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Progress in Organic Coatings xxx (2014) xxx–xxx

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Progress in Organic Coatings


journal homepage: www.elsevier.com/locate/porgcoat

The determination of critical pigment volume concentration (CPVC) in


organic coatings with fluorescence microscopy
Jinhai Wang, Hong Xu, Dante Battocchi, Gordon Bierwagen ∗
Department of Coatings and Polymeric Materials, North Dakota State University, 1735 Research Park Dr., Fargo, ND 58102, United States

a r t i c l e i n f o a b s t r a c t

Article history: The critical pigment volume concentration (CPVC) in pigmented organic coatings is one of the most impor-
Available online xxx tant parameters in coating formulation (Asbeck and Van Loo [1]). It is usually determined experimentally
by tracing the change of those void formation-related properties with PVC or detecting the appearance
Keywords: of voids in micrograph. However, these methods often underestimate the CPVC value because of the
Critical pigment volume concentration non-uniform dispersion of pigment. As discussed by Fishman et al. (1992, 1993 [2,3]), locally poor dis-
Fluorescence microscopy
persion can cause local volumes in a coating film to have a local pigment volume concentration (PVC –
Voids
local volume fraction) that exceeds the CPVC, even if the global or bulk value is not yet exceeded. PVCs at
or above the global CPVC develop many voids, and so a possible measure of the CPVC is a rapid increase
in local voids. In this work, we report a novel method for experimental determination of CPVC. In this
method, fluorescent dye is used to mark the voids in coating layer and the fraction of fluorescent area
is obtained from fluorescence image. The area fraction, which is a measure of voids volume fraction, is
then plotted with PVC to obtain CPVC value. This method eliminates the influence of non-uniform dis-
persion of pigment. To illustrate the utility of this method, the CPVC values of various Mg-rich primers
were determined with this method. The results showed that a reliable and accurate CPVC value can be
obtained by this technique.
© 2014 Elsevier B.V. All rights reserved.

1. Introduction Metal-rich primers such as Zn-rich primers (ZRPs) [9–11] for


steel and Mg-rich primers (Mg RPs) [12,13] for Al alloys also
In coating industry, pigments are widely using in modifying depend on understanding and control of CPVC effects. Control of
paint’s rheological properties, accomplishing the optimal esthetic, the particle-to-particle contact that exists at or above the CPVC is
hiding substrate or primer, achieving desirable anti-corrosion per- crucial to the performance and design of metal rich primers. The
formance, obtaining anti-UV ability to improve durability and renewed interest of this lab in CPVC measurements as shown in
reducing cost. It has been found that coating performance closely this paper and several others on Mg RPS is due to our interest in
depends on the pigment volume concentration (PVC) in dry coating improving our understanding and control of the performance of
film. Many coating properties, such as tensile, permeability, gloss, such coatings [14].
roughness, showed an abrupt change at certain PVC that is defined Usually, a specific change of coating properties with PVC is
as critical pigment volume concentration (CPVC) [4–7]. used to determine CPVC experimentally. By monitoring a partic-
The CPVC is one of the most important parameter in coating ular property change as a function of the PVC, the CPVC can be
design and formulation because the reduced pigment volume con- determined at the PVC value at which the property starts to change
centration () [5,7], which is the ratio of the PVC to CPVC, can abruptly [3]. Bierwagen and co-workers have given reviews of the
be used for predicting coating properties and interpreting coat- literature of the CPVC in 1975 [5], 1992 [6] and 1999 [15]. Various
ing film performance. Based on the dependence of film properties properties, e.g. gloss, internal stress, open circuit potential (OCP)
on , guidelines of optimal  levels for different coating classes [4,16], resistance, [5,17] impedance [18–20] and other electro-
are established [4,8]. With these guidelines, formulation of coat- chemical methods [21] and other mechanical properties [9,22] have
ing can be greatly simplified, saving bench work, time and cost in been reported to be used in CPVC determination. [Schematic figures
developing new coating system. for many of these specific CPVC measurements that have been used
for teaching the CPVC concept at NDSU and have not really been
published are given in Appendix A. These schematics are based on
many of the citations used in this paper or references cited therein.]
∗ Corresponding author.
Directly observing the appearance of voids, the general opera-
E-mail address: Gordon.Bierwagen@ndsu.edu (G. Bierwagen).
tional description of the CPVC seemingly agreed to by all authors

