EMULSION PVC

Emulsion PVC is a fine-particle polyvinyl chloride resin made exclusively by emulsion polymerization of vinyl chloride monomer (VCM) in water with water-soluble initiators and surfactants, giving smooth, solid, spherical primary particles of 0.1–2 µm that cluster into irregular aggregates averaging 40–50 µm.
Emulsion PVC is the preferred PVC grade for plastisols, organosols and paste dispersions, because its fine particles disperse readily in plasticizers to form stable, low-viscosity pastes with controlled rheology.
Emulsion PVC is used in artificial leather, flooring, wallcoverings, coated fabrics, gloves, automotive underbody coatings, foams and carpet backing, and it is processed by coating, spreading, dipping, slush molding, rotational molding and spraying.

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, Polyvinyl Chloride, Poly(1-chloroethylene), CAS 9002-86-2

Emulsion PVC differs fundamentally from suspension PVC (S-PVC), which has a coarser, porous particle structure of 50–250 µm.
Emulsion PVC occurs as aggregates covering a particle size range of 0.1–100 µm.

Emulsion PVC is made by dispersing vinyl chloride monomer in water with soaps, so that the monomer is held inside soap micelles and polymerizes with water-soluble initiators such as persulfates.
Emulsion PVC primary particles take their surface character and size distribution from the emulsifier type and concentration, the initiator system, temperature, pressure and the seed polymerization technique used.

Emulsion PVC primary particles are spray-dried into the commercial paste resin powder, and the resulting aggregates (40–50 µm mean) keep the fine primary size that is responsible for its paste-forming behavior.
Emulsion PVC aggregates break down into primary particles when mixed with plasticizer, and these particles are wetted and surrounded by plasticizer to give a stable, flowable paste.

Emulsion PVC is characterized mainly by its K-value (Fikentscher) or inherent viscosity, which reflects molecular weight and sets the physical properties of the end product.
Emulsion PVC grades range from K-60 to K-80, where lower K-values give lower melt viscosity and higher flow but lower mechanical properties, and higher K-values give greater tensile strength, elongation and heat resistance.

Emulsion PVC is a thermoplastic resin with no cross-linking in the base polymer.
Emulsion PVC in plastisol form is fused by heating to 160–200°C, where the plasticizer is absorbed into the swollen particles and they merge into a continuous, flexible and tough film or molded part whose properties depend on the K-value, the plasticizer type and level, and the stabilizer and additive package.

Uses of Emulsion PVC:
Emulsion PVC is the primary resin in plastisols for coated fabrics and artificial leather used in upholstery, automotive interiors, fashion accessories, luggage, shoes and clothing.
Emulsion PVC plastisol is spread on a fabric substrate by knife-over-roll, reverse roll or rotary screen coating and fused in an oven at 160–200°C to give a durable, flexible synthetic leather surface.

Emulsion PVC is used in floor coverings such as cushion vinyl flooring, homogeneous vinyl tiles, vinyl composition tiles and luxury vinyl tiles (LVT).
Emulsion PVC plastisol is applied there as a foam layer (chemically foamed with azodicarbonamide or mechanically foamed by nitrogen injection), a wear layer or a print layer, and the layers are fused by calendering or in an oven.

Emulsion PVC is used for PVC gloves for medical examination, food handling, industrial protection and household use, made by dip coating.
Emulsion PVC plastisol is applied by dipping fabric or ceramic formers repeatedly, gelling after each dip and finally fusing, which gives a seamless, form-fitting, flexible glove of uniform wall thickness and excellent barrier properties.

Emulsion PVC is used for automotive underbody coatings (stone chip protection and underbody sealant) applied by spray or extrusion to the underbody and wheel arches in vehicle manufacturing.
Emulsion PVC gives such coatings excellent stone chip resistance, sound deadening and corrosion protection through a flexible, adhering PVC film.

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

Emulsion PVC is used for dipped goods such as toys, tool handles, wire forms, industrial parts and automotive components, made by slush molding or rotational molding.
Emulsion PVC plastisol fills the mold, the excess is drained and the coated mold is heated to fuse the PVC layer to the desired thickness.

