Vinyl

VINYL

For more information on resilent materials see resilients, cork, rubber and linoleum

Origin and History

Vinyl was a discovered by accident in the late 19th Century by German scientists who left the newly discovered Polyvinyl Chloride gas out in the sunlight and it turned into powder. This process of heating PVC is now called polymerization. In 1913 PVC became the first synthetic product ever patented and went into mass production in the 1920s. However, the powder- vinyl resin- wasn’t used until the late 1920s because scientists found it too hard to work with. Once they learned how to use it, scientists such as Waldo Semon found a way to create vinyl as a replacement for rubber. Vinyl started to be widely used as a replacement for natural rubber which was becoming more and more costly. It became instantly used for the soles of shoes and for insulation on wiring. Vinyl became a popular source of material during the Second World War because of its versatility and flame-resistant. This is when it was recognized for commercial usage. With this successful discovery, companies started to mass produce products that were made out of polyvinyl chloride. Throughout the centuries, companies created innovative design out of vinyl and they would constantly improve it by making it do more than before.

Polyvinyl Chloride is composed of ethylene and chlorine which are derived from salt (chloride) and petroleum, also known as crude oil (ethylene).

Harvesting and Manufacturing

The two main components of PVC are chlorine and ethylene. Chlorine is obtained from salt which is put through a process called: electrolytic disassociation of salt. The ethylene is obtained from crude oil also known as petroleum by heating it and putting it under extreme pressure to break it down. Louisiana is the petroleum capital, being right off the coast of the Gulf of Mexico, it alone manufactures one third of North America’s PVC.

The first step in creating vinyl is to create the PVC. Ethylene and chlorine are united in a process called the Monomer Process to create a liquid called ethylene dichloride at room temperature. The Ethylene Dichloride it then put through the cracking process and this creates Vinyl Chloride Monomer which is a gas at room temperature. The next step is to turn the Vinyl Chloride Monomer into a polymer so that it can be compounded into vinyl. This process turns the Vinyl Chloride Monomer into Polyvinyl Chloride which is a polymer in powder form. The last step of the process is compounding the polymer by adding modifiers to determine its rigidity or flexibility and pigments for colour.

The vinyl can be processed in a variety of different ways for different uses. The different processes included extrusion moulding, calendaring, injection moulding, thermal moulding, dipping and coating. Extrusion moulding is a process generally used for making pipes and cables. The vinyl resin is heated and pushed through a cylinder much like a meat grinder to shape the finished product. Calendaring is a process where resin is heated and passed through several pairs of rollers which stretch the resin to the right thickness. This process is predominately used for fabricating products which comes in flat sheets such as flooring.

Injection Moulding is a process by which the hot resin is injected into a mould and cooled to shape products. A majority of industrial design products come from and include the production of large scale garbage bins, sealed containers and even toys. Thermal Moulding is yet another method by which vinyl is processed. Thermal Moulding goes hand in hand with Vacuum Moulding and uses the vinyl produced by the process of Calendaring, reheats it and places the heated sheet of vinyl into a cool metal mould to form. Once the vinyl has cooled it is released from the mould by releasing the vacuum. This is the process that plastic containers are most commonly formed by. The Dipping Process is commonly used to form comfort grips on metal tools or to put a resilient layer over an existing object such as a metal frame basket. The object is simply dipped into the PVC solution.Last but not least is the Coating process. This process is used to fabricate tents and large vinyl covers, with the option of embossing to create beautiful designs. PVC solution is applied to the surface of previously fabricated PVC film and dried by heat.

Cultural Significance

Vinyl is used widely all over the world and we see it all around us in our everyday lives, from our cell phones to car seats, computers, credit cards, children’s’ toys and even life saving medical equipment. It seems that vinyl is all around us; however the majority of it goes unnoticed, consumed by the construction industry. In fact 75% of the vinyl industry is in construction. It is our piping, wall and window framing and even replacing the rubber on our electrical wires.

The Vinyl Institute in the United States which was made to promote vinyl builds fast and affordable housing made of predominately vinyl for families that couldn’t normally afford housing. They introduced the all vinyl house and the all vinyl shed which could be built in 20 minutes. The material is light weight as well as rust proof and non degradable unlike aluminum, steel and wood which is typically used for construction. Manufacturers promote PVC’s inability to biodegrade as a positive attribute of the material because it is long lasting while environmentalists see it as a nightmare.

Vinyl has made a big impact in the industrial design market because of its ability to take on a variety of shapes via injection moulding and even maintain flexibility due to the PVC content. Companies such as My Plastic Heart specifically manufacture soft vinyl toys to take advantage of their rubber like properties.

Physical Properties, Installation and Maintenance

PVC the polymer used to make vinyl comes in the form of a white powder which is then mixed with other chemicals such as dioctyl phthalate, trioctyl phosphate and poly(propylene glycol) esters, along with various dies to give it it’s characteristics. Vinyl or PVC can be manufactured to be anything ranging from being flexible to rigid by altering its chemistry. Vinyl is an extremely resilient and durable material, it is resistant to liquids, stains, and heavy traffic.