0300-9440/$ – see front matter © 2014 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.porgcoat.2013.12.010

Please cite this article in press as: J. Wang, et al., The determination of critical pigment volume concentration (CPVC) in organic coatings with
fluorescence microscopy, Prog. Org. Coat. (2014), http://dx.doi.org/10.1016/j.porgcoat.2013.12.010
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is uniform and therefore, the volume concentration of voids ϕv will


Nomenclature be above zero when PVC is larger than CPVC, as given in Eq. (1):

ϕi volume fraction of specific solid phase i in a polymer ⎪
⎨ 0 if PVC < CPVC
composite matrix, such as the phase volume frac- 1
ϕPVC =   if PVC > CPVC (1)
tion of pigments in a coating polymer, ϕpig ; standard ⎪
⎩ CPVC
1−
material science notation PVC
PVC pigment volume concentration in a coating film,
equivalent to ϕpig ; standard coating science nota- According to Eq. (1), voids only appear at PVC that is above CPVC
tion and thus, an abrupt change in ϕv or consequently in various coating
CPVC critical pigment volume concentration; the PVC at properties is expected at CPVC. So the lowest PVC that shows the
which there is just sufficient coating polymer to wet presence of voids is considered the CPVC.
the pigments and fill the voids between pigment This equation is discontinuous at the CPVC in a manner almost
particles exactly like the Heaviside Step function [25,26], often written as
 the reduced pigment volume concentration – H(x). It is defined as follows:
PVC/CPVC

0 if x < 0
SEM scanning electron microscopy H(x) = (2)
1 if x > 0
EIS electrochemical impedance spectroscopy
OCP open circuit potential or free corrosion potential In this notation, one can rewrite, using  = PVC/CPVC [5], Eq. (1)
Gilsonite solution tar-based staining solution used in drop- as
in-reflectance (DIR) measurements
1
H(x) Heaviside step function, see Eq. (2) for definition or ϕv = H( − 1) · (3)
1 − (1/)
Ref. [18]
ULAM ultra low angle microtoming However, it has been observed that in many coating systems
Coarseness standard deviation of the local phase volume the formation of voids actually begins to occur below the CPVC,
concentration of a dispersed phase from the global as indicated by the gradual transformation of coating’s properties
phase volume concentration divided by the global starting at a PVC below the CPVC rather than an abrupt change
phase volume concentration (see Ref. [3]) at the CPVC [6]. This caused the local fluctuations in the pigment
volume concentration caused by non-uniform dispersion of pig-
ment. Because the dispersion of pigment particle is not practically
uniform, the local pigment volume concentration may vary from
region to region [2,3,7]. In some local regions of a paint film, the
cited above, would be a more straightforward way to determine local pigment volume concentration may be larger than CPVC even
CPVC than most of the methods described above. According to the though the global pigment volume concentration is less than the
original concept of the CPVC, voids begin to emerge when the PVC CPVC. As a result, voids may emerge in these regions even though
exceeds the CPVC. Monitoring the point at which voids appear the global PVC of coating is below the CPVC. This also shows up
in coating system should thus accurately measure the CPVC. For in simulations of particle packing that closely emulate packing in
instance, staining by Gilsonite solution has been used to detect the paint films [27,28]. Hence, the experimentally determined CPVC
presence of voids in coating system, as has “scrub resistance”, the value is often underestimated and can be highly dependent on
ability of a coating to withstand multiple “scrub” based cleaning the preparation of coating film. A method that examined the onset
cycles [23,24]. When PVC is larger than CPVC, the coating would and rapid increase of voids with PVC would give a more accurate
be significantly stained due to the existence of voids. If one can experimental description of the CPVC.
unequivocally identify a void in a SEM image, SEM can also be used In present work, a new experimental method for CPVC deter-
to study the cross-section of coating films at different PVCs to detect mination is reported that satisfies the issues just mentioned. By
the appearance of voids, as was done by Lobnig et al. [6,7]. The marking/decorating the voids in a cross-section of coating films
CPVC value obtained in this way showed a good agreement with with a fluorescent dye, the appearance of voids can be clearly
that obtained from EIS measurement.1 detected at very high sensitivity in fluorescence images of coating
However, all these methods suffer the same problem of under- cross section. A quantitative analysis of the fluorescence images
estimating the CPVC because they adopt the same concept that the is used to obtain the voids fraction. Based on the change of voids
CPVC is the smallest PVC at which the voids appear. This is based on fraction as a function of PVC, an accurate estimate of the CPVC can
the assumption that the dispersion of pigment in polymer binder be made. This method removes some of the influence of pigment
agglomeration and leads to more accurate experimental evaluation
of the CPVC.

