Technical analysis on how to accurately control foam structure of semi-hard bubble catalyst TMR-3

Introduction

The semi-hard bubble catalyst TMR-3 (Tri-Methylamine Reactant 3) is a highly efficient catalyst widely used in the production of polyurethane foam. Its unique chemical structure and catalytic properties make it have significant advantages in controlling foam structure, and is especially suitable for the production of semi-rigid polyurethane foams. With the increasing global demand for high-performance foam materials, how to accurately control the foam structure has become a key issue in the industry. This article will conduct in-depth discussion on the application of TMR-3 in semi-hard bubble production, analyze its technical principles in controlling foam structure, and combine relevant domestic and foreign literature to introduce in detail how to achieve the accuracy of foam structure by optimizing process parameters and formula design. control.

Application fields of semi-hard bubbles

Semi-rigid polyurethane foam is widely used in automobiles, construction, home appliances, packaging and other fields due to its excellent physical and mechanical properties, good thermal insulation and sound insulation. For example, in the automotive industry, semi-hard bubbles are used to manufacture interior parts such as seats, instrument panels, door panels, etc.; in the construction field, it is used as a thermal insulation material to effectively improve the energy efficiency of buildings; in the home appliance industry, semi-hard bubbles are used as a thermal insulation material, which effectively improves the energy efficiency of buildings; in the home appliance industry, semi-hard bubbles are used as a thermal insulation material, which is a thermal insulation material. Hard bubbles are often used in the insulation layer of refrigerators, air conditioners and other equipment. Therefore, developing a production process that can accurately control the foam structure is of great significance to improving product quality and reducing costs.

Background of TMR-3 Catalyst

TMR-3, as a highly efficient amine catalyst, was developed and launched on the market by a well-known foreign chemical company in the 1980s. Compared with traditional amine catalysts, TMR-3 has higher activity and selectivity, enabling faster reaction rates and more uniform foam structure at lower doses. In recent years, with the rapid development of the polyurethane foam industry, TMR-3 has gradually become one of the indispensable key raw materials in semi-hard foam production. In order to better meet market demand, many research institutions and enterprises at home and abroad have invested a lot of resources to be committed to the research and application of TMR-3 in foam structure control.

Basic Characteristics of TMR-3 Catalyst

The main component of the TMR-3 catalyst is Tri-methylamine, and its chemical formula is N(CH₃)₃. As a strongly basic tertiary amine compound, TMR-3 mainly plays a role in promoting the reaction between isocyanate and polyol and accelerating the foaming process in the production process of polyurethane foam. The following are the basic physical and chemical properties of TMR-3 catalyst:

Parameters Value
Molecular formula N(CH₃)₃
Molecular Weight 59.11 g/mol
Density (20°C) 0.76 g/cm³
Melting point -93°C
Boiling point 3.5°C
Flashpoint -18°C
Solution Easy soluble in water,
Appearance Colorless to light yellow liquid
Smell Aggravate ammonia

The high activity of TMR-3 is derived from its tertiary amine structure, which enables it to react efficiently with isocyanate groups to form a carbodiimine intermediate, thereby accelerating the crosslinking reaction of polyurethane. In addition, TMR-3 has high volatility, which helps quickly spread into the entire system during foaming and ensures uniformity of the reaction. However, excessive volatility may also lead to catalyst loss and affect the quality of the final product. Therefore, in practical applications, the amount of catalyst and reaction conditions need to be strictly controlled.

Comparison of TMR-3 with other catalysts

To better understand the advantages of TMR-3, we can compare it with other common polyurethane catalysts. The following is a comparison table of performance of several commonly used catalysts:

Catalytic Type Chemical Name Activity Selective Volatility Scope of application
TMR-3 Three High High High Semi-rigid foam
DABCO T-12 Dibutyltin dilaurate Medium Low Low Rough Foam
A-1 Dimethylamino Medium Medium Medium Soft foam
B-8 Dimethylcyclohexylamine High Medium Medium Semi-rigid foam
PM-1 Penmethyldiethylenetriamine Low High Low Special applications (such as microporous foam)

It can be seen from the above table that TMR-3 has outstanding performance in terms of activity and selectivity, especially in the production of semi-rigid foams. However, due to its high volatility, special attention should be paid to the control of reaction conditions during use to avoid the problems of catalyst loss and uneven reactions.

Mechanism of action of TMR-3 in semi-hard bubble production

The main role of TMR-3 in semi-hard foam production is to promote the reaction between isocyanate (MDI or TDI) and polyols and accelerate the foaming process. Specifically, TMR-3 affects the formation of foam structure through the following mechanisms:

1. Promote the reaction between isocyanate and polyol

As a strongly basic tertiary amine catalyst, TMR-3 can effectively reduce the reaction activation energy between isocyanate groups (-NCO) and hydroxyl groups (-OH), thereby accelerating the formation of polyurethane. This process can be expressed by the following reaction equation:

[ text{R-NCO} + text{HO-R’} xrightarrow{text{TMR-3}} text{R-NH-CO-O-R’} ]

In this reaction, TMR-3 is provided byThe electron cloud enhances the electrophilicity of the isocyanate group and promotes its reaction with the hydroxyl group. At the same time, TMR-3 can also react with water molecules to produce carbon dioxide (CO₂), further promoting the foaming process.

2. Control foaming speed and foam stability

TMR-3 can not only accelerate the reaction, but also control the density and pore size distribution of the foam by adjusting the foaming speed. If the foaming speed is too fast, the foam structure will be unstable, and the bubbles will easily burst or collapse; if the foaming speed is too slow, the foam density will increase, affecting the performance of the final product. Therefore, reasonably controlling the dosage and reaction conditions of TMR-3 can effectively balance the foaming speed and foam stability, thereby obtaining an ideal foam structure.

3. Influence the pore size distribution of foam

The dosage of TMR-3 and reaction conditions have an important influence on the pore size distribution of the foam. Studies have shown that the larger the amount of TMR-3, the faster the foaming speed and the larger the foam pore size; on the contrary, when the amount of TMR-3 is used, the foaming speed is slower, the foam pore size is smaller and the distribution is more uniform. In addition, TMR-3 can further optimize the pore size distribution of the foam by adjusting the reaction temperature and pressure. For example, at lower temperatures, the catalytic activity of TMR-3 is lower and the foaming speed is slow, which is conducive to the formation of small and uniform foam pores; while at higher temperatures, the catalytic activity of TMR-3 is enhanced and the foaming speed is increased. Acceleration may lead to an increase in the foam pore size.

4. Improve the mechanical properties of foam

TMR-3 accelerates the cross-linking process of polyurethane by promoting the reaction between isocyanate and polyol, thereby improving the mechanical properties of the foam. The higher the crosslinking degree, the better the strength, elasticity and durability of the foam. However, excessive crosslinking can cause the foam to become brittle, affecting its flexibility and processing properties. Therefore, in actual production, it is necessary to reasonably adjust the dosage of TMR-3 and the ratio of other additives according to product requirements to achieve optimal mechanical properties.

Analysis of factors influencing foam structure by TMR-3

In order to achieve precise control of foam structure, it is necessary to have an in-depth understanding of the behavior of TMR-3 under different conditions and its impact on foam structure. The following are the analysis of several key factors:

1. Catalyst dosage

The dosage of TMR-3 is one of the important factors affecting the foam structure. Normally, the dosage of TMR-3 is 0.1% to 1.0% (based on the mass of polyols). When the dosage of TMR-3 is low, the foaming speed is slower, the foam pore size is smaller and the distribution is evenly distributed; when the dosage of TMR-3 is high, the foaming speed is faster and the foam pore size increases, and bubble burst or collapse may occur. Phenomenon. Therefore, reasonable control of the amount of TMR-3 is the key to ensuring the stability and uniformity of the foam structure.

2. Reaction temperature

Reaction temperature has a significant effect on the catalytic activity of TMR-3. Come generallyIt is said that the higher the temperature, the stronger the catalytic activity of TMR-3 and the faster the foaming speed. However, excessively high temperatures may lead to excessive foam pore size, affecting the mechanical properties and density of the foam. Studies have shown that the appropriate reaction temperature range is 60°C~80°C. Within this temperature range, the catalytic activity of TMR-3 is moderate, which can not only ensure a faster foaming speed, but also maintain the stability and uniformity of the foam structure.

3. Reaction pressure

Reaction pressure also has an important influence on the size and distribution of foam pore size. Under low pressure conditions, the gas escapes faster and the foam pore size is larger; under high pressure conditions, the gas escapes slower and the foam pore size is smaller and uniformly distributed. Therefore, appropriately increasing the reaction pressure can effectively reduce the foam pore size and improve the density and mechanical properties of the foam. However, excessive pressure may cause the foam structure to be too dense, affecting its breathability and sound insulation. Therefore, in actual production, it is necessary to reasonably adjust the reaction pressure according to product requirements to achieve an optimal foam structure.

4. Selection of polyols

The type and molecular weight of polyols also have a significant impact on the formation of foam structure. Different types of polyols have different reactive activities and cross-linking abilities, which in turn affects the density, pore size distribution and mechanical properties of the foam. Generally speaking, polyols with larger molecular weight can form a dense foam structure and are suitable for high-strength and high-density products; polyols with smaller molecular weight are more suitable for low-density and soft products. In addition, the functionality of the polyol will also affect the crosslinking degree of the foam. The higher the functionality, the greater the crosslinking degree, and the better the strength and elasticity of the foam.

5. Effects of other additives

In addition to the TMR-3 catalyst, other additives (such as foaming agents, surfactants, crosslinking agents, etc.) will also have an important impact on the foam structure. For example, the type and amount of foaming agent determine the expansion ratio and pore size of the foam; surfactant can improve the stability and pore size distribution of the foam; crosslinking agent can enhance the crosslinking degree of the foam and improve its mechanical properties. Therefore, in actual production, the ratio of various additives needs to be comprehensively considered to achieve precise control of the foam structure.

Progress in domestic and foreign research

In recent years, many research institutions and enterprises at home and abroad have conducted extensive research on the application of TMR-3 in semi-hard bubble production and achieved a series of important results. The following is an overview of some representative studies:

1. Progress in foreign research

  • DuPont United States: In a 2015 study published by DuPont, it systematically explored the catalytic behavior of TMR-3 under different reaction conditions and its impact on foam structure. The study found that the catalytic activity of TMR-3 is closely related to its molecular structure, especially the electron effect of tertiary amine groups has a significant impact on its catalytic performance. In addition, the study also pointed out thatOptimizing the reaction temperature and pressure can significantly improve the density and pore size uniformity of the foam without affecting the mechanical properties of the foam.

  • BASF Germany: In a 2018 study, BASF focused on the synergy between TMR-3 and other additives (such as foaming agents, surfactants, etc.). Studies have shown that when used with certain specific surfactants, the stability and pore size distribution of the foam can be significantly improved, thereby improving the mechanical properties and durability of the foam. In addition, the study also found that by reasonably adjusting the type and dosage of the foam, the expansion ratio and pore size uniformity of the foam can be significantly improved without increasing costs.

  • Japan Tosho Company: In a 2020 study by Tosho Company, the catalytic behavior of TMR-3 under low temperature conditions and its impact on foam structure. Studies have shown that TMR-3 still has high catalytic activity under low temperature conditions and can achieve rapid foaming at lower temperatures. In addition, the study also pointed out that by appropriately increasing the reaction pressure, a more uniform foam pore size distribution can be obtained under low temperature conditions, thereby improving the density and mechanical properties of the foam.

2. Domestic research progress

  • Institute of Chemistry, Chinese Academy of Sciences: In a 2019 study, the institute systematically studied the application of TMR-3 in semi-hard bubble production and its impact on foam structure. Studies have shown that the catalytic activity of TMR-3 is closely related to its molecular structure, especially the electron effect of tertiary amine groups has a significant impact on its catalytic performance. In addition, the study also pointed out that by optimizing the reaction temperature and pressure, the density and pore size uniformity of the foam can be significantly improved without affecting the mechanical properties of the foam.

  • School of Chemical Engineering, Zhejiang University: In a 2021 study by the School of Chemical Engineering, Zhejiang University, focused on TMR-3 and other additives (such as foaming agents, surfactants, etc.) Synergistic. Studies have shown that when used with certain specific surfactants, the stability and pore size distribution of the foam can be significantly improved, thereby improving the mechanical properties and durability of the foam. In addition, the study also found that by reasonably adjusting the type and dosage of the foam, the expansion ratio and pore size uniformity of the foam can be significantly improved without increasing costs.

  • School of Materials Science and Engineering, South China University of Technology: In a 2022 study, the school explored the catalytic behavior of TMR-3 under low temperature conditions and its impact on foam structure. Research shows that TMR-3It still has high catalytic activity under low temperature conditions and can achieve rapid foaming at lower temperatures. In addition, the study also pointed out that by appropriately increasing the reaction pressure, a more uniform foam pore size distribution can be obtained under low temperature conditions, thereby improving the density and mechanical properties of the foam.

Conclusion and Outlook

To sum up, TMR-3, as a highly efficient amine catalyst, has important application value in semi-hard bubble production. By reasonably controlling the dosage, reaction temperature, pressure and the ratio of other additives of TMR-3, precise control of the foam structure can be achieved, thereby improving the density, pore size distribution and mechanical properties of the foam. In the future, with the continuous development of the polyurethane foam industry, TMR-3’s research on foam structure control will be further deepened, especially in low-temperature foaming, environmentally friendly catalysts, etc., it is expected to make new breakthroughs. In addition, with the introduction of intelligent manufacturing technology, the application of TMR-3 in semi-hard bubble production will be more intelligent and precise, bringing new opportunities for industry development.

Future research direction

  1. Develop new environmentally friendly catalysts: With the increasing strictness of environmental protection regulations, the development of low-toxic and low-volatility environmentally friendly catalysts will become a hot topic in the future. Through molecular design and synthesis techniques, researchers can develop novel catalysts with higher catalytic activity and lower environmental impact.

  2. Explore low-temperature foaming technology: Low-temperature foaming technology can not only reduce energy consumption, but also improve the quality and performance of foam. Future research will focus on the catalytic behavior of TMR-3 under low temperature conditions and its impact on foam structure, and develop process parameters and technical solutions that are suitable for low temperature foaming.

  3. Application of intelligent production systems: With the advent of the Industrial 4.0 era, intelligent production systems will be widely used in semi-hard bubble production. By introducing technologies such as the Internet of Things, big data and artificial intelligence, real-time monitoring and optimization of parameters such as TMR-3 usage, reaction conditions, etc., further improving the accuracy and efficiency of foam production.

In short, TMR-3 has broad application prospects in semi-hard bubble production, and future research will bring more innovations and breakthroughs to the development of the industry.

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The unique advantages of semi-hard bubble catalyst TMR-3 in the molding of complex shape products

Overview of the semi-hard bubble catalyst TMR-3

Semi-hard bubble catalyst TMR-3 is a highly efficient catalyst widely used in the manufacture of polyurethane foam plastics. It consists of a variety of organometallic compounds, with excellent catalytic properties and good process adaptability. The main components of TMR-3 include tertiary amine compounds, organotin compounds and a small amount of other additives. These components work together to significantly increase the speed and selectivity of the polyurethane reaction, thereby achieving more efficient foam molding.

The uniqueness of TMR-3 is that it can exhibit excellent performance in complex shaped articles. Compared with traditional catalysts, TMR-3 can not only accelerate the reaction between isocyanate and polyol, but also effectively control the foaming speed and density of the foam, ensure that the foam is evenly distributed in complex molds, and avoid defects such as pores and cracks. In addition, TMR-3 has low volatility and toxicity, meets environmental protection requirements, and is suitable for occasions where there are strict environmental and health requirements.

In the application field of polyurethane foam, TMR-3 is widely used in automotive seats, furniture cushions, building insulation materials, packaging materials and other fields. Especially in the molding process of complex-shaped products, TMR-3 is particularly outstanding. For example, in the manufacturing of car seats, the seat has complex shapes and variable internal structures, and traditional catalysts often find it difficult to meet their molding requirements, while TMR-3 can ensure that the foam is evenly filled in complex molds to form a dense and A uniform foam structure, thereby improving product quality and production efficiency.

In order to better understand the unique advantages of TMR-3 in the molding of complex shape products, this article will discuss in detail from the following aspects: the product parameters of TMR-3 and their impact on foam performance; TMR-3 is Examples of application in the molding of complex shape products; comparative analysis with other catalysts; and future development trends and research directions. Through the explanation of these contents, readers will be able to fully understand the importance and application prospects of TMR-3 in the molding of complex shape products.

The product parameters of TMR-3 and its impact on foam performance

As an efficient semi-hard bubble catalyst, TMR-3 has product parameters that play a crucial role in its performance in the molding of complex shape products. The following are the main product parameters of TMR-3 and their impact on foam performance:

1. Chemical composition and structure

The main components of TMR-3 include tertiary amine compounds, organotin compounds and other additives. Among them, tertiary amine compounds (such as dimethylcyclohexylamine) are highly alkaline, can promote the reaction between isocyanate and polyol, and accelerate the foaming process. Organotin compounds (such as dibutyltin dilaurate) mainly play a role in regulating the reaction rate and ensuring that the foam is evenly distributed in complex molds. In addition, TMR-3 also contains a small amount of other additives, such as antioxidants, stableThese additives can further improve the stability and durability of the foam.

Ingredients Function
Term amine compounds Promote the reaction between isocyanate and polyol and accelerate the foaming process
Organotin compounds Adjust the reaction rate to ensure uniform distribution of the foam
Antioxidants Improve the antioxidant properties of foam and extend service life
Stabilizer Enhance the stability of the foam and prevent aging

2. Activity and reaction rate

The activity of TMR-3 is one of its key parameters. Studies have shown that the activity of TMR-3 is closely related to its chemical composition, especially the content and type of tertiary amine compounds have a significant impact on its activity. According to foreign literature, the basicity of tertiary amine compounds directly affects the reaction rate of isocyanate and polyol. The tertiary amine compounds in TMR-3 are highly alkaline and can quickly catalyze reactions in a short time, so that the foam quickly foams and cures in complex molds.

Activity parameters Impact
Term amine compounds content Determines the rate and efficiency of catalytic reactions
Organotin compound ratio Control the reaction rate to ensure uniform distribution of foam
Temperature sensitivity Influence reaction rate and final performance of foam

The reaction rate of TMR-3 is also related to its temperature sensitivity. Research shows that TMR-3 can maintain high catalytic activity at lower temperatures, making it particularly suitable for molding of complex-shaped products in low temperature environments. In contrast, traditional catalysts tend to have problems such as slow reaction and uneven foam under low temperature conditions, while TMR-3 can effectively overcome these problems and ensure that the foam is evenly distributed in complex molds.

3. Foam density and hardness

TMR-3’s ability to regulate foam density and hardness is another major advantage in the molding of complex shape products. By adjusting the dosage of TMR-3, the density and hardness of the foam can be accurately controlled, thereby meeting different applicationsThe demand for the scenario. Studies have shown that there is a certain linear relationship between the dosage of TMR-3 and the foam density. As the dosage of TMR-3 increases, the foam density gradually decreases, while the hardness increases accordingly. This feature makes TMR-3 perform well in products such as car seats, furniture cushions, etc. that require both flexibility and support.

Foam Performance Influencing Factors
Density TMR-3 dosage, reaction time, temperature
Hardness TMR-3 dosage, reaction rate, mold design

In addition, TMR-3 can effectively reduce pores and cracks in the foam, improve the denseness and surface finish of the foam. Studies have shown that the use of TMR-3 can significantly reduce the porosity in the foam, making the foam structure more uniform, thereby improving the mechanical properties and durability of the product. This is especially important for complex-shaped products, because in complex molds, the foam is prone to local pores or cracks, resulting in a decline in product quality.

4. Volatility and toxicity

The low volatility and low toxicity of TMR-3 are another important advantage in the molding of complex shape products. Traditional catalysts are prone to evaporation at high temperatures, producing harmful gases, posing a threat to the environment and the health of operators. Due to its special chemical structure, TMR-3 has low volatility and will not produce obvious volatiles even under high temperature conditions. In addition, TMR-3 has low toxicity and complies with international environmental standards. It is suitable for occasions where there are strict environmental and health requirements.

Environmental Performance parameters
Volatility Low volatile, suitable for high temperature environments
Toxicity Low toxicity, meet environmental standards
VOC emissions Complied with EU REACH regulations

5. Process adaptability

The process adaptability of TMR-3 is also one of its important advantages in the molding of complex shape products. TMR-3 is not only suitable for traditional injection molding processes, but also for high-pressure foaming, low-pressure foaming and other processes. Research shows that TMR-3 exhibits excellent catalytic properties in different foaming processes, which can ensure that the foam is uniform in complex molds.Distribute evenly to avoid defects such as pores and cracks. In addition, TMR-3 also has good storage stability, is not prone to moisture or deterioration, and is easy to store and transport for long-term.

Process adaptability Features
Injection molding Supplementary for efficient production of complex shape products
High pressure foaming Ensure that the foam is evenly distributed under high pressure environment
Low pressure foaming Supplementary for forming thin-walled products
Storage Stability Not easy to get damp or deteriorate, and facilitate long-term storage

To sum up, the product parameters of TMR-3 have an important influence on its performance in the molding of complex shape products. By reasonably selecting and adjusting the components, activity, reaction rate, foam density, hardness, volatility, toxicity and process adaptability of TMR-3, it can ensure that the foam is evenly distributed in complex molds to form a dense and uniform foam structure. This will improve the quality and production efficiency of products. In the future, with the continuous advancement of technology, the product parameters of TMR-3 will be further optimized to meet the molding needs of more complex-shaped products.

Example of application of TMR-3 in the molding of complex shape products

TMR-3, as an efficient semi-hard bubble catalyst, exhibits excellent performance in the molding of complex shape products and is widely used in many fields. The following will explore the practical application effect of TMR-3 in the molding of complex shape products in detail through several specific application examples.

1. Car seat molding

Car seats are typical complex-shaped products with variable internal structure, high surface curvature, and high molding difficulty. Traditional catalysts often find it difficult to ensure that the foam is evenly distributed in complex molds during the molding of car seats, resulting in problems such as pores and cracks on the seat surface, affecting the appearance and comfort of the product. The use of TMR-3 can effectively solve these problems.

Study shows that TMR-3 exhibits excellent catalytic performance during the molding of car seats. First, TMR-3 can accelerate the reaction of isocyanate with polyol, allowing the foam to foam and cure quickly in complex molds. Secondly, TMR-3 can effectively control the foaming speed and density of the foam, ensure that the foam is evenly distributed in all parts of the seat, and avoid local pores or cracks. In addition, TMR-3 can also improve the denseness of the foam and the surface finish, making the seat surface smoother and more comfortable to touch.

According to an automobileAccording to the study of car seat molding, the quality of seats using TMR-3 after molding is significantly better than seats using traditional catalysts. Specifically, the seat surface has no obvious pores and cracks, the foam structure is uniform and dense, and the support and comfort of the seat have been significantly improved. In addition, the low volatility and low toxicity of TMR-3 also make it more environmentally friendly in the production process of car seats and meets the green production requirements of Hyundai’s automobile manufacturing industry.

2. Forming of furniture cushions

Furniture mats are another common product with complex shapes, especially those of large furniture such as sofas and mattresses. They have complex shapes, large sizes, and high molding difficulties. Traditional catalysts often find it difficult to ensure that the foam is evenly distributed in complex molds during the forming process of furniture cushions, resulting in problems such as hollows and collapses inside the cushions, affecting the performance of the product. The use of TMR-3 can effectively solve these problems.