Vinyl is popular due to its versatility in characteristics and applications. Such as flooring and wall covering that typically come in either 6feet by 12feet sheets or in 12 inch square tiles or 2 feet square tiles. Vinyl is glued, and sometimes even nailed down for extra adhesion, onto a substrate-usually plywood or concrete. The surface onto which vinyl is installed MUST be completely smooth, free of bumps, dents, nails and any other irregularities because it will accentuate any flaws and affect adhesion. A specific type of glue is used to adhere vinyl and would be best to use one recommended by the vinyl manufacturer. To ensure success of installation, it is recommended that newly installed vinyl shouldn’t be walked on for at least 42 days and no furniture placed on it for at least five days.

Although vinyl is relatively low maintenance it does require occasional cleaning. Vinyl flooring is generally just swept or vacuumed to remove any dirt, sand and dust from the surface. Non abrasive vacuums and cloths should be used to avoid damaging the vinyl surface. If sweeping and vacuuming alone won’t remove the dirt using clean water will usually work. If the dirt proves difficult a manufacturer recommended cleaning solution should be used. The best way to keep vinyl flooring clean and improve its longevity is to avoid staining it. Although vinyl is water resistant, it is not water proof, thus it is best to soak up any water immediately. To maintain the aesthetic integrity of vinyl flooring, use area rugs or floor mats at entrances and exits to remove majority of dirt before walking on vinyl floor. Also, apply good quality protective feet under chairs, tables and other furniture. The most common mistake is using rubber-backed mats or rugs that will stain and potentially permanently discolour the vinyl flooring. The worst thing that can happen to vinyl is a crack or gauge in the material. If the surface is compromised dirt and grit can get trapped in the cracks splitting it open. If a crack does occur the area should be covered immediately to prevent dirt or sand from entering and the manufacturer should be contacted as soon as possible to fix it.

Uses

Since vinyl is extremely versatile and since it became popular do to its low price point it has replaced a lot of common materials. While vinyl is typically used for flooring, furniture and wall coverings in interior applications it is also used in the construction of buildings for window and wall framing as well as drainage piping. Vinyl is increasingly replacing traditional materials like wood and metals in residential, commercial and agricultural applications. The demand for vinyl materials is increasing due to its lower lifecycle cost and lower maintenance making it a preferred alternative to wood for many specifies and consumers.

List and Descriptions of Vinyl Uses:

• Cladding

Vinyl siding can be found on the exteriors of homes, apartment buildings, office parks and many other buildings. It adds a modern or traditional look on buildings exteriors, and is often used by designers. Siding can be found in a variety of styles such as clapboard, dutchlap, beaded panels and shake.

• Electrical

Vinyl is the material used most frequently in wire and cable insulation and jacketing, as it attains high standards of reliability. Flexible vinyl is the material most commonly used in each of the insulation components used in wiring. Most of the half of all wires and cables are manufactured using vinyl. At the same time, rigid vinyl is widely used in conduit, electrical switch boxes, raceways and other cable management products.

• Fencing, Decking & Railing

Vinyl fencing, decking, railing and other outdoor living products - including pergolas, arbors, gazebos and bridges - are among the newest and fastest growing applications in the building products industry. Vinyl offers a lower maintenance and more durable alternative to the traditional materials that have dominated these products, including wood and metals.

• Flooring

Vinyl flooring is also called "resilient" flooring. Resilient floors are durable, easier to maintain and moisture-resistant, therefore vinyl is preferred for use in residential kitchens and bathrooms, healthcare facilities, and commercial and retail establishments, due to its improved performance in heavy-traffic locations, especially when it comes to durability against rips, tears and gouges.

• Healthcare

Designers are using a number of vinyl products in healthcare design such as flooring and wallcovering, in both patient rooms and community spaces.

• Roofing

Approximately ten percent of all commercial and industrial roofs today use vinyl - vinyl roofing membranes. Vinyl roofing membranes are weatherproofing sheets, where flexible vinyl is a main primary component, and all fall into the "single-ply" category of roofing membranes. Vinyl membranes are appropriate for use in any of the main roof applications, such as adhered systems, ballasted systems, or mechanically attached. Due to its flexibility and lightweight, vinyl roofing has been making its way into the global industrial and commercial marketplace for over 30 years.

• Wallcovering

Vinyl wallcovering has grown in popularity for both residential and commercial interiors due to the fact that it offers a wide range of finishes and colors with enhanced durability. Commercial wallcoverings are heavier than residential stock and are produced specifically for use in buildings such as hotels, apartments, offices, hospitals and retail establishments. Wallcoverings containing vinyl also are stronger and easier to clean than alternative products such as papers, linens, foils or grass cloth. Vinyl wallcoverings consist of one or more layers of a vinyl plastic with a backing such as polyester-and-cotton blend woven fabric, nonwoven fabric or paper. Commercial wallcoverings are produced specifically for use in buildings such as hotels, apartments, offices, hospitals and retail establishments and are typically heavier than residential stock.

