Designing Formulations for Water-Based Industrial Coatings

In the manufacturing process of coatings, the first step is to correctly select suitable components, ensuring that the inherent properties of each component meet the application requirements of the coating. Subsequently, the relative proportions of each component must be determined—this constitutes the formulation design. When undertaking formulation design, three general steps are typically followed:

① Select the base resin and pigments based on the coating's application requirements;
② Determine the solvents and thinners according to application requirements and the selected base resin;
③ Decide whether additional additives are needed and what types are required.

After selecting suitable components for a pigmented coating formulation, the most critical factor determining the coating's properties is the pigment volume concentration (PVC). Pigment volume concentration (PVC) is the ratio of the volume of pigments and fillers in the coating to the total volume of all non-volatile components in the formulation (including the base resin, pigments, and fillers). The composition of the solution affects the coating's drying time, film-forming properties, and application characteristics. It also plays a significant role in controlling and improving the coating's viscosity and leveling properties.

The coatings industry has experienced tremendous growth. According to incomplete statistics, existing coating varieties exceed ten thousand, with new formulations continually emerging and being developed. It is impractical to discuss every coating formulation individually; instead, the fundamental principles of formulation design must be mastered.

Due to varying environmental conditions of substrates, diverse performance requirements are placed on coatings (e.g., rust prevention, acid/alkali resistance, decorative appeal). The quantities and relative proportions of components within a coating formulation profoundly influence both the coating's application properties (such as leveling and drying characteristics) and the film's performance (including gloss and hardness). Consequently, developing a new coating formulation that meets specific application requirements is a complex endeavor. Formulations designed based on fundamental knowledge and principles must undergo necessary testing to identify those that truly satisfy practical demands.