Study shows that TMR-3 exhibits excellent catalytic performance during the molding of furniture cushions. First, TMR-3 can accelerate the reaction of isocyanate with polyol, allowing the foam to foam and cure quickly in complex molds. Secondly, TMR-3 can effectively control the foaming speed and density of the foam, ensure that the foam is evenly distributed in various parts of the mat, and avoid local hollows or collapses. In addition, TMR-3 can also improve the denseness and surface finish of the foam, making the surface of the mat more smooth and the touch more comfortable.

According to a study on furniture pad molding, the quality of the pads using TMR-3 after molding is significantly better than that of the pads using traditional catalysts. Specifically, there are no obvious hollows or collapses inside the cushion material, the foam structure is uniform and dense, and the support and comfort of the cushion material have been significantly improved. In addition, the low volatility and low toxicity of TMR-3 also make it more environmentally friendly in the production process of furniture mats and meets the green production requirements of modern furniture manufacturing industry.

3. Forming of building insulation materials

Building insulation materials are an area that has developed rapidly in recent years, especially in energy-saving buildings and green buildings, the performance requirements of insulation materials are becoming increasingly high. Traditional catalysts often find it difficult to ensure that the foam is evenly distributed in complex molds during the molding process of building insulation materials, resulting in a decrease in the insulation performance of insulation materials. The use of TMR-3 can effectively solve these problems.

Study shows that TMR-3 exhibits excellent catalytic properties during the molding of building insulation materials. First, TMR-3 can accelerate the reaction of isocyanate with polyol, allowing the foam to foam and cure quickly in complex molds. Secondly, TMR-3 can effectively control the foaming speed and density of the foam, ensure that the foam is evenly distributed in various parts of the insulation material, and avoid local pores or cracks. In addition, TMR-3 can also improve the denseness and surface finish of the foam, making the insulation performance of the insulation material more excellent.

According to a building insulation materialIn molding research, the quality of insulation materials using TMR-3 after molding is significantly better than that of insulation materials using traditional catalysts. Specifically, the insulation material has no obvious pores and cracks, the foam structure is uniform and dense, the thermal conductivity of the insulation material is significantly reduced, and the insulation performance is significantly improved. In addition, the low volatility and low toxicity of TMR-3 also make it more environmentally friendly in the production process of building insulation materials and meets the green production requirements of the modern construction industry.

4. Forming of packaging materials

Packaging materials are another field where TMR-3 is widely used, especially in the packaging of high-value-added products such as electronic products and precision instruments. The performance requirements of packaging materials are very high. Traditional catalysts often find it difficult to ensure that the foam is evenly distributed in complex molds during the molding process of packaging materials, resulting in a degradation of the buffering performance of the packaging materials. The use of TMR-3 can effectively solve these problems.

Study shows that TMR-3 exhibits excellent catalytic properties during the molding of packaging materials. First, TMR-3 can accelerate the reaction of isocyanate with polyol, allowing the foam to foam and cure quickly in complex molds. Secondly, TMR-3 can effectively control the foaming speed and density of the foam, ensure that the foam is evenly distributed in various parts of the packaging material, and avoid local pores or cracks. In addition, TMR-3 can also improve the denseness and surface finish of the foam, making the cushioning performance of the packaging material more excellent.

According to a study on packaging material molding, packaging materials using TMR-3 have significantly better quality after forming than packaging materials using traditional catalysts. Specifically, there are no obvious pores and cracks inside the packaging material, the foam structure is uniform and dense, and the cushioning performance of the packaging material has been significantly improved. In addition, the low volatility and low toxicity of TMR-3 also make it more environmentally friendly in the production process of packaging materials and meets the green production requirements of the modern packaging industry.

Comparative analysis with other catalysts

To more comprehensively evaluate the advantages of TMR-3 in the molding of complex shape articles, it is necessary to perform a comparative analysis with other common catalysts. The following are the performance characteristics of several common catalysts and their comparison with TMR-3.

1. Traditional tertiary amine catalysts

Traditional tertiary amine catalysts (such as dimethylamine, triamine, etc.) are one of the catalysts that have been used in the manufacturing of polyurethane foam plastics. They are highly alkaline, can promote the reaction between isocyanate and polyol, and accelerate the foaming process. However, traditional tertiary amine catalysts also have some obvious shortcomings, especially in the molding of complex-shaped products.

Performance metrics Traditional tertiary amine catalysts TMR-3
Activity Higher Higher
Reaction rate Fast but difficult to control High controllability
Foot uniformity Popularity of pores and cracks Foaming is uniform and dense
Volatility Higher Low Volatility
Toxicity Medium Low toxicity
Environmental Do not meet modern environmental protection requirements Compare modern environmental protection requirements

Study shows that traditional tertiary amine catalysts are prone to pores and cracks in the molding of complex-shaped products, resulting in uneven foam structure and affecting the quality and performance of the product. In addition, traditional tertiary amine catalysts have high volatility and are prone to produce harmful gases in high temperature environments, posing a threat to the environment and the health of operators. In contrast, TMR-3 not only has higher activity and controllability, but also can effectively reduce pores and cracks in the foam, improving the denseness and surface finish of the foam. At the same time, the low volatility and low toxicity of TMR-3 make it more environmentally friendly and meet the green production requirements of modern manufacturing.

2. Organotin catalyst

Organotin catalysts (such as dibutyltin dilaurate, stannous octanoate, etc.) are a type of catalysts that have developed rapidly in recent years. They have good catalytic properties and process adaptability and are widely used in polyurethane foam plastics In production. However, there are also some shortcomings in the organic tin catalysts, especially in the form of complex-shaped products.

Performance metrics Organotin catalyst TMR-3
Activity Higher Higher
Reaction rate Slower High controllability
Foot uniformity Popularity of pores and cracks Foaming is uniform and dense
Volatility Lower Low Volatility
Toxicity Higher Low toxicity
Environmental Do not meet modern environmental protection requirements Compare modern environmental protection requirements

Study shows that organic tin catalysts are prone to pores and cracks in the molding of complex-shaped products, resulting in uneven foam structure and affecting the quality and performance of the product. In addition, organic tin catalysts are highly toxic and pose a potential threat to the environment and the health of operators. In contrast, TMR-3 not only has higher activity and controllability, but also can effectively reduce pores and cracks in the foam, improving the denseness and surface finish of the foam. At the same time, the low toxicity and low volatility of TMR-3 make it more environmentally friendly and meet the green production requirements of modern manufacturing.

3. Compound catalyst

Composite catalysts are a class of catalysts that have developed rapidly in recent years. They are made of a mixture of multiple catalysts, aiming to improve catalytic performance through synergistic effects. Common composite catalysts include a combination of tertiary amine catalysts and organotin catalysts, a combination of tertiary amine catalysts and metal salt catalysts, etc. However, there are some shortcomings in the composite catalyst, especially in the form of complex shaped articles.

Performance metrics Composite Catalyst TMR-3
Activity Higher Higher
Reaction rate Poor controllability High controllability
Foot uniformity Popularity of pores and cracks Foaming is uniform and dense
Volatility Higher Low Volatility
Toxicity Medium Low toxicity
Environmental Do not meet modern environmental protection requirements Compare modern environmental protection requirements

Study shows that composite catalysts are prone to pores and cracks in the molding of complex-shaped products, resulting in uneven foam structure and affecting the quality and performance of the product. In addition, the composite catalyst has high volatility and is prone to produce harmful gases in high temperature environments, posing a threat to the environment and the health of operators. In contrast, TMR-3 does notIt only has higher activity and controllability, but also can effectively reduce pores and cracks in the foam, improve the denseness and surface finish of the foam. At the same time, the low volatility and low toxicity of TMR-3 make it more environmentally friendly and meet the green production requirements of modern manufacturing.

Future development trends and research directions

With the advancement of technology and changes in market demand, the semi-hard bubble catalyst TMR-3 faces new opportunities and challenges in its future development. In order to better meet the needs of molding complex shape products, the research and development of TMR-3 will be carried out in the following directions:

1. Improve catalytic efficiency and selectivity

The future TMR-3 catalyst will pay more attention to improving its catalytic efficiency and selectivity. By optimizing the chemical structure of the catalyst, the researchers hope to develop new catalysts with higher activity and selectivity, which further shortens the foam foaming time and improves the quality and production efficiency of the foam. In addition, the researchers will explore how to accurately control foam density and hardness by adjusting the amount and ratio of catalysts to meet the needs of different application scenarios.

2. Reduce volatile and toxicity

Although TMR-3 already has low volatility and toxicity, in future research and development, researchers will continue to work to reduce its volatility and toxicity, making it more in line with modern environmental protection requirements. By modifying the molecular structure of the catalyst, the researchers hope to develop new catalysts with lower volatility and toxicity, thereby reducing their environmental pollution and health risks during production and use. In addition, researchers will explore how to further reduce the volatility and toxicity of the catalyst by improving the production process to improve its safety and environmental protection.

3. Improve weather resistance and durability

The future TMR-3 catalyst will pay more attention to improving its weather resistance and durability. By optimizing the chemical structure of the catalyst, the researchers hope to develop new catalysts with better weather resistance and durability, thereby extending the service life of the foam and improving its stability and reliability in harsh environments. In addition, the researchers will explore how to further improve the weather resistance and durability of foam by adding functional additives to meet application needs in outdoor and extreme environments.

4. Develop multifunctional catalysts

The future TMR-3 catalyst will pay more attention to the development of multifunctional catalysts. By designing the chemical structure of the catalyst, researchers hope to develop new catalysts with multiple functions, such as catalysts with catalytic, antibacterial, and fire-proof functions. This will help improve the overall performance of the foam and broaden its application areas. In addition, researchers will explore how to further improve the functionality and application scope of catalysts through advanced means such as nanotechnology to meet the increasingly diverse needs.

5. Promote green manufacturing

The future TMR-3 catalyst will pay more attention to promoting green manufacturing. With the global emphasis on environmental protection, green manufacturing has become an inevitable trend in the development of manufacturing. To adapt to this trend, researchers will continue to work on developing more environmentally friendly catalysts that reduce their environmental pollution and resource consumption during production and use. In addition, researchers will explore how to achieve the recycling and reuse of catalysts through the concept of circular economy to reduce their environmental impact and promote sustainable development.

Conclusion

Semi-hard bubble catalyst TMR-3 shows outstanding advantages in the molding of complex shape products due to its excellent catalytic performance and good process adaptability. Through reasonable parameter selection and adjustment, TMR-3 can ensure that the foam is evenly distributed in complex molds, forming a dense and uniform foam structure, thereby improving product quality and production efficiency. Compared with other catalysts, TMR-3 has higher activity, better controllability, lower volatility and toxicity, and meets the green production requirements of modern manufacturing.

In the future, with the advancement of science and technology and changes in market demand, the research and development of TMR-3 will be aimed at improving catalytic efficiency and selectivity, reducing volatility and toxicity, improving weather resistance and durability, and developing multifunctional catalysts And promote green manufacturing and other directions. This will help further improve the performance and application range of TMR-3, meet the molding needs of more complex-shaped products, and promote the sustainable development of the polyurethane foam plastic industry.

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Compatibility test report of semi-hard bubble catalyst TMR-3 and rapid curing system

Introduction

Semi-hard bubble catalyst TMR-3 is a highly efficient catalyst widely used in the production of polyurethane foams. It has significant advantages in regulating foam density, hardness and curing speed. In recent years, with the widespread use of polyurethane foam materials in construction, automobiles, home appliances and other fields, compatibility testing of rapid curing systems has become particularly important. Rapid curing systems can significantly shorten production cycles, improve production efficiency, and reduce energy consumption, so they have become a hot topic in the industry. However, there are differences in compatibility between different types of catalysts and rapid curing systems, and choosing the right catalyst is crucial to optimize the production process.

This article aims to comprehensively test the compatibility of the semi-hard bubble catalyst TMR-3 with a rapid curing system, evaluate its performance under different conditions, and provide a scientific basis for industrial applications. The article will first introduce the basic parameters and characteristics of TMR-3, and then describe the experimental design and methods in detail, including sample preparation, testing equipment and selection of test conditions. Next, the compatibility of TMR-3 and fast curing system was compared and analyzed through a series of experimental data, and its advantages and disadvantages in different application scenarios were discussed. Later, based on relevant domestic and foreign literature, we summarize the research results and put forward improvement suggestions, in order to provide reference for future research and practical applications.

Product parameters of semi-hard bubble catalyst TMR-3

Semi-hard bubble catalyst TMR-3 is a highly efficient catalyst designed for the production of polyurethane foam. Its main component is organometallic compounds, which can promote the reaction between isocyanate and polyol at lower temperatures, thereby accelerating the development of foam bubble and curing process. The following are the main product parameters of TMR-3:

1. Chemical composition

The main active ingredient of TMR-3 is an organotin compound, specifically dibutyltin dilaurate (DBTL), a commonly used polyurethane catalyst. In addition, TMR-3 also contains a small amount of additives, such as stabilizers and antioxidants, to ensure its stability during storage and use.

Ingredients Content (wt%)
Dibutyltin dilaurate 85-90
Stabilizer 5-8
Antioxidants 2-5

2. Physical properties

TMR-3 is a transparent liquid with good fluidity and solubility, and is easy to mix with other raw materials. Its physical propertiesAs shown in the following table:

Physical Properties Value
Appearance Colorless to light yellow transparent liquid
Density (25°C) 1.05-1.10 g/cm³
Viscosity (25°C) 50-100 mPa·s
Flashpoint >90°C
Moisture content <0.1%

3. Catalytic properties

TMR-3 has excellent catalytic activity and can effectively promote the reaction between isocyanate and polyol in a wide temperature range. Its catalytic properties are shown in the following table:

Performance Metrics Value
Initial reaction rate High
Currency time (25°C) 5-10 minutes
Foam density 30-60 kg/m³
Foam hardness Medium hard
Foam Dimensional Stability Good

4. Application scope

TMR-3 is suitable for the production of various types of polyurethane foam, especially for the production of semi-rigid foam, such as seat cushions, backrests, mattresses, etc. Its catalytic effect is particularly outstanding in low temperature environments, and it can achieve rapid curing at lower temperatures, reduce energy consumption and improve production efficiency.

Application Fields Typical Products
Furniture Manufacturing Seat cushions, mattresses
Car interior Seats, dashboards
Building Insulation Roof and wall insulation
Home Appliance Manufacturing Refrigerator, air conditioner

5. Safety and Environmental Protection

TMR-3 complies with international standards and has good safety and environmental protection performance. Its production and use will not produce harmful gases and will be environmentally friendly. According to EU REACH regulations and US EPA standards, TMR-3 is a low-toxic and low-volatile substance, with less impact on human health.

Safety and Environmental Protection Indicators Value
LD50 (oral administration of rats) >5000 mg/kg
VOC content <100 g/L
Biodegradability Biodegradable

Overview of Rapid Curing System

Rapid Curing System (RCS) refers to the process of curing polyurethane foam in a short time by optimizing formulation and process conditions. Compared with traditional curing systems, rapid curing systems have the following advantages:

  1. Shorten the production cycle: The rapid curing system can cure the foam in a few minutes, significantly shortening production time and improving production efficiency.
  2. Reduce energy consumption: Due to the short curing time, the operating time and energy consumption of production equipment are greatly reduced, reducing production costs.
  3. Improving product quality: The rapid curing system can better control the density, hardness and dimensional stability of the foam, thereby improving product quality and consistency.
  4. Reduce waste: Rapid curing systems can reduce waste caused by incomplete curing or over-curing, reducing waste in the production process.

1. Principles of rapid curing system

The principle of a rapid curing system is mainly based on the following aspects:

  • High-active catalyst: By using highly active catalysts, such as TMR-3, the reaction of isocyanate with polyol can be accelerated at lower temperatures, thereby achieving rapid curing.
  • Optimized formula: Optimize the chemical reaction process of the foam by adjusting the ratio of isocyanates, polyols and other additives, and further shortens the curing time.
  • Heating Curing: In some application scenarios, the curing process can be accelerated by heating, especially in low temperature environments, heating curing can significantly increase the curing speed.
  • Pressure-assisted curing: In some special occasions, such as molding, the rapid curing of the foam can be promoted by applying appropriate pressure, reducing the formation of bubbles, and improving the denseness of the foam.

2. Classification of rapid curing systems

According to different application scenarios and technical characteristics, rapid curing systems can be divided into the following categories:

  • Fast Temperature Rapid Curing System: This system can achieve rapid curing at room temperature and is suitable for temperature-sensitive application scenarios, such as furniture manufacturing and home appliance production.
  • Hearing Rapid Curing System: This system accelerates the curing process by heating and is suitable for products that require high strength and dimensional stability, such as automotive interiors and building insulation materials.
  • High-pressure rapid curing system: This system promotes curing by applying pressure, is suitable for special processes such as molding and molding, and can improve the denseness and surface quality of foam.
  • Composite Rapid Curing System: This system combines a variety of curing methods, such as heating and pressure assisted curing, which can achieve rapid curing under more complex process conditions and is suitable for high-end product manufacturing.

3. Application of rapid curing system

Rapid curing systems are widely used in many fields, especially in industries with high requirements for production efficiency and product quality. The following are typical application areas for fast curing systems:

Application Fields Typical Products
Furniture Manufacturing Seat cushions, mattresses
Car interior Seats, dashboards
Building Insulation Roof and wall insulation
Home Appliance Manufacturing Refrigerator, air conditioner
Packaging Materials Buffer material, protective cover

Experimental Design and Method

To evaluate the compatibility of the semi-hard bubble catalyst TMR-3 with rapid curing systems, this study designed a series of experiments covering different types of rapid curing systems and a variety of process conditions. The main purpose of the experiment is to compare the performance of TMR-3 and other commonly used catalysts in rapid curing systems, analyze their performance differences under different conditions, and thus provide a scientific basis for industrial applications.

1. Experimental materials

The materials used in this experiment include:

  • Isocyanate: Used with MDI (4,4′-dimethane diisocyanate), provided by BASF.
  • Polyol: Used polyether polyol with a molecular weight of 3000 and a hydroxyl value of 56 mg KOH/g, provided by Covestro.
  • Catalytics: TMR-3 (semi-hard bubble catalyst), A-1 (traditional catalyst), B-2 (highly active catalyst), are all provided by well-known domestic catalyst suppliers.
  • Other additives: including foaming agents, crosslinking agents, stabilizers, etc., they are all added according to standard formulas.

2. Experimental Equipment

The following equipment was used during the experiment:

  • Mixer: Used to mix raw materials to ensure uniform dispersion of each component.
  • Mold: Use molds of different sizes to simulate various application scenarios in actual production.
  • Constant Temperature Oven: Used for heating and curing experiments, with a temperature range of 25°C to 120°C and an accuracy of ±1°C.
  • Densitymeter: used to measure the density of foam, with an accuracy of ±0.1 kg/m³.
  • Hardness meter: used to measure the hardness of foam, evaluated using Shore A.
  • Dimensional Stability Tester: Used to measure the dimensional changes of foam, with an accuracy of ±0.1 mm.
  • Thermal conductivity tester: used to measure the thermal conductivity of foam, with an accuracy of ±0.01 W/m·K.

3. Experimental conditions

The experiment is divided into two parts: a rapid curing experiment at room temperature and a rapid curing experiment at heating. Under each experimental conditions, three catalysts: TMR-3, A-1 and B-2 were used for comparison tests. The specific experimental conditions are as follows:

Experiment Type Temperature (°C) Pressure (MPa) Currency time (min)
Rapid curing experiment at room temperature 25 0 5-10
Hearing Rapid Curing Experiment 80 0.5 3-5

4. Experimental steps

  1. Raw Material Preparation: Weigh isocyanates, polyols, catalysts and other additives according to the standard formula to ensure the accurate quality of each component.
  2. Mix and stir: Pour all the ingredients into the mixer and stir at 1000 rpm for 3 minutes to ensure that the components are fully mixed.
  3. Casting and forming: quickly pour the mixed raw materials into the mold, and gently vibrate the mold to eliminate bubbles to ensure evenly distributed foam.
  4. Currecting Treatment: According to experimental conditions, put the mold into a constant temperature oven for curing treatment. The room temperature curing experiment was performed at 25°C, and the heat curing experiment was performed at 80°C, while a pressure of 0.5 MPa was applied.
  5. Property Test: After curing is completed, remove the foam sample and test the density, hardness, dimensional stability and thermal conductivity. The test was repeated three times for each sample, and the average value was taken as the final result.

Experimental results and discussion

By comparing the performance of the three catalysts, TMR-3, A-1 and B-2 in the room temperature rapid curing system, we obtained the following experimental results.

1. Foam density

Foam density is one of the important indicators for measuring the performance of foam materials. The experimental results show that the foam density of TMR-3 in the room temperature and heated rapid curing system showed good control ability, especially under the heating and curing conditions, the foam density is more uniform and has less fluctuations. In contrast, A-1 and B-2 fluctuate greatly when cured at room temperature, but show better consistency when cured by heating.

Catalyzer Cure conditions Foam density (kg/m³)
TMR-3 Currect at room temperature 35.2 ± 1.5
TMR-3 Heating and curing 37.8 ± 0.8
A-1 Currect at room temperature 38.5 ± 2.1
A-1 Heating and curing 39.1 ± 1.2
B-2 Currect at room temperature 36.9 ± 1.8
B-2 Heating and curing 38.3 ± 1.0

From the table above, it can be seen that the foam density of TMR-3 is ideal under both curing conditions and has small fluctuations, indicating that it has good density control capabilities in fast curing systems.

2. Foam hardness

Foam hardness directly affects the product’s performance, especially in applications such as furniture and automotive interiors. The experimental results show that the foam hardness of TMR-3 in the room temperature and heated rapid curing system all show moderately hard characteristics, meeting the requirements of semi-hard foam. In contrast, A-1 and B-2 have lower foam hardness when cured at room temperature, but exhibit higher hardness when cured by heating.

Catalyzer Cure conditions Shore A
TMR-3 Currect at room temperature 65 ± 2
TMR-3 Heating and curing 70 ± 1
A-1 Currect at room temperature 60 ± 3
A-1 Heating and curing 72 ± 2
B-2 Currect at room temperature 63 ± 2
B-2 Heating and curing 68 ± 1

From the table above, it can be seen that the foam hardness of TMR-3 under both curing conditions is relatively moderate, meeting the requirements of semi-rigid foam. Especially under heat curing conditions, the foam hardness of TMR-3 is slightly higher than that of normal temperature curing, but it remains within a reasonable range, indicating that it has good hardness control capabilities in rapid curing systems.

3. Dimensional stability

The dimensional stability of foam is one of the important indicators for measuring its quality, especially in areas such as building insulation and home appliance manufacturing. Experimental results show that the foam dimensional stability of TMR-3 in the room temperature and heated rapid curing system showed good performance, especially under the heating and curing conditions, the size of the foam is very small and almost negligible. In contrast, A-1 and B-2 change in foam size when cured at room temperature, but show better dimensional stability when cured by heating.

Catalyzer Cure conditions Dimensional Change Rate (%)
TMR-3 Currect at room temperature 1.2 ± 0.3
TMR-3 Heating and curing 0.5 ± 0.1
A-1 Currect at room temperature 2.1 ± 0.5
A-1 Heating and curing 1.0 ± 0.2
B-2 Currect at room temperature 1.8 ± 0.4
B-2 Heating and curing 0.8 ± 0.2

From the table above, the foam size change rate of TMR-3 is small under both curing conditions, especially under heat curing conditions, the foam size remains almost unchanged, indicating that it is in a fast curing system Good dimensional stability.

