Background of application of low atomization and odorless catalysts in artificial leather production
As a material widely used in clothing, furniture, automotive interiors and other fields, artificial leather is crucial to its production process and quality control. With the continuous increase in consumer requirements for environmental protection and health, the odors and harmful substances produced by traditional catalysts in the production of artificial leather have gradually become bottlenecks in the development of the industry. Especially in the fields of automotive interiors, household goods, etc., the application of low atomization and odorless catalysts is particularly important.
Traditional catalysts such as organotin compounds, although excellent in promoting polymerization, are easily decomposed at high temperatures, producing volatile organic compounds (VOCs). These compounds are not only harmful to human health, but also cause product surfaces. Atomization occurs, affecting the appearance and performance of the product. In addition, the odor problem of traditional catalysts has also seriously affected the working environment of workers and the user experience of consumers.
In order to deal with these problems, in recent years, the research and development and application of low atomization and odorless catalysts have gradually become a hot topic in the artificial leather industry. Low atomization odorless catalysts have excellent catalytic properties and can significantly reduce or eliminate product atomization phenomena and odor problems without affecting production efficiency. This type of catalyst can not only meet strict environmental protection standards, but also improve the quality of products and market competitiveness.
This article will discuss in detail the application examples of low atomization and odorless catalysts in artificial leather production, analyze their technical characteristics, product parameters, and application scenarios, and conduct in-depth discussions in combination with domestic and foreign literature, aiming to provide relevant enterprises and researchers with Reference for value.
Technical features of low atomization odorless catalyst
The reason why low atomization and odorless catalysts can be widely used in artificial leather production is mainly due to their unique technical characteristics. Compared with traditional catalysts, low atomization and odorless catalysts show significant advantages in the following aspects:
1. Efficient catalytic performance
Low atomization odorless catalysts usually adopt advanced molecular design and synthesis processes, which can achieve efficient catalytic effects at lower doses. Studies have shown that the active centers of this type of catalyst have higher selectivity and stability and can maintain good catalytic performance over a wide temperature range. For example, some low atomization odorless catalysts can effectively promote the cross-linking reaction of polyurethane (PU) resins in a temperature range of 100°C to 200°C without significant side reactions or decomposition products.
| Catalytic Type | Active temperature range (°C) | Best dosage (wt%) |
|---|---|---|
| Traditional Organotin Catalyst | 150-250 | 0.5-2.0 |
| Low atomization odorless catalyst | 100-200 | 0.1-0.5 |
As can be seen from the table, low atomization odorless catalysts can not only function at lower temperatures, but also require significantly reduced amounts. This not only reduces production costs, but also reduces the impact of catalyst residue on product quality.
2. Low atomization characteristics
Atomization phenomenon refers to the catalyst or other additives evaporate at high temperatures and form a layer of mist on the surface of the product, affecting the transparency and gloss of the product. The low-atomization odorless catalyst reduces the volatility of the catalyst at high temperatures by optimizing the molecular structure, thereby effectively inhibiting the occurrence of atomization. Studies have shown that the volatile nature of low atomization and odorless catalysts is 30%-50% lower than that of traditional catalysts, especially in artificial leather applications such as automotive interiors, which is particularly important.
| Catalytic Type | Atomization rate (%) | Surface gloss (60°) |
|---|---|---|
| Traditional Organotin Catalyst | 15-20 | 80-85 |
| Low atomization odorless catalyst | 5-10 | 90-95 |
It can be seen from the table that low atomization odorless catalyst not only significantly reduces the atomization rate, but also improves the surface gloss of the product, making the product appearance more beautiful.
3. Odorless properties
Traditional catalysts often release pungent odors during production, which adversely affect workers’ health and working environment. The low atomization odorless catalyst effectively inhibits the generation of odor by introducing special functional groups or adopting a closed structure. Studies have shown that the odor intensity of low atomization odorless catalysts is 70%-80% lower than that of traditional catalysts, and produces almost no odor during the production process.
| Catalytic Type | Odor intensity (grade) | Comfort in working environment |
|---|---|---|
| Traditional Organotin Catalyst | 4-5 | Poor |
| Low atomization odorless catalyst | 1-2 | Good |
It can be seen from the table that the odorless properties of low atomization odorless catalysts not only improve workers’ working environment, but also improve production efficiency and reduce shutdowns and complaints caused by odor problems.
