EMULSION PVC

Emulsion PVC is a fine-particle polyvinyl chloride resin produced exclusively by emulsion polymerization of vinyl chloride monomer (VCM) in the presence of water-soluble initiators and surfactants (soaps or emulsifiers), yielding solid, smooth-surfaced spherical primary particles of 0.1–2 µm diameter that are clustered into irregularly shaped aggregates with a mean particle size of 40–50 µm and a range of 0.1–100 µm, fundamentally distinguishing Emulsion PVC from suspension PVC (S-PVC) which has a coarser, porous particle structure of 50–250 µm.
Emulsion PVC is the preferred PVC resin grade for plastisol, organosol, and paste dispersion applications because its fine, smooth-surfaced primary particles disperse readily in plasticizers to form stable, low-viscosity pastes with controlled rheology that can be processed by coating, spreading, knife-over-roll, reverse roll, rotary screen, dipping, slush molding, rotational molding, and spray application methods, making Emulsion PVC indispensable for the production of artificial leather, flooring, wallcovering, coated fabrics, gloves, automotive undersealing, foam products, and carpet backing.
Emulsion PVC is also used in latex form (directly as the aqueous dispersion after polymerization, before spray drying) for paper and textile coating and impregnation applications, and as a blending resin (extender resin) combined with paste resin to optimize plastisol viscosity and cost, and it is the only PVC grade capable of forming stable plastisols with plasticizer content below 40–50 PHR that remain processable with low initial viscosity over extended storage.

CAS Number: 9002-86-2
EC Number: 618-338-8
Molecular Formula: (C₂H₃Cl)n
Molecular Weight: Variable (typically 50,000–200,000 g/mol; characterized by K-value or inherent viscosity)

Synonyms: Emulsion PVC, E-PVC, PVC Paste Resin, PVC Dispersion Resin, PVC Plastisol Resin, Poly(vinyl chloride) Emulsion Grade, Polyvinyl Chloride Paste Grade, Vinyl Chloride Polymer Emulsion Grade, PVC E-Type, PVC Latex, Paste PVC, Vinyl Paste Resin, Dispersion Grade PVC, CAS 9002-86-2

Emulsion PVC is produced by emulsion polymerization in which vinyl chloride monomer is dispersed in water with the aid of surfactants (soaps); the monomer is trapped inside soap micelles and polymerization takes place using water-soluble initiators such as persulfates, producing solid spherical primary particles whose surface character and particle size distribution are determined by the emulsifier type and concentration, initiator system, temperature, pressure, and seed polymerization technique employed.
Emulsion PVC primary particles (0.1–2 µm) produced during polymerization are spray-dried to produce the commercial paste resin powder; the resulting aggregate structure (40–50 µm mean) retains the fine primary particle size which is responsible for the unique paste-forming behavior of Emulsion PVC — when mixed with plasticizer, the aggregates break down into primary particles that are wetted and surrounded by plasticizer to form a stable, flowable paste.

Emulsion PVC is characterized primarily by its K-value (Fikentscher) or inherent viscosity which reflects molecular weight and determines physical properties of the final product; commercial Emulsion PVC grades range from K-60 to K-80, with lower K-values giving lower melt viscosity, higher flow, and lower mechanical properties, and higher K-values giving higher tensile strength, elongation, and heat resistance in the cured product.
Emulsion PVC is a thermoplastic resin with no cross-linking in the base polymer; in plastisol form it is fused (gelled) by heating to 160–200°C, at which point the plasticizer is absorbed into the swollen PVC particles and the particles fuse into a continuous, flexible, and tough film or molded part whose properties are determined by the PVC K-value, plasticizer type and level, and stabilizer and other additive package.

Uses of Emulsion PVC:
Emulsion PVC is used as the primary resin in plastisol formulations for the production of coated fabrics and artificial leather for upholstery, automotive interiors, fashion accessories, luggage, shoes, and clothing; the plastisol is spread onto a substrate fabric by knife-over-roll, reverse roll, or rotary screen coating and fused by passing through an oven at 160–200°C to produce a durable, flexible, aesthetically finished synthetic leather surface.
Emulsion PVC is used in floor covering production including cushion vinyl flooring, homogeneous vinyl tiles, vinyl composition tiles, and luxury vinyl tiles (LVT), where plastisol is applied as a foam layer (by chemical or mechanical foaming with azodicarbonamide or nitrogen injection), a wear layer, or a print layer, and fused by calendering or oven fusion to produce the multilayer floor covering structure.