1
One issue not addressed satisfactorily by any author is the effect of the size/size
2. Experimental
distribution of voids on the accuracy of a CPVC measurement. The penetration of
voids by a liquid stain is obviously proportional to the ability of the staining liquid A series of Mg-rich primer samples were prepared by mixing
to enter a void, a process often judged to be controlled by the surface tension of the pure Mg or Mg alloy particles with an epoxy-polyamide system at
liquid entering a void. In the case of using light scattering to characterize voids, the
various PVCs. There were five different types of Mg particles (abbre-
wavelength of the light used is a determining parameter, indicating UV radiation
will measure a smaller void onset size than IR. In general, to the accuracy of the viated as MRP-1 to MRP-5 later) used in this work. Pigment for
measurement method, all CPVC measurements seem to give the same endpoint, but MRP-1 was from Reade Manufacturing company, Manchester, NJ;
with varying degrees of scatter. The statistics of endpoint determination has been pigment for MRP-2 to 4 was from Hart Metals Inc., Tamaqua, PA and
discussed in Ref. [17] where various CPVC measurement procedures are compared pigment for MRP-5 was from Ecka Granules GmbH, Fürth, Germany.
in latex coatings. The sharpness of the endpoint is discussed in Refs. [2,3], where it is
shown to involve the uniformity of the particulate solid concentration distribution
Methyl-ethyl-ketone (MEK) was used as solvent to maintain vis-
in the pigmented coating. The use of the techniques of this paper in this regard will cosity for air-spray application. The formulated Mg-rich primers
be the subject of a future publication. were applied by air-spray on the surfaces of 2024-T3 Al alloy panels

Please cite this article in press as: J. Wang, et al., The determination of critical pigment volume concentration (CPVC) in organic coatings with
fluorescence microscopy, Prog. Org. Coat. (2014), http://dx.doi.org/10.1016/j.porgcoat.2013.12.010
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area. Adamsons [25,26] describes the microtoming methods in


detail.

