Coating Technologies

PG Textiles
 Introduction
• Definitions
• coated fabric : ‘A material composed of
two or more layers, at least one of which is
a textile fabric and at least one of which is
a substantially continuous polymeric layer.
The layers are bonded closely together by
means of an added adhesive or by the
adhesive properties of one or more of the
component layers’.
• coated fabric : ‘A textile fabric on which there has been
formed in situ, on one or both surfaces, a layer or layers of
adherent coating material’.

• ‘laminated fabric’ (or a ‘combined fabric’) as, ‘a material

composed of two or more layers, at least one of which is a
textile fabric, bonded closely together by means of an added
adhesive, or by the adhesive properties of one or more of the
component layers’.

• A ‘laminated fabric’, also sometimes called a ‘bonded fabric’, is

considered to be different from a coated fabric, in that the
layers are already pre-prepared and the second material can
be a film, another fabric, or some other material.
 Properties that can be obtained by fabric resin
coating or by film lamination
• General fabric properties
 Improved dimensional stability
 Less stretch distortion
 Less pattern distortion
 Increased tear strength (use of silicone resins)
 Reduced tear strength (if desirable)
 Anti-fray/reduced unravelling of edges
 Stiffening (when desirable)
 Improved handling (in processing)
 Easier and more accurate panel cutting/sewing
 Increased friction, more grip (if required)
 Increased slide (less friction if required)
 Improved crease resistance
 Improved abrasion/pilling/snagging
 General fabric properties
• Reduced tendency to curl
• Reduced porosity/permeability to gases/liquids
• Full impermeability to gases/liquids
• Improved/easier cleanability
• Soil resistance
• Water/liquid repellence
• Wipe clean properties
• Thermoformability
• Heat sealability
• Weldability
• Thermal insulation
• Acoustic insulation
• Increased bulk
• Increased thickness
• Improved printability
• Improved embossability (patterns/grained effect)
• Artificial leather/suede
 Appearance/aesthetics
 Gloss/matt appearance
 Smooth continuous surface
 Opacity
 Full black-out
 Coloration (by pigments in
coating/film)
 Enhanced printability
 High visibility, ‘dayglow’
 Reflective surfaces
 Metallic effects
 Pearlescent effects
 Iridescent effects
 Glitter effects
 Fluorescent
 Photoluminescence
(glows in dark)
 Hologram effects
 ‘Chameleon’ effects
(colour change
 with heat)
 Barrier properties to produce
 Shower resistance
 Water proofness/water
resistance
 Chemical resistance
 Dust proofness
 Windproof
 Barrier to gases/liquids
 Protection against liquids,
chemicals,
 microbes
 Functional processing aid to
assist
 manufacturing processes,
e.g.
• vacuum moulding
techniques, ‘in situ’
 moulding techniques
 Filtration
 Thermo-shielding
 Light shielding
 EMI/RFI* shielding
 Using coating or film as a matrix/ container for
functional material
• Pigments (various types – see
• appearance/aesthetics)
• Reflective/fluorescent/
• photoluminescence material
• Metal dust/flake (e.g. nickel, iron for
• magnetic strips)
• Conductive material
• Phase change material
• Antistatic material
• Humectants (moisture retention
• materials)
• Antimicrobial chemicals
• Fragrances/perfumes
• Deodorising chemicals
• † Microcapsules (containing different
substances)
• FR chemicals (high loadings possible )
 Activated carbon (for absorption)
 Oil absorbing
 UV/IR absorbing chemicals
 Radiation absorbing material
 Hollow glass/other material
 microspheres (for weight saving or
• thermal insulation)
 Blowing agents for soft touch–pore
• structure
 Adhesives (may be
microencapsulated)
 Fillers for bulk, weight, economy
• Heat/light/UV stabilisers
 Specialist fillers/chemicals
 High tech’ fillers
• Micro-instruments, Sensors, Probes, Heating
elements, Thermo shape memory polymers,
Nano composites.
 Summary: Coatings or film lamination can be used as

