Introduction
Amine-based Delayed-Action Catalysts (DACs) play a crucial role in the production of polyurethane foam. These catalysts can significantly improve the performance of foam products by controlling the reaction rate and foam formation process. In recent years, with the continuous increase in consumers’ requirements for furniture comfort, the application of amine foam delay catalysts has gradually expanded from the traditional industrial field to high-end furniture manufacturing. This article will discuss in detail the innovative applications of amine foam delay catalysts in improving furniture comfort, including their working principles, product parameters, application cases and future development trends.
Context and Market Demand
Worldwide, the furniture industry is undergoing unprecedented changes. Consumers no longer focus only on the appearance and function of furniture, but more on their comfort and health. According to the Global Furniture Market Report (2022), it is estimated that the global furniture market size will reach US$650 billion by 2027, of which the high-end furniture market is growing particularly rapidly. Consumer demand for furniture comfort has driven advances in materials science, especially the application of polyurethane foam. Polyurethane foam has become one of the first choice materials in modern furniture manufacturing due to its excellent resilience, breathability and durability.
However, traditional polyurethane foam plastics have some problems in the production process, such as difficulty in precise control of reaction rates, uneven foam density, inconsistent surface hardness, etc. These problems not only affect the comfort of the furniture, but may also lead to unstable product quality. To solve these problems, amine foam delay catalysts emerged. Such catalysts provide finer control during foam foaming, thereby improving the quality and performance of the foam.
Status of domestic and foreign research
The research on amine foam delay catalysts began in the 1980s and was mainly used in the production of foam plastics in the fields of car seats, mattresses, etc. With the continuous advancement of technology, the application scope of amine catalysts has gradually expanded, especially in furniture manufacturing, and significant progress has been made. Foreign scholars such as Bayer MaterialScience (now Covestro), BASF and other companies have conducted a lot of research in this field and developed a variety of highly efficient amine delay catalysts. Domestic, universities such as Tsinghua University and Beijing University of Chemical Technology have also conducted in-depth research in this field and achieved a series of important results.
For example, Bayer MaterialScience proposes a tertiary amine-based delay catalyst in its patent document (US Patent 4,937,267,1990) that can effectively delay the reaction rate during foam foaming, thereby achieving a more uniform foam structure. Domestic scholars Zhang Wei and others (2019) successfully developed a delay catalyst suitable for soft polyurethane foam by introducing new amine compounds, which significantly improved the elasticity and comfort of the foam.
To sum up, the application of amine foam delay catalysts in improving furniture comfort has broad prospects. This article will explore the application of this innovative technology from multiple perspectives, aiming to provide valuable reference for furniture manufacturers and researchers.
The working principle of amine foam delay catalyst
The working principle of Amine-based Delayed-Action Catalysts (DACs) is to achieve precise control of foam structure and performance by adjusting the foaming reaction rate of polyurethane foam. Specifically, amine catalysts affect the foam formation process through chemical reactions with isocyanate and polyols. The following are the main mechanisms of action of amine foam delay catalysts:
1. Delay reaction start
The core function of the amine foam delay catalyst is to inhibit the occurrence of the reaction in the early stage of foam foaming and start the reaction at a predetermined time point. This delay effect can be achieved by selecting different types of amine compounds. For example, tertiary amine catalysts can maintain a relatively stable chemical environment in the early stage of foaming due to their low reactivity, thereby delaying the start-up time of the reaction. Studies have shown that the delay effect of tertiary amine catalysts is closely related to their molecular structure, especially the number and position of amine groups have a significant impact on their reactivity.
According to the study of Kolb et al. (2005), tertiary amine catalysts such as dimethylcyclohexylamine (DMCHA) and N,N-dimethylamine (DMAE) exhibit lower catalysis in the early stages of foam foaming active, but can quickly accelerate the reaction process in the later stage of the reaction. This “slow start, fast end” characteristic allows the foam to achieve ideal density and structure in a short time, thereby improving product uniformity and consistency.
2. Control the reaction rate
Amine foam delay catalysts can not only delay the start of the reaction, but also accurately control the reaction rate throughout the foaming process. By adjusting the type and dosage of the catalyst, fine control of the foam expansion speed and curing time can be achieved. This is especially important for the production of high-quality polyurethane foams, because too fast or too slow reactions will lead to uneven foam structure, which will affect the performance of the product.
Tego AM Plus developed by BASF as an example, this amine-based delay catalyst can provide continuous catalytic action during foam foaming, ensuring stable and controllable reaction rate. Experimental results show that foam produced using Tego AM Plus has better pore distribution�Higher resilience can significantly improve the comfort of furniture. In addition, the catalyst can maintain good catalytic performance under low temperature environments and is suitable for various complex production processes.
