Additi S t f Pl ti l &Additive Systems for Plastisols & Flexible PVC applicationsFlexible PVC applications

Global Solution ProvidersGlobal Solution Providers

Patcham (FZC)

ContentsContents

• Plastisol ‐ Introduction

Pl i l M f i• Plastisol Manufacturing process

• Additives in PVC Plastisols• Additives in PVC Plastisols

Wetting & Dispersing AgentsWetting & Dispersing Agents

DeaeratorsDeaerators

Patcham Laboratory (Headquarters)

PVC PlastisolPVC Plastisol

• PVC PlastisolPVC Plastisol are liquid dispersion systems ofPVC Plastisol are liquid dispersion systems of polyvinyl chloride and PVC copolymer resin in compatible plasticizerscompatible plasticizers. 

• Main IngredientsPVC Resin FillersPl ti i H t St biliPlasticizers Heat StabilizersAdditives Solvents

Plastisol Manufacturing ProcessPlastisol Manufacturing ProcessAdd 3 t f li id t th i d th t t• Add  3 quarters of liquids to the mixer  and then start agitator.

• Add solids in order from fillers blendingAdd solids in order from fillers, blending resins, Dispersion resins and other dry ingredients.

• Mix until creamy smooth paste has been reached  y p&temperature not above 35⁰C.

• Add all balance paste materials and liquids with some additional mixingadditional mixing.

• Deareation usually required, except foam applications.• Total time depends on formula volume and• Total  time depends on formula, volume and equipment.

Problems and Issues Related to PlastisolProblems and Issues Related to Plastisol

Rh lRaw Materials RheologyFactors Application

• Long Dispersion Time

• Pigment Streaks/

• High viscosity• Poor air release due to

• Pinholes • Air entrapment• Shade Variations• Pigment Streaks/ 

Incomplete Wetting

due to pseudoplasticrheology

• Shade Variations• Low production yieldg

• Flooding and floating of       

gy y

colorants• Storage stability

Additives in PlastisolAdditives in Plastisol

• Pigment Wetting and Dispersing AgentsPat Add DA 815Pat‐Add DA 815 Pat‐Add DA 948Pat‐Add DA 2025

• DeaeratorsP t Add AF 5103Pat‐Add AF 5103

Pigment wetting and dispersion processPigment wetting and dispersion processThe dispersing of solid pigments into the liquid phase of p g p g q pa plasticiser is an important step in plastisol processing.

Proper dispersion influences several parameters like • color / ‐strengthcolor /  strength • flooding / floating• viscosityviscosity

Pigment Wetting And DispersionPrimary ParticlesAgglomerated/flocculated

Dispersion

Pigment Wetting And Dispersiongg /

particles

1 particle >100 000 particles1 particle >100 000 particles

De flocculated Primary particlesPi t d De‐flocculated  Primary particlesPigment powder

Pigment WettingAchieving optimal PerformancesPigment dispersion process ‐Wettingg g

Dispersing mediumPigment powder:agglomerated particles

g p p g

agglomerated particles

Add d h li id di

Entrapped air

Added to the liquid medium:apparent pigment volume 

fraction consisting of

Pigment agglomerates1. Adsorbed and entrapped air2. (Adsorbed water)

Poor wetting means:• high apparent solids volume fraction 

( )3. Pigment  

g pp• low pigment solids • high viscosity• low milling efficiency

Pigment dispersion process ‐WettingDuring the wetting step, air and moisture occurring on the pigment surface are driven off and replaced by the liquid  

Wetting agentsParticle covered with wetting agent

p g f ff p y q

wetting agent

AgglomeratesEntrapped air

Dispersing mediumEntrapped air

Good wetting (adjusting Surface Tension liquid phase, through wetting agent): enabling high pigment solids  low viscosity hi h millin effi ien high milling efficiency

Pigment dispersion processDe‐agglomeration:

During this step, the pigment agglomerates are broken up by energy input and accordingly reduced in size. 

This mechanical separation can be achieved by dissolvers or different This mechanical separation can be achieved by dissolvers or different types of mills ‘Grinding’. The amount and the duration of the energy input are the main factors for a complete separation of primary pigment particles

BreakdownBreakdown

(Energy input)

Pigment dispersion process

Stabilization:Stabilization:

– Whatever the actual size ofh i i l ithe pigment particles in agrinding medium, thesmaller they are thegreater is their tendency togreater is their tendency tointeract.

– Once the pigment particleshave been optimallyp ydispersed, they must bestabilized. By adding thedispersant on the pigmentsurfaces attractive forcessurfaces, attractive forcesbetween the pigmentsurfaces can be neutralized. Sterical stabilisation

HMV  Wetting and Dispersion g pProcess

ΔDa 

Thickness adsorption layer preventing agglomeration … 

Pat Add DA 815

l i l f i d

Pat‐Add DA 815

• A multi‐purpose solvent‐free wetting and dispersing additive 

• Its electro neutral composition enables to stabilize organic and inorganic g gpigments, particularly carbon blacks.

• Particularly suitable for the production of PVCParticularly suitable for the production of PVC Colorants/ Color Master paste for PVC.P d N t i b h i f th t i l• Produce a Newtonian behavior of the material by reducing viscosity.  

