|cu c:cou:agc volu:ta:, i:cust:,
a:ticiatio: a:c co :ot ta|c t|c olc couua:c a:c co:t:ol a:oac|. Dctails oi t|c lca: Ai: Act
a:c :cvicwcc i: c|atc: !o.
SOLVENT SUBSTITUTION
l: t|c ast icw cccaccs, su|stitutio: oi solvc:ts |, saic: :ocucts a:c :occsscs |as |cc: occu::i:g.
liicctivc utilizatio: oi suc:c:itical iluics |as |cc: ccvclocc io: |ig| valuc acccc ciiic:c:tiatcc
:ocucts.
A :cw wavc oi scco:c gc:c:atio: suc:c:itical tcc|:ologics |as sta:tcc to cuc:gc, c:cati:g
:cw :olcs io: cc:sc gascs. uc:c:itical :cic:s to t|c statc oi uattc: i: w|ic| t|c tcuc:atu:c
a:c :cssu:c oi a si:glc couo:c:t iluic a:c a|ovc t|c c:itical oi:t at w|ic| t|c |asc |ou:ca:ics
FIgure 10.21 EmIssIon of 7DCs In the lIfe cycle of a varnIsh.
Emission from
Plants
VOC in mg/m
3

or kg/h respectively
Varnish System
VOC in % or g/kg
or g/l respectively
Inuence from
Surrounding Air on
the Varnish Processor
VOC in g/m
3
or ng/m
3
Emission from
the Surface
VOC in g/m
3

Emission at the
Workplace
VOC in mg/m
3

Inuence
on Interior Air
at the Users Place
VOC in g/m
3
or ng/m
3
88 Plastics Technology HandbookVolume 2
ciui:is|. A o:tiolio oi c|cuical a:c |,sical oc:atio:s ca::icc out i: t|c vici:it, oi t|is :cgio:
ccii:cs suc:c:itical iluic tcc|:olog, ;lI,.
I|c :cssu:c tcuc:atu:c voluuc ;lVI, |c|avio: oi a su|sta:cc ca: |c |cst ccictcc |,
:cssu:c tcuc:atu:c a:c :cssu:c cc:sit, ;voluuc, :o|cctio:s, as s|ow: i: ligu:c 10.!!. I|c
:cssu:c tcuc:atu:c ciag:au icc:tiiics t|c suc:c:itical iluic :cgio:, altc::ativc sca:atio: tcc|
:iqucs t|at i:volvc |asc t:a:sitio: i:cluci:g t|c associatcc |asc |ou:ca:ics, a:c t|c iact t|at
a: isot|c:u |clow c:itical ;Al, lig. 10.!!, i:volvcs |asc t:a:sitio: w|ilc o:c a|ovc ;Al, cocs
:ot. l:cssu:c cc:sit, :o|cctio:s illust:atc tu:a|ilit, oi t|c solvc:t cc:sit, at suc:c:itical co:ci
tio:s ;Al,, a:c agai: t|c co:ti:uit, oi t|c isot|c:u t|at cocs :ot c:cou:tc: a:, |asc t:a:sitio:.
I|c aio:cuc:tio:cc |c|avio: is io: a u:c couo:c:t solvc:t. I|c c:itical :oc:tics oi va:ious
o:ga:ic a:c i:o:ga:ic su|sta:ccs a:c s|ow: i: Ia|lc 10.!.
FIgure 10.22 Pressure temperature and pressure densIty behavIor of matter.
Coating 89
TabIe 10.28 CrItIcal propertIes of solvents