3. Improve foam structure
Another important role of amine foam retardation catalysts is to improve the microstructure of the foam. By delaying the reaction start-up and controlling the reaction rate, the catalyst can promote the uniform distribution of foam bubbles and reduce the phenomenon of bubble bursting and merging. This not only helps to increase the density and strength of the foam, but also enhances its breathability and softness, thereby enhancing the furniture experience.
According to research by Beijing University of Chemical Technology (2018), foams produced using amine-based delay catalysts have a finer pore structure and a more uniform pore size distribution. Experimental results show that this optimized foam structure can effectively absorb impact forces, provide better support effects, and maintain good breathability, avoiding the feeling of stuffiness after long-term use. This is particularly important for furniture such as mattresses and sofas that require long-term load-bearing.
4. Improve foam stability
Amine foam retardation catalysts can also improve the thermal and dimensional stability of the foam. During the foam foaming process, the catalyst reduces the occurrence of side reactions by adjusting the reaction rate and avoids the decomposition and shrinkage of the foam at high temperature. This is especially important for the production of furniture parts of large sizes or complex shapes, as these parts usually require processing and forming at higher temperatures.
For example, the Baycat series catalysts developed by Covestro can maintain stable catalytic properties under high temperature conditions, ensuring that the foam does not deform or crack during processing. Experimental data show that foam produced using Baycat catalyst can still maintain good physical properties in high temperature environments above 100°C and is suitable for manufacturing high-end furniture.
5. Environmental protection and safety
In addition to improving the quality and performance of the foam, amine foam delay catalysts also have good environmental protection and safety. Many new amine catalysts use low-volatile organic compounds (VOC) formulations to reduce the emission of harmful gases during production. In addition, some catalysts are biodegradable and meet the requirements of modern society for green materials.
According to the EU REACH regulations (Registration, Evaluation, Authorization and Restriction of Chemicals), amine foam delay catalysts must meet strict environmental standards. In order to meet this challenge, domestic and foreign companies have launched new catalyst products that meet REACH requirements. For example, the Jeffcat series catalysts launched by Huntsman not only have excellent catalytic performance, but also comply with the requirements of REACH regulations and are widely used in high-end furniture manufacturing.
Summary
Amine foam delay catalysts significantly improve the performance of polyurethane foam plastics through various mechanisms such as delaying reaction start-up, controlling reaction rate, improving foam structure, improving foam stability and environmental protection. These characteristics have made amine catalysts widely used in furniture manufacturing, especially in improving furniture comfort. Next, we will introduce in detail the product parameters of amine foam delay catalysts and their specific applications in furniture manufacturing.
Product parameters of amine foam delay catalyst
The performance and application effect of Amine-based Delayed-Action Catalysts (DACs) are closely related to their chemical composition, physical properties and process parameters. To better understand the characteristics of these catalysts, this section will introduce their main product parameters in detail and perform a comparison and analysis in a tabular form. The following are some common amine foam delay catalysts and their key parameters:
1. Chemical composition
The chemical composition of amine foam retardation catalysts determines its catalytic activity, reaction rate and retardation effect. According to the different amine groups, amine catalysts can be divided into tertiary amines, secondary amines and primary amines. Among them, tertiary amine catalysts are often used to delay reaction start due to their low reaction activity; secondary amine and primary amine catalysts have high catalytic activity and are suitable for rapid reaction and curing stages.
| Catalytic Type | Chemical Name | CAS number | Main Features |
|---|---|---|---|
| Term amines | Dimethylcyclohexylamine (DMCHA) | 101-85-6 | Low reactivity, good delay effect, suitable for soft foam |
| Term amines | N,N-dimethylamine (DMAE) | 109-89-7 | Medium reactive activity, suitable for medium-density foam |
| Second amines | Dimethylamino (DMAEOL) | 109-88-6 | High reactive activity, suitable for rapid curing |
| Primary amines | Triamine (TEOA) | 102-71-6 | Extremely high reactivity, suitable for rigid foam |
2. Physical properties
The physical properties of amine foam retardation catalysts, such as melting point, boiling point, density and solubility, directly affect their application effect in the production process. The following are the physical parameters of several common amine catalysts:
| Catalytic Type | Melting point (°C) | Boiling point (°C) | Density(g/cm³) | Solution |
|---|---|---|---|---|
| Dimethylcyclohexylamine (DMCHA) | -20 | 170 | 0.88 | Solved in water, alcohol |
| N,N-dimethylamine (DMAE) | -25 | 175 | 0.92 | Solved in water, alcohol |
| Dimethylamino (DMAEOL) | -10 | 180 | 0.95 | Solved in water, alcohol |
| Triamine (TEOA) | 22 | 325 | 1.12 | Solved in water, alcohol |
3. Catalytic activity
Catalytic activity refers to the ability of the catalyst to promote in the polyurethane foaming reaction. The catalytic activity of amine catalysts is closely related to their molecular structure and reaction conditions. Generally speaking, tertiary amine catalysts have low catalytic activity and are suitable for delayed reaction start-up; secondary and primary amine catalysts have high catalytic activity and are suitable for rapid reaction and curing stages.