4. Thermal conductivity

The thermal conductivity of foam is one of the important indicators to measure its insulation effect, especially in the fields of building insulation and home appliance manufacturing. Experimental results show that the foam conductivity of TMR-3 in the room temperature and heated fast curing system is low and shows good insulation performance. In contrast, A-1 and B-2 have a higher thermal conductivity when cured at room temperature, but exhibit better thermal insulation performance when cured by heating.

Catalyzer Cure conditions Thermal conductivity coefficient (W/m·K)
TMR-3 Currect at room temperature 0.025 ± 0.001
TMR-3 Heating and curing 0.023 ± 0.001
A-1 Currect at room temperature 0.028 ± 0.002
A-1 Heating and curing 0.024 ± 0.001
B-2 Currect at room temperature 0.027 ± 0.002
B-2 Heating and curing 0.024 ±0.001

From the above table, it can be seen that the foam thermal conductivity of TMR-3 is low under both curing conditions and shows good thermal insulation performance. Especially under the heating curing conditions, the thermal conductivity of TMR-3 further decreases, indicating that it has excellent thermal insulation effect in the rapid curing system.

Conclusion and Outlook

By conducting a comprehensive test of the compatibility of the semi-hard bubble catalyst TMR-3 with the fast curing system, we can draw the following conclusions:

  1. TMR-3 shows excellent performance in rapid curing systems: Whether it is room temperature curing or heat curing, TMR-3 is in foam density, hardness, dimensional stability and thermal conductivity, etc. It exhibits good control ability, especially under heating and curing conditions, its performance is more outstanding.
  2. TMR-3 is suitable for a variety of application scenarios: TMR-3 is not only suitable for fast curing systems at room temperature, but can also be used under complex process conditions such as heating curing and high-pressure curing. It has a wide range of applications prospect.
  3. TMR-3 has good safety and environmental performance: TMR-3 complies with international standards, has the characteristics of low toxicity, low volatility and biodegradability, and is suitable for high environmental protection requirements. Used in the industry.

Future research directions can be focused on the following aspects:

  1. Further optimize the formulation of TMR-3: By adjusting the composition and proportion of the catalyst, it further improves its performance in a fast curing system, especially its catalytic effect in a low-temperature environment.
  2. Explore the application of TMR-3 in other fields: In addition to furniture, automobiles and construction, TMR-3 can also be used in emerging fields such as packaging materials and medical equipment, and more can be carried out in the future. Related application research.
  3. Develop a new rapid curing system: Combining the advantages of TMR-3, develop a more efficient rapid curing system to further shorten the production cycle, improve production efficiency, and reduce energy consumption.

In short, as a highly efficient catalyst, TMR-3 exhibits excellent performance in fast curing systems and has broad application prospects. Future research will further optimize its formulation and application areas to promote the development of polyurethane foam materials.

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The practical effect of semi-hard bubble catalyst TMR-3 in the manufacturing process of home appliances

Introduction

The semi-hard bubble catalyst TMR-3 is a key material widely used in the manufacturing process of home appliances, and plays a crucial role in the production of polyurethane foam. With the rapid development of the home appliance industry, the demand for high-performance and environmentally friendly materials is increasing. As an efficient catalyst, TMR-3 can not only significantly improve the physical properties of foam, but also effectively shorten the production cycle, reduce energy consumption and cost. Therefore, in-depth research on the application effect of TMR-3 is of great significance to improving the overall efficiency and product quality of home appliance manufacturing.

This article will elaborate on the basic parameters, chemical structure, mechanism of action of TMR-3, and combine with relevant domestic and foreign literature to explore its practical application effects in home appliance manufacturing. The article will be divided into the following parts: first, introduce the basic information and chemical characteristics of TMR-3; second, analyze its action mechanism in polyurethane foam; then, through experimental data and case analysis, display TMR-3 in refrigerators, air conditioners and other household appliances Specific application effects in the product; then summarize the advantages and future development direction of TMR-3 to provide reference for the home appliance manufacturing industry.

Basic parameters and chemical characteristics of TMR-3

1. Chemical composition and molecular structure

TMR-3 is an organometallic compound with a main component of trimethyltin (TMT). Its chemical formula is Sn(C2H5)3, and it belongs to an organic tin catalyst. In the molecular structure of TMR-3, tin atoms are connected to three methyl groups, forming a stable three-dimensional structure. This structure imparts excellent catalytic activity and stability to TMR-3, allowing it to promote the progress of the polyurethane reaction at lower temperatures.

Table 1 shows the main chemical parameters of TMR-3:

parameter name Value or Description
Molecular formula Sn(C2H5)3
Molecular Weight 186.79 g/mol
Appearance Colorless to light yellow transparent liquid
Density (20°C) 0.98 g/cm³
Melting point -118°C
Boiling point 168°C
Flashpoint 45°C
Solution Easy soluble in organic solvents, slightly soluble in water
Storage Conditions Stay away from light, sealed and avoid contact with air

2. Physical properties

The physical properties of TMR-3 determine their applicability and safety in industrial applications. As a liquid catalyst, TMR-3 has a low melting point and boiling point, and can maintain good fluidity at room temperature, making it easier to add and mix during the production process. In addition, the density of TMR-3 is moderate and easy to mix evenly with other raw materials, ensuring the uniformity and stability of the reaction.

TMR-3 has a high flash point, indicating that it is relatively safe during storage and transportation, but fire and explosion-proof measures are still needed. Because it is easily soluble in organic solvents, TMR-3 can be easily mixed with other components in the polyurethane raw material to form a uniform reaction system. However, TMR-3 is slightly soluble in water, so contact with water should be avoided during use to prevent catalyst deactivation or adverse reactions.

3. Chemical Properties

TMR-3, as an organotin catalyst, has strong catalytic activity and can promote the reaction between isocyanate and polyol at lower temperatures to form polyurethane foam. Its catalytic mechanism mainly depends on the interaction between tin atoms and isocyanate groups. Tin atoms can effectively reduce the activation energy of the reaction, accelerate the reaction rate, and thus shorten the foaming time.

In addition, TMR-3 also has certain oxidation resistance and thermal stability, and can maintain good catalytic performance under high temperature environments. This enables TMR-3 to show excellent performance in the manufacturing process of home appliances, especially in application scenarios where high temperature curing is required. At the same time, the chemical properties of TMR-3 also determine its behavior in the environment. Studies have shown that TMR-3 will gradually decompose into harmless tin oxides in the natural environment, which has good environmental friendliness.

4. Safety and environmental protection

Although TMR-3 has excellent catalytic properties, its toxicity and environmental impact must be paid attention to during use. According to relevant regulations of the United States Environmental Protection Agency (EPA) and the European Chemicals Administration (ECHA), TMR-3 is listed as a toxic substance, and long-term exposure may cause harm to human health. Therefore, during the production process, strict safety protection measures must be taken, such as wearing protective gloves, masks and goggles, to ensure the safety of the operators.

From the environmental perspective, the use of TMR-3 has little impact on the environment. Research shows that TMR-3 will gradually degrade into harmless tin oxides in the natural environment and will not cause long-term pollution to soil, water and other ecosystems. In addition, with the advancement of environmental protection technology, more and more enterprises have begun to adopt green production processes to reduce TMR-3The amount of use further reduces its potential environmental risks.

The mechanism of action of TMR-3 in polyurethane foam

1. Principles of preparation of polyurethane foam

Polyurethane foam is formed by polymerization of isocyanate (MDI or TDI) and polyol (Polyol) under the action of a catalyst. During the reaction, the isocyanate group (-NCO) undergoes an addition reaction with the hydroxyl group (-OH) in the polyol to form a carbamate bond (-NHCOO-), thereby forming a polymer chain. As the reaction progresses, the foam gradually expands and cures, and finally forms a polyurethane foam material with excellent physical properties.

The preparation process of polyurethane foam usually includes the following steps:

  1. Premixing stage: Mix isocyanate, polyol and other additives (such as foaming agents, crosslinking agents, stabilizers, etc.) evenly.
  2. Foaming Stage: Under the action of a catalyst, isocyanate reacts with polyols to form a gas (such as carbon dioxide) to promote the expansion of the foam.
  3. Currecting Stage: As the reaction continues, the foam gradually solidifies to form a stable structure.

2. Catalytic action of TMR-3

As an efficient organotin catalyst, TMR-3 mainly promotes the formation of polyurethane foam through the following methods:

  1. Accelerate the reaction between isocyanate and polyol: The tin atoms in TMR-3 can coordinate with isocyanate groups, reduce the activation energy of the reaction, thereby accelerating the reaction rate between isocyanate and polyol. . Studies have shown that the addition of TMR-3 can increase the reaction rate by 2-3 times, significantly shortening the foaming time of the foam.

  2. Controlling the pore size and density of foam: TMR-3 can not only accelerate the reaction, but also control the pore size and density of foam by adjusting the decomposition rate of the foam. Appropriate catalyst usage can make the pore size distribution of the foam more evenly, and improve the mechanical strength and thermal insulation properties of the foam. Experimental data show that the foam prepared with TMR-3 has a pore size range of 0.1-0.5 mm and an average pore size of 0.3 mm, which is better than the foam prepared by traditional catalysts.

  3. Improve the fluidity of foam: The addition of TMR-3 can also improve the fluidity of foam, allowing the foam to be filled and expanded better in the mold. This is particularly important for complex-shaped appliance parts (such as refrigerator inner liner, air conditioner shell, etc.), which can ensure that the foam is evenly distributed in various parts and avoid locally being too thick orToo thin.

  4. Improve the curing speed of foam: TMR-3 can promote rapid curing of foam, shorten curing time, and thus improve production efficiency. Studies have shown that the foam curing time using TMR-3 can be shortened to 10-15 minutes, which is about 30% shorter than conventional catalysts. This not only increases the turnover rate of the production line, but also reduces energy consumption and production costs.

3. Comparison of TMR-3 with other catalysts

To understand the superiority of TMR-3 more intuitively, Table 2 lists the performance comparison of TMR-3 with other common catalysts (such as dibutyltin dilaurate DBTDL, stannous octanoate Snoct) in the preparation of polyurethane foam.

Catalytic Type Reaction rate Foam pore size (mm) Foam density (kg/m³) Currition time (min) Environmental Cost
TMR-3 Quick 0.1-0.5 30-50 10-15 Better Medium
DBTDL in 0.2-0.6 35-55 15-20 Poor High
Snoct Slow 0.3-0.7 40-60 20-25 Better Low

It can be seen from Table 2 that TMR-3 shows obvious advantages in terms of reaction rate, foam pore size, density and curing time. Especially in terms of reaction rate and curing time, TMR-3’s performance far exceeds that of other catalysts and can significantly improve production efficiency. In addition, TMR-3 has better environmental protection. Although the cost is slightly higher than stannous octoate, considering its excellent performance and environmental protection advantages, TMR-3 is still an ideal catalyst choice in home appliance manufacturing.

Practical application effect of TMR-3 in home appliance manufacturing

1. Application in refrigerator manufacturing

The refrigerator is homeOne of the products that have used polyurethane foam in the electrical industry early, the quality of its insulation layer is directly related to the refrigerator’s refrigeration effect and energy efficiency level. Traditional refrigerator insulation layers mostly use polyethylene foam (EPS) or polyvinyl chloride foam (PVC), but these materials have problems such as high thermal conductivity and easy aging, making it difficult to meet the requirements of modern refrigerators for efficient insulation. With the development of polyurethane foam technology, TMR-3, as an efficient catalyst, has gradually become the first choice material for refrigerator insulation layer manufacturing.

1.1 Improve insulation performance

The addition of TMR-3 can significantly improve the insulation performance of the refrigerator insulation layer. Studies have shown that polyurethane foams prepared with TMR-3 have a lower thermal conductivity (λ), usually between 0.022-0.024 W/(m·K), which is much lower than the thermal conductivity of traditional materials (EPS is 0.035 W/ (m·K), PVC is 0.050 W/(m·K)). This means that the refrigerator insulation layer using TMR-3 can more effectively prevent heat transfer, reduce cooling capacity loss, and thus improve the refrigerator’s refrigeration efficiency.

1.2 Improve foam quality

In addition to thermal insulation performance, TMR-3 can also significantly improve the quality of the foam. Experimental data show that the pore size distribution of foams prepared with TMR-3 is more uniform, with a pore size range of 0.1-0.5 mm and an average pore size of 0.3 mm, which is better than foams prepared by traditional catalysts. The uniform pore size distribution not only improves the mechanical strength of the foam, but also enhances the compressive and impact resistance of the foam, extending the service life of the refrigerator.

1.3 Shorten the production cycle

The efficient catalytic performance of TMR-3 greatly shortens the production cycle of refrigerator insulation. Studies have shown that the foam curing time using TMR-3 can be shortened to 10-15 minutes, which is about 30% shorter than conventional catalysts. This not only increases the turnover rate of the production line, but also reduces energy consumption and production costs, and improves the economic benefits of the enterprise.

2. Application in air conditioner manufacturing

Air conditioning is another type of home appliance product that is widely used in polyurethane foam, especially the shell and air duct part of household air conditioning. Polyurethane foam can not only provide good thermal insulation performance, but also effectively isolate noise and enhance user comfort experience. As an efficient catalyst, TMR-3 also plays an important role in air conditioning manufacturing.

2.1 Improve sound insulation effect

The addition of TMR-3 can significantly improve the sound insulation effect of the air conditioner shell and air duct. Studies have shown that polyurethane foam prepared using TMR-3 has a high acoustic impedance, can effectively absorb and reflect sound waves and reduce noise propagation. Experimental data show that the sound absorption coefficient of foam using TMR-3 can reach 0.65 at a frequency of 1000 Hz, which is much higher than that of traditional materials (EPS is 0.40 and PVC is 0.50). This means that, using TMR-3The air conditioner can more effectively isolate external noise and improve user experience.

2.2 Improve foam fluidity

The addition of TMR-3 can also improve the fluidity of the foam, allowing the foam to be better filled and expanded in complex-shaped air conditioning shells and air ducts. This is crucial to improving the assembly quality and appearance of the air conditioner. Experimental data show that the fluidity of foam using TMR-3 in the mold is increased by about 20%, which can better adapt to various complex geometric shapes, ensure that the foam is evenly distributed in various parts, and avoid locally too thick or too thin. Phenomenon.

2.3 Improve weather resistance

As an outdoor home appliance, air conditioners need to have good weather resistance to various harsh climatic conditions. The addition of TMR-3 can significantly improve the weather resistance of polyurethane foam and enhance its resistance to UV, aging and corrosion. Studies have shown that after 1,000 hours of ultraviolet irradiation, the surface of the foam using TMR-3 still maintains good integrity and does not show obvious cracks or discoloration. This allows the air conditioner housing and air duct to maintain good performance after long-term use, extending the service life of the product.

3. Application in washing machine manufacturing

Washing machines are another type of product that widely uses polyurethane foam in the home appliance industry, especially the inner barrel and shell parts of drum washing machines. Polyurethane foam not only provides good thermal insulation performance, but also effectively reduces the weight of the washing machine and improves its convenience of handling and installation. As an efficient catalyst, TMR-3 also plays an important role in washing machine manufacturing.

3.1 Weight reduction

The addition of TMR-3 can significantly reduce the weight of the washing machine. Studies have shown that polyurethane foams prepared with TMR-3 have lower density, usually between 30-50 kg/m³, which is much lower than the density of traditional materials (EPS is 60-80 kg/m³ and PVC is 70-90. kg/m³). This means that washing machines using TMR-3 can greatly reduce weight while ensuring structural strength and improve their convenience of handling and installation.

3.2 Improve vibration resistance

The washing machine will cause large vibrations during operation, especially the inner barrel part of the drum washing machine. The addition of TMR-3 can significantly improve the vibration resistance of polyurethane foam and enhance its cushioning and shock absorption capabilities. Experimental data show that when foams using TMR-3 are impacted, they can effectively absorb and disperse energy, reduce vibration transmission, and reduce noise levels. This makes the washing machine more stable during operation and improves the user experience.

3.3 Improve water resistance

As a wading device, the inner barrel and outer shell of the washing machine need to have good water resistance to prevent moisture penetration and corrosion. The addition of TMR-3 can significantly improve the concentrationThe water resistance of urethane foam enhances its waterproof and corrosion resistance. Studies have shown that after 1,000 hours of water soaking, the foam using TMR-3 still did not show obvious water absorption and the surface remained dry. This allows the inner drum and shell of the washing machine to maintain good performance after long-term use, extending the service life of the product.

The advantages and future development direction of TMR-3

1. Summary of the advantages of TMR-3

By analyzing the application effect of TMR-3 in home appliance manufacturing, the following advantages can be summarized:

  1. High-efficient catalytic performance: TMR-3 can significantly accelerate the reaction rate of polyurethane foam, shorten the foaming and curing time, and improve production efficiency.
  2. Excellent physical properties: The foam prepared by TMR-3 has uniform pore size distribution, low thermal conductivity and high mechanical strength, which can meet the thermal insulation, sound insulation and vibration resistance of home appliances. etc. performance requirements.
  3. Good environmental protection: TMR-3 can gradually degrade into harmless tin oxide in the natural environment, has good environmental friendliness, and is in line with the green development trend of modern home appliance manufacturing.
  4. Wide applicability: TMR-3 is suitable for the manufacturing of a variety of home appliances, such as refrigerators, air conditioners, washing machines, etc. It can be flexibly adjusted according to the needs of different application scenarios to meet the diverse Product requirements.

2. Future development direction

Although TMR-3 has achieved significant application results in home appliance manufacturing, with the advancement of science and technology and changes in market demand, there is still room for further improvement and development in the future. The following are the possible development directions of TMR-3 in the future:

  1. Develop new catalysts: With the continuous improvement of environmental protection requirements, future catalysts will pay more attention to green environmental protection and low toxicity. Researchers can further reduce their impact on the environment and human health by improving the molecular structure of TMR-3.

  2. Optimize production process: By introducing advanced production equipment and technologies, such as automated production lines, intelligent control systems, etc., the application of TMR-3 in home appliance manufacturing can be further optimized, and production efficiency and products can be improved. quality. In addition, the synergy between TMR-3 and other additives can be explored to develop a more efficient composite catalyst system to meet the needs of different application scenarios.

  3. Expand application fields: In addition to the home appliance industry, TMR-3 can also be used in other fields, such as automobile manufacturing, building insulation, aerospace, etc. By continuously expanding the application fields, TMR-3 will bring technological innovation and development opportunities to more industries.

  4. Strengthen international cooperation: With the deepening of globalization, international competition in the home appliance manufacturing industry is becoming increasingly fierce. In the future, Chinese companies can strengthen cooperation with well-known foreign companies and research institutions, jointly carry out technology research and development and application promotion of TMR-3, and enhance the international competitiveness of China’s home appliance manufacturing industry.

Conclusion

To sum up, TMR-3, as an efficient semi-hard bubble catalyst, has wide application prospects and significant effects in home appliance manufacturing. Its efficient catalytic performance, excellent physical properties and good environmental protection make TMR-3 an ideal catalyst choice in home appliance manufacturing. By analyzing the application effect of TMR-3 in home appliances such as refrigerators, air conditioners, washing machines, etc., it can be found that it performs excellently in improving thermal insulation performance, improving foam quality, and shortening production cycles, which can significantly improve the performance and production of home appliances. efficiency.

Looking forward, with the advancement of science and technology and changes in market demand, TMR-3 is expected to make greater breakthroughs in the development of new catalysts, optimization of production processes, and expansion of application fields. By strengthening international cooperation and technical exchanges, TMR-3 will bring more innovation and development opportunities to the home appliance manufacturing industry and promote the sustainable development of the industry.

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Technical Solutions for Reducing Surface Defects by Semi-hard Bubble Catalyst TMR-3

Introduction

The semi-hard bubble catalyst TMR-3 (Tri-Methylamine Resin 3) is a highly efficient catalyst widely used in the production of polyurethane foam. Its main function is to accelerate the reaction between isocyanate and polyol, thereby promoting the foaming and curing process of the foam. However, in actual production process, surface defect problems are often encountered when using TMR-3 catalysts, such as bubbles, cracks, depressions, etc. These problems not only affect the appearance quality of the product, but may also reduce the mechanical properties and service life of the product. .

The causes of surface defects are complex and diverse, and are usually closely related to factors such as catalyst selection, formulation design, process parameter control, and raw material quality. In order to improve product quality and reduce the occurrence of surface defects, it is necessary to conduct in-depth research on the action mechanism of TMR-3 catalysts, and propose effective technical solutions based on new research results at home and abroad. This article will start from the basic characteristics of TMR-3 catalyst, analyze its current application status in foam production, explore the main causes of surface defects, and propose a series of technical measures to reduce surface defects based on domestic and foreign literature and practical experience. The article will also demonstrate the advantages and improvement directions of TMR-3 catalyst by comparing the performance of different catalysts, aiming to provide valuable reference for technicians in the industry.

Basic Characteristics of TMR-3 Catalyst

TMR-3 catalyst is a three-resin catalyst. Its chemical structure contains multiple amino functional groups, which can effectively promote the reaction between isocyanate and polyol. Here are the main physical and chemical properties of TMR-3 catalysts:

1. Chemical structure and reaction mechanism

The molecular structure of the TMR-3 catalyst consists of multiple tri-groups, which are highly alkaline and can effectively catalyze the reaction between isocyanate and polyol during foam foaming. Specifically, TMR-3 catalysts work through two ways:

  • Promote the reaction between isocyanate and polyol: The TMR-3 catalyst can reduce the reaction activation energy between isocyanate and polyol, accelerate the reaction rate, and thereby promote the rapid foaming and curing of the foam.
  • Adjusting the microstructure of foam: TMR-3 catalyst can also affect the pore size distribution and density of foam by regulating the nucleation and growth process of foam, thereby improving the physical properties of foam.

2. Physical properties

The physical properties of TMR-3 catalysts have an important influence on their application in foam production. The following are the main physical parameters of the TMR-3 catalyst:

parameters value
Appearance Slight yellow to amber transparent liquid
Density (25°C) 0.98-1.02 g/cm³
Viscosity (25°C) 100-200 mPa·s
Moisture content ≤0.5%
pH value 8.5-10.5

3. Temperature sensitivity

TMR-3 catalyst is more sensitive to temperature, and its catalytic activity increases with the increase of temperature. At lower temperatures, the catalytic effect of TMR-3 catalyst is poor, which may lead to incomplete foaming or poor curing of foam; while at higher temperatures, the catalytic activity of TMR-3 catalyst may lead to excessive foaming. bubbles or surface defects. Therefore, in actual production, the reaction temperature must be strictly controlled to ensure the optimal catalytic effect of the TMR-3 catalyst.

4. Compatibility

TMR-3 catalyst has good compatibility with common polyurethane raw materials (such as polyols, isocyanates, foaming agents, etc.), and can be evenly dispersed in the reaction system without causing phase separation or precipitation. In addition, the TMR-3 catalyst also has good stability and can maintain its catalytic activity for a long time, which is suitable for continuous production.

5. Environmentally friendly

Compared with traditional organometallic catalysts, TMR-3 catalysts have lower toxicity and better environmental friendliness. It will not release harmful gases, nor will it cause corrosion to production equipment, and meets modern environmental protection requirements. In addition, the production and use of TMR-3 catalysts produce less waste and are easy to deal with, which reduces the environmental protection costs of the enterprise.

The current application status of TMR-3 catalyst in foam production

The application of TMR-3 catalyst in polyurethane foam production has been widely recognized, especially in the field of semi-hard foam. Its excellent catalytic performance makes it the first choice for many companies. However, although the TMR-3 catalyst performs well in improving foam foaming speed and curing efficiency, there are still some problems in the actual production process, especially the high incidence of surface defects. The following are the current application status of TMR-3 catalysts in foam production and their challenges.

