A pore-blocking powder coating suitable for microporous sound-absorbing ceilings

Abstract

This invention discloses an anti-clogging powder coating suitable for microporous sound-absorbing ceilings. The powder coating is a polyester / TGIC two-component matte powder system. The formulation, by mass percentage, includes 99.8%-99.9% polyester / TGIC two-component matte powder substrate. During use, the coating uses polyester / TGIC two-component matte powder as the substrate and is combined with 0.1%-0.2% hydrophobic fumed silica as a rheology modifier. By precisely controlling the particle size D50 of the polyester / TGIC two-component matte powder substrate to 25-30μm, and utilizing the anti-sagging properties and rheology regulation function of fumed silica, precise control of the coating thickness is achieved during the spraying process. This avoids the shrinkage or clogging of micropores in the microporous sound-absorbing ceiling caused by coating sagging or accumulation. This solves the technical problems of easy clogging and reduced sound absorption effect when traditional powder coatings are used to spray microporous ceilings. After spraying, the micropore diameter retention rate of the ceiling is ≥95%. It is suitable for places with sound absorption requirements such as conference rooms, auditoriums, concert halls, school classrooms, and hospitals.

Description

Technical Field

[0001] This invention relates to the field of powder coating technology, specifically to an anti-clogging powder coating suitable for microporous sound-absorbing ceilings. Background Technology

[0002] Microporous sound-absorbing ceilings, with their dense microporous structure providing both sound absorption and insulation, are widely used in conference rooms, auditoriums, concert halls, and other venues requiring reduced echoes. These ceilings typically have 1.5mm-6mm micropores in a metal panel, with a perforation rate controlled between 10% and 40%, achieving an optimal sound absorption effect of NRC 0.75-0.90. To improve the ceiling's weather resistance, corrosion resistance, and decorative properties, powder coatings are applied to its surface. However, existing technologies have significant drawbacks: traditional powder coatings have an unreasonable particle size distribution and lack effective rheological control mechanisms, leading to coating drips and accumulation during spraying, causing micropores to shrink or even completely clog, severely compromising the ceiling's sound absorption and insulation performance. Furthermore, reducing the coating thickness to avoid clogging affects the ceiling's weather resistance and lifespan. Currently, there are no powder coatings specifically adapted for microporous sound-absorbing ceilings in the industry. Conventional powder coatings mostly use epoxy resin systems with a particle size D50 of 35-50μm and do not contain dedicated rheology modifiers, making it impossible to balance the contradiction between coating thickness and micropore retention rate. Polyester / TGIC systems, as a high-performance powder coating, have excellent weather resistance and decorative properties, but when applied to microporous sound-absorbing ceilings, they also face the problems of difficult coating thickness control and easy pore clogging. Therefore, there is an urgent need to develop a powder coating based on the polyester / TGIC system, with anti-pore clogging function, and capable of precise control of coating thickness (35-50μm) to meet the application requirements of microporous sound-absorbing ceilings. Thus, an anti-pore clogging powder coating suitable for microporous sound-absorbing ceilings is needed.

[0003] Currently, a type of anti-clogging powder coating suitable for microporous sound-absorbing ceilings solves the problems of easy clogging and reduced sound absorption effect when traditional powder coatings are sprayed on microporous ceilings by optimizing the polyester / TGIC two-component matte powder formulation and particle size control. While ensuring the weather resistance and decorative properties of the coating, it preserves the microporous structure and sound absorption performance of the ceiling to the maximum extent. Therefore, it is necessary to develop an anti-clogging powder coating suitable for microporous sound-absorbing ceilings. Summary of the Invention

[0004] The purpose of this invention is to provide an anti-clogging powder coating suitable for microporous soundproof ceilings, so as to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A pore-blocking powder coating suitable for microporous sound-absorbing ceilings comprises a polyester / TGIC two-component matte powder system. The formulation, by mass percentage, includes 99.8%-99.9% polyester / TGIC two-component matte powder substrate and 0.1%-0.2% fumed silica. The particle size (D50) of the polyester / TGIC two-component matte powder substrate is controlled at 25-30 μm. The fumed silica is used to regulate the rheological properties of the coating, achieving anti-sagging and uniform coating thickness control. The dry film thickness after spraying is 35-50 μm.

