Polymer Coating Formulation and Application Methods

Abstract

A plastisol formulation configured for use in coating substrates and a method for applying the formulation. The inventive formulation has exceptional flexibility over a wide range of temperatures. It is comprised of polyvinyl chloride, a plasticizer, a stabilizer, preferably a pigment, and a UV inhibitor/light stabilizer. The formulation is applied to a substrate and then cured by exposing it to an elevated temperature.

Having described our invention we claim: 
     
         1 . A method of applying a polymer formulation to a substrate, comprising:
 (a) providing a liquid plastisol including the following ingredients stated in terms of a percentage by mass,
 (i) between 10% and 50% polyvinyl chloride resins, 
 (ii) between 25% and 50% plasticizer, 
 (iii) between 2% and 30% stabilizer; 
   (b) precooling said liquid plastisol to a first temperature below −15 degrees centigrade;   (c) creating a gel sheet by applying a first partial curing cycle to said precooled liquid plastisol at a second temperature that is at least 61 degrees centigrade above said first temperature;   (d) applying an adhesive layer to said gel sheet;   (e) providing a substrate;   (f) pressing said adhesive layer against said substrate in order to bond said gel sheet to said substrate; and   (g) applying a second curing cycle at a third temperature that is greater than said second temperature in order to convert said gel sheet to a non-crystalline solid polymer that is adhered to said substrate.   
     
     
         2 . The method of applying a polymer formulation to a substrate as recited in  claim 1 , wherein said second curing cycle comprises heating said substrate before applying said gel sheet to said substrate. 
     
     
         3 . The method for applying a polymer formulation to a substrate as recited in  claim 2 , wherein said substrate is heated to a temperature that is greater than 138 degrees centigrade but less than 182 degrees centigrade. 
     
     
         4 . The method of applying a polymer formulation to a substrate as recited in  claim 1 , wherein said second curing cycle comprises heating said gel sheet after said gel sheet is applied to said substrate. 
     
     
         5 . The method of applying a polymer formulation to a substrate as recited in  claim 1 , further comprising:
 (a) providing a removable backing over said adhesive layer on said gel sheet; and   (b) removing said backing over said adhesive layer before pressing said adhesive layer against said substrate.   
     
     
         6 . The method of applying a polymer formulation to a substrate as recited in  claim 2 , further comprising:
 (a) providing a removable backing over said adhesive layer on said gel sheet; and   (b) removing said backing over said adhesive layer before pressing said adhesive layer against said substrate.   
     
     
         7 . The method of applying a polymer formulation to a substrate as recited in  claim 3 , further comprising:
 (a) providing a removable backing over said adhesive layer on said gel sheet; and   (b) removing said backing over said adhesive layer before pressing said adhesive layer against said substrate.   
     
     
         8 . A method of applying a polymer formulation to a substrate, comprising:
 (a) providing a liquid plastisol including the following ingredients stated in terms of a percentage by mass,
 (i) between 10% and 50% polyvinyl chloride resins, 
 (ii) between 25% and 50% plasticizer, 
 (iii) between 2% and 30% stabilizer; 
   (b) precooling said liquid plastisol to a first temperature below −15 degrees centigrade;   (c) creating a gel sheet by applying a first partial curing cycle to said precooled liquid plastisol;   (d) applying an adhesive layer to said gel sheet;   (e) providing a substrate;   (f) pressing said adhesive layer against said substrate in order to bond said gel sheet to said substrate; and   (g) applying a second curing cycle to said gel sheet while it is bonded to said substrate in order to convert said gel sheet to a non-crystalline solid polymer that is adhered to said substrate.   
     
     
         9 . The method of applying a polymer formulation to a substrate as recited in  claim 8 , wherein said second curing cycle comprises heating said substrate before applying said gel sheet to said substrate. 
     
     
         10 . The method for applying a polymer formulation to a substrate as recited in  claim 9 , wherein said substrate is heated to a temperature that is greater than 138 degrees centigrade but less than 182 degrees centigrade. 
     
     
         11 . The method of applying a polymer formulation to a substrate as recited in  claim 8 , wherein said second curing cycle comprises heating said gel sheet after said gel sheet is applied to said substrate. 
     
     
         12 . The method of applying a polymer formulation to a substrate as recited in  claim 8 , further comprising:
 (a) providing a removable backing over said adhesive layer on said gel sheet; and   (b) removing said backing over said adhesive layer before pressing said adhesive layer against said substrate.   
     
     
         13 . The method of applying a polymer formulation to a substrate as recited in  claim 9 , further comprising:
 (a) providing a removable backing over said adhesive layer on said gel sheet; and   (b) removing said backing over said adhesive layer before pressing said adhesive layer against said substrate.   
     
     
         14 . The method of applying a polymer formulation to a substrate as recited in  claim 10 , further comprising:
 (a) providing a removable backing over said adhesive layer on said gel sheet; and   (b) removing said backing over said adhesive layer before pressing said adhesive layer against said substrate.   
     
     
         15 . A method of applying a polymer formulation to a substrate, comprising:
 (a) providing a liquid plastisol including the following ingredients stated in terms of a percentage by mass,
 (i) between 10% and 50% polyvinyl chloride resins, 
 (ii) between 25% and 50% plasticizer, 
 (iii) between 2% and 30% stabilizer; 
   (b) precooling said liquid plastisol to a first temperature below −15 degrees centigrade;   (c) creating a gel by applying a first partial curing cycle to said precooled liquid plastisol;   (d) forming said gel into a desired shape;   (e) providing a substrate;   (f) bonding said gel in said desired shape to said substrate; and   (g) applying a second curing cycle to said gel while it is bonded to said substrate in order to convert said gel to a non-crystalline solid polymer that is adhered to said substrate.   
     
     
         16 . The method of applying a polymer formulation to a substrate as recited in  claim 15 , wherein said second curing cycle comprises heating said substrate before applying said gel to said substrate. 
     
     
         17 . The method for applying a polymer formulation to a substrate as recited in  claim 16 , wherein said substrate is heated to a temperature that is greater than 138 degrees centigrade but less than 182 degrees centigrade. 
     
     
         18 . The method of applying a polymer formulation to a substrate as recited in  claim 15 , wherein said second curing cycle comprises heating said gel after said gel is applied to said substrate. 
     
     
         19 . The method of applying a polymer formulation to a substrate as recited in  claim 15 , further comprising:
 (a) providing an adhesive layer on said gel; and   (b) using said adhesive layer to bond said gel to said substrate.   
     
     
         20 . The method of applying a polymer formulation to a substrate as recited in  claim 19 , further comprising:
 (a) providing a removable backing over said adhesive layer on said gel sheet; and   (b) removing said backing over said adhesive layer before pressing said adhesive layer against said substrate.