Emulsion PVC is used for PVC foam sheet and foam layers in wallcoverings, floor coverings, shoe soles and packaging.
Emulsion PVC plastisol is blended with a chemical blowing agent and foamed and fused in an oven or on a calender to give a lightweight, cushioned, textured cellular structure.

Emulsion PVC in latex form (before spray drying) is used for paper and textile impregnation and coating.
Emulsion PVC latex gives treated paper and textiles barrier properties, better printability, stiffness or softness modification and flame retardancy.

Emulsion PVC is used in sealants, caulks and gaskets for automotive, construction and industrial uses.
Emulsion PVC plastisols have a paste consistency that allows easy application by extrusion or injection before fusion by heat or UV.

Emulsion PVC is used for toys such as inflatable toys, bath toys, squeeze toys and educational manipulatives, made by slush or rotational molding of food-grade or phthalate-free plastisols that comply with EN 71-3, REACH and CPSC regulations.
Emulsion PVC is used for medical devices and healthcare products such as blood bags, IV bags, tubing, catheters and examination gloves, using DEHP-plasticized or alternative-plasticized formulations that meet ISO 10993 biocompatibility requirements.

Emulsion PVC is also used as a blending (extender) resin together with paste resin to optimize plastisol viscosity and cost.
Emulsion PVC extender grades have a coarser particle size (up to 100 µm) and are used at 10–30% of the total PVC content to improve viscosity control and reduce raw material cost.

Emulsion PVC powder grades with controlled particle size and flow are used in rotational molded products such as playground equipment, kayaks, furniture and industrial containers.
Emulsion PVC free-flowing powder coats the inside of rotating molds before fusion.

Benefits or Advantages of Emulsion PVC:
Emulsion PVC is the only PVC grade that forms stable plastisol dispersions in plasticizers with low initial viscosity and controlled viscosity development over time.
Emulsion PVC can therefore be processed by spreading, coating, dipping, slush molding and spraying, which suspension or bulk PVC grades cannot do.

Emulsion PVC offers exceptional formulation versatility, because plasticizer type and level (typically 40–100 PHR), stabilizer system, filler, pigment, blowing agent and processing conditions can all be varied.
Emulsion PVC fused products cover a very wide property range, from soft and flexible (Shore A 30–50) to semi-rigid (Shore A 90+).

Emulsion PVC in the fused state has excellent chemical resistance to acids, alkalis, alcohols, oils and many organic solvents.
Emulsion PVC has good electrical insulating properties, which suits it for demanding protective, electrical and industrial applications.

Emulsion PVC is inherently flame retardant owing to its high chlorine content (56.7% Cl by weight), without extra halogenated flame retardant additives.
Emulsion PVC meets various building and automotive fire standards when formulated with suitable stabilizer and plasticizer systems.

Emulsion PVC is compatible with a very wide range of plasticizers (phthalates, adipates, trimellitates, citrates, bio-based and polymeric plasticizers).
Emulsion PVC is also compatible with stabilizers (Ca/Zn, Ba/Zn, tin, liquid mixed-metal systems), fillers (calcium carbonate, kaolin), pigments and functional additives.

Emulsion PVC is made in a wide range of K-values and particle size distributions by established producers worldwide.
Emulsion PVC therefore has a 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 and a density of approximately 1.40–1.44 g/cm³.
Emulsion PVC has a bulk density of approximately 0.30–0.60 g/cm³, lower than S-PVC because of its fine, light aggregate structure.

Emulsion PVC has a primary particle size of 0.1–2 µm and an aggregate size distribution of 0.1–100 µm (mean 40–50 µm).
Emulsion PVC is insoluble in water, ethanol and most aliphatic solvents.

Emulsion PVC is swollen or dissolved by ketones (MEK, cyclohexanone), esters (ethyl acetate, butyl acetate), cyclic ethers (THF) and chlorinated solvents (DCM).
Emulsion PVC disperses fully in plasticizers at room temperature to form stable plastisol pastes with viscosities typically between 500 and 50,000 mPa·s, depending on formulation.