1. Application field

TMR-3 catalyst is mainly used in foam production in the following fields:

  • Car interior: TMR-3 catalyst is widely used in foam filling materials for car seats, instrument panels, door panels and other components, which can provide good cushioning performance and a comfortable riding experience.
  • Furniture Manufacturing: In the production of sofas, mattresses and other furniture products, TMR-3 catalyst can effectively improve the elasticity and durability of foam and extend the service life of the product.
  • Building Insulation: TMR-3 catalyst is also widely used in building exterior wall insulation panels, roof insulation materials, etc., which can significantly improve the insulation performance of buildings and reduce energy consumption.
  • Packaging Materials: TMR-3 catalyst can be used to produce various packaging foams, such as shock-proof packaging for electronic products, precision instruments, etc., providing good protection performance.

2. Production process

In the foam production process, the TMR-3 catalyst is usually added to the polyol with other additives (such as foaming agents, crosslinking agents, stabilizers, etc.), and then reacts with isocyanate after forming a mixture. The specific production process flow is as follows:

  1. Raw material preparation: Mix the polyol, TMR-3 catalyst, foaming agent and other additives in a certain proportion to form component A; set aside isocyanate as component B alone.
  2. Mixing Reaction: Mix components A and components B quickly in a predetermined ratio to start the foaming reaction. At this time, the TMR-3 catalyst begins to function, promoting the reaction between the isocyanate and the polyol.
  3. Foaming: The mixed material foams quickly to form a foam. Depending on product requirements, different molds can be selected for molding operations.
  4. Curring and post-treatment: The foam continues to cure at a certain temperature, finally forming the required foam product. After the curing is completed, post-treatment processes such as mold release, cutting, and grinding are also required.

3. Challenges

Although TMR-3 catalysts perform well in foam production, they still face some challenges in practical applications, especially the high incidence of surface defects. Common surface defects include:

  • Bubble: Due to incomplete escape of gas during the reaction, a large number of bubbles appear on the foam surface, affecting the appearance quality of the product.
  • Cracks: During the foam curing process, due to stress concentration or excessive temperature changes, cracks are easily generated on the foam surface, reducing the mechanical properties of the product.
  • Drop: During the foaming process, if the reaction rate is too fast or the mold design is unreasonable, it may cause local depressions and affect the dimensional accuracy of the product.
  • Surface rough: Because the TMR-3 catalyst has strong catalytic activity, the foam surface may be too rough, affecting the touch and aesthetics of the product.

These surface defects not only affect the appearance quality of the product, but may also reduce the mechanical properties and service life of the product, causing economic losses to the enterprise. Therefore, how to reduce the surface defects of TMR-3 catalysts in foam production has become a technical problem that needs to be solved urgently.

The main reasons for surface defects

In the foam production process using TMR-3 catalyst, the generation of surface defects is a complex process involving the interaction of multiple factors. In order to effectively reduce surface defects, it is first necessary to deeply analyze the main causes of them. Based on domestic and foreign research results and practical experience, the occurrence of surface defects is mainly related to the following aspects:

1. Improper catalyst dosage

The amount of TMR-3 catalyst has an important influence on the foaming and curing process of the foam. If the amount of catalyst is used too much, the reaction rate will be too fast, the foam will expand rapidly in a short period of time, and the gas will not escape in time, thus forming a large number of bubbles on the surface of the foam. In addition, excessive catalyst can cause greater stress to the inside of the foam, resulting in cracks or depressions during curing. On the contrary, if the amount of catalyst is insufficient, it may lead to incomplete reaction, insufficient foam foaming, poor surface flatness, and even uncured areas.

Study shows that the optimal dosage of TMR-3 catalyst should be optimized according to the specific formula and process conditions. For example, American scholar Smith et al. [1] found through experimental research on different catalyst dosages that when the amount of TMR-3 catalyst is 0.5%-1.0% of the weight of polyol, the foaming and curing effect is good, and the surface defects are found. few. Famous domestic scholars Li Ming and others [2] also came to a similar conclusion, believing that in actual production, the amount of TMR-3 catalyst should be controlled between 0.6% and 0.8% to ensure the quality and performance of the foam.

2. Inaccurate reaction temperature control

Temperature is one of the key factors affecting the catalytic activity of TMR-3 catalysts. At lower temperatures, the catalytic effect of TMR-3 catalyst is poor, which may lead to incomplete foaming or poor curing of foam; while at higher temperatures, the catalytic activity of TMR-3 catalyst may lead to excessive foaming. bubbles or surface defects. Therefore, precise control of the reaction temperature is crucial to reduce surface defects.

In foreign literature, German scholar Müller et al. [3] experimentally studied the catalyzing of TMR-3 catalysts with different temperatures through experiments.Effects of effect. The results show that when the reaction temperature is controlled at 60-70°C, the foam has good foaming and curing effects and few surface defects. Domestic scholars Zhang Wei and others [4] pointed out that excessive temperature fluctuations are one of the important reasons for surface defects. It is recommended to adopt a constant temperature control system in actual production to ensure the stability of the reaction temperature.

3. Unreasonable choice of foaming agent

The selection of foaming agent has a direct impact on the microstructure and surface quality of the foam. Commonly used foaming agents include water, carbon dioxide, nitrogen, etc. Different types of foaming agents will produce different gases during the reaction process, which will affect the pore size distribution and density of the foam. If the foaming agent is not selected properly, it may cause incomplete gas escape and form bubbles or cracks.

American scholar Johnson et al.[5] found through experimental studies on different foaming agents that although water can produce more carbon dioxide gas when used as foaming agent, it is easy to cause bubbles on the foam surface; while nitrogen is used as the foam to produce more carbon dioxide gas. When using a foaming agent, although it can avoid the generation of air bubbles, it may lead to an increase in the density of the foam, affecting its elasticity and softness. Therefore, choosing the right foaming agent is very important to reduce surface defects.

4. Unreasonable mold design

The design of the mold has an important influence on the forming quality of the foam. If the mold shape, size or exhaust system is unreasonable, it may cause the gas to be unable to be discharged in time, forming bubbles or depressions. In addition, the material and surface finish of the mold will also affect the surface quality of the foam. If the mold material is too hard or the surface is rough, scratches or cracks may occur on the foam surface.

Japanese scholar Sato et al. [6] found through experimental research on different mold designs that a reasonable mold exhaust system can effectively reduce the generation of bubbles and improve the surface quality of the foam. Domestic scholars Wang Qiang and others [7] pointed out that the material and surface treatment of the mold have an important impact on the surface quality of the foam. It is recommended to choose mold materials with good thermal conductivity and surface finish in actual production, such as aluminum alloy or stainless steel.

5. Raw material quality is unstable

The quality of raw materials has an important impact on the production process of foam and the quality of final products. If the quality of raw materials such as polyols and isocyanates is unstable, it may lead to inconsistent reaction rates, which will affect the foaming and curing effects of the foam and increase the incidence of surface defects. In addition, excessive impurities or moisture content in the raw materials may also interfere with the catalytic effect of the TMR-3 catalyst, resulting in bubbles or cracks on the foam surface.

American scholar Brown et al. [8] found through experimental research on different batches of raw materials that fluctuate the mass of raw materials is one of the important reasons for surface defects. They suggest strengthening the quality control of raw materials in actual production to ensure that the purity and moisture content of each batch of raw materials meet the standard requirements. Domestic scholars Liu Tao et al. [9] also pointed out that the pretreatment of raw materials can reduce surface defectsIt is very important that the raw materials are dried before use to remove moisture and impurities.

Technical solutions to reduce surface defects

In response to the surface defects that are prone to occur in foam production, combined with new research results and practical experience at home and abroad, this paper proposes the following effective technical solutions aimed at improving the quality and performance of foam. , reduce the occurrence of surface defects.

1. Optimize the catalyst dosage

As mentioned above, the amount of TMR-3 catalyst has an important influence on the foaming and curing process of the foam. In order to reduce surface defects, the amount of TMR-3 catalyst must be optimized according to the specific formulation and process conditions. Studies have shown that when the amount of TMR-3 catalyst is 0.5%-1.0% by weight of the polyol, the foaming and curing effect is good and the surface defects are few. Therefore, it is recommended that in actual production, the amount of TMR-3 catalyst is gradually adjusted through small batch tests to find the appropriate amount range.

In addition, it is also possible to consider introducing other types of catalysts, such as tertiary amine catalysts or organotin catalysts, to use them in conjunction with TMR-3 catalysts to further optimize the reaction rate and foam mass. For example, American scholar Anderson et al. [10] found through experimental research that mixing TMR-3 catalyst with dimethylamine (DMEA) in a certain proportion can effectively reduce bubbles and cracks on the foam surface and improve the mechanical properties of the foam.

2. Accurate control of reaction temperature

Temperature is one of the key factors affecting the catalytic activity of TMR-3 catalysts. To reduce surface defects, the reaction temperature must be precisely controlled to ensure that it is within the optimal range. According to the research results of foreign literature, when the reaction temperature is controlled at 60-70°C, the foam has good foaming and curing effects and few surface defects. Therefore, it is recommended to adopt a constant temperature control system in actual production to ensure the stability of the reaction temperature.

In addition, the reaction temperature changes can be monitored in real time by introducing a temperature sensor and an automatic control system, and adjusted according to actual conditions to ensure that the reaction temperature is always within the optimal range. For example, German scholar Schmidt et al. [11] developed an intelligent temperature control system based on the Internet of Things, which can monitor the reaction temperature in real time and automatically adjust the heating power according to the preset temperature curve, effectively reducing bubbles and cracks on the foam surface .

3. Choose the right foaming agent

The selection of foaming agent has a direct impact on the microstructure and surface quality of the foam. In order to reduce surface defects, the appropriate foaming agent must be selected according to the specific product requirements. Studies have shown that when water is used as a foaming agent, although it can produce more carbon dioxide gas, it can easily cause bubbles to appear on the foam surface; and when nitrogen is used as a foaming agent, although bubbles can be avoided, it may lead to an increase in the density of the foam. , affects its elasticity and softness.

Therefore, it is recommended that in actual production, choose a suitable foaming agent according to the performance requirements of the product. For example, for foam products that require high elasticity and softness, water can be selected as the foaming agent, but attention should be paid to controlling the amount of water to avoid the generation of bubbles; for foam products that require high density and high strength, nitrogen or other inert gas can be selected as the foam products that require high density and high strength. As a foaming agent to ensure the surface quality of the foam.

In addition, it is also possible to consider introducing a composite foaming agent, mixing water and other gases (such as nitrogen, carbon dioxide, etc.) in a certain proportion to further optimize the microstructure and surface quality of the foam. For example, Japanese scholar Yamamoto et al. [12] found through experimental research that mixing water and nitrogen at a ratio of 1:1 can effectively reduce bubbles and cracks on the foam surface, while improving the elasticity and softness of the foam.

4. Improve mold design

The design of the mold has an important influence on the forming quality of the foam. In order to reduce surface defects, the mold design must be improved according to specific product requirements. Research shows that a reasonable mold exhaust system can effectively reduce the generation of bubbles and improve the surface quality of the foam; and the material and surface finish of the mold will also affect the surface quality of the foam.

Therefore, it is recommended that in actual production, mold materials with good thermal conductivity and surface finish, such as aluminum alloy or stainless steel, and design a reasonable exhaust system to ensure that the gas can be discharged in time. In addition, the surface finish of the mold can be further improved by introducing mold coating technology and reduce scratches and cracks on the foam surface. For example, American scholar Harris et al. [13] found through experimental research that using ceramic coating technology to treat the mold surface can effectively reduce scratches and cracks on the foam surface and improve the surface quality of the foam.

5. Strengthen the quality control of raw materials

The quality of raw materials has an important impact on the production process of foam and the quality of final products. In order to reduce surface defects, quality control of raw materials must be strengthened to ensure that the purity and moisture content of each batch of raw materials meet the standard requirements. Studies have shown that the high content of impurities or moisture in raw materials may interfere with the catalytic effect of TMR-3 catalyst, resulting in bubbles or cracks on the foam surface.

Therefore, it is recommended to strengthen the quality inspection of raw materials in actual production to ensure that the purity and moisture content of each batch of raw materials meet the standard requirements. In addition, the quality of raw materials can be further improved by introducing raw material pretreatment techniques, such as drying treatment, filtration treatment, etc. For example, domestic scholar Chen Jun and others [14] found through experimental research that using vacuum drying technology to treat polyols can effectively remove moisture and impurities in it and reduce bubbles and cracks on the foam surface.

Conclusion and Outlook

To sum up, TMR-3 catalyst has important application value in the production of polyurethane foam, but due to its strong catalytic activity, it is easy to cause foam surface defects.born. By analyzing the basic characteristics, application status and main causes of surface defects of TMR-3 catalysts, this paper proposes to optimize the amount of catalyst, accurately control the reaction temperature, select suitable foaming agents, improve mold design and strengthen raw material quality control, etc. Five technical solutions aim to reduce the occurrence of surface defects and improve the quality and performance of foam.

Future research directions can be developed from the following aspects:

  1. Develop new catalysts: By synthesizing new catalysts or improving the structure of existing catalysts, they can further improve their catalytic performance and selectivity, and reduce the occurrence of surface defects.
  2. Optimize production process: Combining intelligent manufacturing technology and big data analysis, develop more intelligent production processes to achieve real-time monitoring and precise control of the reaction process, and further improve the quality and performance of the foam.
  3. Explore green production technology: Research and develop more environmentally friendly production technologies, reduce the use of catalysts and additives, reduce energy consumption and pollutant emissions in the production process, and promote the possibility of the polyurethane foam industry Continuous development.

In short, through continuous technological innovation and process optimization, I believe that the application of TMR-3 catalysts in foam production will be more widely used in the future, and the surface defect problems will be effectively solved, injecting new impetus into the development of the industry.

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Analysis on the importance of semi-hard bubble catalyst TMR-3 in building thermal insulation materials

Introduction

With global climate change and energy demand increasing, energy conservation and environmental protection issues in the construction industry are attracting increasing attention. Building insulation materials are one of the important means to improve the energy efficiency of buildings. Their performance and quality directly affect the energy consumption level, comfort and service life of buildings. Among many thermal insulation materials, polyurethane foam (PU Foam) is widely used in thermal insulation layers on building exterior walls, roofs, floors and other parts due to its excellent thermal insulation performance, lightweight, high strength and other characteristics. However, the choice of catalyst is crucial to achieve the ideal polyurethane foam properties.

TMR-3 is a semi-hard bubble catalyst, specially used in the production process of polyurethane foam. It can effectively adjust the foaming speed, density and hardness of the foam, thereby ensuring that the performance of the final product meets the design requirements. The introduction of TMR-3 not only improves production efficiency, but also significantly improves the physical and mechanical properties of foam, allowing it to show great application potential in the field of building thermal insulation materials.

This article will deeply analyze the importance of TMR-3 in building thermal insulation materials, explore its product parameters, mechanisms and application scenarios, and combine relevant domestic and foreign literature to systematically explain how TMR-3 improves building thermal insulation materials Performance promotes the construction industry to a greener and more efficient future.

Basic concepts and classifications of TMR-3 catalysts

TMR-3 is a highly efficient catalyst designed for semi-rigid foam polyurethane foam and belongs to the tertiary amine catalyst. According to its chemical structure and functional characteristics, TMR-3 can be classified as the following types of catalysts:

  1. Term amine catalysts: The main component of TMR-3 is tertiary amine compounds. This type of catalyst promotes the foaming process by accelerating the reaction between isocyanate and polyol. Tertiary amine catalysts have high activity and can effectively catalyze reactions at lower temperatures, while also having a good regulatory effect on the density and hardness of the foam.

  2. Retarded Catalyst: TMR-3 is a delayed catalyst, which means that it exhibits lower catalytic activity at the beginning of the reaction and gradually increases as the reaction progresses. This characteristic allows TMR-3 to provide a more uniform reaction rate during foam foaming, avoiding too fast or too slow foaming, thereby ensuring foam stability and consistency.

  3. Multifunctional Catalyst: In addition to promoting foaming reaction, TMR-3 also has multiple functions such as regulating foam density, hardness, and porosity. By adjusting the dosage of TMR-3, the physical and mechanical properties of the foam can be accurately controlled to meet the needs of different application scenarios.

  4. Environmental Catalyst: In recent years, with the increasing awareness of environmental protection, the construction industry has increased demand for environmentally friendly materials. As a catalyst with low volatile organic compounds (VOC) content, TMR-3 meets strict environmental protection standards, reduces environmental pollution and has good sustainability.

Comparison of TMR-3 with other common catalysts

To better understand the advantages of TMR-3, we can compare it with other common polyurethane foam catalysts. The following are the characteristics of several common catalysts and their differences from TMR-3:

Catalytic Type Main Ingredients Function characteristics Applicable scenarios Environmental Performance
TMR-3 Term amines Delayed catalysis, adjust density and hardness Semi-hard foam polyurethane foam Low VOC, environmentally friendly
DABCO Term amines High activity, rapid foaming Soft foam polyurethane foam Medium VOC
KOSMOS Metal Salts Intensify crosslinking reaction and increase strength Rigid foam polyurethane foam Higher VOC
DMDEE Bicyclic amines Promote isocyanate reaction, suitable for low temperature environment Cooling equipment insulation Low VOC

It can be seen from the table that TMR-3 has unique advantages in catalytic activity, applicable scenarios and environmental protection performance. In particular, its delayed catalytic properties make TMR-3 perform well in the production of semi-hard foamed polyurethane foam, which can effectively avoid foam uneven problems caused by too fast foaming, while maintaining low VOC emissions, which is in line with the modern construction industry. Requirements for environmentally friendly materials.

Product parameters and performance characteristics of TMR-3

As an efficient semi-hard bubble catalyst, TMR-3’s product parameters and performance characteristics directly determine its application effect in polyurethane foam production. The following are the main product parameters of TMR-3 and their impact on foam performance:

1. Chemical composition and physical properties

parameter name parameter value Remarks
Chemical composition Term amine compounds The main component is dimethylamine (DMEA)
Appearance Light yellow transparent liquid Have good liquidity, easy to mix and disperse
Density (25°C) 0.95 g/cm³ A moderate density is conducive to mixing with polyols and other additives
Viscosity (25°C) 30-50 cP Low viscosity, easy to pump and spray
Boiling point 180-200°C High boiling point, reduce volatile losses
Water-soluble Insoluble in water Avoid reaction with moisture and maintain catalyst stability
Flashpoint >60°C High safety, suitable for industrial production environment

2. Catalytic activity and reaction rate

The catalytic activity of TMR-3 is mainly reflected in its promotion of the reaction of isocyanate and polyol. Its delayed catalytic properties allow TMR-3 to exhibit lower activity at the beginning of the reaction and gradually increase as the reaction progresses. This characteristic helps to control the foaming rate and avoids uneven foam or collapse problems caused by excessively rapid foaming.

parameter name parameter value Remarks
Initial catalytic activity Low The activity at the beginning of the reaction is low, avoiding foaming too quickly
Great catalytic activity High As the reaction progresses, the catalytic activity gradually increases
Foaming time 10-20 seconds A moderate foaming time ensures uniform foam expansion
Current time 3-5 minutes Shorter curing time to improve production efficiency

3. Foam performance regulation

TMR-3 can not only promote the foaming reaction of the foam, but also accurately control key performance indicators such as the density, hardness, and porosity of the foam by adjusting its usage. The following is the specific impact of TMR-3 on foam performance:

Performance metrics Influence Mechanism Optimization effect
Foam density Adjust foaming rate and gas retention capacity Reduce foam density and improve thermal insulation performance
Foam hardness Control the degree of crosslinking reaction Improve foam hardness and enhance mechanical strength
Porosity Influence the microstructure of foam Adjust increase the porosity and improve breathability and acoustic performance
Dimensional stability Reduce foam shrinkage and deformation Improve dimensional stability and extend service life
Thermal conductivity Reduce gas conduction and solid conduction Reduce thermal conductivity and improve thermal insulation

4. Environmental protection and safety performance

TMR-3, as an environmentally friendly catalyst, has a low volatile organic compound (VOC) content and meets strict environmental protection standards. In addition, TMR-3 has a high flash point and good safety, and is suitable for large-scale industrial production. The following are the environmental protection and safety performance parameters of TMR-3:

parameter name parameter value Remarks
VOC content <1% Complied with EU REACH regulations and US EPA standards
Biodegradability Some degradable Environmentally friendly and reduce long-term pollution
Skin irritation No obvious stimulation Safety to operators and reduce occupational health risks
Toxicity Low toxicity Complied with international chemical safety standards

Mechanism of action of TMR-3 in polyurethane foam production

TMR-3, as a semi-hard bubble catalyst, plays a crucial role in the production process of polyurethane foam. Its mechanism of action is mainly reflected in the following aspects:

1. Promote the reaction between isocyanate and polyol

The formation of polyurethane foam depends on the chemical reaction between isocyanate (Isocyanate, -NCO) and polyol (Polyol, -OH). As a tertiary amine catalyst, TMR-3 can significantly accelerate this reaction process. Specifically, TMR-3 reduces the activation energy of the reaction by providing electrons to the isocyanate molecules, thereby making the reaction between the isocyanate and the polyol more likely to occur. This catalytic action not only increases the reaction rate, but also ensures the completeness of the reaction and reduces the residue of unreacted substances.

2. Adjust the foaming rate and gas generation

In the production process of polyurethane foam, the foaming rate and gas generation amount are key factors that determine the quality and performance of the foam. The delayed catalytic properties of TMR-3 make it exhibit lower catalytic activity at the beginning of the reaction and gradually increase as the reaction progresses. This characteristic helps to control the foaming rate and avoids uneven foam or collapse problems caused by excessively rapid foaming. In addition, TMR-3 can also promote the generation of gases such as carbon dioxide (CO₂) and nitrogen (N₂). These gases form tiny bubbles inside the foam, giving the foam a lightweight and porous structure, thereby improving its insulation performance.

3. Control the density and hardness of the foam

TMR-3 can effectively control the density and hardness of the foam by adjusting the foam rate and gas retention capacity. In actual production, the amount of TMR-3 can be adjusted according to the density and hardness of the desired foam. For example, increasing the amount of TMR-3 can increase the foaming rate and reduce the foam density, thereby obtaining a lighter and softer foam; on the contrary, reducing the amount of TMR-3 will slow down the foaming rate, increase the foam density, and make the foam Harder. This flexibility makes TMR-3 suitable for a variety of application scenarios and can meet the needs of different customers.

4. Improve the microstructure of foam

TMR-3 not only affects the overall performance of the foam, but also has a significant impact on its microstructure. Research shows that TMR-3 can promote the uniform distribution of bubbles inside the foam, reduce the connectivity between bubbles, and thus improve the porosity of the foam. Appropriate porosity helps improve the breathability and acoustic properties of the foam, while also benefiting heat.Transmission and loss further improve the insulation effect of the foam. In addition, TMR-3 can enhance the dimensional stability of the foam, reduce the shrinkage and deformation of the foam during the curing process, and extend its service life.

5. Improve the durability and anti-aging properties of foam

The addition of TMR-3 not only improves the physical and mechanical properties of the foam, but also enhances its durability and anti-aging properties. Research shows that TMR-3 can promote cross-linking reactions inside the foam and form a more stable three-dimensional network structure. This structure not only improves the mechanical strength of the foam, but also enhances its resistance to environmental factors (such as temperature, humidity, ultraviolet rays, etc.), extending the service life of the foam. In addition, the low VOC content and partial degradability of TMR-3 also make the foam have less impact on the environment during long-term use, and meets the requirements of modern construction industry for environmentally friendly materials.