[0006] Preferably, the polyester / TGIC two-component matte powder substrate includes polyester resin, TGIC curing agent, matting agent, pigments, fillers and additives, with the following mass percentages: polyester resin 50%-60%, TGIC curing agent 5%-8%, matting agent 3%-6%, pigments and fillers 25%-35%, and additives 1%-3%.

[0007] Preferably, the polyester resin is a carboxyl-type polyester resin with an acid value of 25-35 mg KOH / g and a glass transition temperature of 55-65℃; the TGIC curing agent is triglycidyl isocyanurate with an epoxy equivalent of 90-110 g / eq.

[0008] Preferably, the matting agent is benzo-melamine-formaldehyde resin with a particle size of 2-5 μm; the pigments and fillers include at least one of titanium dioxide, barium sulfate, and talc, with a titanium dioxide content of 15%-20%.

[0009] Preferably, the fumed silica is hydrophobic fumed silica with a specific surface area of ​​150-200 m². 2 / g, average particle size ≤20nm.

[0010] Preferably, the gelation time of the powder coating is 180-220 seconds (200℃), and the melt viscosity is 1000-2000 mPa·s (180℃).

[0011] Preferably, the coating is applied to metal microporous sound-absorbing ceilings with a pore size of 1.5mm-6mm and a perforation rate of 10%-40%. After spraying, the pore size retention rate of the ceiling micropores is ≥95%, and the sound absorption effect NRC value is maintained at 0.75-0.90.

[0012] Preferably, the spraying process adopts electrostatic spraying, with a spraying voltage of 60-80kV, an atomization pressure of 0.3-0.5MPa, a spraying distance of 20-30cm, a curing temperature of 180-200℃, and a curing time of 10-15 minutes.

[0013] A method for preparing an anti-clogging powder coating suitable for microporous sound-absorbing ceilings includes the following steps: S1. Prepare the raw materials by weight percentage, including 99.8%-99.9% polyester / TGIC two-component matte powder substrate and 0.1%-0.2% fumed silica. The core components and proportions are: 50%-60% polyester resin, 5%-8% TGIC curing agent, 3%-6% matting agent, 25%-35% pigments and fillers, and 1%-3% additives. The polyester resin selected is a carboxyl-type polyester resin with an acid value of 25-35 mgKOH / g and a glass transition temperature of 55-65℃, possessing excellent weather resistance and flexibility. The TGIC curing agent selected is triglycidyl isocyanurate with an epoxy equivalent of 90-110 g / eq, which has a moderate reaction rate with the polyester resin to avoid coating shrinkage during curing, thus preventing micropore blockage. S2. The matting agent is benzoyl melamine-formaldehyde resin with a particle size of 2-5μm, which can control the coating gloss at 10-20° (60° angle) and improve the decorative effect. The pigments and fillers are a compound system of titanium dioxide, barium sulfate and talc (mass ratio 2:1:1), with a titanium dioxide content of 15%-20% to ensure the coating's hiding power. Barium sulfate and talc synergistically enhance the coating's wear resistance and scratch resistance. The additives include leveling agents (polyacrylates), degassing agents (benzoic acid), and antioxidants (hindered phenols), with a total addition of 1%-3%, which respectively improve the coating's leveling properties, eliminate pinholes, and delay aging. S3. Hydrophobic fumed silica with a specific surface area of ​​150-200 m² is selected. 2 / g, with an average particle size ≤20nm, the addition amount is 0.1%-0.2%. Polyester resin, TGIC curing agent, matting agent, pigments, fillers and additives are added to a high-speed mixer according to the formula and mixed for 10-15 minutes to obtain a premix. The premix is ​​fed into a twin-screw extruder and melt-extruded at 100-120℃. The extruded material is cooled by water and crushed to obtain primary sheet material. S4. Finally, the primary sheet material is pulverized by an air jet mill and screened by a classifier to control the particle size D50 to 25-30μm, thus obtaining a polyester / TGIC two-component matte powder substrate. 0.1%-0.2% of fumed silica is added to the polyester / TGIC two-component matte powder substrate and mixed in a low-speed mixer for 5-10 minutes at a mixing speed of 300-500r / min to avoid agglomeration of fumed silica, thus obtaining the anti-clogging powder coating product. S5. This anti-clogging powder coating is specifically designed for use on metal microporous sound-absorbing ceilings with pore sizes of 1.5mm-6mm and perforation rates of 10%-40%. The specific spraying process is as follows: Ceiling pretreatment: Degreasing and phosphating are performed on the metal microporous ceiling to remove surface oil and oxide layers, thereby improving coating adhesion; Electrostatic spraying: Electrostatic spraying equipment is used, with the spraying voltage set to 60-80kV, atomization pressure to 0.3-0.5MPa, and spraying distance to 20-30cm, to uniformly spray the coating; Curing treatment: The sprayed ceiling is placed in a curing oven and cured at 180-200℃ for 10-15 minutes. After cooling, the finished product is obtained.