Emulsion PVC has a glass transition temperature (Tg) of approximately 82°C when unplasticized, which falls below 0°C in highly plasticized flexible formulations.
Emulsion PVC 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 needs heat stabilizers (organotin, Ca/Zn, Ba/Zn or liquid mixed-metal systems) during processing to prevent dehydrochlorination and discoloration.
Emulsion PVC is typically fused at 160–200°C, and the risk of degradation rises above 200°C.

Chemical Properties of Emulsion PVC:
Emulsion PVC is a homopolymer of vinyl chloride (chloroethylene) with the repeat unit –[CH₂–CHCl]n– and the formula (C₂H₃Cl)n, containing 56.7% chlorine by weight.
Emulsion PVC has an atactic (irregular) microstructure that prevents crystallization and gives the amorphous polymer its thermoplastic softening above the glass transition temperature.

Emulsion PVC undergoes thermal dehydrochlorination (loss of HCl) above approximately 100–120°C without adequate heat stabilizer.
Emulsion PVC then forms polyene sequences that cause yellow-to-brown discoloration and finally carbon formation.

Emulsion PVC dehydrochlorination is autocatalytic and is accelerated by HCl, residual catalyst metals, UV radiation and mechanical shear, so stabilizers must be selected carefully.
Emulsion PVC is incompatible with strong oxidizing agents.

Emulsion PVC in the non-fused state is attacked by concentrated acids and certain organic solvents (ketones, cyclic ethers, aromatic hydrocarbons).
Emulsion PVC in the fused state 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.
Emulsion PVC fires therefore present HCl evolution as the primary hazard, which calls for respiratory protection during firefighting.

Production of Emulsion PVC:
Emulsion PVC is produced by dispersing vinyl chloride monomer in water with surfactants (sodium lauryl sulfate, sodium dodecylbenzene sulfonate, fatty acid soaps or non-ionic emulsifiers).
Emulsion PVC polymerization uses water-soluble initiators (potassium persulfate, ammonium persulfate or redox systems) at 40–60°C and 6–12 bar in a jacket-cooled, agitated pressure reactor.

Emulsion PVC polymerization uses emulsifier concentrations of 0.5–3.0% on monomer weight.
Emulsion PVC particle nucleation, growth and final size distribution are controlled by the emulsifier type, its concentration and its addition profile (batch, incremental or continuous).

Emulsion PVC seed polymerization with pre-formed latex seeds is used to produce bimodal or multimodal particle size distributions.
Emulsion PVC with such distributions shows optimized plastisol viscosity behavior.

Emulsion PVC latex is recovered after polymerization (conversion typically 85–95%) by stripping residual vinyl chloride monomer.
Emulsion PVC latex is then spray-dried (inlet 150–200°C, outlet 50–80°C) under controlled conditions that give the target aggregate 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 and plastisol viscosity (Brookfield, ICI cone-and-plate).
Emulsion PVC quality also includes 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.

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 and should not be exposed to elevated temperatures during storage.

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

Conditions to avoid:
Emulsion PVC should not be stored above 40°C, which raises the risk of thermal degradation.
Emulsion PVC should be kept away from direct sunlight and UV radiation.
Emulsion PVC should be kept away from ignition sources, because it can form combustible dust.
Emulsion PVC should be kept away from strong oxidizing agents and moisture, which may cause caking or agglomeration of the powder.

Incompatible materials:
Emulsion PVC is incompatible with strong oxidizing agents.
Emulsion PVC is incompatible with concentrated strong acids and strong alkalis.
Emulsion PVC is incompatible with organic solvents that swell or dissolve PVC (ketones, THF, chlorinated solvents).

Hazardous decomposition products:
Emulsion PVC may release hydrogen chloride (HCl), which is toxic and corrosive.
Emulsion PVC may release carbon monoxide (CO) and carbon dioxide (CO2).
Emulsion PVC may leave soot and carbon residues.