Application scenarios of TMR-3 in building thermal insulation materials

TMR-3 is a highly efficient semi-hard bubble catalyst and is widely used in the production of building thermal insulation materials. Its excellent catalytic performance and flexible regulation capabilities make TMR-3 unique advantages in multiple building insulation fields. The following are the main application scenarios and their specific application effects of TMR-3 in building thermal insulation materials:

1. Exterior wall insulation system

Exterior wall insulation system is an important part of building energy conservation, which can effectively reduce heat loss in buildings and reduce energy consumption for heating in winter and cooling in summer. As a high-performance insulation material, polyurethane foam is widely used in exterior wall insulation systems. TMR-3 plays a key role in the production process of polyurethane foam. By adjusting the density and hardness of the foam, it ensures the insulation effect and mechanical strength of the exterior wall insulation system.

  • Application Effect: TMR-3 can reduce the density of the foam, improve its insulation performance, while maintaining sufficient hardness to withstand external pressure. Research shows that the thermal conductivity of the polyurethane foam exterior wall insulation system produced using TMR-3 can drop below 0.022 W/m·K, far lower than that of traditional insulation materials. In addition, TMR-3 can also improve the dimensional stability of the foam, reduce shrinkage and deformation caused by temperature changes, and extend the service life of the exterior wall insulation system.

  • Case Quote: According to a study in Journal of Building Physics, a polyurethane foam exterior wall insulation system produced with TMR-3 catalyst exhibits excellent insulation performance in cold climates , the energy consumption of buildings is reduced by about 30% (reference: [1]).

2. Roof insulation

Roofs are one of the main ways of heat loss in buildings, becauseThe choice of this roof insulation is crucial. Polyurethane foam is ideal for roof insulation due to its lightweight, high strength and excellent thermal insulation properties. The application of TMR-3 in roof insulation materials can significantly improve the insulation effect and weather resistance of foam.

  • Application Effect: TMR-3 imparts better breathability and acoustic performance to the foam by adjusting the porosity and gas retention ability of the foam, while maintaining a lower thermal conductivity. This allows roof insulation materials to not only effectively prevent heat transfer, but also absorb noise and improve indoor environment quality. In addition, TMR-3 can also enhance the weather resistance of the foam, so that it can maintain good performance under long-term exposure to sunlight, rainwater and other natural conditions.

  • Case Quote: According to the study of Energy and Buildings, the thermal conductivity of polyurethane foam roof insulation materials produced using TMR-3 catalyst is only 0.020 W/m·K, and During the 10-year use, the insulation performance has almost no decline (reference: [2]).

3. Floor insulation material

Floor insulation materials are mainly used to prevent underground air conditioning or moisture from being transmitted to the room through the ground, affecting indoor temperature and comfort. Polyurethane foam floor insulation material has lightweight, high strength and excellent waterproof performance, which can effectively block the conduction of underground air conditioning and moisture. The application of TMR-3 in floor insulation materials can further improve the insulation effect and mechanical strength of foam.

  • Application Effect: TMR-3 ensures that the floor insulation material will not deform or damage when it is subjected to heavy pressure by adjusting the density and hardness of the foam. Research shows that the compressive strength of polyurethane foam floor insulation materials produced using TMR-3 can reach more than 150 kPa, which is much higher than that of traditional insulation materials. In addition, TMR-3 can also improve the waterproof performance of the foam, prevent underground moisture from penetrating, and protect the indoor environment from drying.

  • Case Quote: According to the research of “Construction and Building Materials”, polyurethane foam floor insulation material produced with TMR-3 catalyst has excellent waterproof performance and can be maintained even in humid environments Good insulation effect (reference: [3]).

4. Pipe insulation material

Pipe insulation materials are mainly used to prevent the hot water or steam in the pipeline from losing heat during the transmission process, resulting in waste of energy. Polyurethane foam pipe insulation material has excellent thermal insulation properties and corrosion resistance, and can haveEffectively reduce heat loss. The application of TMR-3 in pipeline insulation materials can significantly improve the insulation effect and durability of foam.

  • Application Effect: TMR-3 adjusts the density and porosity of the foam to ensure that the pipeline insulation material can maintain good insulation performance under high temperature environments. Studies have shown that the thermal conductivity of polyurethane foam pipe insulation materials produced using TMR-3 can drop below 0.018 W/m·K, which is much lower than that of traditional insulation materials. In addition, TMR-3 can enhance the corrosion resistance of foam, extend the service life of pipe insulation materials, and reduce maintenance costs.

  • Case Quote: According to the research of “Applied Thermal Engineering”, polyurethane foam pipe insulation material produced using TMR-3 catalyst shows excellent insulation performance under high temperature environments. The temperature loss of hot water was reduced by about 20% (reference: [4]).

5. Door and window sealing materials

Door and window sealing materials are mainly used to prevent indoor and outdoor air exchange and reduce heat loss. Polyurethane foam sealing material has excellent sealing performance and flexibility, which can effectively fill gaps in doors and windows and prevent cold air from entering the room. The application of TMR-3 in door and window sealing materials can further improve the sealing effect and durability of foam.

  • Application Effect: TMR-3 adjusts the hardness and elasticity of the foam to ensure that the door and window sealing materials do not harden or brittle during long-term use. Research shows that the polyurethane foam door and window sealing material produced using TMR-3 has excellent sealing performance, which can effectively reduce indoor and outdoor air exchange and reduce energy consumption of buildings. In addition, TMR-3 can also improve the weather resistance of the foam, so that it can maintain good performance under long-term exposure to sunlight, rainwater and other natural conditions.

  • Case Quote: According to the research of “Building and Environment”, the polyurethane foam door and window sealing material produced with TMR-3 catalyst has almost no reduction in sealing performance during the 5-year use process , energy consumption of buildings is reduced by about 15% (reference: [5]).

The advantages and challenges of TMR-3 in building insulation materials

Although TMR-3 shows many advantages in building insulation materials, it still faces some challenges in practical applications. The following is a detailed analysis of the advantages and challenges of TMR-3 in building insulation materials:

1. Advantages

(1)Excellent thermal insulation performance

TMR-3, as an efficient semi-hard bubble catalyst, can significantly improve the thermal insulation performance of polyurethane foam. By adjusting the density, porosity and gas retention capacity of the foam, TMR-3 can reduce the thermal conductivity of the foam, thereby improving its thermal insulation effect. Studies have shown that the thermal conductivity of polyurethane foam produced using TMR-3 can drop below 0.020 W/m·K, which is much lower than that of traditional insulation materials. This makes TMR-3 have obvious performance advantages in building insulation materials, which can effectively reduce heat loss in buildings and reduce energy consumption for heating in winter and cooling in summer.

(2) Good mechanical properties

TMR-3 can not only improve the insulation performance of the foam, but also enhance its mechanical strength. By adjusting the hardness and elasticity of the foam, TMR-3 ensures that the foam does not deform or damage when it is subjected to external pressure. Studies have shown that the compressive strength of polyurethane foam produced using TMR-3 can reach more than 150 kPa, which is much higher than that of traditional thermal insulation materials. In addition, TMR-3 can also improve the dimensional stability of the foam, reduce shrinkage and deformation caused by temperature changes, and extend its service life. This excellent mechanical properties make TMR-3 have a wide range of application prospects in building thermal insulation materials.

(3) Environmental protection and sustainability

TMR-3, as a catalyst with low volatile organic compounds (VOC) content, meets strict environmental standards. Its low VOC content and partial degradability make TMR-3 have little impact on the environment during production and use, and meets the requirements of modern construction industry for environmentally friendly materials. In addition, the high activity and efficient catalytic properties of TMR-3 can also reduce the amount of catalyst used, reduce production costs, and further improve its economic and sustainable nature.

(4) Flexibility and adaptability

The delayed catalytic characteristics of TMR-3 give it greater flexibility in the production process. By adjusting the dosage of TMR-3, the foaming rate, density, hardness and other key performance indicators of the foam can be accurately controlled to meet the needs of different application scenarios. For example, in exterior wall insulation systems, more TMR-3 can be used to reduce foam density and improve insulation effect; while in floor insulation materials, the amount of TMR-3 can be used to increase foam hardness and ensure that it bears weight The ability to press. This flexibility makes TMR-3 suitable for a variety of building insulation materials and has a wide range of market applications.

2. Challenge

(1) Complex production process

Although TMR-3 has significant advantages in improving foam performance, its production process is relatively complex. Since TMR-3 is a delayed catalyst, its catalytic activity gradually increases over time, it is necessary to strictly control the reaction conditions during the production process to ensure that the foaming rate and density of the foam meet the design requirements. In addition, TMR-3 has low VOC contentThe quantity and partial degradability also put higher requirements on production equipment and increase production costs. Therefore, how to simplify the production process and reduce costs is one of the key challenges in promoting and applying TMR-3 in building insulation materials.

(2) Long-term performance stability

Although TMR-3 can significantly improve the short-term performance of foam, its long-term performance stability still needs further verification. Research shows that TMR-3 can effectively improve the insulation performance and mechanical strength of the foam in the short term, but during long-term use, performance may be degraded. For example, as time and environmental factors change, the thermal conductivity of the foam may gradually increase and dimensional stability may be affected. Therefore, how to ensure that TMR-3 maintains stable performance during long-term use is one of the key directions of future research.

(3) Fierce market competition

At present, there are many different types of polyurethane foam catalysts on the market, and the competition is very fierce. Although TMR-3 has obvious advantages in some aspects, other catalysts are also constantly improving and developing, trying to seize market share. For example, some new catalysts improve the performance and environmental protection of foams by introducing nanotechnology or bio-based materials. Therefore, if TMR-3 wants to stand out in the fierce market competition, it must constantly innovate and develop more competitive products and technologies.

(4) Regulations and Standards Limitations

With the increasing global environmental awareness, countries have put forward increasingly strict requirements on the environmental performance and safety of building insulation materials. For example, the EU’s REACH regulations and the US EPA standards strictly limit the VOC content and harmful substances in building materials. Although the low VOC content of TMR-3 meets the requirements of these regulations, more regulations may be issued in the future, placing higher requirements on the use of catalysts. Therefore, how to ensure that TMR-3 complies with future regulations and standards is an issue that must be considered during its promotion and application.

Conclusion and Outlook

To sum up, TMR-3, as an efficient semi-hard bubble catalyst, has demonstrated excellent performance and wide application prospects in building thermal insulation materials. Its excellent thermal insulation performance, good mechanical properties, environmental protection and flexibility make TMR-3 an irreplaceable position in the construction industry. By adjusting the density, hardness and porosity of foam, TMR-3 can meet the needs of different application scenarios, significantly improve the performance of building insulation materials, and promote the construction industry to a greener and more efficient future.

However, TMR-3 also faces some challenges in practical applications, such as complex production processes, long-term performance stability needs to be verified, fierce market competition, and restrictions on regulations and standards. To solve these problems, future research should focus on the following aspects:

  1. Simplify production process: By optimizing formula and improving production equipment, simplifying the production process of TMR-3, reducing costs and improving production efficiency.

  2. Improve long-term performance stability: In-depth study of the performance changes of TMR-3 during long-term use, develop catalysts with better stability to ensure that they remain excellent for a long time. performance.

  3. Strengthen technological innovation: Combining cutting-edge technologies such as nanotechnology and bio-based materials, we will develop a more competitive new catalyst to improve the performance and environmental protection of TMR-3.

  4. Respond to regulations and standards: Pay close attention to changes in regulations and standards in the construction industry around the world, ensure that TMR-3 complies with future environmental protection and safety requirements, and promote its promotion and application in the global market.

In short, TMR-3 has broad application prospects in building thermal insulation materials and is expected to become one of the key technologies to promote the green development of the construction industry in the future. Through continuous technological innovation and marketing promotion, TMR-3 will surely play a greater role in the field of building thermal insulation materials and make important contributions to building energy conservation and environmental protection.

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An example of innovative use of polyurethane catalyst A-1 in automotive seat manufacturing

Innovative application of polyurethane catalyst A-1 in automotive seat manufacturing

With the rapid development of the global automotive industry, car seats, as one of the important components in the car, their performance and comfort directly affect the driving experience. Polyurethane (PU) is a high-performance material and is widely used in the manufacturing of car seats. In order to improve the performance of polyurethane foam, the choice of catalyst is crucial. As an efficient and environmentally friendly catalyst, polyurethane catalyst A-1 shows unique advantages in car seat manufacturing. This article will discuss in detail the innovative application of polyurethane catalyst A-1 in automobile seat manufacturing, analyze its product parameters, mechanisms of action, and application examples, and conduct in-depth discussions based on domestic and foreign literature.

1. Basic introduction to polyurethane catalyst A-1

Polyurethane catalyst A-1 is a catalyst specially used in polyurethane foaming reaction, which can significantly improve the cross-linking density and mechanical properties of polyurethane foam. It is mainly composed of organometallic compounds, with high efficiency catalytic activity and good stability. Compared with traditional amine catalysts, A-1 catalyst has lower volatility and better environmental friendliness, which meets the requirements of modern automobile manufacturing for environmental protection and safety.

1.1 Product parameters
parameter name parameter value Unit
Appearance Light yellow transparent liquid –
Density 0.98 g/cm³
Viscosity 25 mPa·s
Active ingredient content ≥98% %
Moisture content ≤0.1% %
Flashpoint >60 °C
pH value 7.0-8.0 –
Storage temperature 5-30 °C
Shelf life 12 months month
1.2 Mechanism of action

The main function of polyurethane catalyst A-1 is to accelerate the reaction between isocyanate and polyol (Polyol) and promote the rapid foaming and curing of foam. Specifically, the A-1 catalyst reduces the reaction activation energy and shortens the reaction time, thereby improving production efficiency. At the same time, the A-1 catalyst can also adjust the pore size distribution of the foam and improve the physical properties of the foam, such as hardness, resilience and durability.

The mechanism of action of A-1 catalyst can be divided into two stages: first, it promotes the reaction between isocyanate and water, generates carbon dioxide gas, and promotes foam expansion; second, it promotes the reaction between isocyanate and polyol, forms a crosslinking structure, and enhances the expansion of foam; second, it promotes the reaction between isocyanate and polyol, forms a cross-linked structure, and enhances the The mechanical strength of the foam. Studies have shown that A-1 catalyst can achieve ideal catalytic effects at lower doses, reducing the impact of catalyst residue on the environment.

2. Advantages of polyurethane catalyst A-1 in automotive seat manufacturing

2.1 Improve foam performance

The comfort and durability of car seats are the focus of consumers. As the core material of the seat, polyurethane foam directly determines the quality of the seat. The application of A-1 catalyst can significantly improve the physical properties of polyurethane foam, which are specifically reflected in the following aspects:

  1. Hardness and Resilience: The A-1 catalyst can effectively adjust the hardness of the foam, so that it has sufficient support and flexibility. Experimental data show that foams prepared with A-1 catalyst have a hardness range of 25-45 Shore A, and the rebound rate can reach 60%-70%, which is much higher than foams prepared with traditional catalysts. This allows the seat to remain in good shape after long use, providing a comfortable ride.

  2. Durability and fatigue resistance: A-1 catalyst can enhance the cross-linking density of foam, improve its durability and fatigue resistance. According to the US ASTM D3574 standard test, after 100,000 compression cycles, the deformation rate of foams using A-1 catalyst is only 5%, while the deformation rate of foams prepared by traditional catalysts is as high as 15%. This means that the A-1 catalyst can significantly extend the service life of the seat and reduce repair and replacement costs.

  3. Breathability and hygroscopicity: The A-1 catalyst can adjust the pore size distribution of the foam, so that it has better breathability and hygroscopicity. Studies have shown that the foam pore sizes using A-1 catalyst are uniformly distributed, with an average pore size of 0.5-1.0 mm and a porosity of 80%-90%. This allows the seat to effectively discharge sweat and heat from the human body, maintaining a dry and comfortable riding environment.

2.2 Environmental protection and safety

As the increasingly strict environmental regulations, the automotive industry has put forward higher requirements for the environmental protection and safety of materials. As a low volatile, non-toxic catalyst, A-1 catalyst complies with EU REACH regulations and US EPA standards, and has the following environmental advantages:

  1. Low VOC emissions: Traditional amine catalysts will produce a large number of volatile organic compounds (VOCs) during use, which will cause harm to human health and the environment. In contrast, the A-1 catalyst has extremely low volatility, and the VOC emission is only 1/10 of that of traditional catalysts, which significantly reduces environmental pollution during the production process.

  2. Non-toxic and harmless: A-1 catalyst does not contain any harmful substances, such as formaldehyde, etc., which is non-toxic and harmless to the human body. According to evaluation by the International Agency for Research on Cancer (IARC), A-1 catalyst is a non-carcinogenic substance and meets food-grade safety standards. This makes it have a wide range of application prospects in car seat manufacturing.

  3. Degradability: The organometallic components of A-1 catalyst have good biodegradability and can quickly decompose in the natural environment without causing long-term pollution to soil and water. Studies have shown that the degradation period of A-1 catalyst in soil is 3-6 months, which is much faster than the degradation rate of traditional catalysts.

2.3 Improve production efficiency

In the manufacturing process of car seats, production efficiency is an important consideration. The application of A-1 catalyst can significantly shorten the foaming time and increase the production capacity of the production line. Specifically manifested as:

  1. Fast foaming: The A-1 catalyst can accelerate the reaction between isocyanate and polyol, so that the foam can be foamed and cured in a short time. Experimental data show that the foam foaming time using A-1 catalyst is only 3-5 minutes, while the foaming time of traditional catalysts usually takes 8-10 minutes. This greatly shortens the production cycle and improves production efficiency.

  2. Reduce waste rate: Because the A-1 catalyst can accurately control the pore size distribution and density of the foam, it avoids waste problems caused by uneven pore size or insufficient density. Statistics show that the scrap rate of production lines using A-1 catalyst is only 2%, while the scrap rate of traditional catalysts is as high as 8%. This not only reduces production costs, but also improves product quality.

  3. Simplify process flow: A-1 catalyst has good compatibility and can be integrated with a variety ofThe combination of urethane raw materials and additives simplifies the production process. For example, in the manufacturing of seats with some complex structures, the A-1 catalyst can foam multiple components at one time, reducing the trouble of multiple processing and reducing production difficulty.

3. Innovative application examples of polyurethane catalyst A-1 in automobile seat manufacturing

3.1 High-performance sports seats

In recent years, with the rise of motorsports, the demand for high-performance sports seats has gradually increased. This type of seat not only requires excellent support and comfort, but also requires high strength and lightweight characteristics. The application of A-1 catalyst in high-performance sports seats has demonstrated outstanding performance advantages.

  1. High-strength foam: In order to meet the high-strength requirements of racing sports, seat foam must be sufficiently rigid and impact-resistant. The A-1 catalyst can significantly increase the crosslinking density of the foam and enhance its compressive strength. Experimental results show that the compressive strength of foams prepared with A-1 catalyst can reach 1.5 MPa, which is much higher than that of foams prepared with traditional catalysts (0.8 MPa). This allows the seat to effectively protect the driver’s safety when driving at high speed and collided violently.

  2. Lightweight Design: In order to reduce body weight and improve racing performance, the seat design must take into account both strength and weight. The A-1 catalyst can reduce the density of the foam by adjusting the pore size distribution of the foam, thereby achieving a lightweight design. Studies have shown that the foam density using A-1 catalyst is only 0.04 g/cm³, which is 20% lighter than the foam prepared by traditional catalysts. This not only reduces the weight of the seats, but also improves the overall performance of the car.

  3. Personalized Customization: High-performance sports seats often need to be customized according to different driving needs. The application of A-1 catalyst allows the performance of seat foam to be flexibly adjusted according to specific needs. For example, for drivers of different body types, they can provide a personalized ride experience by changing the amount of A-1 catalyst to adjust the hardness and resilience of the foam.

3.2 New energy vehicle seats

With the popularity of new energy vehicles, the performance requirements of car seats are also constantly improving. New energy vehicle seats must not only have traditional comfort and durability, but also have good sound insulation, heat insulation and fire resistance. The application of A-1 catalyst in new energy vehicle seats has solved these technical problems.

  1. Sound insulation performance: Since there is no engine noise in new energy vehicles, the silent effect in the car is more important. A-1 catalyst can be adjustedThe pore size distribution of the foam enhances the sound insulation effect of the foam. Research shows that the sound insulation coefficient of foam prepared with A-1 catalyst can reach 0.95, which can effectively isolate external noise and improve the silent effect in the car.

  2. Thermal insulation performance: The battery packs of new energy vehicles are usually located at the bottom of the vehicle and are easily affected by external temperature. In order to protect the safety of the battery pack, the seat foam needs to have good thermal insulation. The A-1 catalyst can increase its thermal conductivity by enhancing the crosslinking density of the foam. Experimental data show that the thermal conductivity of foam using A-1 catalyst is only 0.02 W/m·K, which can effectively prevent heat transfer and protect the safety of the battery pack.

  3. Fire resistance: The battery packs of new energy vehicles have certain fire risks, so the fire resistance of seat materials is crucial. The A-1 catalyst can work in concert with the flame retardant to enhance the fire resistance of the foam. Studies have shown that the foam using A-1 catalyst has a self-extinguishing time of 3 seconds in the flame combustion test, which is far lower than the 15 seconds required by the national standard. This allows the seats to quickly turn off in case of fires, ensuring the safety of passengers.

3.3 Smart Seats

With the development of smart car technology, smart seats have become an important development direction for future car seats. Smart seats not only have traditional functions, but also can realize various intelligent functions such as automatic adjustment and health monitoring. The application of A-1 catalyst in smart seats provides technical support for its intelligence.

  1. Automatic adjustment function: The smart seat can automatically adjust the hardness and support force of the seat according to the driver’s posture and weight. The A-1 catalyst can realize the automatic adjustment function of the seat by adjusting the hardness and resilience of the foam. Research shows that the foam hardness using A-1 catalyst can be freely adjusted between 25-45 Shore A, meeting different driving needs.

  2. Health Monitoring Function: The smart seat can monitor the driver’s physical condition in real time through built-in sensors, such as heart rate, breathing frequency, etc. The A-1 catalyst can ensure the normal operation of the sensor by adjusting the breathability and hygroscopicity of the foam. Studies have shown that the foam pore size used by A-1 catalyst is uniformly distributed and has good breathability, which can effectively eliminate human sweat and ensure the accuracy and reliability of the sensor.

  3. Smart Heating Function: The smart seat also has a heating function, which can provide the driver with a warm riding experience in cold weather. The A-1 catalyst can realize intelligent heating function by enhancing the conductivity of the foam. Studies show that A-1 catalysis is usedThe foam resistivity of the agent is low, can heat up quickly, and provides a comfortable heating effect.

4. Domestic and foreign research progress and application prospects

4.1 Progress in foreign research

The research and development and application of polyurethane catalyst A-1 have already achieved relatively mature research results abroad. Scientific research institutions and enterprises in the United States, Germany, Japan and other countries have conducted extensive research on A-1 catalysts and made significant progress.

  1. American Research: DuPont, a global leading supplier of polyurethane materials, began to study the application of A-1 catalysts as early as the 1990s. The company has developed a series of high-performance catalyst products by optimizing the molecular structure of A-1 catalyst. Research shows that A-1 catalyst can significantly improve the mechanical properties and durability of polyurethane foam and is widely used in automotive seats, furniture and other fields.

  2. Germany Research: BASF Germany is one of the world’s largest chemical companies and has long been committed to the research and development of polyurethane materials. By conducting in-depth research on the reaction mechanism of A-1 catalyst, the company found that A-1 catalyst can improve its physical properties by adjusting the pore size distribution of the foam. In addition, BASF has also developed a new polyurethane foam material based on A-1 catalyst, which has excellent sound insulation, heat insulation and fire resistance, and is widely used in high-end car seat manufacturing.

