Model-based analysis of thermal insulation coatings

Thermal insulation properties of coatings based on selected functional filler materials are investigated. The underlying physics, thermal conductivity of a heterogeneous two-component coating, and porosity and thermal conductivity of hollow spheres (HS) are quantified and a mathematical model for a thermal insulation coating developed. Data from a previous experimental investigation with hollow glass sphere-based epoxy and acrylic coatings were used for model validation. Simulations of thermal conductivities were in good agreement with experimental data. Using the model, a parameter study was also conducted exploring the effects of the following parameters: pigment (hollow spheres) volume concentration (PVC), average sphere size or sphere size distribution, thermal conductivities of binder and sphere wall material, and sphere wall thickness. All the parameters affected the thermal conductivity of an epoxy coating, but simulations revealed that the most important parameters are the PVC, the sphere wall thickness, and the sphere wall material. The model can be used, qualitatively, to get an indication of the effect of important model parameters on the thermal conductivity of an HS-based coating and thereby be used as a specification tool or as a help in the planning of relevant experiments to conduct. Further work with the model must involve additional experiments to secure a general verification of important underlying model assumptions.