Handling and Storage of Emulsion PVC:

Handling:
Emulsion PVC should be handled according to good industrial hygiene practice.
Emulsion PVC powder dust should not be inhaled, and adequate local exhaust ventilation should be used.
Emulsion PVC handling calls for a dust mask or respirator where dust cannot be controlled.
Emulsion PVC powder should be kept off the skin and eyes.
Emulsion PVC handling should be followed by washing the hands.
Emulsion PVC powder should be kept away from ignition sources, since it may form combustible dust clouds.

Storage:
Emulsion PVC should be stored in original sealed bags in a cool, dry, well-ventilated area at 5–40°C.
Emulsion PVC should be protected from direct sunlight, heat and moisture.
Emulsion PVC should be stored away from strong oxidizing agents and other incompatible materials.
Emulsion PVC has a typical shelf life of 12–24 months in original sealed packaging under the recommended storage conditions.

First Aid Measures of Emulsion PVC:

Inhalation:
After inhalation of Emulsion PVC dust, move the person to fresh air.
Emulsion PVC dust that causes respiratory irritation or coughing calls for medical advice.

Skin contact:
After skin contact with Emulsion PVC, wash the skin with soap and water.
Emulsion PVC powder is not expected to cause skin irritation under normal handling.

Eye contact:
After eye contact with Emulsion PVC, rinse immediately with plenty of clean water for at least 15 minutes.
Emulsion PVC eye contact calls for medical attention if irritation persists.

Ingestion:
Emulsion PVC is not expected to be hazardous when ingested in small quantities, because it is biologically inert and passes through the gastrointestinal tract without significant absorption.
After ingestion of Emulsion PVC, rinse the mouth with water and seek medical advice if large amounts were swallowed.

Firefighting Measures of Emulsion PVC:

Suitable extinguishing media:
Emulsion PVC fires can be fought with water spray, foam, dry chemical powder or carbon dioxide.

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

Protective equipment for firefighters:
Emulsion PVC fires require firefighters to wear self-contained breathing apparatus (SCBA) and full chemical protective clothing because of HCl evolution.

Firefighting instructions:
Emulsion PVC containers and storage areas exposed to fire should be cooled with water spray.
Emulsion PVC firefighting run-off should be kept out of drains and waterways, and the area should be evacuated because of HCl gas evolution.

Accidental Release Measures of Emulsion PVC:

Personal precautions:
Emulsion PVC dust should not be inhaled, and appropriate respiratory protection should be worn.
Wet spilled Emulsion PVC powder creates a slipping hazard, and the powder can form combustible dust clouds.

Environmental precautions:
Emulsion PVC should be kept out of waterways and drains, since PVC is not biodegradable.

Methods for cleaning up:
Emulsion PVC spilled powder should be swept or vacuumed carefully into labeled waste containers without generating dust clouds.
Emulsion PVC waste should be disposed of according to local regulations, and PVC waste may be recyclable.

Exposure Controls / Personal Protective Equipment of Emulsion PVC:

Engineering controls:
Emulsion PVC operations should have local exhaust ventilation where dust is generated during transfer, weighing or mixing.
Emulsion PVC exposure limits are TLV (ACGIH) 10 mg/m³ (inhalable) and 3 mg/m³ (respirable), and PEL (OSHA) 15 mg/m³ (inhalable) and 5 mg/m³ (respirable).

Eye protection:
Emulsion PVC handling calls for safety glasses or goggles where dust generation is possible.

Hand protection:
Emulsion PVC handling calls for gloves to prevent skin contact with the powder.

Respiratory protection:
Emulsion PVC dust above the TLV calls for a certified particulate respirator (N95 or FFP2).

Hygiene measures:
Emulsion PVC handling should be followed by washing the hands, and always before eating, drinking or smoking.

Properties of Emulsion PVC:
Physical state: Solid (white, free-flowing powder)
Appearance: White, fine, free-flowing powder
Odor: Mild, characteristic 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 as hazardous (base resin); formulated plastisols may carry additional hazards
NFPA 704: Health 1 / Flammability 1 / Reactivity 0

Specifications of Emulsion PVC:
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
Paste PVC
Polyvinyl Chloride
Poly(1-chloroethylene)