PVA- Bentonite-Water Coatings: Experimental and Simulation Studies

This study explores the drying kinetics and film formation behavior of polyvinyl alcohol (PVA)-based and PVA-bentonite composite coatings with initial thicknesses of approximately 2500 µm and 2000 µm. Four coating formulations were investigated, varying in PVA concentration and presence of bentonite as an inorganic filler. The drying process was monitored through changes in solid concentration, residual solvent content, and film thickness over time. Results revealed that coatings with higher PVA content exhibit slower drying rates, due to the transition from evaporation-controlled to diffusion-limited mechanisms, attributed to polymer densification and reduced solvent diffusivity. In contrast, coatings incorporating bentonite dried more rapidly despite their similar or higher total solids content, indicating a beneficial role of bentonite in facilitating moisture transport. Thinner coatings demonstrated faster drying but retained the characteristic mechanistic transitions observed in thicker films. A simple realistic model to simulate the drying rate was also proposed. Overall, the study highlights the significant influence of formulation variables on drying behavior and final film properties, offering valuable guidance for the design and optimization of waterborne coatings in industrial applications.