Preparation and Performance Characterization of Melamine-Formaldehyde-Microencapsulated Waterborne Topcoat–Brass Powder–Waterborne Acrylic Coating

A novel self-healing brass powder/waterborne acrylic decorative coating for wooden substrates was developed, in which γ-methacryloxypropyltrimethoxysilane (KH570)-modified brass powder (with a coupling agent concentration of 6% and reaction solution pH of 5) was employed as the filler, and melamine-formaldehyde (MF) resin-encapsulated water-based paint microcapsules were utilized as the healing agent. The brass powder content and the core–wall ratio of the topcoat microcapsules were identified as the predominant factors affecting both the optical and mechanical properties of the self-healing brass powder/waterborne acrylic coating on Basswood surfaces. Therefore, the brass powder content was selected as the primary influencing factor. With concentration gradients of 0.5%, 1%, 3%, 5%, 7%, 9%, and 10%, and under constant conditions of 3% microcapsule content and room temperature curing, the effect of brass powder content on the properties of self-healing microcapsule coatings with different core–wall ratios was investigated. The waterborne acrylic wood coating containing 3% brass powder and 3% microcapsules with a core–wall ratio of 0.58:1 exhibited superior overall performance. This optimized formulation not only maintained excellent optical properties but also significantly enhanced mechanical performance, while preserving outstanding aging resistance, liquid resistance, and self-healing capability. The coating demonstrated the following comprehensive performance metrics: a glossiness of 24.0 GU, color difference (ΔE) of 2.13, chromatic aberration (ΔE*) of 13.68, visible light reflectance of 0.5879, dominant wavelength of 587.47 nm, visible light transmittance of 74.33%, pencil hardness of H grade, impact resistance of 2 kg·cm, adhesion rating of class 2, surface roughness of 2.600 μm, along with excellent aging resistance and liquid resistance properties, while achieving a self-healing efficiency of 19.62%. The coating also exhibited a smooth and uniform microscopic morphology, with the chemical bonds of both the modified brass powder and microcapsules remaining intact within the coating matrix.