Ethan Clarke
Plastic coating is a versatile process used to enhance the appearance and functionality of various objects, from car parts to tools and appliances. The process involves applying a layer of liquefied plastic to an object by dipping or molding, creating a protective and durable coating. The most common technique is the hot dip method, where a mold is heated to a specific temperature, partially or fully dipped into a liquid polymer, and then cooled. This technique offers precise control over the coating thickness and internal dimensions of the object. The plastic coating improves safety, durability, strength, and protection from damage, abrasion, and corrosion.
| Characteristics | Values |
|---|---|
| Plastic coating techniques | Dip coating, spray coating, fluidized bed techniques, powder coating, wet coating, vacuum coating, thermal spraying, hot dipping, steam deposition, electrodeposition, flame spraying, cladding, hot-dip coating, electrodeposited coating, anodizing, porcelain enamel, conversion coating, conventional paints, lacquers, fusion-bonded plastic coatings, temporary protective materials, tribological polymer coatings, PVD coating, etc. |
| Plastic coating applications | Cable sheathing for electrical cables, cutlery baskets in dishwashers, car parts, safety equipment, tool handles, wire storage racks, etc. |
| Plastic coating advantages | Improved safety, enhanced durability, better strength, reduced noise and vibrations, protection from damage, abrasion, electrical current, impacts, corrosion, oxidation, and other environmental hazards, accurate internal dimensions, seamless and double-walled parts, limited restrictions on product size and design, flexibility in tooling modification, low operational and investment cost, minimal polymer wastage, etc. |
| Plastic coating use cases | Automotive industry, aerospace industry, metal, flooring, medical products, etc. |
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What You'll Learn
- Phosphating: Applying a thin phosphate layer before plastic coating for added corrosion resistance
- Shot peening: Striking a surface with round particles to strengthen it and relieve residual stress
- Blasting: Modifying the surface of the substrate by inducing microscopic holes for better adhesion
- Pre-treatment: Drying the mould to remove moisture and prevent bubble formation
- Dip coating: Dipping a heated mould into a liquid polymer to achieve precise internal dimensions
Phosphating: Applying a thin phosphate layer before plastic coating for added corrosion resistance
Plastic coating is a versatile process used to enhance the appearance and functionality of items such as car parts, tools, appliances, and safety equipment. The coating provides improved safety, durability, strength, and protection from damage, abrasion, corrosion, and other environmental hazards.
One important pre-treatment step before plastic coating is phosphating, also known as phosphate conversion. This process involves applying a thin layer of phosphate to the substrate before plastic coating. Common phosphate layers used in dip coating include zinc phosphate, iron phosphate, and tricationic phosphate.
Phosphating is an essential step as it provides additional corrosion resistance to the substrate. This is particularly useful in cases where damage to the plastic coating is inevitable. By applying a phosphate layer, the substrate gains enhanced protection against corrosion, ensuring the longevity of the coated item.
The process of phosphating typically involves preparing the phosphate solution and applying it to the substrate through dipping or spraying. The substrate is then dried to remove moisture, as retained moisture can cause expansion and result in void or bubble formation during the subsequent heating steps.
After phosphating, the substrate undergoes the plastic coating process. This typically involves dip coating or dip molding, where the substrate is partially or fully immersed into a liquid polymer. The polymer attaches to the surface of the substrate, forming a protective, decorative, or functional layer. The thickness of the plastic coating depends on various factors, including dwell time, temperature, and immersion rate.
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Shot peening: Striking a surface with round particles to strengthen it and relieve residual stress
Shot peening is a surface treatment technique that has been used in various industries since the 1940s. It is a cold working process where the surface of a metal object is bombarded with a stream of small, spherical particles called shots. These shots can be made of metal, glass, or ceramic, and they act as tiny, rounded hammers, striking the surface and creating dimples. This process introduces compressive residual stress on the surface of the metal, strengthening it and relieving any residual tensile stress.
The compressive residual stress in a metal alloy is produced by the transfer of kinetic energy from the moving shots to the metal surface, which plastically deforms under the impact. Shot peening can increase the fatigue life of a metal part by up to 1000%, making it highly effective in aircraft repairs to relieve tensile stresses built up during grinding. It also improves resistance to metal fatigue and certain types of stress corrosion. Additionally, shot peening can be used for cosmetic purposes, as the overlapping dimples scatter light upon reflection, creating a unique surface appearance.
The effectiveness of shot peening depends on several factors, including part geometry, part material, shot material, shot quality, shot intensity, and shot coverage. For example, using the same shot peening process on a hardened steel part and an unhardened part could result in over-peening the unhardened part, sharply decreasing its surface residual stresses. To mitigate this issue, a multi-stage post-process with varied shot diameters and other surface treatments can be employed to remove the low residual stress layer.
Double shot peening is a variation of the technique that involves performing two shot-peening operations at different intensities. The first operation uses high-intensity shots, followed by a second operation at a lower intensity. This method can further modify the surface topography and achieve higher surface compressive residual stress. Additionally, shot peening can be combined with other treatments, such as applying solid lubricants like molybdenum disulphide or biocompatible ceramics to biomedical implants.
Laser peening, or laser shot peening, is a recent development in the field. It offers a non-contact, media-free, and contamination-free peening method. Before treatment, the workpiece is covered with a protective ablative layer and a thin layer of water. High-intensity laser light beam pulses generate a plasma that creates a shock wave, which induces compressive residual stress beneath the surface of the workpiece, strengthening it and improving its fatigue life.