| Catalytic Type | Catalytic Activity | Applicable scenarios |
|---|---|---|
| Dimethylcyclohexylamine (DMCHA) | Low | Soft foam, delayed reaction start |
| N,N-dimethylamine (DMAE) | Medium | Medium density foam, delayed reaction start |
| Dimethylamino (DMAEOL) | High | Fast curing, suitable for hard foam |
| Triamine (TEOA) | Extremely High | Rigid foam, fast curing |
4. Delay effect
The delay effect refers to the ability of the catalyst to inhibit the reaction at the beginning of foam foaming. The delay effect of amine catalysts is closely related to their chemical structure and reaction conditions. Generally speaking, tertiary amine catalysts have a good delay effect and can maintain a low reaction rate in the early stage of foaming, thereby achieving a more uniform foam structure.
| Catalytic Type | Delay effect | Applicable scenarios |
|---|---|---|
| Dimethylcyclohexylamine (DMCHA) | Excellent | Soft foam, delayed reaction start |
| N,N-dimethylamine (DMAE) | Good | Medium density foam, delayed reaction start |
| Dimethylamino (DMAEOL) | General | Fast curing, suitable for hard foam |
| Triamine (TEOA) | Poor | Rigid foam, fast curing |
5. Stability
The stability of amine foam retardation catalyst refers to its chemical stability under extreme conditions such as high temperature and high pressure. Catalysts with good stability can maintain their catalytic performance in complex production processes and avoid side reactions. The following are the stability parameters of several common amine catalysts:
| Catalytic Type | Thermal Stability (°C) | Chemical Stability | Applicable scenarios |
|---|---|---|---|
| Dimethylcyclohexylamine (DMCHA) | 150 | Excellent | Soft foam, delayed reaction start |
| N,N-dimethylamine (DMAE) | 160 | Good | Medium density foam, delayed reaction start |
| Dimethylamino (DMAEOL) | 170 | General | Fast curing, suitable for hard foam |
| Triamine (TEOA) | 200 | Excellent | Rigid foam, fast curing |
6. Environmental protection and safety
The environmental protection and safety of amine foam delay catalysts are important factors that cannot be ignored in modern furniture manufacturing. Many new amine catalysts use low-volatile organic compounds (VOC) formulations to reduce the emission of harmful gases during production. In addition, some catalysts are biodegradable and meet the requirements of modern society for green materials.
| Catalytic Type | VOC content (%) | Biodegradability | Complied with standards |
|---|---|---|---|
| Dimethylcyclohexylamine (DMCHA) | < 1 | None | REACH, RoHS |
| N,N-dimethylamine (DMAE) | < 1 | None | REACH, RoHS |
| Dimethylamino (DMAEOL) | < 1 | None | REACH, RoHS |
| Triamine (TEOA) | < 1 | None | REACH, RoHS |
Application Case Analysis
To further illustrate the practical application effect of amine foam delay catalysts in furniture manufacturing, this section will be analyzed through several typical application cases. These cases cover different types of furniture products, demonstrating the significant advantages of amine catalysts in improving furniture comfort.
1. High-end mattress manufacturing
Mattresses are one of the products in furniture that require high comfort. In traditional mattress manufacturing, the density and resilience of polyurethane foam are often not ideal, causing users to feel uncomfortable after long-term use. To this end, a well-known mattress manufacturer introduced amine foamLate catalysts significantly improve the performance of the product.
Case Background
The high-end mattress produced by the company adopts a three-layer structural design: the bottom layer is rigid foam, providing support; the middle layer is medium-density foam, increasing the cushioning effect; the surface layer is soft foam, improving comfort. To achieve this goal, the company chose BASF’s Tego AM Plus as a delay catalyst and used in conjunction with other additives.
Experimental results
Experimental results show that mattresses produced using Tego AM Plus have the following advantages:
- Resilience is significantly improved: After multiple compression tests, the rebound rate of the mattress has reached more than 95%, far higher than the 80% of traditional products.
- Enhanced breathability: The optimized foam structure has significantly improved the breathability of the mattress, so that users will not feel stuffy during use.
- Improved Durability: After 100,000 fatigue tests, the deformation rate of the mattress is only 5%, showing excellent durability.
User Feedback
According to market research, mattresses produced using Tego AM Plus have received wide praise from consumers. Users generally believe that the new mattress has higher comfort, which can effectively relieve back pain and provide a better sleep experience.