 Coverings or as a barrier for protection, separation or containment

 For appearance modification for decorative or functional purposes

 Improving dimensional stability, controlling stretch, preventing edges from fraying

or curling

 For control of porosity, e.g. for filtration

 As a matrix for holding some functional material, chemical, pigment or other agent

 As a processing aid, for example in ‘in situ’ moulding, vacuum technique or

thermomoulding

 Combining the specialist properties of polymers with the flexibility, strength, drape
ability and covering power of a fabric.
 Novel properties and exploratory development chart

Material : Material : Material :

Fibre or Fabric Polymer/resin/ Filler
General property: General property: General property:
Tear and tensile strength Covering power from Coloration
Stretch and recovery 100% downwards opportunities:
Covering power compound Chemical pigments
Filtering ability
resistance pearlescent
Speciality types available:
high tenacity Thermoformability metallic
FR (moderate to very high) Enhanced printability, FR chemicals
anti-static ‘anti-cut’ receptive to artwork Encapsulated material
energy absorbing Some have weldability UV and other radiation
anti-microbial aramids/UHM* absorbing
polyethylene, high strength to Heat stabilisers
weight ratio and other Many other properties
exceptional properties.
possible, virtually all
Easy handling and storage (rolls)
Easy fabrication textile
chemicals may be used
as filler or additive,
 Novel properties and exploratory development chart
Material : Material : Material :
Film Foam Non-woven/ Soft touch
compound fabric
General property: General property: General property:
100% covering with smooth Soft touch Thermal
surface Barrier properties Improved aesthetics insulation/sound
Printability/receptive to artwork (deep sew lines, e.g. car insulation
Some have weldability Allows
seat (e.g. tufted fabric,
film technology to be combined
with fabric technology and fabric covers) Controllable filtering
properties Thermal insulation ability
Tedlar – PTFE – wide Sound insulation wadding) Bulkiness
temperature resistance Bulkiness (enhanced (enhanced safety)
Kapton – polyimide – wide safety) Impact absorbing
temperature resistance Impact absorbing Non-woven fabric can
PVDC (exceptional Controllable filtering be a speciality fibre or
impermeability)
ability an
Decorative films – e.g. Mearl
(Mearl Corporation) inexpensive base
Reflective surface (heat, light, material, i.e. allow a
other radiation) cost saving
 Textile Substrate for
Coated Fabrics
• Fibres for Substrates:
– Cotton, Polyester, Kevlar, Polybenzimidazole, Acrylic fibers Glass,
Polypropylene.

• The emerging trends

– Development of polyester fiber with lower elongation or higher modulus,
higher adhesion, and microdenier filament for greater cloth cover/surface
area
– Greater use of polypropylene
– Use of longer roll length and wider fabric to lower the cost
– More use of textured, Dref, and core spun yarns for improved adhesion
• selection of fabric
– Strength and modulus
– Creep behaviour
– Resistance to acids and chemicals
– Adhesion requirement
– Resistance to microbiological attack
– Environment of use
– Durability
– Dimensional stability
– Cost

o Designing a textile substrate to meet specific end-use requirements:

– Fiber type and form (such as staple, filament, etc.)

– Yarn type and construction
– Fabric forms (i.e., woven, nonwoven, knitted) and their construction
 Coating Methods
• Fluid coating (coating material is in the form
of paste, solution, or lattices):
– Knife coaters: Wire wound bars, round bars, and so forth. These are
postmetering devices.
– Roll coaters: Reverse roll coaters, kiss coaters, gravure coaters, dip
coaters, etc. These are premetered application systems.
– Impregnators: Material to be coated is dipped in the fluid, and the
excess is removed by squeeze roll or doctor blades.
– Spray coaters: The material is sprayed directly on the web or onto a
roll for transfer.
 Coating Methods
• Coating with dry compound (solid powder or
film):
– Melt coating: Extrusion coating, powder coating,
and so forth.
– Calendering: For thermoplastic polymers and
rubber compounds, Zimmer process, and Bema
Coater.
– Lamination.
 Coating Methods
• The choice of a coating method depends on
several factors:
– Nature of the substrate
– Form of the resin and viscosity of the coating fluid
– End product and accuracy of coating desired
– Economics of the process
Common Features of Fluid Coating
Units
 Fabric substrates for coating
Fabric Advantages Disadvantages
Cotton Excellent coating adhesion Low strength to weight Low strength to weight ratio,
No bonding agents required. absorbs moisture
Vulnerable to mildew,
rotting, insects
Polyester Strong with HT, low shrinkage Low moisture Low moisture absorbency
absorbency (for garment comfort)
and many other variants available Limited resilience Limited resilience (not
relatively inexpensive Resistant to mildew, rotting used in carpets)
and insects High abrasion resistance Blendable with
cotton for garments and other end uses Good
overall properties/price.