3. Results and discussion

The main idea of using fluorescence microscopy for determin-


ing CPVC is to use fluorescent dye to mark (or decorate) the
coating microstructures, particularly voids. It makes voids easy to
be detected with fluorescence microscope. The images obtained
by fluorescence microscope not only can identify the coating
microstructures distinguishably but also can be quantitatively ana-
lyzed by image process software to obtain information of their
spatial location and concentration in coating layer.
The workflow for determining CPVC is schematically shown in
Fig. 1. Scheme of ultra-low angle microtome (ULAM) setup. Fig. 2. It consists of three steps: sample preparation, fluorescent
image collection and image process.
The first step is sample preparation. The purpose of sample
(3 in. × 6 in. × 0.05 in., Q panel lab, Cleaveland, OH), which were pre-
preparation is to obtain an observable sample for fluorescence
treated to remove the oxide layer and followed by hexane rinse to
microscope that fulfills the two requirements:
clean the surface. All the primers were cured at room temperature.
The panels coated with Mg-rich primers were cut into
0.75 in. × 0.75 in. coupons for fluorescent dye staining. The coupons (1) the microstructures of interest can be stained by chosen fluo-
were first immersed in 0.1% Rhodamine-B (Sigma, St. Louis, MO) rescent dye;
aqueous solution for 4 h followed by rinsing with de-ionized water, (2) the inner microstructures can be revealed for imaging by fluo-
then air-dried coupons for further sample preparation. rescence microscope, which is only sensitive to sample surfaces
Low angle cross sections of the coating samples were prepared or transparent samples. Therefore, a cross section sample of
by ultra-low angle microtome (ULAM) techniques. A coupon were stained coating coupon was prepared by immersing coating
fixed on a customized low angle stage and cut by a Leica SM-2500 coupon in aqueous solution of chosen fluorescent dye followed
sliding microtome in horizontal direction. A schematic of the sam- by cutting with ultra-low angle microtome.
ple setup is shown in Fig. 1 and the process was described in detail
elsewhere [29]. Cutting at an angle ˛ away from surface plane yields The fluorescent dye used in this work was Rhodamine-B in
a cross-section width of 1/tan(˛) folds of coating thickness. This 0.1% aqueous solution. It can stain the polymer binder (epoxy-
means that with a small angle such as 1◦ , the width of cross section polyamide in this work) effectively and also move into the void
can be nearly 60 times that of the coating thickness. Microtoming structures of the coating and concentrate there as the water evap-
slices of coatings have been used by several laboratories for other orates. At the same time, no diffusion into polymer binder was
analytical purposes [30] and the many references in the bibliogra- observed. After drying under ambient lab conditions, a coating
phy of this paper. A more recent paper by this same author was coupon with the voids decorated by the fluorescent stain was
recently published [31]. obtained. The surface of the coating was completely stained by fluo-
An Olympus LM60 fluorescence microscope (Olympus Amer- rescent dye and the more important thing is fluorescent dye can fill
ican Inc., Center Valley, PA) equipped with U/B/G filter (Chroma the voids and stained the polymer binder on the wall of voids. The
Technology Corp., Rockingham, VT) was used to obtain fluores- dye does not preferentially concentrate in the bulk coating polymer
cence images from the low angle cross section of fluorescent matrix. As a result, both coating surface and voids are stained, as
dye-stained coating films. The fluorescent images were ana- schemed in Fig. 2a and b.
lyzed by using ImageJ software (National Institute of Health, Following staining the coating coupon was cut with an ultra-
http://rsbweb.nih.gov/ij/) to obtain the area fraction of fluorescent low angle microtome (ULAM) to prepare a low angle cross section

Fig. 2. Schematic of workflow of taking fluorescent images of coating samples.

Please cite this article in press as: J. Wang, et al., The determination of critical pigment volume concentration (CPVC) in organic coatings with
fluorescence microscopy, Prog. Org. Coat. (2014), http://dx.doi.org/10.1016/j.porgcoat.2013.12.010
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Fig. 3. Fluorescent images of MRP-2 primers at various PVCs. (For interpretation of the references to color near citation of this figure, the reader is referred to the web version
of this article.)

