METHOD OF FORMING A LOW SPECULAR REFLECTANCE SURFACE
A method for making a low-specular-reflectance coating composition, includes providing a plurality of batches of substantially spherical particles including a first batch of particles having a first single mode particle size distribution with a peak corresponding to a first particle size, and a second batch of particles having a second single mode particle size distribution with a peak corresponding to a second particle size. A ratio of the second particle size to the first particle size is between 1.7-4.0. A binder and a solvent are provided and are combined with the plurality of batches of particles and mixed to form the low-specular-reflectance coating composition. A volume percent of the particles is between 2-30 volume percent, a volume percent of the binder is between 1-25 volume percent, and a volume percent of the solvent is between 45-97 volume percent.
1 . A method for making a low-specular-reflectance coating composition, comprising:
providing a plurality of batches of substantially spherical particles including:
a first batch of particles having a first particle size distribution having a single mode with a peak corresponding to a first particle size, and wherein a mode width parameter for the mode of the first particle size distribution is less than or equal to 1.0, the mode width parameter being given by a ratio of a full-width half-maximum width of the mode to the particle size of the mode; and
a second batch of particles having a second particle size distribution having a single mode with a peak corresponding to a second particle size, wherein the mode width parameter for the mode of the second particle size distribution is less than or equal to 1.0, and wherein a ratio of the second particle size to the first particle size is between 1.7-4.0;
providing a binder;
providing a solvent; and
combining the plurality of batches of particles with the binder and the solvent, and mixing to form the low-specular-reflectance coating composition;
wherein a volume percent of the particles in the low-specular-reflectance coating composition is between 2-30 volume percent;
wherein a volume percent of the binder in the low-specular-reflectance coating composition is between 1-25 volume percent; and
wherein a volume percent of the solvent in the low-specular-reflectance coating composition is between 45-97 volume percent.
2 . The method of claim 1 , wherein a total volume of the particles in the first batch of particles is in the range of 20-70% of a total volume of all of the particles.
3 . The method of claim 1 , wherein a total volume of the particles in the second batch of particles is in the range of 20-70% of a total volume of all of the particles.
4 . The method of claim 1 , wherein the plurality of batches of particles further includes a third batch of particles having a third particle size distribution having a single mode with a peak corresponding to a third particle size, wherein the mode width parameter for the mode of the third particle size distribution is less than or equal to 1.0, and wherein a ratio of the third particle size to the second particle size is between 1.7-4.0.
5 . The low method of claim 4 , wherein a total volume of the particles in the third batch of particles is between 10-40% of a total volume of all of the particles.
6 . The method of claim 4 , wherein the plurality of batches of particles further includes a fourth batch of particles having a fourth particle size distribution having a single mode with a peak corresponding to a fourth particle size, wherein the mode width parameter for the mode of the fourth particle size distribution is less than or equal to 1.0, and wherein a ratio of the third particle size to the second particle size is between 1.7-4.0.
7 . The low method of claim 6 , wherein a total volume of the particles in the fourth batch of particles is between 5-20% of a total volume of all of the particles.
8 . The method of claim 1 , wherein a volume percent of the particles in the low-specular-reflectance coating composition is between 2-30 volume percent.
9 . The method of claim 1 , wherein a volume percent of the binder in the low-specular-reflectance coating composition is between 1-25 volume percent.
10 . The method of claim 1 , wherein a volume percent of the binder in the low-specular-reflectance coating is less than a volume percent of the particles.
11 . The method of claim 1 , wherein the mode width parameter for the modes of each of the particle size distributions is less than or equal to 0.6.
12 . The method of claim 1 , wherein the first particle size is at least 2 microns.
13 . The method of claim 1 , wherein the particles in at least one of the batches of particles are substantially transparent.
14 . The 1 method of claim 1 , wherein the particles in at least one of the batches of particles include a colorant.
15 . The method of claim 1 , wherein the particles in at least one of the batches of particles are inorganic particles.
16 . The low method of claim 1 , wherein the particles in at least one of the batches of particles are polymeric particles.
17 . The method of claim 1 , wherein the particles in at least one of the batches of particles are porous.
18 . The method of claim 1 , wherein one or more of the batches of particles is a combination of two or more types of particles.