Nylon Strong with HT variants available Good elasticity and UV resistance low unless
resilience High abrasion resistance Resistant to protected
mildew, rotting and insects Good thermal Fabric may sag due to
absorbency (used moisture absorption
in airbags). Relatively expensive
compared to polyester
 Fabric substrates for coating:
Fabric Advantages Disadvantages
Polyethylene, Lightweight Inexpensive Low melting point –
polypropylene Chemically inert Resistant to mildew, especially polyethylene
rotting and insects. Adhesion difficult to
some substances

Aramid Very high tensile strength Expensive

Excellent strength to weight ratio High Degraded by sunlight/UV.
melting point
Good FR properties.

Glass Very high temperature resistance High Adhesion difficulties

tenacity Relatively heavy
Excellent FR properties Brittle, poor flexing
Good dimensional stability Properties.
Resistant to mildew, rotting and
Insects Zero moisture absorbance
Excellent UV stability.
 Polymeric Materials for Coating (Rubbers)

Natural Rubber
• Natural rubber (NR) is obtained from the exudation of the rubber plant, Hevea
brasiliensis.
• The rubber is obtained from the latex by coagulation, sheeting, drying, and baling.
• Natural rubber contains about 90% rubber hydrocarbon as cis-1,4-polyisoprene,
along with naturally occurring resins, proteins, sugars, and so forth, that
precipitate during latex coagulation.
GENERAL DESCRIPTION:
• Natural Rubber has a typical service temperature range between –67° F and +180° F.

ADVANTAGES:
• Natural rubber has excellent tensile, elongation, tear resistance, resilience, and electrical insulation.
• Natural rubber’s high resilience is only outperformed by some of the more recent man-made
polyisoprenes and polybutadienes.
• Natural rubber exhibits excellent resistance to water and cold flow.
• Natural rubber has low compression set and can be bonded to a wide range of materials. It also has good
flexing qualities at low temperatures that are better than most synthetics, but it is not as good as silicone
or some of the special butadiene and SBR compounds.
• Natural rubber has superb abrasion resistance when it is compounded with carbon black.

LIMITATIONS:
• Natural rubber deteriorates when exposed to oils, fuels, solvents, petroleum derivatives, and hydraulic
fluids.
• Without special additives, natural rubber has poor resistance to sunlight, oxygen, ozone, and high
temperatures.

COMMON APPLICATIONS:
• Natural rubber can be easily bonded to a wide variety of materials, including fabric and metal.
• Natural rubber is widely used where many types of acids and bases, except those types that are highly
oxidizing, are present.
• Common applications include tires, tubing, gaskets, belts, hoses, seals, shock mounts, rolls, vibration
isolators, electrical components, bumpers, and drive wheels.
 Rubber Additives
• Raw rubber
• Cross-linking agents
• Accelerators
• Accelerator activators
• Anti-degradants
• Fillers, reinforcing, diluents
• Processing aids
• Pigments and dyes
• Special additives (e.g., flame retardants, fungicides)
Vulcanization
 Polymeric Materials for Coating (Rubbers)