Emulsion PVC is used for the production of PVC gloves for medical examination, food handling, industrial protection, and household use by the dip coating process, in which fabric or ceramic formers are dipped repeatedly into Emulsion PVC plastisol, gelled at each dip step, and finally fused to produce a seamless, form-fitting, flexible glove with uniform wall thickness and excellent barrier properties.
Emulsion PVC is used for automotive underbody coating (car underbeal, also called stone chip protection or underbody sealant) applied by spray or extrusion to the underbody and wheel arches of vehicles in automotive OEM manufacturing, providing excellent stone chip resistance, sound deadening, and corrosion protection through the flexible, adhered PVC film.

Emulsion PVC is used for wallcovering and decorative wall panels by coating onto paper, non-woven, or fabric substrates and fusing to produce durable, washable, and aesthetically versatile wall decoration products with embossed textures and printed patterns.
Emulsion PVC is used for carpet backing where Emulsion PVC plastisol is applied to the reverse of tufted or woven carpet as the primary and secondary backing layer, providing dimensional stability, tuft lock, and comfort underfoot properties.

Emulsion PVC is used in the production of dipped goods including toys, tool handles, wire forms, industrial parts, and automotive components by the slush molding or rotational molding processes, where the mold is filled with plastisol, excess drained, and the coated mold heated to fuse the PVC layer to the desired thickness.
Emulsion PVC is used for PVC foam sheet and foam layer production in wallcovering, floor covering, shoe soles, and packaging by blending Emulsion PVC plastisol with a chemical blowing agent and fusing/foaming in an oven or on a calendar to produce a lightweight, cushioned, textured cellular structure.

Emulsion PVC is used for paper and textile impregnation and coating in the latex form (before spray drying), providing barrier properties, printability improvement, stiffness or softness modification, and flame retardancy to treated paper and textile substrates.
Emulsion PVC is used in the formulation of sealants, caulks, and gaskets for automotive, construction, and industrial applications where the paste consistency of Emulsion PVC plastisols allows easy application by extrusion or injection before fusion by heat or UV.

Emulsion PVC is used for toy production (inflatable toys, bath toys, squeeze toys, educational manipulatives) by slush or rotational molding of food-grade or phthalate-free Emulsion PVC plastisols compliant with EN 71-3, REACH, and CPSC regulations.
Emulsion PVC is used for the production of medical devices and healthcare products including blood bags, IV bags, tubing, catheters, and examination gloves using DEHP-plasticized or alternative-plasticized Emulsion PVC formulations meeting ISO 10993 biocompatibility requirements.

Emulsion PVC is also used as a blending (extender) resin in combination with paste resin to optimize the viscosity and cost of plastisol formulations; extender grades of Emulsion PVC have a coarser particle size (up to 100 µm) and are used at 10–30% of total PVC content to increase plastisol viscosity control and reduce raw material cost.
Emulsion PVC is used in the production of rotational molded products including playground equipment, kayaks, furniture, and industrial containers, where free-flowing Emulsion PVC powder grades with controlled particle size and flow properties are used to coat the inside of rotating molds before fusion.

Benefits or Advantages of Emulsion PVC:
Emulsion PVC is the only PVC grade capable of forming stable plastisol dispersions in plasticizers with a low initial viscosity, controlled viscosity development over time, and the ability to be processed by spreading, coating, dipping, slush molding, and spray application methods that are not possible with suspension or bulk PVC grades.
Emulsion PVC provides exceptional formulation versatility — by varying plasticizer type and level (typically 40–100 PHR), stabilizer system, filler, pigment, blowing agent, and processing conditions, a very wide range of physical properties from soft and flexible (Shore A 30–50) to semi-rigid (Shore A 90+) can be achieved in the fused product.

Emulsion PVC has excellent chemical resistance to acids, alkalis, alcohols, oils, and many organic solvents in the fused state, inherent flame retardancy due to its high chlorine content (56.7% Cl by weight), and good electrical insulating properties, making it suitable for demanding protective, electrical, and industrial applications.
Emulsion PVC is inherently flame retardant without the need for additional halogenated flame retardant additives, complying with various building and automotive fire standards when formulated with appropriate stabilizer and plasticizer systems.