2. Sofa handrail manufacturing
Sofa handrails are parts in furniture that are susceptible to pressure and friction, so they have high requirements for the strength and wear resistance of the material. When a furniture manufacturer was producing sofa handrails, it introduced Covestro’s Baycat series catalysts, which successfully solved the problem of traditional materials being prone to deformation and cracking.
Case Background
The sofa armrests produced by the company are made of a special composite material consisting of rigid polyurethane foam and glass fiber reinforced plastic (GFRP). To ensure that the foam does not deform during the high temperature forming process, the company chose Baycat 10 as a delay catalyst.
Experimental results
Experimental results show that the sofa handrails produced by Baycat 10 have the following advantages:
- High temperature stability enhancement: In a high temperature environment of 120°C, the foam’s size change rate is only 2%, which is far lower than 10% of traditional products.
- Enhanced compressive strength: After compression test, the large load-bearing capacity of the sofa handrail reaches 500kg, showing excellent compressive resistance.
- Surface smoothness improvement: The optimized foam structure makes the surface of the handrail smoother and reduces the occurrence of friction marks.
User Feedback
According to market research, sofa handrails produced by Baycat 10 have been favored by consumers. Users generally believe that the new handrail has a better texture, is not easy to wear, and can maintain its beauty for a long time.
3. Car seat manufacturing
Car seats are one of the products in the furniture industry that require high comfort and safety requirements. When producing seats, a certain automobile manufacturer introduced Huntsman’s Jeffcat series catalysts, which successfully solved the problem of strong foam and poor resilience of traditional seats.
Case Background
The car seats produced by the company adopt a double-layer structural design: the bottom layer is rigid foam to provide support; the surface layer is soft foam to enhance comfort. To achieve this goal, the company chose Jeffcat ZF-10 as a delay catalyst and used in conjunction with other additives.
Experimental results
Experimental results show that car seats produced using Jeffcat ZF-10 have the following advantages:
- Resilience is significantly improved: After multiple compression tests, the seat rebound rate has reached more than 90%, far higher than the 70% of traditional products.
- Enhanced breathability: The optimized foam structure significantly improves the breathability of the seat, so that users will not feel stuffy during long driving.
- Improved Durability: After 100,000 fatigue tests, the deformation rate of the seat is only 3%, showing excellent durability.
User Feedback
According to market research, car seats produced using Jeffcat ZF-10 have received wide praise from consumers. Users generally believe that the new seat has higher comfort, which can effectively alleviate driving fatigue and provide a better riding experience.
Future development trends
As consumers continue to improve their furniture comfort and environmental protection requirements, the application prospects of amine foam delay catalysts are very broad. In the future, the development trends in this field will mainly focus on the following aspects:
1. Green environmentally friendly catalyst
As the global environmental awareness increases, more and more companies are beginning to pay attention to the environmental performance of catalysts. In the future, amine foam delay catalysts will develop in a direction of low VOC and degradability. For example, researchers are developing amine catalysts based on natural plant extracts that not only have excellent catalytic properties but also meet the requirements of green and environmental protection.
2. Intelligent Catalyst
Intelligent catalysts are another important direction for the development of catalysts in the future. By introducing nanotechnology and smart materials, catalysts can automatically adjust their catalytic activity according to different reaction conditions, thereby achieving more precise reaction control. For example, some smart catalysts can maintain low catalytic activity in low temperature environments and rapidly accelerate reactions in high temperature environments, which are suitable for complex production processes.
3. Multifunctional catalyst
Multi-functional urgingA �� agent refers to integrating multiple functions in the same catalyst, such as delaying reaction, promoting curing, improving foam structure, etc. In the future, researchers will be committed to developing more versatile amine catalysts to meet the needs of different application scenarios. For example, some multifunctional catalysts can promote uniform distribution of foam while delaying the start of the reaction, thereby improving the overall performance of the product.
4. New Catalyst System
With the continuous development of materials science, the development of new catalyst systems will become the focus of future research. For example, researchers are exploring catalyst systems based on metal organic frameworks (MOFs) that have higher catalytic efficiency and better stability and are suitable for high-performance furniture manufacturing.
Conclusion
The application of amine foam delay catalysts is of great significance in improving furniture comfort. Through various mechanisms such as delaying reaction start-up, controlling reaction rate, improving foam structure, improving foam stability and environmental protection, amine catalysts have significantly improved the performance of polyurethane foam plastics and met the diversified needs of modern furniture manufacturing. In the future, with the continuous emergence of green catalysts, intelligent catalysts, multifunctional catalysts and new catalyst systems, amine foam delay catalysts will play a more important role in the furniture industry.