• Styrene–Butadiene Rubber
• Styrene–butadiene rubber (SBR) is a copolymer of styrene and butadiene. The styrene
content ranges from about 25 to 30 wt%.
• SBR is mainly prepared by emulsion polymerization.
• These rubbers have much higher cis-1,4-butadiene content (50 to 55%), less chain branching, and narrower
molecular weight distribution.
GENERAL DESCRIPTION:
• SBR, also known as Buna-S, is a synthetic copolymer of styrene and butadiene. SBR was
originally developed to replace natural rubber in tires and its use in the manufacture of tires
continues to the present day. SBR and natural rubber account for 90% of the total world
rubber consumption.
• SBR has a typical service temperature range between –50° F and +225° F.
ADVANTAGES:
• SBR has similar properties to natural rubber, but SBR has superior water resistance, heat
resistance, abrasion resistance, low-temperature flexibility, and heat aging properties (i.e., in
excess heat SBR hardens and becomes brittle instead of softening like natural rubber does).
• SBR also has good electrical insulation, alcohol resistance, oxygenated solvent resistance, and
mild acid resistance.
• SBR can be successfully bonded to a wide range of materials.

LIMITATIONS:
• SBR has poor resistance to oils, fuels, hydraulic fluids, strong acids, greases, fat, and most
hydrocarbons.
• Without special additives, SBR is vulnerable to ozone, oxygen and sunlight.

COMMON APPLICATIONS:
• SBR is recommended for applications where water, automotive brake fluid, or alcohols with a
low molecular weight are present.
• Common applications include tire, tubes, gaskets, belts, hoses, seals, shock mounts, skirt
board rubber, lining rubber, and conveyor belt covers. SBR is not normally produced in o-ring
form.
 Polymeric Materials for Coating (Rubbers)

• Isoprene–Isobutylene Rubber, Butyl Rubber

• Butyl rubber is a copolymer of 97 to 99.5 mol% of isobutylene and 0.5 to 3
mol% isoprene.
• The isoprene unit provides the double bond required for sulfur
vulcanization.
• The polymer chains are highly saturated and have a very regular structure
due to the symmetrical nature of the monomer. As a result, butyl rubber
exhibits very low gas permeability, ozone, heat, weathering, and chemical
resistance. Butyl rubbers are self-reinforcing with a high gum tensile
strength.
GENERAL DESCRIPTION:
• Butyl is produced by copolymerizing isobutylene with small amounts of isoprene (typically 98% polyisobutylene
and 2% isoprene). Butyl rubber was first commercialized in the early 1940s. With excellent gas impermeability and
air retention along with good flex properties, the first major application of butyl rubber was tire inner tubes.
• Butyl rubber has a typical service temperature range between –75° F and +250° F.
ADVANTAGES:
• Butyl rubber has exceptional resistance to gas and moisture (water and steam) permeation.
• Butyl rubber also has excellent resistance to oxygenated solvents (ketones and alcohols), alkalis, flexing, and
abrasion.
• Butyl is capable of providing high energy absorption (damping) and thus has excellent electrical isolation
performance.
• Butyl has good resistance to sunlight, ozone, heat aging, animal and vegetable oils, oxidizing chemicals, silicone
fluids and greases, ammonia, hydrazine, and phosphate ester type hydraulic fluids (e.g., Skydol, Fyrqeul, Pydraul).
• The molecular structure of butyl rubber can be oriented to resist stress. Mechanical properties are retained over a
relatively wide stiffness range since reinforcement is not required for good tensile and tear strength.
LIMITATIONS:
• Butyl rubber is difficult to handle during manufacturing because of its tendency to trap air, blister, and creep.
• Cold flow characteristics and flame resistance are poor.
• Butyl is not recommended for use with petroleum oils, fluids, or solvents.
• Butyl has poor resistance to aromatic hydrocarbons (e.g., Benzol, Toloul), aliphatic hydrocarbons (e.g., kerosene,
turpentine), coal, tar, and diester-based lubricants. Cold weather properties for butyl rubber are fair.
COMMON APPLICATIONS:
• Butyl’s excellent impermeability to gas makes it very useful in seals for vacuum applications. Butyl’s gas
impermeability coupled with its air retention capabilities make butyl popular for use in tire inner liners and inner
tubes.
• Butyl is also used in hydraulics applications where synthetic fluids are used.
 Polymeric Materials for Coating (Rubbers)