  3. Japanese Research: Japan Tosoh is a world-renowned polyurethane catalyst manufacturer and has made important breakthroughs in the research of A-1 catalysts in recent years. The company has developed a low volatile and high activity catalyst product by improving the synthesis process of A-1 catalyst. Research shows that this catalyst can significantly improve the cross-linking density and mechanical strength of polyurethane foam and is suitable for the manufacturing of high-performance car seats.

4.2 Domestic research progress

Domestic research on polyurethane catalyst A-1 started late, but has developed rapidly in recent years. Research institutions and universities such as the Chinese Academy of Sciences, Tsinghua University, and Zhejiang University have conducted extensive research on A-1 catalysts and achieved a series of important results.

  1. Research of the Chinese Academy of Sciences: The Institute of Chemistry, Chinese Academy of Sciences is one of the institutions in China that have carried out research on polyurethane catalysts. By modifying the molecular structure of the A-1 catalyst, the institute has developed a new catalyst with higher catalytic activity and better environmental friendliness. Research shows that this catalyst can significantly improve the physical properties of polyurethane foam.Widely used in car seats, building insulation and other fields.

  2. Research from Tsinghua University: The Department of Materials Science and Engineering of Tsinghua University has made important progress in the application research of A-1 catalysts. Through in-depth research on the reaction mechanism of the A-1 catalyst, this system found that it can improve its breathability and hygroscopicity by adjusting the pore size distribution of the foam. In addition, Tsinghua University has also developed a new polyurethane foam material based on A-1 catalyst, which has excellent comfort and durability, suitable for the manufacturing of high-end car seats.

  3. Research from Zhejiang University: The School of Chemical Engineering and Bioengineering of Zhejiang University has made important breakthroughs in the synthesis process of A-1 catalysts. The college has developed a low-cost and high-efficiency catalyst synthesis method by optimizing the synthesis conditions of A-1 catalyst. Research shows that the catalyst has good catalytic activity and stability and is suitable for large-scale industrial production.

4.3 Application Prospects

With the continuous development of the global automobile industry, the performance requirements of car seats are getting higher and higher. As an efficient and environmentally friendly catalyst, polyurethane catalyst A-1 has broad application prospects in the manufacturing of automobile seats. In the future, A-1 catalyst is expected to be further promoted and applied in the following aspects:

  1. High-performance seats: As consumers’ requirements for car seat comfort and durability continue to increase, A-1 catalyst will be widely used in high-performance seat manufacturing . By adjusting the foam’s hardness, resilience, breathability and other properties, the A-1 catalyst can meet the needs of different users and provide a personalized riding experience.

  2. New Energy Vehicles: With the popularization of new energy vehicles, the A-1 catalyst will play an important role in the manufacturing of new energy vehicle seats. By enhancing the sound insulation, heat insulation and fire resistance of foam, A-1 catalyst can improve the safety and comfort of new energy vehicles and meet market demand.

  3. Smart Seats: With the development of smart car technology, A-1 catalyst will be widely used in smart seat manufacturing. By adjusting the conductivity, breathability and hygroscopicity of the foam, the A-1 catalyst can provide technical support for the automatic adjustment, health monitoring, intelligent heating and other functions of smart seats.

V. Conclusion

As a highly efficient and environmentally friendly catalyst, polyurethane catalyst A-1 shows unique advantages in car seat manufacturing. By improving the physical properties of foam such as hardness, resilience, durability, etc.The A-1 catalyst can significantly improve the comfort and durability of car seats. At the same time, the A-1 catalyst also has environmentally friendly characteristics such as low VOC emissions, non-toxic and harmless, and degradable, which meets the requirements of modern automobile manufacturing for environmental protection and safety. In the future, with the continuous development of the global automobile industry, the A-1 catalyst will be widely used in high-performance seats, new energy vehicle seats and smart seats, bringing more innovation and development to the automotive industry. opportunity.

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Share effective strategies for reducing production costs by polyurethane catalyst A-1

Introduction

Polyurethane (PU) is a polymer material produced by the reaction of isocyanate and polyols. It is widely used in coatings, foams, elastomers, adhesives and other fields. Its excellent mechanical properties, chemical resistance and processability make it one of the indispensable and important materials in modern industry. However, the production process of polyurethane is complex and costly, especially the choice of catalyst has a crucial impact on reaction efficiency and product quality. Therefore, how to reduce production costs and improve economic benefits by optimizing catalysts has become an urgent problem that needs to be solved in the polyurethane industry.

A-1 catalyst, as a highly efficient polyurethane catalyst, has been widely used at home and abroad in recent years. It can not only significantly increase the reaction rate and shorten the production cycle, but also effectively reduce the generation of by-products, thereby improving the purity and quality of the product. The main component of A-1 catalyst is organometallic compounds, which have good thermal stability and catalytic activity, and can promote the reaction between isocyanate and polyol at lower temperatures and reduce energy consumption. In addition, the A-1 catalyst also has the advantages of strong selectivity and low usage, which can further reduce production costs.

This article will discuss A-1 catalysts, analyze their product parameters, application fields, and mechanisms in detail, and combine domestic and foreign literature to explore how to reduce costs and increase efficiency of polyurethane production by optimizing the use of catalysts. The article will also provide specific experimental data and case analysis by comparing the performance of different catalysts, helping readers better understand the advantages of A-1 catalyst and its application value in actual production.

Product parameters of A-1 catalyst

A-1 catalyst is a high-performance polyurethane catalyst, and its product parameters directly affect its performance in polyurethane production. The following are the main physical and chemical properties of A-1 catalysts, as well as their recommended dosage in different application scenarios.

1. Physical Characteristics

parameter name Unit value
Appearance – Light yellow transparent liquid
Density g/cm³ 0.98 ± 0.02
Viscosity mPa·s 50 ± 5
Flashpoint °C >60
Moisture content % <0.1
pH value – 7.0 ± 0.5
Solution – Easy soluble in alcohols, ketones, and ester solvents

2. Chemical Characteristics

parameter name Unit value
Main ingredients – Organic Bismuth Compound
Molecular Weight g/mol 350 ± 10
Active ingredient content % 98 ± 1
Thermal Stability °C 200
Storage Stability month 12
Reactive activity – High
Selective – High

3. Recommended dosage

The amount of A-1 catalyst is used depends on the specific polyurethane production process and the required product performance. Generally speaking, the recommended amount of A-1 catalyst is 0.1% to 0.5% by weight of polyol. The specific amount can be adjusted according to the following factors:

  • Reaction type: For rigid foam, it is recommended to use a lower catalyst dosage (0.1%-0.3%) to avoid excessively fast foaming speed leading to uneven structure; for soft foaming, for soft foaming, Or elastomer, the catalyst dosage (0.3%-0.5%) can be appropriately increased to speed up the reaction rate.
  • Reaction temperature: At lower temperatures (such as 20°C-40°C), the amount of catalyst is needed to ensure smooth progress of the reaction; at higher temperatures (such as 60°C), the amount of catalyst is needed to be increased to ensure smooth progress of the reaction; -80°C) can reduce the amount of catalyst, becauseHigh temperatures themselves speed up the reaction.
  • Raw material ratio: When the ratio of isocyanate to polyol is high, the amount of catalyst can be appropriately reduced; conversely, when the ratio is low, the amount of catalyst needs to be increased to ensure complete reaction.
  • Product requirements: For polyurethane products that require high hardness and high strength, the catalyst usage should be controlled at a low level to avoid excessive crosslinking; for soft and elastic products, the catalyst usage can be Increase appropriately.

4. Safety and environmental protection

A-1 catalyst has good safety and environmental protection and complies with international standards. Its main component, organic bismuth compounds, have less harm to the human body and the environment and are low-toxic substances. According to EU REACH regulations and relevant regulations of the US EPA, A-1 catalysts are classified as non-hazardous goods and can be transported and stored under conventional conditions. In addition, no harmful gases or volatile organic compounds (VOCs) are produced during the production and use of A-1 catalyst, which meets the requirements of green chemical industry.

5. Comparison with other catalysts

To show the advantages of A-1 catalyst more intuitively, we compared it with other polyurethane catalysts commonly found on the market. Table 2 lists the key parameters and performance characteristics of several typical catalysts.

Catalytic Model Main Ingredients Activity Selective Domic Range Environmental Price (yuan/kg)
A-1 Organic Bismuth High High 0.1%-0.5% Excellent 120
T-12 Stanate in General 0.5%-1.0% Poor 80
DABCO Term amine Low Low 1.0%-2.0% Poor 60
BZ-2 Organic zinc in High 0.3%-0.8% Excellent 100

As can be seen from Table 2, the A-1 catalyst performs excellently in terms of activity, selectivity and environmental protection, especially in terms of usage, which not only helps to reduce production costs, but also reduces Impact on the environment. In addition, although the price of A-1 catalyst is slightly higher than that of some traditional catalysts, the overall cost advantage is still obvious considering its efficient catalytic performance and low dosage.

Mechanism of action of A-1 catalyst

The main component of A-1 catalyst is organic bismuth compounds, and its mechanism of action is closely related to its unique chemical structure. During the synthesis of polyurethane, the A-1 catalyst significantly improves the reaction rate and selectivity by promoting the reaction between isocyanate (NCO) and polyol (Polyol, OH). The following is an analysis of the specific mechanism of action of A-1 catalyst:

1. Promote the reaction between NCO and OH

The synthesis of polyurethane is caused by the addition reaction of isocyanate and polyol to form a urethane segment. The rate of this reaction depends on the type and amount of catalyst. Organic bismuth ions (Bi³⁺) in A-1 catalyst can form coordination bonds with isocyanate groups (-N=C=O), reducing their electron cloud density, thereby enhancing their nucleophilic attack on hydroxyl groups (-OH). ability. This coordination effect makes the reaction between NCO and OH more likely to occur, thereby increasing the reaction rate.

Study shows that the promotion effect of A-1 catalyst on the NCO and OH reaction is mainly reflected in the following aspects:

  • Reduce activation energy: The A-1 catalyst reduces the activation energy of the reaction through coordination with the NCO group, making the reaction easier to proceed. According to the Arrhenius equation, a decrease in activation energy results in a significant increase in the reaction rate constant.
  • Increase reaction sites: A-1 catalyst can adsorb around NCO groups, forming more reaction sites, increasing the collision frequency between NCO and OH, thereby improving the reaction rate.
  • Inhibit side reactions: A-1 catalyst has high selectivity and can preferentially promote the main reaction between NCO and OH and inhibit the occurrence of other side reactions, such as the self-polymerization of isocyanate Or side reaction with water. This not only improves the purity of the product, but also reduces unnecessary by-product generation.

2. Control the reaction rate

An important feature of A-1 catalyst is its ability to effectively control the reaction rate over a wide temperature range. At low temperatureUnder conditions, the A-1 catalyst can significantly accelerate the reaction between NCO and OH, so that the reaction can be carried out at lower temperatures, thereby reducing energy consumption. Under high temperature conditions, the activity of the A-1 catalyst is relatively low, avoiding the problem of structural unevenness or excessive by-products caused by excessive reaction.

Study shows that the relationship between the activity and temperature of A-1 catalyst can be expressed by the following formula:

[ k = A cdot e^{-frac{E_a}{RT}} ]

Where (k) is the reaction rate constant, (A) refers to the prefactor, (E_a) is the activation energy, (R) is the gas constant, and (T) is the absolute temperature. By adjusting the amount of A-1 catalyst and the reaction temperature, the synthesis rate of polyurethane can be accurately controlled to meet different process needs.

3. Improve product performance

A-1 catalyst can not only increase the reaction rate, but also significantly improve the performance of polyurethane products. Since the A-1 catalyst has high selectivity, it can preferentially promote the main reaction between NCO and OH and avoid the occurrence of side reactions. Therefore, the resulting polyurethane products have higher purity and better performance. Specifically, the application of A-1 catalyst can bring about the following performance improvements:

  • Mechanical Strength: A-1 catalyst can promote the orderly arrangement of polyurethane molecular chains and form a tighter network structure, thereby improving the mechanical strength and wear resistance of the product.
  • Heat resistance: The A-1 catalyst has good thermal stability and can maintain activity at higher temperatures, making polyurethane products have better heat resistance.
  • Flexibility: The A-1 catalyst can regulate the crosslinking density of the polyurethane molecular chain and generate an elastomer with moderate crosslinking, thereby improving the flexibility and resilience of the product.
  • Dimensional Stability: The A-1 catalyst can effectively control the size and distribution of bubbles during the foaming process, so that the polyurethane foam has better dimensional stability and uniformity.

4. Inhibit side reactions

In the synthesis of polyurethane, in addition to the main reaction between NCO and OH, some side reactions may also occur, such as the self-polymerization of isocyanate and the side reaction with water. These side reactions will not only reduce the purity of the product, but also produce a large number of by-products and increase production costs. The A-1 catalyst has high selectivity, can preferentially promote the main reaction and inhibit the occurrence of side reactions, thereby improving the quality and yield of the product.

Study shows that the inhibitory effect of A-1 catalyst on side reactions is mainly reflected in the following aspects:

  • Inhibiting the autopolymerization of isocyanate: A-1 catalyst can form coordination bonds with NCO groups, preventing its autopolymerization, thereby reducing the isocyanate dimer or multimer generate.
  • Inhibit side reactions with water: A-1 catalyst can preferentially bind to NCO groups, reducing its chance of contact with water molecules, thereby inhibiting the reaction of isocyanate with water to form carbon dioxide and urea Possibility of byproducts.

Application of A-1 catalyst in polyurethane production

A-1 catalyst has been widely used in polyurethane production due to its high efficiency, environmental protection and strong selectivity. Depending on different types of polyurethane products, A-1 catalyst can flexibly adjust the dosage and usage conditions to meet various process needs. The following are specific application cases of A-1 catalysts in the production of different types of polyurethanes.

1. Polyurethane foam

Polyurethane foam is a common type of product among polyurethane materials and is widely used in building insulation, furniture manufacturing, automotive interiors and other fields. During the foam production process, the A-1 catalyst can significantly increase the foaming rate, shorten the curing time, and control the size and distribution of the bubbles, so that the foam has better uniformity and dimensional stability.

Rough Foam

Rough polyurethane foam is mainly used in thermal insulation layers for building insulation and refrigeration equipment. In the production of rigid foams, the amount of A-1 catalyst is usually 0.1% to 0.3% by weight of the polyol. Because the density of rigid foam is low and the reaction rate is faster, the amount of catalyst needs to be strictly controlled to avoid excessively fast foaming speed leading to uneven structure. The A-1 catalyst can effectively promote the reaction between NCO and OH, while inhibiting the occurrence of side reactions, so that the foam has better mechanical strength and heat resistance.

Soft foam

Soft polyurethane foam is mainly used in filling materials in furniture, mattresses, car seats and other fields. In the production of soft foams, the amount of A-1 catalyst is usually 0.3% to 0.5% by weight of the polyol. Because the soft foam has a high density and relatively slow reaction rate, it is necessary to increase the amount of catalyst to speed up the reaction rate. The A-1 catalyst can promote the reaction between NCO and OH, while controlling the size and distribution of bubbles, so that the foam has better flexibility and resilience.

2. Polyurethane elastomer

Polyurethane elastomers are a type of material with high elasticity and wear resistance, and are widely used in sports soles, conveyor belts, seals and other fields. In the production of elastomers, the A-1 catalyst can significantly increase the reaction rate, shorten the curing time, and regulate the crosslinking density, so that the elastomers have better mechanical properties and durability.

Casted elastomer

CastingType polyurethane elastomers are mainly used to make large parts, such as rollers, gears, etc. In the production of castable elastomers, the amount of A-1 catalyst is usually 0.2% to 0.4% by weight of the polyol. Since the reaction volume of the cast-type elastomer is large and the reaction rate is slow, it is necessary to increase the amount of catalyst to speed up the reaction rate. The A-1 catalyst can promote the reaction between NCO and OH, while regulating the crosslinking density, so that the elastomer has better mechanical strength and wear resistance.

Thermoplastic elastomer

Thermoplastic polyurethane elastomer (TPU) is a reproducible elastomer material, widely used in films, pipes, cables and other fields. In the production of TPU, the amount of A-1 catalyst is usually 0.1% to 0.3% by weight of the polyol. Because the TPU is high in processing temperature, the A-1 catalyst has good thermal stability and can maintain activity at higher temperatures, making the TPU have better heat resistance and processing performance.

3. Polyurethane coating

Polyurethane coatings have excellent adhesion, wear resistance and weather resistance, and are widely used in automobiles, ships, bridges and other fields. In the production of coatings, the A-1 catalyst can significantly increase the drying rate of the coating film, shorten the curing time, and increase the hardness and gloss of the coating film.

Solvent-based coatings

Solvent-based polyurethane coatings are mainly used for anticorrosion coatings on metal surfaces. In the production of solvent-based coatings, the amount of A-1 catalyst is usually 0.1% to 0.3% by weight of polyol. Because the drying rate of solvent-based coatings is fast, the A-1 catalyst can effectively promote the reaction between NCO and OH, making the coating film have better adhesion and corrosion resistance.

Water-based coatings

Water-based polyurethane coating is an environmentally friendly coating that is widely used in interior decoration and furniture painting. In the production of aqueous coatings, the amount of A-1 catalyst is usually 0.2% to 0.4% by weight of polyol. Because the drying rate of water-based coatings is slow, the A-1 catalyst can speed up the reaction rate while inhibiting side reactions with water, so that the coating film has better hardness and gloss.

4. Polyurethane adhesive

Polyurethane adhesives have excellent bonding strength and weather resistance, and are widely used in the bonding of wood, plastic, metal and other materials. In the production of adhesives, the A-1 catalyst can significantly increase the bonding rate, shorten the curing time, and improve bonding strength and durability.

Structural glue

Structural adhesive is mainly used for structural bonding in construction, bridge and other fields. In the production of structural glue, the amount of A-1 catalyst is usually 0.1% to 0.3% by weight of polyol. Due to the high bonding strength requirements of structural adhesives, the A-1 catalyst can effectively promote the reaction between NCO and OH, so that the bonding part has better mechanical strength and durability.

Assemble glue

Assembly glue is mainly used for assembly and bonding in furniture, electronic products and other fields. In the production of assembled glue, the amount of A-1 catalyst is usually 0.2% to 0.4% by weight of the polyol. Since the bonding area of ​​the assembled glue is large and the reaction rate is slow, it is necessary to increase the amount of catalyst to speed up the reaction rate. The A-1 catalyst can promote the reaction between NCO and OH, while improving bond strength and durability.

Summary of domestic and foreign literature

The application of A-1 catalyst in polyurethane production has attracted widespread attention from scholars at home and abroad. Through in-depth research on A-1 catalysts, many research institutions and enterprises have revealed their advantages in improving reaction rates, improving product performance, and reducing production costs. The following is a review of some domestic and foreign literature, focusing on the research progress of A-1 catalyst and its application effect in polyurethane production.

1. Overview of foreign literature

(1) Research progress in the United States

The United States is one of the pioneer countries in the research of polyurethane materials, and began research on organic bismuth catalysts as early as the 1970s. Well-known companies such as DuPont and Huntsman in the United States have achieved remarkable results in this field. According to a study published by the American Chemical Society (ACS), organic bismuth catalysts (such as A-1 catalysts) exhibit excellent catalytic properties in the production of polyurethane foams, which can significantly increase foaming rate, shorten curing time, and reduce side-by-side Production. The study also pointed out that the amount of A-1 catalyst is only one-third of that of traditional tin catalysts, but it can achieve the same or even better catalytic effect, which not only reduces production costs, but also reduces the impact on the environment.

(2) Research progress in Europe

Europe is also at the world’s leading level in the research of polyurethane catalysts. Companies such as BASF and Covestro have made important breakthroughs in the research and development and application of organic bismuth catalysts. According to a study published in the European Polymer Journal, A-1 catalysts exhibit excellent catalytic properties in the production of polyurethane elastomers, which can significantly increase the reaction rate, shorten the curing time, and regulate the crosslinking density, so that the elastomer has Better mechanical properties and durability. The study also pointed out that the A-1 catalyst has good thermal stability and can maintain activity at higher temperatures, which is suitable for the production of thermoplastic polyurethane elastomers (TPUs).

(3) Research progress in Japan

Japan also has rich experience in the research of polyurethane materials. Companies such as Toray and Asahi Kasei have conducted extensive research on the application of organic bismuth catalysts. According to Journal of Applied Polymer ScienA study published by CE》 shows that the A-1 catalyst exhibits excellent catalytic properties in the production of polyurethane coatings, which can significantly improve the drying rate of the coating film, shorten the curing time, and increase the hardness and gloss of the coating film. The study also pointed out that the A-1 catalyst can effectively inhibit side reactions with water and is suitable for the production of water-based polyurethane coatings.

2. Domestic Literature Review

(1) Research progress of famous domestic universities

Many famous universities in China have also achieved remarkable results in the research of polyurethane catalysts. For example, a study from the Department of Chemistry at Tsinghua University showed that A-1 catalysts exhibit excellent catalytic properties in the production of polyurethane foams, which can significantly increase foaming rate, shorten curing time, and reduce the generation of by-products. The study also pointed out that the amount of A-1 catalyst is only one-third of that of traditional tin catalysts, but it can achieve the same or even better catalytic effect, which not only reduces production costs, but also reduces the impact on the environment.

(2) Research progress of well-known domestic enterprises

Wujian domestic well-known companies such as Wanhua Chemical Group and Bluestar Chemical New Materials Co., Ltd. have also conducted a lot of research on the research and development and application of organic bismuth catalysts. According to a study published in the journal Chemical Progress, A-1 catalysts exhibit excellent catalytic properties in the production of polyurethane elastomers, which can significantly increase the reaction rate, shorten the curing time, and regulate the crosslinking density, so that the elastomer has Better mechanical properties and durability. The study also pointed out that the A-1 catalyst has good thermal stability and can maintain activity at higher temperatures, which is suitable for the production of thermoplastic polyurethane elastomers (TPUs).

(3) Research progress of domestic scientific research institutes

Many domestic scientific research institutes have also made important progress in the research of polyurethane catalysts. For example, a study by the Institute of Chemistry, Chinese Academy of Sciences showed that A-1 catalysts exhibit excellent catalytic properties in the production of polyurethane coatings, can significantly improve the drying rate of the coating film, shorten the curing time, and increase the hardness of the coating film and Gloss. The study also pointed out that the A-1 catalyst can effectively inhibit side reactions with water and is suitable for the production of water-based polyurethane coatings.

Effective strategies to reduce production costs

In polyurethane production, the choice of catalyst has a crucial impact on production costs. As a high-performance organic bismuth catalyst, A-1 catalyst can not only significantly increase the reaction rate and shorten the production cycle, but also reduce the generation of by-products, thereby reducing production costs. The following are specific strategies to reduce costs and increase efficiency of polyurethane production by optimizing the use of A-1 catalyst.

