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A series of high solid content carboxylic acid/sulfonic acid waterborne polyurethanes was prepared by the emulsion dispersion method. The particle size and solid content were measured. By changing the particle size of the large particles to achieve different particle size ratios, high solid content waterborne polyurethanes were obtained at specific particle size ratios. When the particle size ratio was >7, 4–5 or 2–3, the aqueous polyurethane could reach a higher solid content (more than 56%). This indicated that solid content is related to particle size distribution in high solid content waterborne polyurethane. Moreover, the corresponding three-dimensional stacked models (simple cubic accumulation, face-centered cubic accumulation, cubic close packing and hexagonal closest packing) were established.

Particle shape is a significant feature of irregular particles. The interferometric particle imaging (IPI) technique has been introduced to retrieve submillimetric irregular rough particle shapes, while inevitable experimental noises hinder the convergence of two-dimensional (2D) particle shapes from single speckle patterns. In this work, a hybrid input–output algorithm with shrink-wrap support and oversampling smoothness constraints is utilized to suppress the Poisson noise in IPI measurement and recover accurate 2D shapes of particles. Our method is tested in numerical simulations on ice crystal shapes and actual IPI measurements on four different types of irregular, rough particles. The shape similarity of the reconstructed 2D shape has reached an average Jaccard Index score of 0.927, and the relative deviation of the reconstructed size is within 7% for all 60 tested irregular particles at the maximum shot noise level of 7.4%. Furthermore, our method has obviously reduced the uncertainty in the 3D shape reconstruction of irregular, rough particles.

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