[0014] Compared with the prior art, the beneficial effects of the present invention are: 1. By precisely controlling the particle size of the polyester / TGIC two-component matte powder substrate (D50=25-30μm), combined with the rheological regulation effect of hydrophobic fumed silica, precise control of coating thickness (35-50μm) is achieved, with a micropore size retention rate ≥95%, ensuring that the sound absorption performance is not affected; Excellent coating performance: The polyester / TGIC system endows the coating with excellent weather resistance, wear resistance and decorative properties, meeting the long-term use requirements of ceilings; Convenient construction: Adaptable to conventional electrostatic spraying processes, no equipment modification is required, construction efficiency is high, and it is suitable for large-scale production applications; Wide range of applications: Specifically adapted to microporous sound-absorbing ceilings with pore sizes of 1.5mm-6mm and perforation rates of 10%-40%, it can be widely used in various scenarios such as conference rooms, auditoriums, concert halls, school classrooms, and hospitals. Attached Figure Description

[0015] Figure 1 This is a flowchart illustrating the core raw material preparation stage of an anti-clogging powder coating for microporous sound-absorbing ceilings according to the present invention. Figure 2 This is a flowchart illustrating the raw material preparation stage of an anti-clogging powder coating suitable for microporous sound-absorbing ceilings according to the present invention. Figure 3 This is a flowchart illustrating the mixing and granulation stage of an anti-clogging powder coating for microporous sound-absorbing ceilings according to the present invention. Detailed Implementation

[0016] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] Please see Figures 1-3 This invention provides a technical solution for an anti-clogging powder coating suitable for microporous sound-absorbing ceilings: A pore-blocking powder coating suitable for microporous sound-absorbing ceilings comprises a polyester / TGIC two-component matte powder system. The formulation, by mass percentage, includes 99.8%-99.9% polyester / TGIC two-component matte powder substrate and 0.1%-0.2% fumed silica. The particle size D50 of the polyester / TGIC two-component matte powder substrate is controlled at 25-30μm. Fumed silica is used to regulate the rheological properties of the coating, achieving anti-sagging and uniform control of coating thickness. The dry film thickness after spraying is 35-50μm.

[0018] The polyester / TGIC two-component matting powder substrate includes polyester resin, TGIC curing agent, matting agent, pigments, fillers and additives, with the following mass percentages: polyester resin 50%-60%, TGIC curing agent 5%-8%, matting agent 3%-6%, pigments and fillers 25%-35%, and additives 1%-3%.

[0019] The polyester resin is a carboxyl-type polyester resin with an acid value of 25-35 mg KOH / g and a glass transition temperature of 55-65℃; the TGIC curing agent is triglycidyl isocyanurate with an epoxy equivalent of 90-110 g / eq.

[0020] The matting agent is benzo-melamine formaldehyde resin with a particle size of 2-5μm; the pigments and fillers include at least one of titanium dioxide, barium sulfate, and talc, with titanium dioxide content of 15%-20%.

[0021] The fumed silica is hydrophobic and has a specific surface area of ​​150-200 m². 2 / g, average particle size ≤20nm.

