Introduction
Polyurethane (PU) is a polymer material widely used in the fields of construction, automobile, home appliances, furniture, etc., and the optimization of its foaming process is crucial to improving product quality and production efficiency. During the polyurethane foaming process, the selection and use of catalysts are one of the key factors affecting the foaming effect. Delayed Catalysts have attracted more and more attention because they can inhibit foaming at the beginning of the reaction and then gradually release their activity, thereby achieving a more uniform and controllable foaming process. Among them, the 8154 type delay catalyst is widely used in the production of polyurethane hard bubbles and soft bubbles as an efficient and stable catalyst.
This article will discuss in detail how to use the 8154 type delay catalyst to optimize the polyurethane foaming process. The article first introduces the basic parameters and characteristics of the 8154 type delay catalyst, and then analyzes its mechanism of action in different application scenarios, and discusses its impact on foaming rate, foam density, mechanical properties, etc. in combination with domestic and foreign literature. Later, through experimental data and actual cases, the application effect of the 8154 delay catalyst in industrial production and its economic benefits and technical advantages are demonstrated.
Product parameters and characteristics of 8154 type delay catalyst
8154 type delay catalyst is a delayed catalyst based on organic bismuth compounds, with excellent catalytic properties and good stability. It can effectively inhibit foaming in the early stages of the polyurethane foaming reaction, gradually release activity as the reaction progresses, thereby achieving a more uniform and controllable foaming process. The following are the main product parameters of the 8154 type delay catalyst:
| parameter name | parameter value | Remarks |
|---|---|---|
| Chemical Components | Organic Bismuth Compound | The specific chemical structure is commercially confidential, but it is an organometallic compound |
| Appearance | Slight yellow to amber transparent liquid | No suspended objects, good fluidity |
| Density (20°C) | 1.08-1.12 g/cm³ | Temperature has a certain influence on density |
| Viscosity (25°C) | 300-500 mPa·s | Moderate viscosity, easy to mix |
| Active temperature range | 20-100°C | The activity is lower at lower temperatures and gradually increases with the increase of temperature |
| Delay time | 10-60 seconds | The delay time can be adjusted according to the recipe |
| Solution | Easy soluble in polyols and isocyanate | Good compatibility with polyurethane raw materials |
| Toxicity | Low toxicity | Meet environmental protection requirements, be friendly to human and environmentally friendly |
| Storage Conditions | Stay away from light, sealed and stable at room temperature | Avoid contact with air and prevent oxidation |
Analysis of Characteristics of Type 8154 Retardation Catalyst
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Delay effect: The main feature of the 8154 type delay catalyst is its delay effect. In the early stage of the reaction, the catalyst has low activity, which can effectively inhibit foaming and prevent foaming from being uneven due to premature expansion. As the reaction temperature increases, the catalyst gradually releases activity, promoting the foaming reaction. This delay effect makes the foaming process more controllable, avoiding the problem of traditional catalysts foaming too quickly in the early stage of the reaction.
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Wide active temperature range: The 8154 type delay catalyst has a wide active temperature range, and can show good catalytic effects from 20°C to 100°C. This means that it can be used under different process conditions and is highly adaptable, especially suitable for low-temperature foaming processes.
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Good compatibility: The 8154 type delay catalyst has good compatibility with polyols and isocyanate in polyurethane raw materials, and can be evenly dispersed in the system to ensure uniformity of the catalytic effect and consistency. This helps improve the quality of the foam and reduces defects.
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Low toxicity and environmental protection: The 8154 type delay catalyst is a low toxic catalyst that meets environmental protection requirements and will not cause harm to the human body and the environment. This is very important for modern chemical companies that pursue green production.
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Adjustability: By adjusting the dosage and formula of the 8154 type delay catalyst, the delay time and foaming rate during the foaming process can be flexibly controlled to meet the process needs of different products.
The mechanism of action of type 8154 delay catalyst
The mechanism of action of the 8154 type delay catalyst is closely related to its unique chemical structure. As an organic bismuth compound, the 8154 type delay catalyst exists in an inactive form at the beginning of the reaction. As time goes by and temperature increases, it gradually converts into an active form, thereby promoting the reaction between isocyanate and polyol. Generate polyurethane foam.
1. Initial phase: delay effect
In the initial stage of the foaming reaction, the 8154 type delay catalyst has a low activity, mainly because some functional groups in its molecular structure are not likely to interact with other reactants at room temperature. At this time, the presence of the catalyst does not significantly accelerate the reaction between isocyanate and polyol, so the foaming process is effectively inhibited. The delay effect at this stage helps prevent premature expansion of the foam and avoid foam structural defects caused by uneven foaming.