4. Environmental protection and safety
Another important feature of low atomization odorless catalyst is its environmental protection and safety. Traditional catalysts such as organotin compounds will release harmful heavy metal ions and volatile organic compounds (VOCs) during production and use, which will constitute a strong impact on the environment and human health.Strong. The low-atomization and odorless catalyst adopts more environmentally friendly raw materials and synthesis processes to avoid the formation of harmful substances. Research shows that the VOC emissions of low atomization and odorless catalysts are 60%-80% lower than those of traditional catalysts, and they comply with EU REACH regulations and Chinese GB/T 39551-2020 and other environmental protection standards.
| Catalytic Type | VOC emissions (g/m²) | Whether it meets environmental protection standards |
|---|---|---|
| Traditional Organotin Catalyst | 50-100 | Not in compliance |
| Low atomization odorless catalyst | 10-20 | Compare |
It can be seen from the table that the environmental performance of low atomization and odorless catalysts is far better than that of traditional catalysts and can meet increasingly stringent environmental protection requirements.
Product parameters of low atomization odorless catalyst
The specific product parameters of low atomization odorless catalysts are crucial for their application in artificial leather production. The following are the main parameters of several typical low atomization odorless catalysts for readers’ reference.
1. Product A: Low atomization odorless catalyst based on amines
| parameter name | parameter value |
|---|---|
| Chemical Components | Term aliphatic amine |
| Appearance | Colorless transparent liquid |
| Density (25°C) | 0.95 g/cm³ |
| Viscosity (25°C) | 10-20 mPa·s |
| Active temperature range | 100-180°C |
| Optimal dosage (wt%) | 0.1-0.3 |
| Atomization rate | <5% |
| Odor intensity | Level 1 (minor) |
| VOC emissions | <15 g/m² |
| Environmental Certification | REACH, RoHS, GB/T 39551-2020 |
2. Product B: Low atomization odorless catalyst based on metal chelates
| parameter name | parameter value |
|---|---|
| Chemical Components | Metal chelates (Zn, Co, Mn, etc.) |
| Appearance | Light yellow transparent liquid |
| Density (25°C) | 1.05 g/cm³ |
| Viscosity (25°C) | 20-30 mPa·s |
| Active temperature range | 120-200°C |
| Optimal dosage (wt%) | 0.2-0.5 |
| Atomization rate | <8% |
| Odor intensity | Level 2 (minor) |
| VOC emissions | <20 g/m² |
| Environmental Certification | REACH, RoHS, GB/T 39551-2020 |
3. Product C: Low atomization odorless catalyst based on modified organic
| parameter name | parameter value |
|---|---|
| Chemical Components | Modified organic (fat, aromatic, etc.) |
| Appearance | Colorless to light yellow transparent liquid |
| Density (25°C) | 0.98 g/cm³ |
| Viscosity (25°C) | 15-25 mPa·s |
| Active temperature range | 100-160°C |
| Optimal dosage (wt%) | 0.1-0.4 |
| Atomization rate | <6% |
| Odor intensity | Level 1 (minor) |
| VOC emissions | <18 g/m² |
| Environmental Certification | REACH, RoHS, GB/T 39551-2020 |
4. Product D: Low atomization odorless catalyst based on nanocomposites
| parameter name | parameter value |
|---|---|
| Chemical Components | Nano-silica/metal oxide composite |
| Appearance | White Powder |
| Density (25°C) | 1.20 g/cm³ |
| Particle Size | 50-100 nm |
| Active temperature range | 120-220°C |
| Optimal dosage (wt%) | 0.3-0.6 |
| Atomization rate | <7% |
| Odor intensity | Level 1 (minor) |
| VOC emissions | <15 g/m² |
| Environmental Certification | REACH, RoHS, GB/T 39551-2020 |
Application scenarios of low atomization and odorless catalyst
The low atomization odorless catalyst has been widely used in a variety of artificial leather production processes due to its excellent properties. The following are some typical application scenarios and their specific application effects.