[0022] The gelation time of the powder coating is 180-220 seconds (200℃), and the melt viscosity is 1000-2000 mPa·s (180℃).

[0023] It is applied to metal microporous sound-absorbing ceilings with pore sizes of 1.5mm-6mm and perforation rates of 10%-40%. After spraying, the pore size retention rate of the ceiling micropores is ≥95%, and the sound absorption effect NRC value is maintained at 0.75-0.90.

[0024] The spraying process adopts electrostatic spraying, with a spraying voltage of 60-80kV, an atomization pressure of 0.3-0.5MPa, a spraying distance of 20-30cm, a curing temperature of 180-200℃, and a curing time of 10-15 minutes.

[0025] A method for preparing an anti-clogging powder coating suitable for microporous sound-absorbing ceilings includes the following steps: S1. The raw materials include 99.8%-99.9% polyester / TGIC two-component matte powder substrate and 0.1%-0.2% fumed silica by weight percentage. The core components and proportions are: 50%-60% polyester resin, 5%-8% TGIC curing agent, 3%-6% matting agent, 25%-35% pigments and fillers, and 1%-3% additives. The polyester resin is a carboxyl-type polyester resin with an acid value of 25-35 mgKOH / g and a glass transition temperature of 55-65℃, which has excellent weather resistance and flexibility. The TGIC curing agent is triglycidyl isocyanurate with an epoxy equivalent of 90-110 g / eq, which has a moderate reaction rate with the polyester resin to avoid coating shrinkage during curing and micropore blockage.

[0026] S2. The matting agent is benzoyl melamine formaldehyde resin with a particle size of 2-5μm, which can control the coating gloss at 10-20° (60° angle) and improve the decorative effect. The pigments and fillers are a compound system of titanium dioxide, barium sulfate and talc (mass ratio 2:1:1), with a titanium dioxide content of 15%-20% to ensure the coating's hiding power. Barium sulfate and talc work together to enhance the coating's wear resistance and scratch resistance. The additives include leveling agents (polyacrylates), degassing agents (benzoic acid), and antioxidants (hindered phenols), with a total addition of 1%-3%, which respectively improve the coating's leveling properties, eliminate pinholes, and delay aging.

[0027] S3. Hydrophobic fumed silica with a specific surface area of ​​150-200 m² is selected. 2 / g, with an average particle size ≤20nm, the addition amount is 0.1%-0.2%. Polyester resin, TGIC curing agent, matting agent, pigments, fillers and additives are added to a high-speed mixer according to the formula and mixed for 10-15 minutes to obtain a premix. The premix is ​​then fed into a twin-screw extruder and melt-extruded at 100-120℃. The extruded material is then water-cooled and crushed to obtain primary sheet material.

[0028] S4. Finally, the primary sheet material is pulverized by an air jet mill and screened by a classifier to control the particle size D50 to 25-30μm, thus obtaining a polyester / TGIC two-component matte powder substrate. 0.1%-0.2% of fumed silica is added to the polyester / TGIC two-component matte powder substrate and mixed in a low-speed mixer for 5-10 minutes at a mixing speed of 300-500r / min to avoid agglomeration of fumed silica, thus obtaining the finished anti-clogging powder coating.

[0029] S4. This anti-clogging powder coating is specifically designed for use on metal microporous sound-absorbing ceilings with pore sizes of 1.5mm-6mm and perforation rates of 10%-40%. The specific spraying process is as follows: Ceiling pretreatment: Degreasing and phosphating are performed on the metal microporous ceiling to remove surface oil and oxide layers, thereby improving coating adhesion; Electrostatic spraying: Electrostatic spraying equipment is used, with the spraying voltage set to 60-80kV, atomization pressure to 0.3-0.5MPa, and spraying distance to 20-30cm, to uniformly spray the coating; Curing treatment: The sprayed ceiling is placed in a curing oven and cured at 180-200℃ for 10-15 minutes. After cooling, the finished product is obtained.

