Preparation of Urea-Formaldehyde-Coated Cationic Red-Ternary System Microcapsules and Properties Optimization

Thermochromic microcapsules were synthesized and optimized using crystal violet lactone, bisphenol A, and decanol as the core materials, a dispersible cationic red dye as the color-modifying additive, and urea-formaldehyde resin as the wall material, based on orthogonal and single-factor experiments. The effects of the proportion of cationic red dye in the core material, the mass ratio of formaldehyde to urea, the emulsifier HLB value, and the core–wall mass ratio on yield, encapsulation rate, thermochromic ΔE, and formaldehyde release of microcapsules were systematically investigated. The results showed that the core–wall ratio was the key factor affecting the comprehensive performance of the microcapsules. Through the comparison of orthogonal and single-factor tests, 11# microcapsule was identified as having the best overall performance in terms of ΔE, and encapsulation rate. The ΔE value was increased by about 165% compared with the lowest-performing sample, significantly enhancing the thermochromic response. The encapsulation rate was improved by nearly 40%, effectively enhancing the encapsulation quality and core stability, with overall performance standing out. The best preparation process was to add 0.5% of the core material mass of dispersible cationic red dye, the mass ratio of formaldehyde and urea was 1.2:1, the HLB value of emulsifier was 10, and the core–wall ratio was 1:1.1. The yield of 11# microcapsules prepared under this condition was 31.95%, the encapsulation rate was 68%, the thermochromic ΔE was 9.292, and the formaldehyde release concentration was 1.381 mg/m3. Furthermore, 11# microcapsules with different addition levels were introduced into the UV primer to evaluate their effects on the mechanical and optical properties of the coating. The results showed that the addition of microcapsules weakened the gloss and light transmittance of the coating, increased the surface roughness, and decreased the elongation at break. When the addition amount was 5%, the coating exhibited the best overall performance: UV-visible light transmittance reached 91.92%, 60° gloss was 42.2 GU, elongation at break was 9.3%, and surface roughness was 0.308 μm. This study developed a purple thermochromic microcapsule system by regulating the dispersible dye content and interfacial conditions. In coating applications, the system exhibited a strong ΔE response and excellent overall performance, offering great advantages over existing similar systems in terms of color-change efficiency, ΔE enhancement, and coating adaptability.