• Ethylene–Propylene Polymers and Terpolymers, EPM and EPDM

• Copolymers of ethylene and propylene (ethylene–propylene [EPM]) are made by
solution polymerization using vanadium containing alkyl aluminum, Ziegler-type
catalyst. These are elastomers, but they do not contain a double bond.
• For good elastomeric properties, the ethylene-propylene ratio ranges from 45 to
60 wt%, and the monomers are arranged randomly. Consequently, these polymers
are predominantly amorphous, and the pure gum strength is low.
• Both EPM and EPDM have excellent resistance to oxygen, ozone, heat, and
ultraviolet (UV) radiation.
GENERAL DESCRIPTION:
• There are two basic types of EP rubber available in today's market—EP and EPDM. EP is a
copolymer of ethylene and propylene, while EPDM is a terpolymer combining ethylene, propylene
and a diene monomer. EP uses a peroxide curesystem. EPDM uses a sulfur cure system.
• EPDM has a typical service temperature range between –65° F and +300° F.
ADVANTAGES:
• EPDM exhibits exceptionally good resistance to weather aging, ozone, UV exposure, water, heat,
phosphate ester base hydraulic fluids (Skydrol, Fyrquel, Pydraul), dilute acids, electrical insulation.
• EPDM has good to very good resistance to steam, oxygenated solvents (acetone, methyl, ethyl
ketone and other ketones), animal and vegetable oils, alkalis, brake fluids, and compression set.
EPDM’s dynamic and mechanical properties are, in general, between natural rubber and SBR.
LIMITATIONS:
• EPDM is not recommended for use with petroleum oils, fluids, or solvents because significant
swelling would result.
• EPDM has poor resistance to aromatic hydrocarbons (e.g., Benzol, Toloul) and aliphatic
hydrocarbons (e.g., kerosene, turpentine).
COMMON APPLICATIONS:
• EPDM is one of the most widely used synthetic rubbers in many static and dynamic applications.
• EPDM is used extensively in outdoor applications where weather and water resistance is required.
• It can be found in several industries ranging from automotive to HVAC. Gaskets, bumpers, auto
parts, auto brake systems, electrical installation, dust covers, weather stripping and conveyor belts
are just of the many products that use EPDM.
 Polymeric Materials for Coating (Rubbers)

Neoprene or Polychloroprene Rubber (CR)

