Delta Chemistry Plastisol
Plastisols produced by Delta Kimya are offered for sale under its own registered trademark PLASTO ®. They can be prepared in the desired color and shore (hardness). Smooth and Texture surface options are available and do not contain phytelates. Please contact us for reports, TDS and SDS of our products.
POLYMER
A polymer is a substance or material consisting of very large molecules made up of many repeating subunits. Due to their wide range of properties, both synthetic and natural polymers play a fundamental and ubiquitous role in everyday life. Polymers range from familiar synthetic plastics such as polystyrene to natural biopolymers such as DNA and proteins, which are fundamental for biological structure and function. Both natural and synthetic polymers are formed through the polymerization of many small molecules known as monomers. They have a larger molecular mass than small molecule compounds and this produces unique physical properties such as stiffness, high elasticity, viscoelasticity and a tendency to form amorphous and semi-crystalline structures rather than crystalline.
Polymers are divided into two main groups: natural and synthetic. Natural polymeric materials such as amber, wool, silk and natural rubber have been used for centuries. There are a variety of other natural polymers, such as cellulose, the main component of wood and paper.
The list of synthetic polymers includes polyethylene (PE), polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC), synthetic rubber, neoprene, nylon, polyacrylonitrile, PVB, silicone and more, roughly in order of worldwide demand.
Polyvinyl chloride (PVC) is preferred in many fields due to its material properties, inherent flame retardancy, thermal stability, economy and product success. For more than 50 years, PVC has been one of the most important plastics with the development of plasticizers. PVC has many applications in various sectors as profiles, films, sheets and bottles. Most of the application areas are plasticized PVC products called flexible PVC. Additives added to polymers are intended to change polymer properties or to extend the life of the polymer. The use of plasticizers allows PVC to be used in the production of flexible products by lowering its glass transition temperature. Plastisol is obtained by combining PVC or various polymers and plasticizers.
PVC Plastisols, which we are the pioneer in the sector, production and R&D studies; It has a wide range of usage areas from the production of labels processed by micro injection method to metal coating applications with dip coating method.
WHAT IS PLASTISOL AND WHERE IS IT USED?
Plastisol is the general name for PVC or other polymer particles dispersed in plasticizers that come together to form a plastic film when heat treated. Plastisol coating is the process of plastisol coating of metal surfaces with different methods according to the needs of various sectors.
Plastisol is used in many different industries with different application and coating methods. Dip coating, dip molding and micro injection processing are the most common applications.
It has various application areas ranging from the automotive industry and the production of military equipment to the coating of children's play groups, from the textile industry to toys, from the coating of hand tools to gloves. The product, which can be easily applied to sheet metal surfaces and galvanized sheets, is also suitable for the marine environment.
Metal fences, outdoor sports equipment, lighting poles, handrails, battery cases; water, gas and oil pipes; fire extinguishers, etc. are among the other application areas of plastisols.
Reasons why plastisol is especially preferred for use on metal surfaces;
PLASTICYOL APPLICATIONS
The use of PVC plastisol in applications such as coating, molding, immersion and casting has increased dramatically because it is cost-effective; plastisol formulations can be varied to achieve the desired end results.
Parts to be coated must be chemically cleaned before coating. This is an important step to remove grease and dirt from the part.
PVC plastisol has acceptable adhesion to metal, but if more adhesion is desired, the metal should be primed. The primer can be applied by spraying, spraying or dipping. The cleaned metal surface is primed and dried, then heated to 180-200ºC. This step is necessary in case of changing the polymer system of the primer and hot dipping.
1- Dip coating
Hot dip coating is by far one of the most common plastisol processing techniques. Hand tools, children's play groups, outdoor furniture, ball valve handles are coated with dip coating. The part to be coated is dipped in plastisol and cured, this process is called dip coating. Adhesive primer may be required for the metal surface.