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Blasting: Modifying the surface of the substrate by inducing microscopic holes for better adhesion
Plastic coating is a process that involves applying a layer of liquefied plastic to an object through dipping or moulding. It is a versatile process used for protection, convenience, and decoration. The process increases the durability, strength, and corrosion and chemical resistance of the coated object.
One of the pre-treatment steps in the plastic coating process is blasting. Blasting modifies the surface of the substrate by creating microscopic holes, thereby increasing the surface area for the adhesion of the primer, undercoat, and plastic coating. This process improves the overall adhesion of the coating.
There are several blasting processes, including sand, metal grit, glass bead, and plastic bead blasting. The choice of blasting process depends on the specific requirements and characteristics of the substrate.
The blasting process involves creating controlled cracks or holes on the substrate's surface. This is achieved by using explosives and specific drilling patterns. The cracks or holes facilitate the formation of controlled pre-cracks, which help reduce vibrations and minimise "overbreak". Overbreak refers to the excessive cracking or breaking beyond the intended area, which can lead to inefficiencies and damage to adjacent structures.
By inducing microscopic holes, the blasting process enhances the mechanical interlocking between the substrate and the applied coating. This results in improved adhesion and compatibility, ensuring a stronger and more durable plastic coating. The blasting process is carefully controlled to create the desired pattern and density of holes, optimising the adhesion and overall performance of the plastic coating.
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Pre-treatment: Drying the mould to remove moisture and prevent bubble formation
Plastic coating is a process that involves applying a layer of liquefied plastic to an object through dipping or moulding. This process enhances the durability, insulation and protection of the object.
Before plastic coating, it is essential to perform a pre-treatment step to dry the mould and eliminate moisture. Retained moisture can cause expansion when heat is applied in subsequent steps, leading to voids or bubble formation. To prevent this, the mould must be thoroughly dried before proceeding with the plastic coating process.
The specific drying method employed depends on the plastic's properties, production batch size, and moulding conditions. Common techniques include hot air circulation drying, infrared heating drying, vacuum heating drying, fluidized bed drying, and air drying. For small batch productions, hot air circulation ovens and infrared heating are typically used. In contrast, mass-produced plastics are often dried through boiling and air drying. Certain plastics, like PA, which are sensitive to heat and prone to oxidation, should be dried in a vacuum oven to prevent discolouration.
The drying temperature and drying time are critical factors in the pre-treatment process. The mould must be heated uniformly to achieve consistent coating thickness. Higher temperatures expedite the evaporation of low molecules and water, but it is crucial not to exceed the softening temperature or melting point of the plastic to prevent softening. Once dried, the mould should be used immediately, as dried resin can reabsorb moisture over time, requiring re-drying before use.
By ensuring that the mould is thoroughly dried during the pre-treatment step, you can prevent bubble formation and achieve a consistent, high-quality plastic coating.
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Dip coating: Dipping a heated mould into a liquid polymer to achieve precise internal dimensions
Plastic coating is a versatile and effective method of protection that is used in a variety of applications, from tool handles to car parts. One of the most common techniques for plastic dip coating is the hot dip method, which involves dipping a heated mould into a liquid polymer. This process is known as dip coating or dip moulding.
To begin the dip coating process, the mould is heated in an oven to a specific temperature for a predetermined amount of time. The heating temperature and dwell time (the length of time the mould is submerged in the liquid polymer) are crucial factors in determining the coating thickness of the final part. The mould is then partially or fully immersed into the liquid polymer, allowing the polymer to adhere to its surface. The outer dimensions of the mould define the internal shape of the part.
The liquid polymer used in dip coating is typically plastisol, a vinyl compound that is liquid at room temperature and transforms into a solid, flexible material when heated. Plastisol is known for its durability, corrosion resistance, and impact strength, making it ideal for a variety of applications. It can also be coloured to achieve desired finishes.
Dip coating offers several advantages over other moulding methods. Firstly, it produces seamless, double-walled parts, increasing the durability of the final product. Secondly, it has limited restrictions on product size and design, and offers flexibility in tooling modification. Additionally, dip coating has low operational and investment costs and minimal polymer wastage.
However, one of the challenges of dip coating is achieving an exact coating thickness. This is because it depends on various factors, including dwell time, tooling temperature, immersion rate, withdrawal speed, and the properties of the polymer solution. These variables can also make it difficult to achieve a uniform coating thickness distribution.
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Frequently asked questions
Plastic coating is the application of liquid polymers or plastic on the surface of an object by dipping, molding, or spraying. It is used to enhance the appearance and functionality of the object, as well as provide protection.
The first step is to prepare the plastic coating material, typically a liquid polymer or vinyl/PVC-based plastisol. The mold is then heated in an oven to a specific temperature for a set duration. The heated mold is then partially or fully dipped or immersed into the liquid polymer, allowing the polymer to adhere to its surface. The mold is then removed from the liquid polymer and allowed to cool, resulting in a plastic coating.
Plastic coating offers several advantages, including improved safety, enhanced durability, better strength, reduced noise and vibrations, and protection from damage, abrasion, and corrosion, electrical current, impacts, and other environmental hazards. It also provides a decorative finish and can be applied to almost any surface.
Plastic coating is commonly used in the automotive industry, for example, in car parts and accessories. It is also used in tool handles, wire storage racks, safety equipment, and medical products. Plastic coating is versatile and can be applied to a wide range of products to enhance their functionality and appearance.
