A model for the drying process during film formation in waterborne acrylic coatings

Establishing drying mechanisms during film formation in waterborne acrylic coatings is a technologically important problem, however complex, and still poorly understood. A model for the prediction of evaporation kinetics is proposed in this paper, where films are supposed to dry normally with respect to the film surface, and a drying front separates a top dry region from a bottom wet region. The model accounts for the competition between water evaporation and particle diffusion that determines the degree of vertical homogeneity, but also for the competition between water evaporation and particle deformation that ultimately establishes the rate-determining step in film formation processes. The model was validated by performing gravimetric water-loss experiments on latexes of acrylic polymers of various composition, various particle size and stabilizing systems, under different environmental temperatures and humidity, and various initial film thicknesses in order to evaluate the effect of the different factors that can in principle influence the film formation process.