The primed and heated metal surface is dipped into the plasticizer. The immersion speed should be slow and uniform to avoid different film thicknesses and dripping. A thickness of up to 10 mm can be achieved in plastisol coating. The coating thickness depends on the mass of the part, the preheating temperature and the time the hot part remains in the immersion tank. The higher the temperature of the metal and/or the immersion time, the greater the thickness of the coating. Usually parts are dipped vertically, the dipping angle should be chosen to prevent dripping and air bubbles.
Then the curing process is necessary. When the curing step is completed, the part is plastisol coated.
We can explain the dip coating application with a very simple visual as follows. In dip coating applications, the dimensions of the pool to be immersed may also vary according to the material to be coated with plastisol.
Dip Coating, also known as dip coating, dip plating or metal surface coating, is among the benefits of the coating process;
- Resistance to peeling, cracking and chemicals,
- Long lasting color and gloss on the surface,
- In hardware products such as small hand tools, etc., the products look decorative and their grip is more ergonomic,
- Improving protection performance in environmental factors that require long term durability,
- Especially in metal surface coatings and in the coating of children's playgrounds, sharp parts are completely eliminated or minimized.
Cold dip coating does not require preheating of the metal part. The amount of plastisol taken up by the part is usually based on the plastisol ratio and viscosity. In the case of cold dip coating, the curing step is always necessary.
As Delta Kimya, we provide production in all main colors with our registered trademark PLASTO® in dip coating applications made with plastisol. Please contact our R&D department for different colors and shore (hardness) applications with smooth and texture surface options that can be customized for you.
2- Immersion Molding
It is the process of heating the mold and immersing it in plastisol. After the plastisol is cured, it is removed from the mold. Examples of this application are gloves, caps, handles and grips, anti-vibration parts.
3- Splash Coating
Splash coating is achieved by filling female molds with plastisol to produce hollow, flexible items and heating the plastisol layer sufficiently on the inner mold surface, the excess plastisols are then removed. Parts produced by splash coating are interior automotive parts, open parts such as rain boots, shoes, toys, etc.
4- Rotational Molding
Rotational molding is a process for producing parts of complex dimensions in flexible or rigid forms. Parts produced by rotational molding processes are usually closed parts such as game balls. Rotational molding is performed by inserting a predetermined weight of plastisol into a heated oven and then rotating it simultaneously on the mold wall on both sides.
5- Open Molding
Open coating refers to the direct molding of a finished material (such as car air filters). Plastisol at room temperature is poured into a mold at room temperature, cured and the final result is obtained. Car air filters and gaskets are obtained by open molding.
6- Casting Coating
Cast coating is a coating in which plastisol is applied as a substrate and undergoes several processes, either permanent or temporary. Typically cast coating techniques include knife and reverse folding technique.
Plastisol is poured onto a substrate. The substrate can be a temporary material such as paper or part of the product.
The coating thickness is controlled by the plastisol application rate. Once coated, the substance is melted and can be embossed if desired. Cast coating products are usually flat but may have some three-dimensional details. It is a method used for the production of artificial leather, conveyor belts and durable flooring, usually in roll form.
7- Hot Molding
Plastisols used in such applications have low viscosity, making them easy to flow and spill.
Plastisol is first heated and when it reaches the appropriate temperature, it is poured into the cold mold. When it cools down, it becomes a soft plastic and can be easily removed from the mold. It is used in the preparation of fish feeds and casting molding.
Physical Properties | |
| Viscosity | 100 cP to pasty |
| Gelation temperature | 60ºC – 93ºC |
| Curing temperature | 140ºC – 220ºC |
| Density | 0,5- 2 g/cm3 |
| Hardness | Shore A5 – D80 |
| Flammability | Self-extinguishing |
| Wear resistance | Excellent |
| Pulse resistance | Excellent |
Other features | |
| Color range | Unlimited |
| Adhesion property | Self-coupling available |
| Flare protection | Very good |