of coating layer. There are two reasons for using cross section of between 27% and 31%. The volume of voids kept increasing as the
coatings for measurement. The first one is that void volume fraction PVC increased higher. At PVC of 42%, voids seemed to connect with
is essentially a property of coating bulk but fluorescence micro- each other and a bicontinuous network of voids formed.
scope is a surface sensitive approach. By using cross section sample, In step 3, the fluorescence images obtained in step 2 were ana-
the structure of coating bulk is exposed in the new section surface lyzed by ImageJ software to obtain the area fraction of the region
and becomes accessible to fluorescence microscope. The second stained by the fluorescent dye. Since the fluorescent areas origi-
one is that the interference from stained coating surface is elim- nated from voids, the area fraction of fluorescent regions can be
inated because it is removed during cross-section preparation. It considered as a measure of volume fraction of voids and the plot
has to be emphasized that low angle cross section is a necessity in of the fraction of fluorescent region vs. PVC can be used for CPVC
our work. In conventional cross section preparation, coating sam- determination.
ple is cut perpendicularly to coating surface. The width of prepared In performing the image analysis to determine the area of
cross section across coating layer is equal to the coating thickness. stained voids, a fluorescence image was split into red, blue and
As a result, only a tiny part of coating layer can be explored from green color channels. The image in red channel was selected for
this cross section. In contrast, using ultra low angle microtome, the the marker of void area because it provided the highest contrast
coating layer is cut at a small angle (e.g. 1–2◦ ) away from surface between voids and other two phases. After masking the image with
(as shown in Fig. 2c). The width of obtained cross section can be a certain threshold of brightness of emission, a binary image was
many time the coating thickness and across a large area of coating obtained and analyzed by the particle analysis module in ImageJ to
layer. This enables one to sample much larger longitudinal area than obtain the area fraction of fluorescing voids. Then multiple images
a cross-section prepared by cutting normal to the coating surface are analyzed from randomly chosen areas to minimize the statisti-
and makes the results more statistically representative. cal errors due to sampling. The final result of area fraction at certain
After ULAM, three coating phases are exposed to cross-section PVC shown here is an average of results from 20 to 24 images that
surface: pigment, unstained polymer binder and voids with their taken on the areas randomly chosen on a cross section. This method
wall stained by fluorescent dye. Under fluorescence microscope, was used in CPVC measurements described in an earlier publication
stained voids wall emits fluorescence and forms the bright spots in [33].
the image while the other two phases only give dark background. Fig. 4 shows the plot of the fraction of fluorescent region against
Hence, the voids can be clearly distinguished with high contrast in PVC with MRP-2 primer. From Fig. 4, it can observed that the area
fluorescent images. fraction is almost 0 at 27% PVC, which is consistent with the obser-
The second step is collecting the fluorescent images. This is vation from fluorescence image. A gradual increase of area fraction
conducted via standard procedure in reflective mode with a con- is found at PVC between 27% and 34%, reflecting the influence
ventional fluorescence microscope. Rhodamine-B has an emission of non-uniform dispersion of pigment. Beyond PVC of 34%, the
maximum at ∼560 nm and exhibits an emission spectrum tail increase becomes abrupt. If one examines Fig. 4* [By permission
to700 nm [32]. With a U/B/G filter, the fluorescent areas are shown from G.P. Bierwagen, R.S. Fishman, T. Storsved, J. Johnson, “Recent
as orange spots in viewfinder and the images were taken by CCD studies of particle packing in organic coatings,” Prog. Org. Coatings,
camera. 35 (1999) 1–10], one can see the similarity to the theoretical predic-
Fig. 3 shows a series of typical fluorescence images taken with tions of the earlier work of Fishman et al. and Bierwagen et al., of the
MRP-2 primers at various PVC’s. It can be seen that the three phases onset of voids in systems with non-ideal distribution of pigments
in coating layer can be clearly distinguished: pigment in black, and polymer (coarseness = / 0) to the results of Fig. 3.
polymer binder in cyan while voids in orange. As mentioned before, ideally an abrupt increase of area fraction
As expected, it can be observed that the amount of voids is expected at CPVC, as shown in blue solid line in Fig. 4. But with the
increased with increasing PVC. At PVC of 27%, almost no voids influence of non-uniform dispersion of pigment particles, a gradual
were detected. A few orange spots were observed in the image of transition onset takes the place at PVC around CPVC, as indicated
primer at 31%, indicating voids starting to occur in coating layer by the red dot curve in Fig. 4. Hence, if the extrapolation of the

Please cite this article in press as: J. Wang, et al., The determination of critical pigment volume concentration (CPVC) in organic coatings with
fluorescence microscopy, Prog. Org. Coat. (2014), http://dx.doi.org/10.1016/j.porgcoat.2013.12.010
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0.6 Table 1
CPVC values of various MRP system determined by fluorescence microscopy method,
as a comparison with value from OA measurement, value from EIS and value from
a modified model to correct the influence of particle shape [34].
0.5
Fluorescence EIS (%) Modified OA method
microscopy method (%) [Appendix A] (%)

0.4 MRP-1 40.4 36.9


MRP-2 32.6 30.8 33.4
Area Fraction

MRP-3 33.5 34.8 32.6


MRP-4 48.5 46.7
0.3
MRP-5 41.4 39.1 41.2

0.2
be noticed that this value is larger than the PVC at which voids start
to emerge.
CPVC From Table 1, it can be seen that the CPVC values obtained from
0.1
fluorescence microscopy method presented in this paper showed
good agreement with the values obtained from EIS measurement
(32.6, 0) (Fig. 5). They are also consistent with the values calculated from
0.0
0 10 20 30 40 50 60 modified OA method. These consistent results indicated that the
CPVC determination with fluorescence microscopy method is suit-
PVC (%)
able for MRP coatings.
Fig. 4. Plot of area fraction of fluorescent area change with PVC. (For interpretation With the plot of change of area fraction of fluorescent areas as
of the references to color near citation of this figure, the reader is referred to the a function of PVC, the abrupt change in void volume fraction with
web version of this article.) PVC can be identified and therefore an accurate CPVC value can be
determined. This method eliminates the influence of non-uniform
pigment dispersion and avoids the underestimation of CPVC that
commonly existing in the other experimental CPVC determination
methods. When the onset of void-formation related properties is
used as criterion of CPVC, the CPVC may easily be underestimated,
as shown in Fig. 4* and other predictions [15]. This method has
shown promising results in determining CPVC of MgRP coating sys-
tems and is being applied other coating systems. Future work will
include the examination of the influence of pigment size, fluores-
cent dyes and other factors introduced by the various features of
this new test method.