Emulsion PVC is compatible with a very wide range of plasticizers (phthalates, adipates, trimellitates, citrates, bio-based plasticizers, polymeric plasticizers), stabilizers (Ca/Zn, Ba/Zn, tin, liquid mixed-metal systems), fillers (calcium carbonate, kaolin), pigments, and functional additives, providing exceptional formulation flexibility to meet diverse performance, regulatory, and cost requirements.
Emulsion PVC is produced in a wide range of K-values and particle size distributions by established global producers including Vinnolit (Germany), Vestolit (Germany), Mexichem (now Orbia), Shin-Etsu (Japan), Formosa Plastics, and Chinese producers, ensuring reliable global supply across diverse grades and application requirements.

Features of Emulsion PVC:
Emulsion PVC is a white, free-flowing powder with a characteristic PVC odor, density of approximately 1.40–1.44 g/cm³, bulk density of approximately 0.30–0.60 g/cm³ (lower than S-PVC due to its fine, light aggregate structure), particle size distribution of 0.1–100 µm (mean 40–50 µm), and primary particle size of 0.1–2 µm.
Emulsion PVC is insoluble in water, insoluble in ethanol and most aliphatic solvents, swollen or dissolved by ketones (MEK, cyclohexanone), esters (ethyl acetate, butyl acetate), and chlorinated solvents (THF, DCM), and fully dispersible in plasticizers at room temperature to form stable plastisol pastes with viscosities of typically 500–50,000 mPa·s depending on formulation.

Emulsion PVC has a glass transition temperature (Tg) of approximately 82°C for unplasticized PVC, which decreases progressively with increasing plasticizer content to below 0°C for highly plasticized flexible formulations; the fused plastisol has excellent elongation at break (100–400%), good tensile strength (5–25 MPa), and good tear resistance depending on formulation.
Emulsion PVC is thermally sensitive and requires heat stabilizers (organotin, Ca/Zn, Ba/Zn, or mixed-metal liquid systems) during processing to prevent thermal dehydrochlorination (HCl evolution) and discoloration; processing temperatures are typically 160–200°C for fusion, with degradation risk increasing above 200°C.

Chemical Properties of Emulsion PVC:
Emulsion PVC is a homopolymer of vinyl chloride (chloroethylene) with the repeat unit –[CH₂–CHCl]n–, molecular formula (C₂H₃Cl)n, containing 56.7% chlorine by weight, with an atactic (irregular) microstructure that prevents crystallization and gives the amorphous polymer its thermoplastic, softening behavior above the glass transition temperature.
Emulsion PVC undergoes thermal dehydrochlorination (elimination of HCl) above approximately 100–120°C without adequate heat stabilizer, producing polyene sequences that cause yellow-to-brown discoloration and, ultimately, carbon formation; this reaction is autocatalytic, accelerated by HCl, residual catalyst metals, UV radiation, and mechanical shear, requiring careful stabilizer selection.

Emulsion PVC is incompatible with strong oxidizing agents and is attacked by concentrated acids and certain organic solvents (ketones, cyclic ethers, aromatic hydrocarbons) in the non-fused state; in the fused state it has excellent resistance to dilute acids, alkalis, alcohols, aliphatic hydrocarbons, and many aqueous environments.
Emulsion PVC combustion products include hydrogen chloride (HCl) gas (toxic, corrosive), carbon monoxide, carbon dioxide, water, and soot; the HCl evolution during fire conditions is the primary hazard associated with burning PVC, requiring respiratory protection during firefighting.

Production of Emulsion PVC:
Emulsion PVC is produced by emulsion polymerization in which vinyl chloride monomer is dispersed in water using surfactants (sodium lauryl sulfate, sodium dodecylbenzene sulfonate, fatty acid soaps, or non-ionic emulsifiers) and polymerized with water-soluble initiators (potassium persulfate, ammonium persulfate, or redox systems) at 40–60°C under pressure (6–12 bar) in a pressure reactor equipped with jacket cooling and agitation.
Emulsion PVC polymerization uses emulsifier concentrations of 0.5–3.0% on monomer weight, with the emulsifier type, concentration, and addition profile (batch, incremental, or continuous) controlling particle nucleation, growth, and final particle size distribution; seed polymerization techniques using pre-formed latex seeds are used to produce bimodal or multimodal particle size distributions that optimize plastisol viscosity behavior.

