Waterborne wood lacquer is produced through a straightforward physical mixing process. The main challenge lies in ensuring complete homogenization of the components during production and maintaining this uniformity throughout storage and application. Here's a detailed breakdown of the entire manufacturing procedure.
1. Begin by weighing the required amount of resin emulsion or dispersion into a clean paint tank or beaker. Start the mixer and stir slowly at a speed not exceeding 300 revolutions per minute (RPM).
2. Carefully add excess water to the mixture, after subtracting the water needed for pre-prepared additives. Only use deionized or distilled water for the production process—avoid tap, well, or river water unless it has been purified. Add water and other additives gradually, either drop by drop or in a fine stream, to prevent separation or clumping. Stir for about 5 to 10 minutes after each addition.
3. Pre-dilute the anti-fungal agent with 3 to 10 times its volume in water. The more diluted, the better. Slowly introduce the diluted solution into the mixing container while stirring. Increase the stirring speed if necessary to speed up the process. Some mold inhibitors may cause gel formation if added directly, so it's important to add them gradually and thoroughly mix to avoid clumps.
4. Add wax oil and continue stirring for 5 to 10 minutes. Wax emulsions typically blend easily with resin emulsions.
5. Introduce the film-forming aid directly into the mixer. Once added, increase the RPM to between 500 and 800 and stir for 10 to 20 minutes. The film-forming aid can be used alone or mixed with wetting agents, surface modifiers, or part of the defoamer beforehand.
6. Add other additives such as wetting agents and surface modifiers. Stir at 300 to 500 RPM for 5 to 10 minutes.
7. Dilute the thickener with water or film-forming aid before adding it slowly to prevent clumping. Stir for 10 to 15 minutes once fully incorporated.
8. Add fragrance and stir for 3 to 5 minutes. Reduce the speed to 300 RPM to minimize evaporation of the scent. Most waterborne wood lacquers are slightly alkaline, so pH adjustment is usually unnecessary. If needed, a pH adjuster can be used to bring the pH to between 7.5 and 9.
9. If any defoamer was left out earlier, add it now for final defoaming.
10. After all ingredients are added, continue stirring for 10 to 15 minutes, gradually reducing the speed from 500 to 100 RPM.
11. Perform sample testing, including visual inspection, viscosity measurement, solid content analysis, and painting tests to check leveling, sagging, shrinkage, bubbles, and bulges. Leave samples for a 50°C thermal stability test. If all criteria are met, filter and package the product.
12. Pump the material through a 200-mesh (preferably 300-mesh or finer) filter.
13. Each batch must be stored for quality inspection.
14. After production, clean all equipment and pipelines with tap water for future use.
Water-reducible paints are made by first dissolving solvent-based resins in an organic solvent and then dispersing them in water using mechanical agitation and emulsifiers, resulting in a post-emulsified emulsion. These paints can be diluted with water during application. Water-dispersible lacquers, on the other hand, primarily use synthetic resin emulsions as the film-forming material. Emulsions are formed when unsaturated vinyl monomers polymerize under specific conditions in the presence of emulsifiers, creating a stable dispersion in water. A paint made by blending a small amount of emulsion with a water-soluble resin is not considered true latex paint. While technically not classified as latex, these products are commonly referred to as such in industry practice.
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