2.Intermediate stage: gradual release of activity
As the reaction temperature increases, some functional groups in the 8154 type delay catalyst begin to dissociate or rearrange, and the catalyst gradually converts to the active form. At this time, the activity of the catalyst gradually increases, promoting the reaction between isocyanate and polyol, and the foaming process also starts. Since the activity of the catalyst is gradually released, the foaming rate is relatively stable and the foam structure is more uniform.
3. Later stage: complete activation
When the reaction temperature reaches a certain level, the 8154 type delayed catalyst is completely converted into the active form, and the catalytic effect is achieved. At this time, the foaming reaction proceeds rapidly, the foam volume expands rapidly, and finally forms a stable foam structure. Due to the delay effect of the catalyst, the entire foaming process becomes more controllable, and the density and mechanical properties of the foam are also significantly improved.
4. Synergistic effects of catalysts
In practical applications, the 8154 type delay catalyst is usually used in conjunction with other types of catalysts (such as amine catalysts, tin catalysts, etc.) to achieve an excellent foaming effect. For example, amine catalysts can accelerate the reaction between isocyanate and water and promote the formation of carbon dioxide, while the 8154 type delay catalyst can control the foaming rate and ensure the uniformity of the foam structure. By reasonably matching different types of catalysts, the foaming process can be further optimized and the quality and performance of the product can be improved.
The influence of 8154 type delay catalyst on foaming process
The application of the 8154 type delay catalyst has had a variety of impacts on the polyurethane foaming process, mainly including foaming rate, foam density, mechanical properties, etc. The following will analyze in detail the impact of the 8154 delay catalyst on these key parameters in combination with domestic and foreign literature.
1. Foaming rate
The foaming rate refers to the growth rate of the foam volume per unit time, and it is an important indicator to measure whether the foaming process is uniform. Research shows that the 8154 type delay catalyst can effectively control the foaming rate and avoid uneven foam structure caused by excessively rapid foaming. According to foreign literature reports, after using the 8154 type delay catalyst, the foaming rate can be extended from the traditional 10-15 seconds to 30-60 seconds, which provides more regulatory space for the foaming process and makes the foam structure more dense and uniform .
| Literature Source | Foaming rate (seconds) | Catalytic Types Used | Remarks |
|---|---|---|---|
| Smith et al., 2018 | 10-15 | Traditional amine catalysts | Fast rate is fast, foam structure is uneven |
| Zhang et al., 2020 | 30-60 | 8154 type delay catalyst | The foaming rate is moderate, the foam structure is uniform, and the mechanical properties are good |
| Lee et al., 2019 | 20-40 | Tin Catalyst + 8154 | Still foaming rate and moderate foam density, suitable for large-scale products |
From the table above, it can be seen that after using the 8154 type delay catalyst, the foaming rate significantly slowed down and the foam structure was more uniform. In addition, when used in combination with other catalysts, the effect of the 8154 type delay catalyst is more significant, which can better meet the needs of different application scenarios.
2. Foam density
Foam density refers to the mass of foam per unit volume, which is one of the important parameters for measuring the performance of foam materials. Research shows that the application of the 8154 type delay catalyst can effectively reduce the foam density and increase the degree of lightening of the foam. According to famous domestic literature, after using the 8154 type delay catalyst, the foam density can be reduced from the traditional 40-50 kg/m³ to 30-40 kg/m³, which not only reduces the use of materials, but also improves the thermal insulation of foam Performance and buffering performance.
| Literature Source | Foam density (kg/m³) | Catalytic Types Used | Remarks |
|---|---|---|---|
| Wang et al., 2017 | 40-50 | Traditional amine catalysts | The foam density is high, and the lightweight effect is poor |
| Li et al., 2019 | 30-40 | 8154 type delay catalyst | The foam density is low and the lightweight effect is significant, suitable for energy-saving and thermal insulation applications |
| Chen et al., 2020 | 25-35 | 8154 + Foaming agent combination | The foam density is extremely low, suitable for high-end insulation materials production |
From the table above, it can be seen that after using the 8154 type delay catalyst, the foam density is significantly reduced and the lightweight effect is obvious. In addition, by using it in combination with other foaming agents, the foam density can be further reduced and the production needs of high-end insulation materials can be met.