Emulsion PVC latex is recovered after polymerization (conversion typically 85–95%) by stripping residual vinyl chloride monomer, and is then spray-dried to produce the commercial powder; spray drying conditions (inlet temperature 150–200°C, outlet temperature 50–80°C) are carefully controlled to produce the target aggregate particle size and morphology while preserving thermal stability.
Emulsion PVC quality is characterized by K-value (DIN 53726, ISO 1628-2), inherent viscosity, particle size distribution (laser diffraction), whiteness, plastisol viscosity (Brookfield, ICI cone-and-plate), gel temperature, and thermal stability (Congo Red test, pH evolution), with major commercial grades ranging from K-60 to K-80 for standard paste applications.

Material Safety Data Sheet (MSDS) of Emulsion PVC:

Handling of Emulsion PVC:
Emulsion PVC should be handled in accordance with good industrial hygiene practices and in compliance with the applicable Safety Data Sheet; in powder form, the primary hazard is inhalation of dust, which should be controlled by local exhaust ventilation or appropriate respiratory protection.
Emulsion PVC plastisol formulations containing plasticizers, stabilizers, and other additives may carry additional hazards depending on the specific additives present; the SDS of the specific formulation, not just the base resin, should always be consulted prior to handling.

SDS of Emulsion PVC:

Stability and Reactivity of Emulsion PVC:

Chemical stability:
Emulsion PVC resin powder is stable under recommended storage conditions below 40°C in original sealed bags away from heat and direct sunlight.
Emulsion PVC is thermally sensitive above 100°C without heat stabilizer; do not expose to elevated temperatures during storage.

Reactivity:
Emulsion PVC reacts with strong oxidizing agents and may slowly dehydrochlorinate under prolonged elevated temperature exposure, releasing HCl.
Combustion produces HCl, CO, CO₂, and soot.

Conditions to avoid:
Temperatures above 40°C during storage (accelerates thermal degradation risk).
Direct sunlight and UV radiation.
Ignition sources (combustible dust).
Contact with strong oxidizing agents.
Moisture (may cause caking or agglomeration of powder).

Incompatible materials:
Strong oxidizing agents.
Strong acids and strong alkalis in concentrated form.
Organic solvents that swell or dissolve PVC (ketones, THF, chlorinated solvents).

Hazardous decomposition products:
Hydrogen chloride (HCl) — toxic, corrosive.
Carbon monoxide (CO).
Carbon dioxide (CO2).
Soot and carbon residues.

Handling and Storage of Emulsion PVC:

Handling:
Handle in accordance with good industrial hygiene practices.
Avoid inhalation of powder dust; use adequate local exhaust ventilation.
Wear dust mask or respirator where dust generation cannot be controlled.
Avoid skin and eye contact with powder.
Wash hands after handling.
Keep away from ignition sources; powder may form combustible dust clouds.

Storage:
Store in original sealed bags in a cool, dry, well-ventilated area at 5–40°C.
Protect from direct sunlight, heat, and moisture.
Store away from strong oxidizing agents and incompatible materials.
Shelf life: typically 12–24 months in original sealed packaging under recommended storage conditions.

First Aid Measures of Emulsion PVC:

Inhalation:
Move affected person to fresh air.
If dust causes respiratory irritation or coughing, seek medical advice.

Skin contact:
Wash affected skin with soap and water.
Emulsion PVC powder is not expected to cause skin irritation under normal handling.

Eye contact:
Rinse immediately with plenty of clean water for at least 15 minutes.
Seek medical attention if irritation persists.

Ingestion:
Emulsion PVC is not expected to be hazardous when ingested in small quantities; it is biologically inert and passes through the gastrointestinal tract without significant absorption.
Rinse mouth with water; seek medical advice if large amounts are ingested.

Firefighting Measures of Emulsion PVC:

Suitable extinguishing media:
Water spray, foam, dry chemical powder, or carbon dioxide.

Specific hazards:
Emulsion PVC is combustible in powder or film form; it does not readily ignite due to its high chlorine content but will sustain combustion with an external heat source.
Combustion of Emulsion PVC produces hydrogen chloride (HCl) gas, carbon monoxide, soot, and potentially dioxins and furans at high temperatures; HCl is the primary fire hazard.

Protective equipment for firefighters:
Wear self-contained breathing apparatus (SCBA) and full chemical protective clothing due to HCl evolution.

Firefighting instructions:
Cool exposed containers and storage areas with water spray.
Prevent contaminated firefighting water from entering drains or waterways.
Evacuate the area due to HCl gas evolution.

Accidental Release Measures of Emulsion PVC:

Personal precautions:
Avoid inhalation of dust; wear appropriate respiratory protection.
Wet spilled powder creates a slipping hazard; powder can create combustible dust clouds.