• CRs are produced by an emulsion polymerization process of 2-
chloro-1,3-butadiene.
• The polymer chains consist of approximately 98% 1,4 addition
products that are mostly trans in configuration, and the rest are 1,2
addition products.
• The 1,2 addition product contains a chlorine atom attached to a
tertiary allylic carbon atom that is highly activated and thus
becomes the curing site in the polymer chain.
GENERAL DESCRIPTION:
• Neoprene was created in 1930 by DuPont as an air and oil resistant substitute for natural rubber. It was the first
massproduced synthetic rubber. Neoprene is a polymer of chloroprene and is considered a general or all-purpose rubber.
• Neoprene is available in many varieties including non-sulfur modified "W" and the more common sulfur modified "GN"
types.
• Neoprene has a typical service temperature range between –50° F and +275° F.
ADVANTAGES:
• Neoprene is known for its versatility. It provides good resistance to moderate exposure to ozone, sunlight, oxidation,
weather,
• oils, gasoline, greases, solvents, petroleum oils, animal and vegetable oils, compression set, silicone oil, refrigerants,
• ammonia, carbon dioxide, water, and steam. Certain compounds of neoprene are flame resistant and will not support
• combustion. The tear resistance is equal to natural rubber at room temperature; at elevated temperatures tear resistance is
• poor but can be improved to some extent by compounding with reinforcing materials. Resilience and abrasion strength are
• good. Adhesion to metals and fabrics is very good.
LIMITATIONS:
• The cost of neoprene is its greatest disadvantage. It is a good multipurpose rubber, but there are other types that offer much
• better oil, ozone, weather and oxidation resistance at a lower cost when they are used for specific applications. Neoprene
has poor resistance to strong oxidizing acids, esters, ketones, chlorinated, aromatic, and nitro hydrocarbons.
COMMON APPLICATIONS:
• Neoprene is primarily used in applications when the seal is exposed to weathering refrigerants, silicate ester lubricants and
• high aniline point petroleum oils. Neoprene can be formulated for use in mass transit industries due to its ability to meet
• ASTM c1166, e162, e662 and SMP800C standards. Common applications include refrigeration seals, Freon/air conditioning,
• motor mounts, engine coolants, petroleum and chemical tank linings, automotive gaskets and seals, and weather stripping.
 Polymeric Materials for Coating (Rubbers)
Nitrile–Butadiene Rubber (NBR)
• NBR is a copolymer of acrylonitrile and butadiene obtained by emulsion
polymerization.
• The acrylonitrile content varies from 18 to 50%, depending on the properties
desired. The molecular weight ranges from 20,000 to 100,000.
• Like SBR, varying temperatures of polymerization produce different grades of
• NBR. NBR produced at low temperatures, cold rubber, shows less branching than
• hot rubbers. The steric configuration (i.e., cis-1,4; trans-1,4; and trans-1,2
structures) is also influenced by polymerization temperature.
• The lack of compositional uniformity along the polymer chains prevents formation
of crystallites on extension. This results in poor tensile properties of NBR gum
vulcanizes.
• Nitrile rubbers are of special interest because of their high degree of resistance to
fuels, oils, vegetable oils, and fats.
GENERAL DESCRIPTION:
• Nitrile, or Buna-N, is a copolymer of butadiene and acrylonitrile. It is a general purpose oil-resistant polymer.
• Nitrile has a typical service temperature range between –40° F and +275° F.
ADVANTAGES:
• Nitrile has excellent resistance to oil, gasoline, solvents, mineral and vegetable oils, hydraulic fluid, and fuels. It is recommended for
applications that require good oil and grease resistance as well as moderate ozone resistance. With compounding, it is possible to get a
fairly good balance between low creep, good resilience, low permanent set and good abrasion resistance.
• Nitrile is superior to most elastomers with regard to compression set or cold flow, tear and abrasion resistance.
• Nitrile resists acids and bases with the exception of those having strong oxidizing effects. Nitrile is resistant to a broader range of
aromatic hydrocarbons than neoprene. Resistance to heat aging is good.
LIMITATIONS:
• Nitrile has poor resistance to ketones, chlorinated hydrocarbons, and nitro hydrocarbons. It does not have good ozone, oxygen or
sunlight resistance without the addition of special additives.
• Nitrile’s low-temperature resistance is inferior to natural rubber, and although nitrile can be compounded to give improved
performance in this area, the gain is normally at the expense of oil and solvent resistance.
• Conversely, with higher acrylonitrile contents, the solvent resistance is increased but low-temperature flexibility is decreased. Nitrile,
like SBR, does not crystallize on stretching. Thus, reinforcing materials, such as carbon blacks, are required to obtain high strength.
• Tear resistance is inferior to that of natural rubber and electrical insulation is lower.
COMMON APPLICATIONS:
• Nitrile is recommended when excellent resistance to petroleum oils, gasoline, and/or greases is needed.
• Nitrile is the most widely used elastomer for sealing products due to its excellent resistance to petroleum products and its wide
temperature
• range. More than 50% of the o-rings sold are nitrile o-rings.
• Nitrile is also widely used with hydraulic fluid and alcohol applications.
• Nitrile is commonly used for industrial and automotive applications, in products such as fuel and oil handling hoses, petroleum oil seals,
grommets, hydraulic hoses, hydraulic fluid seals, transmission fluid seals, rollers, shock and vibration mounts, and o-rings.
• Typical applications of the premium grades of NBR include carburetor gaskets, fuel pumps, diaphragms and aircraft hose gaskets.
• The commercial grades of NBR are usually blends of NBR with other polymers. These less costly blends accommodate less demanding
applications where oils and heat are prevalent. Ozone-resistant nitriles are recommended where extended exposure to air and ozone is
anticipated.
 Polymeric Materials for Coating (Rubbers)