• Windows & Doors

Today vinyl is replacing traditional materials like wood in fenestration applications like windows and glass doors, providing comparable or better energy efficiency, design flexibility, aesthetics at lower costs. Vinyl windows and glass doors are used in many types of residential and light commercial construction, such as schools, churches and office parks to apartment buildings, assisted living facilities and hotels. Today, vinyl can be found in a variety of traditional window styles, picture windows, sliding door systems, French doors, bay, bow and garden windows, transom window and skylights. Some window manufacturers also offer vinyl-clad windows, which are simply wood frames with a top layer of vinyl. Vinyl is also available in many colors to match the building paint and is used as an alternative to painted wood, and is very suitable for window panels and frames.

Uses of vinyl are open to interpretation and choice, as it has the properties and capabilities to be adapted to suit different needs.

Ecological Footprint, VOCs

Although it is one of the most widely used products around the world, much controversy has surrounded vinyl and its impact on the environment. With the building and design industry moving more towards creating sustainable buildings and interiors, this controversy has been primarily centered upon the hazardous by-products and toxins that are produced and released during manufacturing and production. Concern has also been raised around the release of these by-products and toxins when PVC is intentionally or accidentally burned.

During the manufacturing process, when ethylene dichloride and the vinyl chloride monomer (EDC and VCM) are synthesized, dioxins are released which pose the most concern from a health and environmental standpoint. Because chlorine is one of the main components in the production of PVC, it has become the only building material that is an organochlorine. During production, chlorine will react with any carbon-containing substance and form these persistent organochlorine by-products. Even though manufacturers attempt to remove any organic carbon-containing impurities, PVC production still accounts for the production of 1,400 and 7,200 pounds of HCB and hexachloroethane (HCE) substances annually.

In order to produce soft forms of vinyl and extend the life of the PVC when it’s exposed to light, phthalate plasticizers and metallic stabilizers are added. These plasticized phthalates and metallic stabilizers are not chemically bonded to the PVC polymers, and overtime these additives begin to leach into the air and water supply where the product was installed.Once it rains, the water and plants surrounded the area become contaminated. The contamination then enters the food chain when Fish and farm animals drink the water from lakes, rivers and ponds, and eat the contaminated plants. Once the animals are processed into food and we consume them, humans can become contaminated with toxins. There is evidence to suggest that there is a correlation between phthalate exposure and cancer, neurological and respiratory disorders. This full circle process is called bioaccumulation.

PVC and fires are a dangerous combination especially since the majority of the vinyl industry is in construction. The dioxin is highly toxic and the chlorine ash produced is tough to clean up. The hydrochloric acid (HCL) produced in the burning of vinyl can cause severe damaged to electrical equipment and exposure to a single PVC fire has been shown to cause permanent respiratory disease and ailments.

Size and Cost

Since vinyl is such a versatile product and has many manufacturing process options, it comes in various amounts and sizes. For interior applications such as flooring and walls vinyl is typically sold in either rolls 6ft or 12 ft wide, or tiles 9, 12, 14, 16, 18, or 24 inches square. Vinyl also comes in various thicknesses but for interior applications is usually 1/8 inch thick. In the 1940s when vinyl first started being mass produced it was the most inexpensive material that could be used for manufacturing and it soon replaced a lot of other materials such as rubber in various applications due to its economical value. Today vinyl is no longer the most economical solution and definitely not the most ecological (refer to appendix 1). For interior design applications there are a variety of other materials which can be used especially in residential design. In fact the only place where vinyl still holds its place as the most economical material is in construction. While vinyl is typically considered low maintenance and lost cost, its highest cost is to the environment.

Recycling

Vinyl doesn't have many recycling and biodegradability opportunities. In fact vinyl doesn't have any biodegradability options. Vinyl cannot be degraded by neither our bodies or by the planet. The main bi-product of vinyl fabrication, dioxin, one of the most volatile and toxic chemicals known to man can stay in our bodies and in the earth for an extremely long time. If you had 10 units of Dioxin in your body, in 10 years 5 units will still be there. The chlorine in vinyl is what makes it different from all other types of plastics. Most recycling companies refuse vinyl because it is too dangerous and expensive to recycle. In order for vinyl to be recycled, the PVC must be removed because even the smallest bit of chlorine can contaminate a large amount of plastic rendering it useless and unrecyclable. In order to recycle plastics they must be heated and melted which is a big issue concerning vinyl because the gases released create dioxin. This is why the majority of vinyl either ends up in the landfill and the toxic chemicals eventually leach into our groundwater, causing bio accumulation. Majority of post-consumer vinyl ends up in the incinerator, releasing large amounts of dioxin and many other toxic gases. Incinerating vinyl without pollution control is commonly practiced because it is cheap and a convenient way of disposing it.

However, there are some companies such as the National Recovery Technologies in Nashville, Tennessee who take the initiative to make plastic separation more efficient. They have even identified over 100 potential applications for post consumer recycled vinyl such as packaging, piping, siding, and even traffic cones, known as down-cycling. Also, if the vinyl or PVC has not been used or combined with any foreign material like adhesives, it can easily be recycled. For example during the manufacturing process the scraps are recycled with rest of mix for the finished product, this is called pre-consumer recycling.

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