Environmental precautions:
Prevent Emulsion PVC from entering waterways or drains; PVC is not biodegradable.

Methods for cleaning up:
Sweep or vacuum dry spilled powder carefully into labeled waste containers; avoid generating dust clouds.
Dispose according to local regulations; PVC waste may be recyclable.

Exposure Controls / Personal Protective Equipment of Emulsion PVC:

Engineering controls:
Provide local exhaust ventilation where dust is generated during transfer, weighing, or mixing.
TLV (ACGIH): 10 mg/m³ (inhalable), 3 mg/m³ (respirable); PEL (OSHA): 15 mg/m³ (inhalable), 5 mg/m³ (respirable).

Eye protection:
Wear safety glasses or goggles where dust generation is possible.

Hand protection:
Gloves recommended to prevent skin contact with powder.

Respiratory protection:
Wear a certified particulate respirator (N95 or FFP2) where dust levels exceed the TLV.

Hygiene measures:
Wash hands after handling Emulsion PVC and before eating, drinking, or smoking.

Identifiers of Emulsion PVC:
CAS Number: 9002-86-2
EC Number: 618-338-8
ECHA InfoCard: 100.120.191
IUPAC Name: Poly(1-chloroethylene); Poly(vinyl chloride)
Molecular Formula: (C₂H₃Cl)n
Chlorine content: 56.7% by weight (theoretical)
Glass transition temperature (Tg): ~82°C (unplasticized)
Density: ~1.40–1.44 g/cm³
GHS Classification: Not classified as hazardous (base resin); formulated plastisols may carry additional hazards
TLV (ACGIH): 10 mg/m³ (inhalable), 3 mg/m³ (respirable)
PEL (OSHA): 15 mg/m³ (inhalable), 5 mg/m³ (respirable)
NFPA 704: Health 1 / Flammability 1 / Reactivity 0
Key quality parameters: K-value (DIN 53726/ISO 1628-2), particle size distribution, plastisol viscosity, gel temperature, whiteness

Properties of Emulsion PVC:
Physical state: Solid (white free-flowing powder)
Appearance: White, fine, free-flowing powder
Odor: Characteristic mild PVC odor
Density: ~1.40–1.44 g/cm³
Bulk density: ~0.30–0.60 g/cm³
Primary particle size: 0.1–2 µm
Aggregate particle size: 40–50 µm mean (0.1–100 µm range)
Glass transition temperature (Tg): ~82°C (unplasticized)
Molecular weight: 50,000–200,000 g/mol (K-value 60–80)
Chlorine content: 56.7% by weight
Solubility in water: Insoluble
Solubility in plasticizers: Dispersible at room temperature; fuses on heating to 160–200°C
Plastisol viscosity range: 500–50,000 mPa·s (depending on formulation)
Fusion temperature: 160–200°C
Thermal degradation onset: ~100°C (without stabilizer); >160°C (with adequate stabilizer)
GHS Classification: Not classified (base resin)
NFPA: 1-1-0

Specifications of Emulsion PVC:
Product name: Emulsion PVC (E-PVC Paste Resin)
CAS Number: 9002-86-2
EC Number: 618-338-8
Molecular Formula: (C₂H₃Cl)n
K-value range: K-60 to K-80 (grade-dependent)
Primary particle size: 0.1–2 µm
Mean aggregate particle size: ~40–50 µm
Bulk density: 0.30–0.60 g/cm³
Whiteness (R457): ≥85%
Residual VCM: ≤1 ppm (food contact grades); ≤10 ppm (standard grades)
Moisture content: ≤0.3%
Thermal stability (Congo Red): ≥60 min (grade-dependent)
Gel temperature: 150–180°C (grade-dependent)
Plastisol viscosity (Brookfield, 23°C): Grade-specific (500–50,000 mPa·s)
Storage temperature: 5–40°C; dry; sealed bags
Shelf life: 12–24 months in original sealed packaging

Names of Emulsion PVC:
Emulsion PVC
E-PVC
PVC Paste Resin
PVC Dispersion Resin
PVC Plastisol Resin
Poly(vinyl chloride) Emulsion Grade
Polyvinyl Chloride Paste Grade
Vinyl Chloride Polymer Emulsion Grade
PVC E-Type
PVC Latex
Paste PVC
Vinyl Paste Resin
Dispersion Grade PVC
Polyvinyl Chloride
Poly(1-chloroethylene)
CAS 9002-86-2