• Chlorosulfonated Polyethylene (CSM) Rubber

• CSM is produced by reaction of polyethylene solution with chlorine
and sulphur dioxide in the presence of UV radiation. Commercial
grades contain 25 to 40 wt% of chlorine and about 1% of sulfur.
• The chlorine and sulfur are randomly distributed along the polymer
chain. It is cross-linked by metal oxides through the chlorine atom and
the chlorosulfonyl group.
• These rubbers are characterized by a unique combination of special
properties like ozone resistance, flame retardance, and resistance to
corrosive chemicals and oxidizing agents.
 Polymeric Materials for Coating (Rubbers)
• Silicone Rubber
• Silicone rubber is obtained from silicones. Chemically, silicones are polysiloxanes
containing Si–O- bonds. The most important polymers are polydimethylsiloxane,
polymethyl phenyl siloxane, and vinyl methyl siloxane.
• They are manufactured by the hydrolysis of the appropriate dichlorosilane R2 Si
Cl2. Silicones are available in a wide range of molecular weights and viscosities,
from fluid to gums. The stability of silicones over a wide range of temperature is
outstanding and is not found in any other rubber.
• Silicones are extraordinarily resistant to aging, weathering, and ozone. They have,
however, lower mechanical properties, but they do not change much with
temperature. The vulcanizates are hydrophobic and are resistant to chemicals.
Because of their unique properties, they find specialized application, for example,
in gasket O rings, wire cables, and so forth.
• They form a transparent or translucent coating, and because they are UV resistant,
they do not yellow or oxidize on exposure to sunlight. Because silicones are
available in a wide range of viscosities (5000 to 80,000 cps), they can be coated
without solvent.
• They have a high oxygen index, and as such, the coatings are flame retardant.
GENERAL DESCRIPTION:
• Silicone rubber is a semi-organic synthetic made from sand and alkyl or aryl halides. While silicone
rubber looks and feels like organic rubber, it has a completely different type of structure than other
elastomers.
• Silicone rubber consists of a chain of silicon and oxygen atoms rather than carbon and hydrogen
atoms as found in other types of rubber. This structure gives silicone rubber a very flexible but
weak chain. Silicone’s structure also provides a material that has very small change in dynamic
characteristics over a wide range of temperature.
• Silicone has a typical service temperature range between –150° F and +450° F.
ADVANTAGES:
• Silicone has a broad temperature range and is generally odorless / non-toxic.
• Silicone offers excellent resistance to high temperatures, ozone, oxygen, UV light, moisture, and
fungus.
• Silicone also has excellent vibration damping and maintains its dielectric strength.
• Silicone has low compression set and offers good fatigue resistance, flex resistance, and elongation.
LIMITATIONS:
• Silicone has poor tensile, tear and abrasion resistance, and is not recommended for use in dynamic
applications. Although high strength silicones have been developed, tear and tensile strengths
remain relatively low.
• Silicone has poor resistance to most concentrated solvents, concentrated acids, concentrated
alkalines, oils, fuels, hydrocarbons, and steam.
COMMON APPLICATIONS:
• Silicone is recommended for applications subjected to extremely high or low temperatures.
• Silicone is often used in industrial applications due to its long service life.
• Common applications include gaskets, seals, o-rings, and bellows.
 Polymeric Materials for Coating (Polyvinyl Chloride)

• Polyvinyl chloride (PVC) is one of the few synthetic polymers which has found
wide industrial application.
• The popularity of PVC is due to its low cost, excellent physical properties, unique
ability to be compounded with additives, and usefulness for a wide range of
applications and processability by a wide variety of techniques.
• The units are linked mainly head to tail, with a very few head-to-head links. PVC is
considered to be an amorphous polymer. The crystallinity is only about 10%.
• This is attributed to the nonregular position of the chlorine atoms around the
carbon chain. Branching is low in PVC.
• Lower polymerization temperature favors more linear structure. The molecular
weight (Mn) of commercial resins ranges from 50,000 to 100,000.
• The main use of emulsion PVC is in plastisol and organosol preparation, which are
extensively used in coating and slush molding.
• The solution process is almost exclusively restricted to the manufacture of PVC
copolymers for use in surface coatings.
PVC
Properties/ Advantages
Versatile material. Plastisols and water-based available which can
becompounded to give wide range ofproperties Good inherent FR which
can be improved Good oil, solvent and abrasion resistance Heat and RF
weldable for good watertight seams.
Disadvantages
Cracks when cold Plasticiser migration Moderate heat and age resistance.
Typical Products
Tarpaulins, coverings, large tents and architectural uses Seat upholstery
‘Leathercloths’ Protective clothing, aprons Leisure products, banners,
bunting
 Polymeric Materials for Coating (Polyurethanes)