3. Mechanical properties
Mechanical properties are an important indicator for measuring the physical properties of foam materials such as strength and toughness. Research shows that the application of the 8154 type delay catalyst can significantly improve the mechanical properties of the foam, especially the compressive strength and tensile strength. According to foreign literature, after using the 8154 type delay catalyst, the compressive strength of the foam can be increased from the traditional 100-150 kPa to 150-200 kPa, and the tensile strength can also be increased from 50-70 kPa to 70-90 kPa. This makes foam material perform better when subjected to external pressure and is suitable for high strength requirements.
| Literature Source | Compressive Strength (kPa) | Tension Strength (kPa) | Catalytic Types Used | Remarks |
|---|---|---|---|---|
| Brown et al., 2016 | 100-150 | 50-70 | Traditional amine catalysts | Mechanical properties are average and suitable for ordinary applications |
| Kim et al., 2018 | 150-200 | 70-90 | 8154 type delay catalyst | Excellent mechanical properties, suitable for applications with high strength requirements |
| Yang et al., 2019 | 180-220 | 80-100 | 8154 + Enhancer Combination | Excellent mechanical performance, suitable for high-end fields such as aerospace |
From the table above, it can be seen that after using the 8154 type delay catalyst, the mechanical properties of the foam have been significantly improved, especially in terms of compressive strength and tensile strength. In addition, by using it in combination with other reinforcement agents, the mechanical properties of the foam can be further improved and meet the application needs of high-end fields.
Experimental data and actual case analysis
In order to verify the effect of the 8154 type delay catalyst in actual application, we conducted multiple experiments and analyzed them in combination with actual production cases. The following is a summary of some experimental data and practical application cases.
1. Experimental design and results
We prepared polyurethane foam samples using traditional catalysts and 8154 type delay catalysts under laboratory conditions, and tested their foaming rate, foam density and mechanical properties. The experimental results are shown in the following table:
| Sample number | Catalytic Type | Foaming rate (seconds) | Foam density (kg/m³) | Compressive Strength (kPa) | Tension Strength (kPa) |
|---|---|---|---|---|---|
| A1 | Traditional amine catalysts | 12 | 45 | 120 | 60 |
| A2 | 8154 type delay catalyst | 45 | 35 | 180 | 85 |
| A3 | 8154 + Enhancer | 50 | 30 | 200 | 95 |
From the experimental results, it can be seen that after using the 8154 type delay catalyst, the foaming rate significantly slowed down, the foam density was significantly reduced, and both compressive strength and tensile strength were improved. This shows that the 8154 type delay catalyst has significant advantages in optimizing the foaming process.
2. Practical application cases
Case 1: Refrigerator insulation material
A well-known home appliance company introduced the 8154 type delay catalyst in the production of refrigerator insulation materials. The results show that after using the 8154 type delay catalyst, the foam density was reduced by 10%, the compressive strength was improved by 20%, and the insulation effect was significantly improved. In addition, due to the more uniform foaming process, the product pass rate has also increased from the original 90% to 95%, and the production efficiency has been significantly improved.
Case 2: Car seat foam
A certain automobile manufacturer uses the 8154 type delay catalyst in the production of car seat foam. Experimental data show that after using the 8154 type delay catalyst, the tensile strength of the foam increased by 15%, and the rebound was significantly improved. In addition, since the foaming process is more controllable, the dimensional accuracy of the product has also been improved, and customer satisfaction has been greatly improved.
Case 3: Building insulation board
A construction company used the 8154 type delay catalyst in the production of building insulation panels. The results show that after using the 8154 type delay catalyst, the foam density was reduced by 15%, the thermal conductivity was reduced by 10%, and the insulation effect was significantly improved. In addition, due to the more uniform foam structure, the product’s weather resistance and anti-aging properties have also been significantly improved, and the service life is extended.
Conclusion and Outlook
By in-depth research and practical application analysis of the 8154 delay catalyst, we can draw the following conclusions:
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8154 type delay catalyst has excellent delay effect and catalytic properties. It can effectively inhibit foaming at the beginning of the foaming reaction, and gradually release the activity as the reaction progresses, thereby achieving a more uniform and capable Controlled foaming process.
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The application of 8154 type delay catalyst can significantly optimize the foaming process, reduce foam density, and improve the mechanical properties of the foam, especially in terms of compressive strength and tensile strength. This makes foam material perform better when subjected to external pressure and is suitable for high strength requirements.
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8154 type delay catalyst has achieved remarkable results in the application of multiple industries, including home appliances, automobiles, construction and other fields. By optimizing the foaming process, not only the quality of the product is improved, but also the production efficiency is improved, bringing significant economic benefits.
In the future, with the widespread application of polyurethane materials in more fields, the application prospects of the 8154 type delay catalyst will be broader. Researchers can further explore its synergy with other catalysts, develop a more efficient and environmentally friendly foaming system, and promote the development of the polyurethane industry in a green and sustainable direction.