Multilayer Coating with Dual-Scale Pigments for Metallic Uniformity
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Solution Overview
Problem
Metallic unevenness occurs in coating films containing flake-like aluminum pigments due to their alignment, despite existing technologies focusing on enhancing particle feeling, brilliance, and flip-flop properties.
Innovation Solution
A specific composition of flake-like aluminum pigments with defined average particle diameters and a binder component, including a hydroxyl group-containing acrylic resin, is used to form a coating film that prevents metallic unevenness while maintaining high particle feeling and flip-flop properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If flake-like aluminum pigment is aligned parallel to the object surface to achieve metallic color and brilliance, then particle feeling and flip-flop property are improved, but metallic unevenness occurs in the coating film
Solution Approach 1:
The patent applies local quality by using two different flake-like aluminum pigments with distinct size characteristics: first pigment particles (1-10 μm) provide brilliance and flip-flop property, while second pigment particles (11-30 μm) provide metallic unevenness control. Each pigment size fraction is optimized for specific local functions within the coating film structure, allowing simultaneous achievement of high brilliance and reduced metallic unevenness.
Solution Approach 2:
The patent employs composite materials by combining two different flake-like aluminum pigments with different particle size distributions into a single coating composition. The first flake-like aluminum pigment (smaller particles) and second flake-like aluminum pigment (larger particles) work synergistically to achieve both high brilliance/flip-flop property and controlled metallic unevenness, creating a composite pigment system that resolves the contradiction.
2Reliability
If larger flake-like aluminum pigment particles are used to enhance particle feeling, then distinctness of image is improved, but metallic unevenness increases
Solution Approach 1:
The patent applies segmentation by dividing the flake-like aluminum pigment into two distinct size categories: first pigment particles (1-10 μm) for brilliance and flip-flop property, and second pigment particles (11-30 μm) for particle feeling and metallic unevenness control. This segmentation allows each size fraction to be optimized for its specific function, preventing the metallic unevenness that would result from using uniformly large particles.
Data Source
AI summary
The present invention relates to a coating composition which contains (A) a binder component, (B) a scale-like aluminum pigment having an average particle diameter (d50) of 18-25 µm, and (C) a scale-like pigment having an average particle diameter (d50) of 8-30 µm, which is different from the scale-like aluminum pigment. The content of the pigment (B) is 10-50 parts by mass and the content of the pigment (C) is 0.5-10 parts by mass based on 100 parts by mass of the component (A); and the content ratio of the pigment (B) to the pigment (C), namely (B)/(C) is from 2/1 to 50/1 in terms of the solid content mass ratio.