Vinyl Coating

The heated particles produce liquid plastisol, which coats hot objects by dipping them into it. The appropriate thickness, from 1/16" to 1/4", can be obtained using multiple dips. As a result, the metal objects have a soft but durable polish after curing.

In spray coating, it must eliminate substrate flaws, and the substrate must be deburred before spraying. Otherwise, the final output carries these flaws. The liquid vinyl fills in such flaws with precision dip coating to provide a uniform surface. Throughout the three-step dip-coating procedure, a covering of vinyl plastisol develops.

Vinyl Dip Coating Process

Hot dip coating is a typical technique for applying a protective, adornment, or functional vinyl plastisol coating to various metal objects. Products like tool handles and playground equipment fall within the category of typical applications.

Precoating Process

Part Cleaning: Following procedures frequently used to prepare substrates for paint applications, parts to be plastisol coated should be chemically cleaned and phosphate or chromate treated. Substrates can also be vapor-degreased; however, there are better techniques than this. Greater adherence to the primer results from cleaning the substrates of impurities. The corrosion resistance of the metal substrate will also be improved by phosphate or chromate treatments, which will provide adhesion superior to that obtained on metal that has merely been cleaned. Additionally, cleaning the substrate reduces the risk of metal impurities "poisoning" the primer and plastisol liquids.

Part Priming: Vinyl plastisol doesn't adhere to metal very well and needs to be primed if adhesion is required. Primers can be sprayed using standard air spray equipment or dipped into a tank and applied. Primer dip tanks are typically fitted with a pump that redistributes or agitation equipment to reduce pigment separating small particles and sediments in water and stratification by solvent evaporation. Viscosity increases, brought on by the evaporation and adjusted with thinner, should be checked in primer tanks to maintain a constant solids level. In all areas where plastisol adhesion is needed, the prepared metal substrate is covered with primer, flash-dried, and baked until the surface metal temperature reaches between 350°F (177°C) and 400°F (204°C). This procedure prepares the item for the hot dipping procedure and converts the primer polymer system.

Coating Process

Immersion: The substrate is moved steadily and fully or partially submerged in the liquid vinyl tank to accomplish a smooth finish at this stage; it's crucial to maintain consistent speeds and calm, unruffled circumstances.

Dip Time: This relates to how long the coating is in contact with the substrate material. The substrate doesn't move while the liquid is allowed to gel, with plastisol fused to the object. Therefore, it's crucial to keep movement to a minimum during this phase to prevent uneven and erratic coating.

Removal: Removal is the last and, in many ways, the most crucial step. During the withdrawal stage, the object is slowly removed from the coating material and allowed to drain. Time your removal carefully because a thicker covering will develop from removing material more quickly.

Applications of Vinyl Coating

Everything from household improvement products to furniture and military equipment can benefit from hot-dip molding. Here are a few examples of commonplace items benefitting from vinyl dip coatings:

• Any metal exposed to the elements
• Electrical wire insulation
• Military equipment handles and hardware
• Tool handles and grips
• Automotive parts
• Cages for small animals that have surfaces that are resistant to chewing
• Wheelchair rims
• Picnic benches and tables
• Dishwasher racks
• Playground equipment
• Deep fryer baskets
• Outdoor furniture
• Hangers

Advantages of Vinyl Coating

• It's quick, flexible, and environmentally responsible.
• It coats various metal molds and substrates with a strong, long-lasting synthetic rubber covering.
• Due to the dipping technique, it is simple to coat objects of unusual shapes.
• It creates a barrier resistant to wear, corrosion, and abrasion.
• Vinyl plastisol is fire-retardant.

Disadvantages of Vinyl Coating

However, as with any coating, there are some drawbacks to be aware of, including:

• Once it has dried, it is challenging to remove, especially from cracks, corners, and edges.
• It can ruin the paintwork if you remove it after painting it.
• Specialized equipment and tools are needed for the process.
• It is simple to end up with an inconsistent coating thickness.