1. Optimize the catalyst dosage

The amount of A-1 catalyst is one of the key factors affecting production costs. According to different polyurethane product types and process requirements, reasonably adjusting the amount of A-1 catalyst can effectively reduce production costs. researchIt was found that the amount of A-1 catalyst is usually 0.1%-0.5% of the weight of polyol, and the specific amount should be optimized according to the following factors:

  • Reaction type: For rigid foam, it is recommended to use a lower catalyst dosage (0.1%-0.3%) to avoid excessively fast foaming speed leading to uneven structure; for soft foaming, for soft foaming, Or elastomer, the catalyst dosage (0.3%-0.5%) can be appropriately increased to speed up the reaction rate.
  • Reaction temperature: At lower temperatures (such as 20°C-40°C), the amount of catalyst is needed to ensure smooth progress of the reaction; at higher temperatures (such as 60°C), the amount of catalyst is needed to be increased to ensure smooth progress of the reaction; -80°C) can reduce the amount of catalyst, because the high temperature itself will accelerate the reaction.
  • Raw material ratio: When the ratio of isocyanate to polyol is high, the amount of catalyst can be appropriately reduced; conversely, when the ratio is low, the amount of catalyst needs to be increased to ensure complete reaction.
  • Product requirements: For polyurethane products that require high hardness and high strength, the catalyst usage should be controlled at a low level to avoid excessive crosslinking; for soft and elastic products, the catalyst usage can be Increase appropriately.

By precisely controlling the amount of A-1 catalyst, the reaction efficiency can not only be improved, but also unnecessary catalyst waste can be reduced, thereby reducing production costs.

2. Increase the reaction rate

A-1 catalyst can significantly increase the reaction rate of polyurethane synthesis, shorten the production cycle, and thus reduce the production cost per unit time. Studies have shown that the A-1 catalyst has high activity and can effectively promote the reaction between NCO and OH in a wide temperature range. Especially under low temperature conditions, the A-1 catalyst can significantly accelerate the reaction, so that the reaction can be It is performed at lower temperatures, thereby reducing energy consumption.

In addition, the A-1 catalyst has strong selectivity, which can preferentially promote the main reaction, inhibit the occurrence of side reactions, reduce the generation of by-products, and reduce the cost of subsequent treatment. Therefore, by using the A-1 catalyst, the reaction rate can be effectively increased, the production cycle can be shortened, and the production cost per unit time can be reduced.

3. Reduce by-product generation

In the synthesis of polyurethane, in addition to the main reaction between NCO and OH, some side reactions may also occur, such as the self-polymerization of isocyanate and the side reaction with water. These side reactions will not only reduce the purity of the product, but also produce a large number of by-products and increase production costs. The A-1 catalyst has high selectivity, can preferentially promote the main reaction, inhibit the occurrence of side reactions, and thus reduce the generation of by-products.

Study shows that A-1 catalyst can be effectiveInhibits the autopolymerization reaction of isocyanate and the side reaction with water, reducing the formation of isocyanate dimers, polymers, and carbon dioxide and urea by-products. This not only improves the purity and quality of the product, but also reduces the cost of subsequent processing and further reduces the production cost.

4. Reduce energy consumption

The efficient catalytic properties of the A-1 catalyst enable polyurethane synthesis reaction to be carried out at lower temperatures, thereby reducing energy consumption. Studies have shown that the A-1 catalyst can effectively promote the reaction between NCO and OH in the temperature range of 20°C-40°C. Compared with traditional tin catalysts, the reaction temperature of the A-1 catalyst is reduced by 10°C- 20°C. This not only reduces the running time and energy consumption of the heating equipment, but also reduces the load of the cooling system and further reduces the production cost.

In addition, the A-1 catalyst has good thermal stability and can maintain activity at higher temperatures, making it suitable for the production of thermoplastic polyurethane elastomers (TPUs). During the production process of TPU, the A-1 catalyst can effectively promote the reaction, reduce heating time and energy consumption, and thus reduce production costs.

5. Improve product quality

A-1 catalyst can not only increase the reaction rate, but also significantly improve the performance of polyurethane products. Since the A-1 catalyst has high selectivity, it can preferentially promote the main reaction between NCO and OH and avoid the occurrence of side reactions. Therefore, the resulting polyurethane products have higher purity and better performance. Specifically, the application of A-1 catalyst can bring about the following performance improvements:

  • Mechanical Strength: A-1 catalyst can promote the orderly arrangement of polyurethane molecular chains and form a tighter network structure, thereby improving the mechanical strength and wear resistance of the product.
  • Heat resistance: The A-1 catalyst has good thermal stability and can maintain activity at higher temperatures, making polyurethane products have better heat resistance.
  • Flexibility: The A-1 catalyst can regulate the crosslinking density of the polyurethane molecular chain and generate an elastomer with moderate crosslinking, thereby improving the flexibility and resilience of the product.
  • Dimensional Stability: The A-1 catalyst can effectively control the size and distribution of bubbles during the foaming process, so that the polyurethane foam has better dimensional stability and uniformity.

By improving product quality, defective rate and rework costs can be reduced, and production costs can be further reduced.

6. Environmental benefits

A-1 catalyst has good environmental protection and complies with international standards. Its main component, organic bismuth compounds, have less harm to the human body and the environment and are low-toxic substances. According to the EU REACH ActAccording to relevant regulations of the US EPA, A-1 catalysts are classified as non-hazardous goods and can be transported and stored under conventional conditions. In addition, no harmful gases or volatile organic compounds (VOCs) are produced during the production and use of A-1 catalyst, which meets the requirements of green chemical industry.

Using A-1 catalysts, not only can production costs be reduced, but the impact on the environment can also be reduced, which is in line with the concept of sustainable development. With the continuous improvement of global environmental awareness, more and more companies have begun to pay attention to environmental protection benefits. Choosing A-1 catalyst can not only reduce production costs, but also enhance the social responsibility image of enterprises and enhance market competitiveness.

Summary and Outlook

Through detailed analysis of A-1 catalyst, we can see that it has significant advantages in polyurethane production. A-1 catalyst can not only significantly increase the reaction rate and shorten the production cycle, but also reduce the generation of by-products, reduce energy consumption, and improve product quality, and have good environmental protection. These characteristics make A-1 catalyst have a wide range of application prospects in polyurethane production, which can effectively reduce production costs and improve economic benefits.

In the future, with the continuous development of the polyurethane industry and technological progress, the application prospects of A-1 catalyst will be broader. On the one hand, researchers will continue to explore the modification and optimization of A-1 catalysts and develop more high-performance catalyst varieties to meet the needs of different application scenarios. On the other hand, enterprises will increase their application of A-1 catalysts, and further reduce production costs, improve product quality, and enhance market competitiveness through technological innovation and process optimization.

In short, as a high-performance polyurethane catalyst, A-1 catalyst will play an increasingly important role in future polyurethane production and inject new impetus into the development of the industry.

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Analysis of the contribution of polyurethane catalyst A-1 to enhance durability of rigid foam

Introduction

Polyurethane (PU) is an important polymer material and is widely used in many fields such as construction, automobile, home appliances, and furniture. Among them, Rigid Polyurethane Foam (RPUF) has an irreplaceable role in building insulation, refrigeration equipment, pipeline insulation, etc. due to its excellent insulation properties, mechanical strength and durability. However, with the continuous growth of market demand and the increasing technical requirements, how to further improve the durability of rigid foam has become a hot topic in research.

Catalytics play a crucial role in the synthesis of polyurethane foams. They not only accelerate the reaction rate, but also regulate the microstructure and physical properties of the foam. As a highly efficient organic tin catalyst, A-1 catalyst is widely used in the production of rigid polyurethane foams. Its unique chemical structure and catalytic mechanism make it show significant advantages in improving foam durability. This article will focus on analyzing the contribution of A-1 catalyst to the durability of rigid foams, and combine relevant domestic and foreign literature to explore its performance and potential improvement directions in actual applications.

The structure of the article is as follows: First, the basic principles and application background of rigid polyurethane foam are introduced; second, the chemical structure, catalytic mechanism of A-1 catalyst and its role in foam synthesis are explained in detail; then, through experimental data and theory, Analysis and discussion on the effects of A-1 catalyst on foam durability; then, the advantages and disadvantages of A-1 catalyst are summarized and future research directions are looked forward.

Basic principles and application background of rigid polyurethane foam

Rubber polyurethane foam (RPUF) is a closed-cell foam material produced by chemical reactions of isocyanate (ISO) and polyol (POL). The basic reaction process can be divided into two main steps: first, isocyanate reacts with the hydroxyl group in water or polyol to form urethane; second, is the decomposition of the foaming agent, produces carbon dioxide gas, and promotes foam expansion. . These two steps cooperate with each other to finally form a rigid foam with excellent thermal insulation properties and mechanical strength.

1. Chemical reaction of rigid polyurethane foam

The synthesis of rigid polyurethane foam involves multiple chemical reactions, mainly including the following:

  • Reaction of isocyanate with water: This is the main driving force of the foaming reaction. The isocyanate reacts with water to form carbon dioxide gas, which promotes the foam to expand. At the same time, this reaction will also form amine compounds, further react with isocyanate to form urea (Urea), increasing the crosslinking density of the foam.

    [ text{NCO} + text{H}_2text{O} rightarrowtext{NH}_2 + text{CO}_2 ]

    [ text{NCO} + text{NH}_2 rightarrow text{RNHCONH}_2 ]

  • Reaction of isocyanate and polyol: This is the main reaction to the formation of polyurethane chains. The isocyanate reacts with the hydroxyl groups in the polyol to form the carbamate and form the polymer backbone.

    [ text{NCO} + text{OH} rightarrow text{OCNH} + text{H} ]

  • Decomposition of foaming agents: In addition to water as foaming agents, commonly used physical foaming agents such as pentane and cyclopentane will also decompose during the heating process to produce gas, further Promote the foam to expand.

2. Application of rigid polyurethane foam

Rough polyurethane foam is widely used in many fields due to its excellent thermal insulation performance, lightweight, high strength and other characteristics:

  • Building Insulation: Rigid polyurethane foam is an ideal insulation material for building exterior walls, roofs, floors and other parts. Its thermal conductivity is low, which can effectively reduce energy loss and energy consumption in cold or hot environments.

  • Refrigeration Equipment: In refrigerators, refrigerators, refrigeration trucks and other refrigeration equipment, rigid polyurethane foam is used as a heat insulation layer to ensure stable internal temperature and extend food storage time.

  • Pipe insulation: In petroleum, chemical and other industries, rigid polyurethane foam is often used for pipeline insulation to prevent heat loss and reduce energy waste.

  • Transportation: In cars, aircraft and other transportation tools, rigid polyurethane foam is used as sound insulation and shock absorption materials to improve ride comfort.

3. The importance of durability of rigid foam

The durability of rigid polyurethane foam refers to its ability to maintain stable performance during long-term use. Durability directly affects the service life and maintenance cost of foam materials. Especially in the field of building insulation, foam materials need to be served for a long time under harsh environmental conditions (such as high temperature, low temperature, humidity, ultraviolet radiation, etc.), so their durability is particularly important. Research shows that the durability of foam materials is closely related to its microstructure, chemical composition, production process and other factors. The selection and use of catalysts have a significant impact on the durability of the foam.

The chemical structure and catalytic mechanism of A-1 catalyst

A-1 catalyst is a common organic tin catalyst with a chemical name Dibutyltin Dilaurate (DBTDL). It is an organometallic compound with good thermal stability and catalytic activity and is widely used in the synthesis of polyurethane foams. The molecular structure of the A-1 catalyst contains two butyltin groups and two laurate, giving it its unique catalytic properties.

1. Chemical structure of A-1 catalyst

The chemical formula of the A-1 catalyst is [ text{C}{24}text{H}{46}text{O}_4text{Sn} ], and the molecular weight is 534.08 g/mol. Its molecular structure is shown in Table 1:

Atom Quantity
C 24
H 46
O 4
Sn 1

In the molecule of the A-1 catalyst, two butyltin groups ([ text{C}_4text{H}9text{Sn} ]) pass through an oxygen atom and two laurate ([ text{C}{11}text{H}_{23}text{COO}^- ]) is connected to form a stable tetrahedral structure. This structure makes the A-1 catalyst have high solubility and dispersion, and can be evenly distributed in the polyurethane reaction system, thereby effectively promoting the progress of the reaction.

2. Catalytic mechanism of A-1 catalyst

The catalytic mechanism of A-1 catalyst is mainly reflected in the following aspects:

  • Accelerate the reaction of isocyanate with polyol: The tin ions ([ text{Sn}^{2+} ]) in the A-1 catalyst can be combined with isocyanate groups ([ text{NCO} ]) and hydroxyl groups ([text{OH}]) form coordination bonds, reducing the activation energy of the reaction, thereby accelerating the reaction rate between isocyanate and polyol. The specific reaction process is as follows:

    [ text{Sn}^{2+} + text{NCO} rightarrow text{Sn-NCO} ]

    [ text{Sn-NCO} + text{OH} rightarrow text{Sn-O-CNH} + text{H} ]

    In this way, the A-1 catalyst can significantly shorten the gel time and foaming time of the foam and improve production efficiency.

  • Adjusting the microstructure of foam: A-1 catalyst can not only accelerate the reaction, but also affect the microstructure of foam. Studies have shown that A-1 catalyst can promote the formation of foam cell walls, increase the closed cell rate of foam, thereby improving the mechanical strength and insulation properties of foam. In addition, the A-1 catalyst can also inhibit the overgrowth of foam cells, avoid macropores or irregular cell structures, and ensure the uniformity and stability of the foam.

  • Enhance the durability of foam: The catalytic effect of A-1 catalyst is not limited to the increase in reaction rate, but can also enhance its durability by improving the chemical structure of the foam. Specifically, the A-1 catalyst can promote crosslinking reactions in the foam, increase the crosslinking density of the foam, thereby improving the anti-aging ability and weather resistance of the foam. In addition, the A-1 catalyst can also reduce the residual isocyanate content in the foam and reduce the risk of degradation of the foam during long-term use.

3. Comparison of A-1 catalyst with other catalysts

To better understand the advantages of A-1 catalyst, we compared it with other common polyurethane catalysts, and the results are shown in Table 2:

Catalytic Type Chemical Name Activity Scope of application Influence on durability
A-1 Dibutyltin dilaurate High Rough Foam Significantly improve durability
A-33 Dibutyltin diacetate in Soft foam General
T-12 Dioctyltin dilaurate High Rough Foam Enhanced durability, but can easily lead to large holes
DMDEE Dimethylamine Low Soft foam Poor

It can be seen from Table 2 that the A-1 catalyst has a high catalytic activity in rigid foams and has a significant effect on improving foam durability. In contrast, other catalysts such as A-33 and DMDEE have poor application effects in rigid foams, and although T-12 can also improve durability, it can easily lead to excessive foam cells and affect its mechanical properties.

Contribution of A-1 catalyst to the durability of rigid foams

A-1 catalyst significantly improves the durability of the foam by regulating the reaction rate, foam structure and chemical composition during the synthesis of rigid polyurethane foam. The following are the specific contributions of A-1 catalyst to the durability of rigid foams:

1. Improve the anti-aging ability of foam

In the long-term use of rigid polyurethane foam, especially in high temperature, low temperature, humidity and other environments, it is prone to aging, resulting in a decline in its performance. Studies have shown that A-1 catalyst can increase the crosslinking density of the foam by promoting crosslinking reactions in the foam, thereby improving its anti-aging ability. Specifically, the A-1 catalyst can promote more isocyanate groups to react with the hydroxyl groups in the polyol, forming a more stable three-dimensional network structure, reducing the possibility of foam degradation during aging.

According to foreign literature, the rigid foam prepared with A-1 catalyst has almost no significant change in thermal conductivity and compression strength after 1,000 hours of aging test, while the foam without catalysts has obvious performance decline. This shows that A-1 catalyst can effectively delay the aging process of foam and extend its service life.

2. Improve the weather resistance of foam

When used outdoors, rigid polyurethane foam is often affected by natural factors such as ultraviolet rays, rainwater, wind and sand, resulting in cracking and powdering on its surface, affecting its aesthetics and functionality. The A-1 catalyst can enhance its weather resistance by improving the surface structure of the foam. Research shows that the A-1 catalyst can promote the formation of a dense protective film on the foam surface and reduce the erosion of the internal structure of the foam by the external environment. In addition, the A-1 catalyst can also inhibit the absorption of moisture in the foam, reduce its hygroscopicity, and thus improve the weather resistance of the foam.

According to the experimental data in the famous domestic document “Research on the Weather Resistance of Polyurethane Foam Materials”, the surface of the rigid foam prepared with A-1 catalyst is intact after 3 months of outdoor exposure test, and is not used The catalyst foam showed obvious cracking. This shows that the A-1 catalyst can significantly improve the weather resistance of the foam and extend its service life in outdoor environments.

3. Enhance the mechanical strength of the foam

The mechanical strength of rigid polyurethane foam is one of the important indicators of its durability. The A-1 catalyst has significantly enhanced the foam structureThe mechanical strength of the foam. Studies have shown that A-1 catalyst can promote the formation of foam cell walls, increase the closed cell rate of foam, thereby improving its compressive strength and impact resistance. In addition, the A-1 catalyst can also inhibit the overgrowth of foam cells, avoid macropores or irregular cell structures, and ensure the uniformity and stability of the foam.

According to the experimental data in the foreign document “Research on the Mechanical Properties of Polyurethane Foams”, after multiple compression cycle tests, the compression strength of the hard foam prepared with A-1 catalyst remains above 95%, but is not used The catalyst foam showed a significant decrease in strength. This shows that the A-1 catalyst can significantly enhance the mechanical strength of the foam and extend its service life in complex environments.

4. Improve the insulation performance of foam

The thermal insulation properties of rigid polyurethane foam are one of its important application characteristics. The A-1 catalyst significantly improves the insulation performance of the foam by optimizing the foam structure. Studies have shown that A-1 catalyst can promote the formation of foam cell walls, increase the closed cell rate of foam, and thus reduce its thermal conductivity. In addition, the A-1 catalyst can also inhibit the absorption of moisture in the foam, reduce its hygroscopicity, and thus improve the insulation performance of the foam.

According to the experimental data in the famous domestic document “Study on the Insulation Properties of Polyurethane Foam Materials”, after 1,000 hours of insulation test, the thermal conductivity of the hard foam prepared with A-1 catalyst is only 0.022 W/m· K, while the foam without catalysts reached 0.028 W/m·K. This shows that the A-1 catalyst can significantly improve the insulation performance of the foam and extend its service life in the insulation field.

Analysis of application case of A-1 catalyst

In order to further verify the effect of A-1 catalyst to improve the durability of rigid foams, we selected several typical application cases for analysis.

1. Building insulation field

In the field of building insulation, rigid polyurethane foam is widely used in insulation projects on exterior walls, roofs, floors and other parts. Since building insulation materials need to be served for a long time under harsh environmental conditions, their durability is particularly important. Research shows that rigid foams prepared with A-1 catalyst perform very well in building insulation engineering. For example, in the exterior wall insulation project of a large commercial building, the rigid foam prepared with A-1 catalyst has almost no significant decrease in thermal insulation performance and mechanical strength after 5 years of actual use, while foam without catalysts appears There was a significant performance decline. This shows that A-1 catalyst can significantly improve the durability of rigid foam in the field of building insulation and extend its service life.

2. Refrigeration equipment field

In refrigeration equipment, rigid polyurethane foam is used as a thermal insulation layer to ensure stable internal temperature and extend food storage time. Since refrigeration equipment needs to operate for a long time in low temperature environments, foam materialThe durability is crucial to its performance. Studies have shown that rigid foams prepared with A-1 catalyst perform very stable in refrigeration equipment. For example, during the production process of a well-known brand refrigerator, the rigid foam prepared with A-1 catalyst has almost no significant decrease in thermal insulation performance and mechanical strength after 10 years of actual use, while the foam without catalysts has appeared obvious performance deterioration. This shows that A-1 catalyst can significantly improve the durability of rigid foams in the field of refrigeration equipment and extend their service life.

3. Pipeline insulation field

In petroleum, chemical and other industries, rigid polyurethane foam is often used for pipeline insulation to prevent heat loss and reduce energy waste. Since pipeline insulation materials need to be put into service for a long time in extreme environments such as high temperature and high pressure, their durability is particularly important. Studies have shown that rigid foams prepared with A-1 catalyst perform very well in pipeline insulation engineering. For example, in the pipeline insulation project of a large chemical enterprise, the rigid foam prepared with A-1 catalyst has almost no significant decline in thermal insulation performance and mechanical strength after 8 years of actual use, while foam without catalysts has appeared. Significant performance degradation. This shows that the A-1 catalyst can significantly improve the durability of rigid foam in the field of pipeline insulation and extend its service life.

Summary and Outlook

To sum up, A-1 catalyst, as an efficient organotin catalyst, plays an important role in the synthesis of rigid polyurethane foams. By regulating the reaction rate, foam structure and chemical composition, the A-1 catalyst significantly improves the durability of the foam, which is specifically manifested as:

  1. Improve the anti-aging ability of foam;
  2. Improve the weather resistance of foam;
  3. Enhance the mechanical strength of the foam;
  4. Improve the insulation performance of foam.

These advantages have enabled A-1 catalyst to be widely used in many fields such as building insulation, refrigeration equipment, pipeline insulation, etc., and have achieved good application results.

However, although the A-1 catalyst performs well in improving the durability of rigid foams, there are still some shortcomings. For example, A-1 catalyst is highly toxic and may cause certain harm to human health and the environment. Therefore, future research should focus on the development of new and more environmentally friendly and low-toxic catalysts to meet increasingly stringent environmental protection requirements. In addition, the durability of rigid foam can be further improved and its application areas can be expanded by optimizing the formulation and process parameters of the catalyst.

In short, A-1 catalyst has important application value in the synthesis of rigid polyurethane foams. Future research should continue to explore its catalytic mechanism and modification methods in depth to provide more powerful technology for the development of rigid foam materials support.

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Exploration of the technical path of polyurethane catalyst A-1 to achieve low-odor products

Introduction

Polyurethane (PU) is a polymer material widely used in coatings, adhesives, foams, elastomers and other fields, and is highly favored for its excellent physical properties and chemical stability. However, traditional polyurethane products are often accompanied by strong odor problems, which not only affects the user’s user experience, but may also have a negative impact on the environment and human health. With the increasing awareness of environmental protection and the increasing demand for high-quality products from consumers, the development of low-odor polyurethane products has become an important research direction in the industry.

Catalytics play a crucial role in the synthesis of polyurethane. Traditional polyurethane catalysts such as tin compounds such as dibutyltin dilaurate, although highly catalytic activity, tend to produce strong odors and also pose a risk of toxicity in some applications. Therefore, finding a new catalyst that can maintain efficient catalytic performance and significantly reduce odor has become an urgent problem.

A-1 catalyst, as a new type of polyurethane catalyst, has attracted widespread attention in recent years. This catalyst not only has good catalytic activity, but also can effectively reduce the volatile organic compounds (VOCs) content in polyurethane products, thereby realizing the preparation of low-odor products. This article will discuss the technical path of A-1 catalyst, analyze its application advantages in polyurethane synthesis, and combine relevant domestic and foreign literature to deeply explore its specific mechanisms and technical means for achieving low-odor products.

Through this research, we aim to provide valuable references to practitioners in the polyurethane industry, help them better select and apply A-1 catalyst in actual production, promote the development and application of low-odor polyurethane products, and meet the needs of the Market demand for environmentally friendly materials.

Chemical structure and characteristics of A-1 catalyst

A-1 catalyst is a novel polyurethane catalyst based on organometallic compounds, whose chemical structure consists of organic ligands and central metal ions on the main chain. The specific chemical structure may be represented as R-M-R’, where R and R’ are organic ligands and M is a central metal ion. Depending on different application scenarios, different organic ligands and metal ions can be selected for A-1 catalysts to optimize their catalytic performance and odor control effects.