4. Conclusion

A new method that using fluorescence microscopy for CPVC


determination was reported and the results of determining CPVC
of Mg-rich primer system are given. By measuring the voids frac-
tion of coating layer against PVC, a more accurate CPVC value can
Fig. 4*. Void fraction vs. reduced PVC (PVC/CPVC) for various values of “coarseness”
of pigment distribution in a paint film.
be determined. The results agree with earlier theoretical predic-
tions of a more gradual onset of void occurrence below the CPVC
in non-ideally dispersed pigment/polymer systems [2,3] and show
abrupt increase part is plot, its intercept with X-axis (marked as the value of developing a method capable of making numerical
red triangle) will give the accurate CPVC value and the influence of assessment of void fraction in coatings as well as clearly visualizing
non-uniform dispersion of pigment can be eliminated. Following the presence and distribution of voids. The CPVC values obtained
this analysis, the CPVC of MRP-2 can be determined as 32.6%. It can showed good agreement with those measured by EIS method and

10 10 10

MPR-2
AM60
LNR91
MPR-5
8 8 8
MPR-3
AZ91B
Log |Z| (ohm)

Log |Z| (ohm)


Log |Z| (ohm)

39.1%
30.8%

6 6 6
34.8%

4 4 4

25 30 35 40 45 30 35 40 45 30 35 40 45 50
PVC (%) PVC (%) PVC (%)

Fig. 5. Impedance modulus at 0.01 Hz (|Z|0.01 Hz ) of primer samples as a function of PVC and the determination of CPCV.

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calculated values indicating this method is reliable and successfully


applied to MRP system. Further extension of this method to other
coating systems is still ongoing and it could be developed to be a
high reliable method for CPVC determination.

Appendix A. Schematics of common methods for CPVC


determination

See Figs. A1–A10.

Fig. A4. Schematic of CPVC determination by measurement of permeability (see


Refs. [1,5,7,21]).

Fig. A1. Schematic of CPVC by light scattering/reflectance (see Refs. [3,5,23]).

Fig. A5. Schematic of CPVC determination by measurement of gloss (see Refs.


[5,23]).

Fig. A2. Schematic of CPVC determination by film density measurement (see Refs.
[2,3,5,6]).


Enamel Holdout
G = Drop in gloss of coating over
film of varying PVC
-method affected
by pigment PSD +
viscosity of paint

G
Gloss Drop
due to
Polymer
from wet
coating loss
into voids
PVC ( φpig )
Fig. A6. Schematic of CPVC determination by measurement of enamel holdout (see
Ref. [5]).
Fig. A3. Schematic of CPVC determination by film scrub resistance (see Refs. [5,23]).

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DIR ≡ Drop in reflectance upon staining with Film Elastic Modulus/Tensile Strength
black ink and subsequently wiping surface:
Ink cannot be removed from voids which form E = Elastic Modulus of Composite: film gets
above CPVC.
Loss of reflectance stronger and more rigid as φ pig increases,then
from black ink breaks easily in the presence of voids.
penetration into voids

DIR
Good Method. E
Accurate. Accurate Method.
Easy to Perform Difficult to Perform.

PVC (φpig)
PVC ( φpig)
Fig. A7. Schematic of CPVC determination by measurement of drop in reflectance
(see Refs. [4,5,6,23]). Fig. A10. Schematic of CPVC determination by measurement of tensile strength (see
Refs. [2,3,5,15,23]).

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Please cite this article in press as: J. Wang, et al., The determination of critical pigment volume concentration (CPVC) in organic coatings with
fluorescence microscopy, Prog. Org. Coat. (2014), http://dx.doi.org/10.1016/j.porgcoat.2013.12.010

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