• Polyurethanes are polyaddition products of di- or polyisocyanate with a dior

polyfunctional alcohol (polyol).
• PU
Properties/ Advantages
Several grades available in solvent and latex form. Tough, good extensibility, good
weathering and abrasion resistance. Films available for lamination
Disadvantages
Some grades (aliphatic) discolour and have limited hydrolysis resistance . FR is only
moderate . Relatively expensive.

Typical Products

Waterproof protective clothing

Waterproof/breathable protective clothing
Aircraft life jackets
Adhesives
Used as lacquers for PVC
tarpaulins and leather
 Polymeric Materials for Coating (Acrylic Polymers)

• Acrylic polymers are commonly known as acrylics. The monomers are esters of
acrylic and methacrylic acid.
• Acrylate emulsions are extensively used as thickeners and for coatings.
Acrylics have exceptional resistance to UV light, heat, ozone, chemicals,
water, stiffening on aging, and dry-cleaning solvents. As such, acrylics are
used as back coating materials in automotive upholstery fabric and carpets,
for window drapes, and for pile fabrics used for outerwear.
Acrylic
Properties/ Advantages
Large number of variants and co-polymers. Wide range of properties. Blendable with
other latices. Good UV resistance and optical clarity, generally inexpensive.

Disadvantages
FR may be poor unless compounded with FR chemicals.

Typical Products
Back coatings for upholstery including auto seats.
Binders for nonwovens and glass fibres
Adhesives
Used as lacquers for tarpaulins
 Resin compounders:
Synthomer, Noveon
(formerly Mydrin/BG
Goodrich), Industrial Latex,
Texas Adhesives, Vitabond
(adhesives).

 General textile chemicals:

Clariant, Ciba, CHT-
Tubungen, Dr TH Boehme,
Huls.

 Specialist FR chemicals:
Albright & Wilson, Thor,
Schill and Seilacher, Great
Lakes.

 Crosslinking agents: BIP

(Beetle Resins), Clariant
(Cassurit), Ciba (Knittex and
Lyofix), Bayer (bonding agents
for rubbers and
polyurethane).

 In addition: Clariant
manufacture a whole range
of water-based resins of
different chemical
constitution under the trade
name Appretan. Ciba have
ranges under the trade name
Dicrylan.
Recipes
Recipes
Recipes
Recipes
 Recipes

Zinc Oxide is activator for sulphur vulcanisation

 Rheology and Surface
Chemistry
Rheology
• High viscosity coatings also take longer to flow out when applied.
• With Newtonian fluids, viscosity is constant over any region of shear.
• Very few liquids are truly Newtonian.
• More typically, liquids drop in viscosity as shear or work is applied. The
phenomenon was identified above as shear thinning.
• It is very likely that the material will have a different viscosity at each stage. In fact, a
good product should change in viscosity under applications processing.
 Surface Tension
• All liquids are made up of submicroscopic combinations of atoms called molecules
(a very few liquids are made up of uncombined atoms). All molecules that are
close to one another exert attractive forces. It is these mutual attractions that
produce the universal property called surface tension.
• The units are force per unit length: dynes per centimeter.
 Leveling
• Leveling depends on both rheology and surface chemistry.

The shear stress on a wet coating must be

greater than the yield value for leveling to
take place.

The relationship between various

parameters and shear stress
 The work of adhesion (Wa)
The work of adhesion (Wa) is the thermodynamic work necessary to separate
the liquid from the solid without performing any additional work, such as
viscous or elastic deformation of either the liquid or the solid.
 Polymeric Materials for Coating (Adhesive Treatment)

• Mechanism of Adhesion