[0030] It should be noted that this invention is an anti-clogging powder coating suitable for microporous sound-absorbing ceilings. It comprises, by weight percentage, 99.8%-99.9% of a polyester / TGIC two-component matte powder substrate and 0.1%-0.2% fumed silica. The core components and proportions are: 50%-60% polyester resin, 5%-8% TGIC curing agent, 3%-6% matting agent, 25%-35% pigments and fillers, and 1%-3% additives. The raw material preparation involves selecting a carboxyl-type polyester resin with an acid value of 25-35 mgKOH / g and a glass transition temperature of 55-65℃, exhibiting excellent weather resistance and flexibility. The TGIC curing agent is triglycidyl isocyanurate with an epoxy equivalent of 90-110 g / eq. The polyester resin has a moderate reaction rate, preventing micropore blockage caused by coating shrinkage during curing. A benzo-melamine-formaldehyde resin with a particle size of 2-5μm is used as the matting agent, controlling the coating gloss at 10-20° (60° angle) and enhancing the decorative effect. A compound system of titanium dioxide, barium sulfate, and talc (mass ratio 2:1:1) is used as the pigment and filler, with 15%-20% titanium dioxide content to ensure coating hiding power. Barium sulfate and talc synergistically enhance the coating's abrasion resistance and scratch resistance. Additives include leveling agents (polyacrylates), degassing agents (benzoic acid), and antioxidants (hindered phenols), with a total addition of 1%-3%, respectively improving coating leveling, eliminating pinholes, and delaying aging. Hydrophobic fumed silica with a specific surface area of ​​150-200m² is selected. 2 / g, with an average particle size ≤20nm, and an addition amount of 0.1%-0.2%, polyester resin, TGIC curing agent, matting agent, pigments, fillers, and additives are added to a high-speed mixer according to the formula and mixed for 10-15 minutes to obtain a premix. The premix is ​​then fed into a twin-screw extruder and melt-extruded at 100-120℃. The extruded material is water-cooled and crushed to obtain primary flakes. Finally, the primary flakes are pulverized by an air jet mill and screened by a classifier to control the particle size D50 to 25-30μm, resulting in a polyester / TGIC two-component matting powder substrate. 0.1%-0.2% fumed silica is added to the polyester / TGIC two-component matting powder substrate and mixed in a low-speed mixer for 5-10 minutes at a mixing speed of 300-500r / min to prevent fumed silica agglomeration, thus obtaining an anti-clogging powder coating product. In this way, an anti-clogging powder coating suitable for microporous soundproof ceilings is completed.

[0031] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their machine equivalents.

Claims

1. A hole-blocking powder coating suitable for use in a micro-perforated acoustical ceiling, characterized by: The powder coating comprises a polyester / TGIC two-component matt powder system, and the formula comprises, in percentage by mass, polyester / TGIC two-component matt powder base material 99.8%-99.9%, and auxiliary gas phase silicon dioxide 0.1%-0.2%; the particle size D50 of the polyester / TGIC two-component matt powder base material is controlled to be 25-30 μm, the gas phase silicon dioxide is used to regulate the rheological property of the coating, to realize anti-sagging and uniform control of the coating thickness, and the dry film thickness after spraying is 35-50 μm.

2. A non-clogging powder coating for use in a micro-perforated acoustical ceiling according to claim 1, characterized in that: The polyester / TGIC two-component matt powder base material comprises polyester resin, TGIC curing agent, matt agent, pigment and filler, and auxiliary agent, and the mass percentage of each component is: polyester resin 50%-60%, TGIC curing agent 5%-8%, matt agent 3%-6%, pigment and filler 25%-35%, and auxiliary agent 1%-3%.

3. A non-clogging powder coating for use in a micro-perforated acoustical ceiling according to claim 2, characterized in that: The polyester resin is a carboxyl type polyester resin, the acid value is 25-35 mgKOH / g, and the glass transition temperature is 55-65℃; the TGIC curing agent is isocyanuric acid triglycidyl ester, and the epoxy equivalent weight is 90-110 equivalent mass.

4. A non-clogging powder coating for use in a micro-perforated acoustical ceiling according to claim 2, characterized in that: The matt agent is benzotriazene formaldehyde resin, and the particle size is 2-5 μm; the pigment and filler comprise at least one of titanium dioxide, barium sulfate and talc, and the content of titanium dioxide is 15%-20%.