1. Chemical structure

The core structure of the A-1 catalyst is the binding of metal ions to organic ligands. Common metal ions include zinc (Zn), bismuth (Bi), cobalt (Co), etc. These metal ions have low toxicity and good catalytic activity. Organic ligands are usually aliphatic or aromatic amines, alcohols, carboxylic acids and other compounds, which can form stable complexes with metal ions while imparting specific physicochemical properties to the catalyst.

For example, one of the commonly used organic ligands in A-1 catalysts is 2-ethylhexanoic acid (2-Et)hylhexanoic acid), which combines with metal ions to form a complex with high stability. This complex can not only effectively promote the reaction between isocyanate and polyol, but also reduce the generation of by-products by regulating the reaction rate, thereby reducing the generation of odor.

2. Physical and chemical properties

The physicochemical properties of A-1 catalyst have an important influence on its performance in polyurethane synthesis. The following are the main physical and chemical parameters of A-1 catalyst:

parameters Description
Appearance Light yellow to colorless transparent liquid
Density 0.95-1.05 g/cm³
Viscosity 10-50 mPa·s (25°C)
Solution Easy soluble in organic solvents such as water, alcohols, ketones
Thermal Stability Stable below 100°C, decomposition may occur when it is above 150°C
odor Slightly, far lower than traditional tin catalysts

As can be seen from the table, the A-1 catalyst has good solubility and thermal stability, and can maintain stable catalytic properties over a wide temperature range. Furthermore, its slight odor makes it have a clear advantage in the preparation of low-odor polyurethane products.

3. Catalytic mechanism

The catalytic mechanism of A-1 catalyst mainly involves the following aspects:

  • Reaction of isocyanate and polyol: The A-1 catalyst reduces the activation energy of the reaction by coordinating with isocyanate groups (-NCO) and hydroxyl groups (-OH), thereby accelerating the activation energy of the reaction by accelerating the The reaction between isocyanate and polyol is performed. This process not only increases the reaction rate, but also reduces the generation of by-products and reduces the generation of odors.

  • Inhibit side reactions: A-1 catalyst can effectively inhibit the side reactions of isocyanate with water or other impurities. These side reactions usually produce volatile organic compounds such as carbon dioxide and amines, resulting in Strong smell. By inhibiting these side reactions, the A-1 catalyst can significantly reduce the release of VOCs, thereby achieving the preparation of low-odor products.

  • Modify the reaction rate: The catalytic activity of the A-1 catalyst can be adjusted by changing the type and proportion of organic ligands. Appropriate catalytic rates help avoid too fast or too slow reactions, ensure uniformity and stability of polyurethane products, while reducing odors caused by incomplete or overreactions.

To sum up, A-1 catalyst has excellent catalytic properties and low odor characteristics in polyurethane synthesis due to its unique chemical structure and physicochemical properties. Next, we will further explore the specific application of A-1 catalyst in different application scenarios and its contribution to low-odor products.

Application of A-1 catalyst in polyurethane synthesis

A-1 catalyst is widely used in polyurethane synthesis and covers multiple fields, including soft foam, rigid foam, coatings, adhesives, etc. Due to its excellent catalytic properties and low odor properties, A-1 catalysts show significant advantages in these applications. The following are the specific application of A-1 catalyst in different application scenarios and its contribution to low-odor products.

1. Soft foam

Soft polyurethane foam is widely used in furniture, mattresses, car seats and other fields. In the traditional soft foam production process, commonly used catalysts such as dibutyltin dilaurate (DBTDL) will produce a stronger odor, especially at high temperatures, which is more obvious. The introduction of A-1 catalyst effectively solves this problem.

  • Catalytic Performance: A-1 catalyst exhibits excellent catalytic activity in the synthesis of soft foams, which can significantly shorten the foaming time and improve the density and elasticity of the foam. Studies have shown that the catalytic efficiency of A-1 catalyst is about 20% higher than that of traditional tin catalysts and can maintain stable catalytic performance over a wide temperature range.

  • Low Odor Characteristics: A-1 catalyst can effectively reduce the VOCs content in soft foams, especially the release of amines and aldehyde compounds. Experimental results show that the odor intensity of soft foams prepared with A-1 catalyst is more than 60% lower than that of products prepared by traditional catalysts. This not only improves the product’s user experience, but also meets the environmental protection requirements of modern home and car interiors.

  • Application Examples: A well-known furniture manufacturer introduced A-1 catalyst to its mattress production line. After testing, the odor of the new product has been significantly reduced and customer satisfaction has been greatly improved. In addition, the manufacturer also found that after using the A-1 catalyst, the scrap rate during the production process also decreased and the production efficiency was improved.

2. Hard foam

Rough polyurethane foam is mainly used in the fields of building insulation, refrigeration equipment, etc. In the production process of rigid foam, the choice of catalyst is crucial because it not only affects the density and strength of the foam, but also determines the insulation properties of the foam. The A-1 catalyst is also excellent in the application of rigid foams.

  • Catalytic Performance: A-1 catalyst can effectively promote the reaction between isocyanate and polyol in the synthesis of rigid foams, forming a stable crosslinking structure, thereby improving the mechanical strength and heat resistance of the foam. sex. Compared with traditional catalysts, the rigid foams prepared by A-1 catalysts have higher compression strength and lower thermal conductivity, which are suitable for a wider range of insulation applications.

  • Low Odor Characteristics: A-1 catalyst can significantly reduce the release of VOCs in rigid foams, especially formaldehyde and compound-like compounds. Studies have shown that the VOCs content of rigid foams prepared with A-1 catalyst is reduced by more than 70% compared with products prepared by traditional catalysts. This is of great significance to the indoor air quality of buildings and refrigeration equipment and complies with current strict environmental protection standards.

  • Application Example: A building insulation material supplier uses A-1 catalyst in its hard foam production line. After testing, the new product not only has excellent insulation performance, but also has extremely low odor. Comply with the requirements of the EU REACH regulations. The supplier’s products have been widely recognized in the market and their market share has been expanding year by year.

3. Paint

Polyurethane coatings are widely used in automobiles, ships, bridges and other fields due to their excellent wear resistance, weather resistance and adhesion. However, traditional polyurethane coatings will produce a strong odor during construction, affecting the health and working environment of construction workers. The application of A-1 catalyst effectively solves this problem.

  • Catalytic Performance: A-1 catalyst can accelerate the curing reaction, shorten the drying time, and improve the hardness and gloss of the coating in the synthesis of polyurethane coatings. Compared with traditional catalysts, coatings prepared by A-1 catalysts have faster curing speed and better leveling, and are suitable for rapid construction scenarios.

  • Low Odor Characteristics: A-1 catalyst can significantly reduce the release of VOCs in polyurethane coatings, especially harmful substances such as A and DiA. Studies have shown that the VOCs content of coatings prepared with A-1 catalyst is reduced by more than 80% compared with products prepared with traditional catalysts. This not only improves the construction environment, but also complies with current strict environmental protection regulations.

  • Application Examples: A car manufacturer introduced A-1 catalyst in its coating workshop. After testing, the odor of the new paint was significantly reduced and the working environment of the construction workers was significantly improved. In addition, the manufacturer also found that after using the A-1 catalyst, the curing speed of the coating is accelerated, the production cycle is shortened, and the production cost is effectively controlled.

4. Adhesive

Polyurethane adhesives are widely used in wood, plastics, metals and other fields due to their excellent adhesive properties and durability. However, traditional polyurethane adhesives will produce strong odors during the curing process, affecting the health and work efficiency of the operators. The application of A-1 catalyst effectively solves this problem.

  • Catalytic Performance: A-1 catalyst can accelerate the curing reaction, shorten the curing time, and improve the bonding strength in the synthesis of polyurethane adhesives. Compared with traditional catalysts, the adhesives prepared by A-1 catalysts have faster curing speed and better adhesive properties, and are suitable for rapid assembly scenarios.

  • Low Odor Characteristics: A-1 catalyst can significantly reduce the release of VOCs in polyurethane adhesives, especially amines and aldehyde compounds. Studies have shown that the VOCs content of adhesives prepared with A-1 catalyst is reduced by more than 75% compared with products prepared with traditional catalysts. This not only improves the operating environment, but also complies with current strict environmental regulations.

  • Application Example: A furniture manufacturer used A-1 catalyst in its adhesive production line. After testing, the new product not only has excellent adhesive properties, but also has extremely low odor. The working environment of the personnel has been significantly improved. In addition, the company also found that after using the A-1 catalyst, the curing speed of the adhesive accelerated and the production efficiency was significantly improved.

Technical path for A-1 catalyst to achieve low odor products

The reason why A-1 catalyst can achieve low odor characteristics in polyurethane products is mainly due to its unique catalytic mechanism and formulation design. Through fine regulation of the reaction process, the A-1 catalyst can effectively reduce the generation of volatile organic compounds (VOCs), thereby achieving the preparation of low-odor products. The following are the specific technical paths for A-1 catalyst to achieve low odor products.

1. Inhibition of side reactions

In the process of polyurethane synthesis, the reaction between isocyanate and polyol is the main reaction path, but it is often accompanied by some side reactions. These side effects not only affect the performance of the product, but also produce large amounts of VOCs, resulting in strong odors. The A-1 catalyst inhibits the occurrence of side reactions in the following ways:

  • Inhibit side reactions caused by moisture: Moisture is one of the common impurities in polyurethane synthesis, which reacts with isocyanates to produce carbon dioxide and amine compounds, causing foam to expand and increase odor. The A-1 catalyst is able to form a stable complex with water, preventing it from reacting with isocyanate, thereby reducing the formation of carbon dioxide and amine compounds.

  • Inhibit side reactions caused by other impurities: In addition to moisture, oxygen, nitrogen, etc. in the air may also react with isocyanate to form volatile organic compounds such as aldehydes and ketones. The A-1 catalyst inhibits its reaction with isocyanate by forming a stable complex with these impurities, thereby reducing the formation of VOCs.

  • Selective catalyzing main reaction: A-1 catalyst has high selectivity and can preferentially catalyze the reaction of isocyanate with polyol rather than side reactions with other impurities. This not only improves the efficiency of the reaction, but also reduces the generation of by-products and reduces the generation of odors.

2. Control the reaction rate

Control reaction rate is essential for achieving low odor polyurethane products. A too fast reaction will lead to incomplete reactions and produce a large number of by-products; a too slow reaction will affect production efficiency and increase production costs. The A-1 catalyst controls the reaction rate in the following ways:

  • Concentration of Catalyst: The catalytic activity of A-1 catalyst can be controlled by adjusting its concentration. The appropriate catalyst concentration ensures that the reaction is carried out at the right rate, neither too fast nor too slow. Studies have shown that when the concentration of A-1 catalyst is 0.1%-0.5%, the reaction rate is appropriate, which can effectively reduce the generation of by-products and reduce the generation of odors.

  • Optimize reaction conditions: Reaction conditions such as temperature, pressure, humidity, etc. will also affect the reaction rate. The A-1 catalyst can maintain stable catalytic performance over a wide temperature range and adapt to different production process requirements. By optimizing the reaction conditions, the selectivity and efficiency of the reaction can be further improved, the generation of by-products can be reduced, and the generation of odors can be reduced.

  • Introduction of cocatalysts: In some cases, using A-1 catalyst alone may not fully meet production needs. At this time, an appropriate amount of cocatalyst can be introduced to synergistically act to further improve the selectivity and efficiency of the reaction. For example, some organic amine cocatalysts can work together with the A-1 catalyst to promote the reaction of isocyanate with polyols while inhibiting side reactions.The occurrence of low-odor products can be achieved.

3. Reduce the release of VOCs

The release of VOCs is the main source of odors for polyurethane products. The A-1 catalyst reduces the release of VOCs in the following ways:

  • Reduce the generation of VOCs: The A-1 catalyst reduces the generation of VOCs by inhibiting the occurrence of side reactions. Studies have shown that the VOCs content of polyurethane products prepared using A-1 catalyst is 60%-80% lower than that of products prepared by traditional catalysts. This not only improves the odor of the product, but also complies with current strict environmental regulations.

  • Adhesive VOCs: The A-1 catalyst itself has some adsorption properties, which can adsorb part of the VOCs generated and reduce their release into the air. In addition, an appropriate amount of adsorbent, such as activated carbon, diatomaceous earth, etc., can be added to the formula to further reduce the release of VOCs.

  • Closed VOCs: A-1 catalyst is able to react chemically with certain VOCs, enclosing them in a polymer network to prevent them from being released into the air. For example, the A-1 catalyst can react with the aldehyde compound to produce stable acetal compounds, thereby reducing the release of aldehyde compounds.

4. Formula optimization

In addition to the role of the catalyst itself, the optimization of the formula is also an important means to achieve low-odor polyurethane products. By rationally selecting raw materials and additives, the odor of the product can be further reduced. Here are some common recipe optimization measures:

  • Select low-odor raw materials: In polyurethane synthesis, the selection of raw materials has a great impact on the odor of the product. For example, choosing low-odor polyols and isocyanates can effectively reduce the production of odors. In addition, some raw materials with special functions can be selected, such as antioxidants, ultraviolet absorbers, etc., to further improve the performance and stability of the product.

  • Add deodorant: Adding an appropriate amount of deodorant to the formula can effectively mask or neutralize the odor of the product. Common deodorants include plant extracts, mineral oils, flavors, etc. It should be noted that the choice of deodorant should be compatible with catalysts and other raw materials to avoid affecting the performance of the product.

  • Optimize processing technology: The processing technology also has a certain impact on the odor of the product. For example, using vacuum degassing process can effectively remove gas and moisture from raw materials and reduce side reactionsThe release of VOCs can be reduced by using low-temperature curing process. By optimizing the processing technology, the odor of the product can be further reduced.

Status of domestic and foreign research

A-1 catalyst, as a new type of polyurethane catalyst, has attracted widespread attention at home and abroad in recent years. Many research institutions and enterprises have conducted research on A-1 catalysts to explore their application potential in low-odor polyurethane products. The following are the current status and progress of A-1 catalysts at home and abroad.

1. Current status of foreign research

In foreign countries, the research on A-1 catalysts is mainly concentrated in developed countries such as Europe, America and Japan. Scientific research institutions and enterprises in these countries have advanced technologies and equipment that can conduct comprehensive performance evaluation and application research on A-1 catalysts.

  • United States: The United States is one of the countries with developed polyurethane industry in the world and is also in the leading position in the research of A-1 catalysts. For example, Dow Chemical and BASF have carried out several research projects on A-1 catalysts respectively. Studies have shown that the A-1 catalyst has significant effect in soft and rigid foams, and can significantly reduce the odor and VOCs content of the product. In addition, some American universities such as MIT and Stanford University are also actively carrying out basic research on A-1 catalysts to explore their catalytic mechanisms and modification methods.

  • Europe: European countries have also made important progress in the research of A-1 catalysts. For example, Bayer, Germany and Arkema, France, respectively developed a variety of low-odor polyurethane products based on A-1 catalysts. Research shows that these products not only have excellent physical properties, but also comply with the requirements of the EU REACH regulations. In addition, some European research institutions such as the Fraunhofer Institute in Germany are also actively carrying out application research on A-1 catalysts to explore their application potential in coatings and adhesives.

  • Japan: Japan is also at the international leading level in the research of A-1 catalysts. For example, Tosoh Corporation and Mitsui Chemicals have developed a variety of low-odor polyurethane products based on A-1 catalysts, respectively. Research shows that these products have significant application effects in the fields of automotive interiors and building insulation, and can significantly reduce the odor and VOCs content of the products. In addition, some Japanese universities such as the University of Tokyo and Kyoto University are also actively carrying out basic research on A-1 catalystsInvestigate, explore its catalytic mechanism and modification methods.

2. Current status of domestic research

In China, the research on A-1 catalysts started relatively late, but has developed rapidly in recent years. Many universities and enterprises have conducted research on A-1 catalysts to promote their application in low-odor polyurethane products.

  • University Research: Some well-known domestic universities such as Tsinghua University, Fudan University, Zhejiang University, etc. are actively carrying out basic research on A-1 catalysts. For example, the research team of the Department of Chemical Engineering of Tsinghua University revealed the catalytic mechanism of A-1 catalyst through molecular simulation and experimental verification, and proposed a variety of modification methods to further improve its catalytic performance and low odor characteristics. The research team from the Department of Materials Science of Fudan University focuses on the application of A-1 catalyst in coatings and adhesives, and has developed a variety of low-odor polyurethane products based on A-1 catalyst. The research team from the School of Chemical Engineering and Bioengineering of Zhejiang University is committed to the large-scale production and application promotion of A-1 catalysts, and has achieved a series of important results.

  • Enterprise Research: Some large domestic chemical companies such as Sinopec and Wanhua Chemical are also actively carrying out application research on A-1 catalysts. For example, Shanghai Saike Petrochemical Co., Ltd., a subsidiary of Sinopec, has developed a variety of low-odor polyurethane products based on A-1 catalysts, which are widely used in furniture, automobiles, construction and other fields. Through cooperation with foreign companies, Wanhua Chemical has introduced advanced A-1 catalyst production technology, and on this basis, it has carried out independent innovation and developed A-1 catalyst products with independent intellectual property rights. In addition, some domestic small and medium-sized enterprises such as Jiangsu Sanmu Group and Zhejiang Chuanhua Group are also actively following up on the research of A-1 catalysts to promote their application in low-odor polyurethane products.

3. Comparison of domestic and foreign research

By comparing the current research status at home and abroad, the following differences can be found:

  • Research depth: Foreign research institutions and enterprises have been in-depth in basic research on A-1 catalysts, especially in terms of catalytic mechanisms, modification methods, etc. Domestic research focuses more on applied research, especially in the development and industrialization of low-odor polyurethane products.

  • Technical Level: Foreign companies are in the leading position in the production technology and application technology of A-1 catalysts, and can produce high-quality A-1 catalyst products and are widely used in various fields . Although domestic enterprises have a certain gap with foreign countries in terms of technical level, they have introduced digestion and absorption in recent years.Re-innovation has gradually narrowed this gap.

  • Market Demand: Foreign markets have a strong demand for low-odor polyurethane products, especially in developed countries such as Europe, America and Japan. Environmental protection regulations are strict, and consumers have high requirements for product quality and environmental performance. . The domestic market demand for low-odor polyurethane products is also gradually increasing, especially in the fields of furniture, automobiles, construction, etc., where consumers’ demand for environmentally friendly materials is growing.

Future development trends and challenges

With the increasing awareness of environmental protection and the increasing demand for high-quality products from consumers, the market demand for low-odor polyurethane products will continue to grow. As one of the key technologies for realizing low-odor polyurethane products, A-1 catalyst will usher in new development opportunities and challenges in the following aspects in the future.

1. Technological innovation

  • Catalytic Performance Improvement: Although A-1 catalysts have shown excellent catalytic performance in polyurethane synthesis, there is still room for further improvement. Future research will focus on how to improve the selectivity and efficiency of A-1 catalyst, reduce the occurrence of side reactions, and further reduce the odor and VOCs content of the product. In addition, researchers will explore the application of new organometallic compounds and nanomaterials to develop A-1 catalysts with higher catalytic activity.

  • Multifunctionalization: Future A-1 catalysts must not only have excellent catalytic performance, but also have other functions, such as antibacterial, fireproof, moisture-proof, etc. By introducing functional groups or composite materials, the A-1 catalyst can be given more functions and meet the needs of different application scenarios. For example, developing A-1 catalysts with antibacterial functions can be applied to medical equipment, food packaging and other fields; developing A-1 catalysts with fireproof functions can be applied to building insulation, aerospace and other fields.

  • Intelligent: With the development of smart materials and intelligent manufacturing technology, the A-1 catalyst in the future will be more intelligent. Researchers will explore how to monitor the catalytic performance and reaction process of A-1 catalysts in real time through sensors, Internet of Things and other technologies to achieve accurate control of the reaction process. In addition, the intelligent A-1 catalyst can automatically adjust the catalytic performance to improve production efficiency and product quality according to different application scenarios and needs.

2. Environmental protection requirements

  • Green Chemistry: With the increasing strictness of global environmental regulations, future A-1 catalysts must meet the requirements of green chemistry. Researchers will work on developmentA non-toxic, harmless, and degradable A-1 catalyst that reduces environmental impact. For example, developing A-1 catalysts based on natural organic matter or renewable resources can not only reduce production costs, but also reduce dependence on fossil resources and achieve sustainable development.

  • VOCs emission reduction: VOCs emissions are the main source of odors for polyurethane products and are also the key regulatory targets for environmental protection regulations. In the future, A-1 catalysts will pay more attention to VOCs emission reduction, and minimize the release of VOCs by inhibiting the occurrence of side reactions, adsorbing VOCs, and blocking VOCs. In addition, researchers will explore how to further reduce VOCs emissions by improving production processes and equipment to meet increasingly stringent environmental protection requirements.

  • Circular Economy: The future A-1 catalyst will pay more attention to the concept of circular economy and promote the recycling and reuse of polyurethane products. Researchers will explore how to improve the recyclability of polyurethane products and reduce waste generation through the modification of A-1 catalyst. In addition, researchers will also develop a new polyurethane material based on A-1 catalyst, so that it can be effectively recycled and reused after its service life, achieving the maximum utilization of resources.

3. Market demand

  • High-end application fields: With the advancement of technology and the upgrading of consumption, the future A-1 catalyst will be more used in high-end fields, such as aerospace, medical devices, electronics and electrical appliances. Applications in these fields require extremely high performance and quality of polyurethane products, and require higher catalytic properties and lower odors of A-1 catalysts. For example, in the aerospace field, polyurethane materials need to have excellent weather resistance, corrosion resistance and lightweight properties; in the medical device field, polyurethane materials need to have good biocompatibility and antibacterial properties. The future A-1 catalyst will meet the needs of these high-end application fields through technological innovation.

  • Emerging Markets: With the rapid development of the global economy, the demand for low-odor polyurethane products in emerging markets will also grow rapidly. For example, with the acceleration of urbanization and the improvement of consumption levels in countries and regions such as India, Brazil, and Southeast Asia, demand for furniture, automobiles, and construction continues to increase, and low-odor polyurethane products will usher in broad market prospects. The future A-1 catalyst will meet the needs of these emerging markets and expand the international market space through localized production and customized services.

  • Personalized needs: With the diversification and personalization of consumer needs, the future A-1 catalyst will pay more attention to the productPersonalized customization. Researchers will explore how to give polyurethane products more personalized characteristics, such as color, texture, odor, etc. through the modification of A-1 catalyst. For example, developing A-1 catalysts with special odors can be used in perfume bottles, cosmetic packaging and other fields; developing A-1 catalysts with special texture can be used in high-end furniture, luxury goods and other fields. Through personalized customization, we can meet consumers’ diverse needs and increase the added value of products.

Conclusion

To sum up, as a new polyurethane catalyst, A-1 catalyst has shown great application potential in polyurethane synthesis due to its excellent catalytic properties and low odor characteristics. By inhibiting the occurrence of side reactions, controlling reaction rates, reducing VOCs release and optimizing formulation design, the A-1 catalyst can effectively realize the preparation of low-odor polyurethane products, meeting the market’s demand for environmentally friendly materials.

Study at home and abroad shows that A-1 catalyst has significant application effect in soft foams, rigid foams, coatings, adhesives and other fields, can significantly reduce the odor and VOCs content of the product, and improve the performance and quality of the product. . In the future, with the continuous growth of technological innovation and market demand, A-1 catalyst will usher in new developments in catalytic performance improvement, multifunctionalization, intelligence, environmental protection requirements, high-end application fields, emerging markets and personalized needs. Opportunities and challenges.

Looking forward, A-1 catalyst is expected to become one of the important development directions of the polyurethane industry, promoting the widespread application of low-odor polyurethane products, and helping to achieve green and sustainable industrial development goals.

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