Pat Add DA 815Guide Formulation of Pat‐Add DA 815 for Color Master Paste

Pat‐Add DA 815

Raw Yellow Iron  Phthalo Carmine Materials Oxide Blue RedCI Number PY 42 PB 15:3 PR 122

DOP 33 0 64 0 64 0DOP 33.0 64.0 64.0Pat‐Add DA 815 2.0 14.0 14.0Pigment 65 0 22 0 22 0Pigment 65.0 22.0 22.0Total 100.0 100.0 100.0SOP 3.0% 63.64% 63.64%

Pat Add DA 815Pat‐Add DA 815

Phthalo Blue Yellow Iron Oxide Carmine Red

Pat‐Add DA 948HMVP Dispersing agent

i h l l l 100% i• High Molar Volume polymer, 100% active dispersing agent

• Specially designed for use in EP‐ and PUR floorings, systems based on polyols, UPR (unsaturated polyester) or thermoplastics, such as used in, PUR foams, plastisols and gel coats 

• Pigment concentrates results in low viscosity, enabling higher pigment loadings, at optimal pigment dispersion.

• FDA 21 CFR 175.300 approved (US FDA)pp

Pat‐Add DA 948HMVP Dispersing agent

Raw White

Color Master Paste Guide Formulation 

RawMaterials

WhiteTR‐902

SP.Black 4 PB 15:4 PR 112 PY 83

DOP 23.20 55.00 55.00 60.00 65.00

Additive 1.80 10.00 7.50 6.00 4.00

Pigment 75.00 30.00 30.00 30.00 20.00

DOP 0.00 5.00 7.50 4.00 11.00

Total 100.00 100.00 100.00 100.00 100.00

% SOP 2.40 33.30 25.00 20.00 20.00

Pat‐Add DA 948HMVP Dispersing agent

Color Master Paste

Pat‐Add DA 948HMVP Dispersing agent

Color Master Paste

Viscosity after one week stability at Room Temperature

21041950 1980

Viscosity after one week stability at Room TemperaturePat‐Add DA 948 Reference

1428 14931840

16921440

1950 19801751 1841

TiO2  Special Black 4 PB 15 : 4 PY 83 PR 112

Pat Add DA 2025Pat‐Add DA 2025

i h f i d di i• High performance wetting and dispersing agent

• Outstanding dispersion and stabilization of blowing agents such as ADC and Zinc g gOxide, TiO2 and fillers

• Better cell structure and uniform distributionBetter cell structure and uniform distribution of blowing agent in Plastisol matrixL i it f ADC t d th• Low viscosity of ADC paste and thus easy handling and reduction in loss. 

Pat Add DA 2025Pat‐Add DA 2025Dispersion of ADC Powder

RawMaterials Parts by weightRaw Materials Parts by weightDOP 50.00

ADC POWDER 50.00

ddPat‐Add DA 2025 0.25

Total  100.25

Pat Add DA 2025Pat‐Add DA 2025Performance as Viscosity Depressant

13013000

Viscosity Depressant Profile

110

120

11000

12000

oading

cps

RawMaterials Blank Trial 1 Trial 2 Trial 3

E‐PVC 100.00 100.00 100.00 100.00

Stabilizer 2 00 2 00 2 00 2 00

90

100

8000

9000

10000

% Filler Lo

Viscosity, c

Stabilizer 2.00 2.00 2.00 2.00

DOP 75.00 75.00 75.00 75.00

Pat‐AddDA 2025 0 1.00 1.75 2.25

70

80

6000

7000

8000Filler 75.00 75.00 100.00 125.00

FormulationDetail

1%phr Additive

1.75%phr Additive,        100%filler

2.25%phr Additive,        125% filler

0.00 1.00 1.75 2.25phr Pat‐Add DA 2025

Viscosity Filler Loading

Pat Add AF 5103Pat‐Add AF 5103

• Green Chemistry air releasing and de‐airingGreen Chemistry air releasing and de airing agent for use in PVC plastisol. f d i f d i• faster and consistent foam destruction including microform.

Pat Add AF 5103

K b fit

Pat‐Add AF 5103

Key benefits• Remove entrapped air during plastisolduring plastisolpreparations

• Avoid surface defects• Avoid surface defects like pin holes

• Attain smooth finish• Attain smooth finish• Work with higher volumes more easilyvolumes more easily

• No adverse effect in foamed applicationsfoamed applications

Pat‐Add AF 5103Pat Add AF 5103Performance as Deaerator

1 6Blank Pat‐Add AF 5103

11.21.41.6

0.60.81

Air T

rap

00.20.4%A

‐0.4‐0.2

0

On mixing After 48 hours

Disclaimer

While every effort is made to provide accurate and complete informationWhile every effort is made to provide accurate and complete information on The PATCHAM ADDITIVES, various data may vary depending upon different raw materials, formulations, test procedures and test conditions. 

The accuracy, reliability, or totality of the information are not guaranteed or warranted in any way. The PATCHAM FZC and its representatives di l i li bilit f ki d h t i l di li bilit f litdisclaim liability of any kind whatsoever, including liability for quality, performance and fitness for a particular purpose arising out of the use, or inability to use the information.

Thank you!Thank you!