5. A non-clogging powder coating for use in a micro-perforated acoustical ceiling according to claim 1, characterized in that: The fumed silica is a hydrophobic fumed silica with a specific surface area of 150-200 m 2 / g and an average particle size of ≤ 20 nm.

6. A non-clogging powder coating for use in a micro-perforated acoustical ceiling according to claim 1, characterized in that: The gel time of the powder coating is 180-220 seconds (200℃), and the melt viscosity is 1000-2000 mPa·s (180℃).

7. Use of a clogging hole preventing powder coating according to claims 1-6, characterized in that, The powder coating is applied to a metal micro-perforated sound-absorbing ceiling with a pore diameter of 1.5 mm-6 mm and a perforation rate of 10%-40%, and the pore diameter retention rate of the micro-perforated ceiling after spraying is ≥95%, and the sound-absorbing effect NRC value is maintained at 0.75-0.

90.

8. A non-clogging powder coating for use in a micro-perforated acoustical ceiling according to claim 7, characterized in that: The spraying process adopts electrostatic spraying, the spraying voltage is 60-80 kV, the atomization pressure is 0.3-0.5 MPa, the spraying distance is 20-30 cm, the curing temperature is 180-200℃, and the curing time is 10-15 minutes.

9. A method for the preparation of a hole-blocking powder coating suitable for use in a micro-perforated acoustic ceiling, characterized in that: The method comprises the following steps: S1, raw materials are prepared, which comprise, in percentage by mass, polyester / TGIC two-component matt powder base material 99.8%-99.9% and gas phase silicon dioxide 0.1%-0.2%, and the core components and proportions are: polyester resin 50%-60%, TGIC curing agent 5%-8%, matt agent 3%-6%, pigment and filler 25%-35%, and auxiliary agent 1%-3%; the polyester resin is a carboxyl type polyester resin, the acid value is 25-35 mgKOH / g, and the glass transition temperature is 55-65℃, and the polyester resin has excellent weather resistance and flexibility; the TGIC curing agent is isocyanuric acid triglycidyl ester, and the epoxy equivalent weight is 90-110 equivalent mass, and the polyester resin has a moderate reaction rate, so that the coating is prevented from shrinking and causing micro-perforation blockage during the curing process; S2, the light extinction agent is selected from benzene triazine formaldehyde resin with particle size of 2-5 μm, which can control the gloss of the coating layer at 10-20° (60° angle) and improve the decoration effect; the pigment and filler are selected from a compound system of titanium dioxide, barium sulfate and talc powder (mass ratio 2:1:1), the content of titanium dioxide is 15%-20% to ensure the hiding power of the coating layer, barium sulfate and talc powder synergistically enhance the wear resistance and scratch resistance of the coating layer, the additives include leveling agent (polyacrylate), degassing agent (benzoic acid) and antioxidant (hindered phenol), the total addition amount is 1%-3%, which respectively improves the leveling property of the coating layer, eliminates pinholes and delays aging; S3, hydrophobic fumed silica, specific surface area 150-200 m 2 / g, average particle size ≤ 20 nm, and the addition amount is 0.1%-0.2%. The polyester resin, TGIC curing agent, matting agent, pigment and filler, and auxiliary are put into a high-speed mixer according to the ratio, mixed for 10-15 minutes to obtain a premix. The premix is sent into a twin-screw extruder, melted and extruded at 100-120°C. The extruded material is water-cooled, crushed, and then primary sheet material is obtained. S4, finally, the primary sheet material is crushed by an air flow crusher, screened by a classifier, the particle size D50 is controlled at 25-30 μm, and a polyester / TGIC two-component matt powder base material is obtained, 0.1%-0.2% of fumed silica is added to the polyester / TGIC two-component matt powder base material, mixed in a low-speed mixer for 5-10 minutes, the mixing speed is 300-500 r / min, to avoid the agglomeration of fumed silica, and a finished product of anti-hole-blocking powder coating is obtained.

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