Acrylic Emulsion Used in Textile Coating

1. Introduction

Acrylic emulsions are among the most widely used polymer binders in the textile coating industry. As water-based polymer dispersions, acrylic emulsions provide an optimal balance of performance, processability, and environmental compliance. With increasing demand for functional textiles—such as waterproof fabrics, coated upholstery, industrial textiles, and performance apparel—acrylic emulsions have become a core material in modern textile finishing and coating systems.

Textile coating refers to the application of a polymer layer onto the surface of a fabric to enhance or impart specific properties, including durability, water resistance, abrasion resistance, dimensional stability, and aesthetic effects. Acrylic emulsions are particularly favored because of their excellent film-forming ability, strong adhesion to fibers, flexibility, and resistance to aging.

2. Composition and Structure of Acrylic Emulsions

Acrylic emulsions are produced through emulsion polymerization of acrylic and methacrylic monomers such as methyl acrylate, ethyl acrylate, butyl acrylate, and their copolymers. The polymer particles are dispersed in water with the help of surfactants and stabilizers, forming a stable colloidal system.

Key formulation parameters include:

• Solids content, typically ranging from 40% to 55%

• Glass transition temperature (Tg), which determines film hardness or softness

• Particle size, influencing penetration and surface smoothness

• pH value, ensuring storage and processing stability

By adjusting these parameters, manufacturers can tailor acrylic emulsions for soft hand feel, elastic coatings, or harder, more abrasion-resistant films depending on textile application requirements.

3. Role of Acrylic Emulsion in Textile Coating

In textile coating systems, acrylic emulsions function primarily as binders. After application and drying, the water evaporates, and the polymer particles coalesce to form a continuous film on the fabric surface or within the fiber structure.

The key roles include:

• Binding pigments, fillers, and functional additives to the textile substrate

• Enhancing mechanical strength and dimensional stability

• Improving resistance to washing, rubbing, and environmental exposure

• Providing a uniform and controllable coating layer

Compared with solvent-based resins, acrylic emulsions offer safer processing conditions and improved compliance with environmental regulations.

4. Application Methods in Textile Coating

Acrylic emulsions are compatible with various textile coating techniques, including:

Padding and Dip-Coating

The fabric is immersed in a coating bath containing acrylic emulsion and then passed through squeeze rollers to control pickup. This method ensures uniform distribution and is widely used for lightweight coatings.

Knife-Over-Roll and Blade Coating

In this method, the acrylic emulsion is applied onto the fabric surface using a knife or blade. It allows precise control of coating thickness and is commonly used for coated upholstery, blackout fabrics, and technical textiles.

Foam Coating

Acrylic emulsions can be foamed with surfactants and applied to the fabric to reduce water usage and energy consumption during drying. Foam coating is popular for back-coating applications where softness and bulk are required.

Spray and Screen Coating

Used mainly for special designs or localized coating effects, especially in decorative or functional textile applications.

5. Key Performance Advantages

Excellent Film-Forming Properties

Acrylic emulsions form smooth, flexible films at relatively low drying temperatures. This is particularly important for heat-sensitive textiles and energy-efficient production lines.

Strong Adhesion to Fibers

Acrylic polymers exhibit strong affinity to both natural fibers (cotton, wool) and synthetic fibers (polyester, nylon), ensuring durable bonding even after repeated washing.

Durability and Resistance

Textiles coated with acrylic emulsions show enhanced abrasion resistance, tensile strength, and resistance to cracking or peeling. This makes them suitable for high-use applications such as upholstery and automotive interiors.

Weather and UV Resistance

Acrylic polymers are known for excellent resistance to ultraviolet radiation and aging, making them ideal for outdoor textiles, awnings, and protective fabrics.

6. Functional Textile Applications

Acrylic emulsions are used across a wide range of textile coating applications:

• Upholstery and home textiles: sofa fabrics, curtains, mattress fabrics

• Outdoor textiles: tents, awnings, sunshades, and protective covers

• Industrial textiles: conveyor belts, tarpaulins, filtration fabrics

• Apparel and performance fabrics: rainwear, workwear, and coated garments

• Pigment printing binders: fixing pigments onto textile surfaces with good color fastness

Through formulation adjustment, acrylic emulsions can also support functional finishes such as water repellency, flame retardancy, anti-static performance, and antimicrobial effects.

7. Environmental and Regulatory Benefits

One of the most significant advantages of acrylic emulsions is their environmental profile. Being water-based, they contain low or negligible levels of volatile organic compounds (VOCs), contributing to improved workplace safety and reduced environmental impact.

Modern textile acrylic emulsions are often:

• APEO-free

• Formaldehyde-free

• Compliant with REACH, OEKO-TEX®, and other global textile standards

This makes acrylic emulsion systems suitable for sustainable textile production and export-oriented manufacturing.

8. Processing and Storage Considerations

For industrial textile coating plants, acrylic emulsions are typically supplied in bulk packaging such as drums or IBC containers. Proper storage is essential to maintain emulsion stability.

Recommended practices include:

• Storage at moderate temperatures (avoid freezing and excessive heat)

• Gentle stirring before use to ensure uniformity

• Avoiding contamination with incompatible chemicals

When processed correctly, acrylic emulsions offer long shelf life and consistent coating performance.

9. Future Trends in Textile Acrylic Emulsions

With growing emphasis on sustainability and performance textiles, the development of acrylic emulsions continues to evolve. Current trends include:

• Bio-based and partially renewable acrylic polymers

• Lower-temperature film-forming emulsions for energy savings

• Multi-functional coatings combining durability with comfort

• Improved recyclability and compatibility with circular textile systems

These innovations are expanding the application scope of acrylic emulsions while supporting environmentally responsible manufacturing.

10. Conclusion

Acrylic emulsions play a critical role in the textile coating industry due to their versatility, performance reliability, and environmental advantages. From upholstery and industrial fabrics to functional apparel and outdoor textiles, acrylic emulsion-based coatings deliver durability, flexibility, and design freedom. As textile markets continue to demand high performance and sustainability, acrylic emulsions will remain a key material in advanced textile coating technologies.