Since its development, water-in-sand coating has been widely recognized as an upgraded alternative to real stone paint, boasting huge market demand in the future. An increasing number of manufacturers are engaged in its production, yet most are unable to realize single-batch, large-scale and high-speed production.
Manufacturers capable of efficient mass production can seize market shares rapidly. So how to expand production capacity and boost efficiency? What are the key factors restricting mass production of water-in-sand coatings?
The core lies in colorful particles. However, common problems frequently occur during actual production and spraying, such as color bleeding, poor shear resistance, easy breakage and agglomeration of colorful particles. What are the main causes of these issues and how should we solve them?
01 Color Bleeding of Colorful Particles
Causes
This phenomenon means the pigment in the dispersed phase penetrates through the protective film into the continuous phase, causing the continuous phase to turn turbid. After construction, the edges of particles in different colors become blurred and the base color changes, which greatly damages the decorative effect of colorful coatings.
Solutions
This problem is generally caused by overly soft and low-strength particle protective film. Increase the solvent concentration to enhance the film strength.
Avoid excessive solvent concentration, otherwise the particle surface will become too hard, resulting in uneven coating surface and rough hand feel after spraying. Adopt moderate concentration to eliminate color bleeding and turbidity effectively.
02 Floating or Settling of Colorful Particles
Causes
There is an excessive difference in density and viscosity between the dispersed phase and continuous phase. Excessively high density of the dispersed phase leads to particle settling, while overly low density causes particles to float upward, resulting in delamination of the two phases.
Solutions
Control the density difference between dispersed phase and continuous phase reasonably. Add inorganic or organic thickeners into the continuous phase to strengthen its bearing capacity for colorful particles.
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03 Colorful Particles Shrinking and Breaking Under Extrusion
Causes
During storage and transportation, particles squeeze against each other and get deformed. Once exceeding the surface tension limit, they break into fine particles. Extrusion also accelerates mutual penetration between particles, blurring edges and causing slurry bleeding among particles.
Solutions
This issue is closely related to particle strength. Strong internal cross-linking inside the dispersed phase can effectively prevent particles from being crushed by external force. Optimize weak components in the dispersed phase and adopt a stable product system to lower production risks.
04 Agglomeration of Dispersed Phase Particles
Causes
Unstable dispersed phase particles tend to polymerize with one another. They will clump together after a period of storage, breaking the original state of mutual separation and immiscibility.
Solutions
This problem is also related to the preparation method of protective glue and film strength. The solution is the same as that for colorful particle color bleeding.
05 Expansion of Colorful Particles
Causes
Excessively high crosslinking degree leads to poor viscoelasticity, making spraying impossible. The finished coating surface will be overly bulged and uneven.
Solutions
Reasonably control the crosslinking degree and strength of particles.
To sum up, choosing cost-effective and high-quality protective glue can effectively reduce risks in production and construction, and improve the stability of finished products.