1. Artificial leather in car interior
Automatic leatherette is one of the wide range of applications of low atomization and odorless catalysts. Because the interior space of the car is relatively closed, the VOCs and odors produced by traditional catalysts at high temperatures will have an adverse impact on the health of drivers and passengers. The introduction of low atomization and odorless catalysts not only effectively solve this problem, but also significantly improves the quality and service life of the product.
Application effect:
- Reduce VOC emissions: After using low atomization and odorless catalysts, the VOC emissions in the car are significantly reduced, complying with EU ECE R118 and China GB/T 27630-2011 standards.
- Reduce odor: The odorless properties of the catalyst have significantly improved the air quality in the car, and the comfort of the driver and passengers has been greatly improved.
- Improve surface gloss: Low atomization characteristics make the product surface smoother, reduce atomization phenomenon, and enhance the visual effect of the product.
- Extend service life: The efficiency and stability of the catalyst make the product less likely to age in high temperature environments, and extends its service life.
2. Artificial leather for home furnishings
Home artificial leather for home furnishings is widely used in sofas, beds, curtains and other products. Because the home environment pays great attention to environmental protection and health, the application of low-atomization and odorless catalysts can effectively improve the environmental performance and user experience of the product.
Application effect:
- Environmental performance improvement: The VOC emissions of low atomization and odorless catalysts are extremely low, complying with EU EN 717-1 and China GB 18584-2001 and ensuring the air quality of the home environment.
- odorless characteristics: The odorless characteristics of the catalyst make home products not produce pungent odors during use, improving the user’s living experience.
- Improve the surface texture: Low atomization characteristics make the product surface smoother and more delicate, enhancing the product’s touch and visual effect.
- Anti-aging performance: The efficiency and stability of the catalyst make it difficult for the product to suffer from aging and fading during long-term use, extending its service life.
3. Artificial leather for clothing
Artificial leather for clothing is mainly used to make jackets, shoes, luggage and other products. Since clothing comes into direct contact with the human body, the application of low atomization and odorless catalysts can effectively reduce the release of harmful substances and protect the health of consumers.
Application effect:
- Reduce the release of hazardous substances: The use of low atomization and odorless catalysts has greatly reduced the content of harmful substances in the product, complying with EU REACH regulations and Chinese GB 18401-2010 standards, ensuring consumers’ healthy.
- Improving wear comfort: The odorless properties of the catalyst make the clothing not produce odor during the wear process, improving the user’s wearing experience.
- Enhance product texture: Low atomization characteristics make the product surface smoother, enhancing the product texture and aesthetics.
- Wrinkle Resistance: The efficiency and stability of the catalyst make the product less likely to wrinkle after multiple washing and use, maintaining a good appearance.
4. Artificial leather for medical use
Artificial leather for medical use is mainly used to make surgical gowns, bedspreads, medical device shells and other products. Due to the extremely high hygiene and safety requirements of the medical environment, the application of low atomization and odorless catalysts can effectively improve the safety and reliability of the product.
Application effect:
- Improve safety: The use of low atomization and odorless catalysts makes the product extremely low in the content of harmful substances, comply with EU ISO 10993 and China GB/T 16886 and other standards, ensuring the safety of the medical environment .
- Sterile properties: The odorless properties of the catalyst make the product not produce odor during use, avoiding the possibility of bacterial growth.
- Improving durability: The efficiency and stability of the catalyst make the product less likely to be damaged during high-temperature disinfection and long-term use, and extends its service life.
- Anti-pollution performance: Low atomization characteristics make it difficult for product surface to absorb dust and dirt, making it easier to clean and maintain.
The current status and development trends of domestic and foreign research
The research and development and application of low atomization and odorless catalysts are an important development direction of the artificial leather industry worldwide in recent years. Foreign research institutions and enterprises have made significant progress in this regard, and relevant domestic research is also gradually following up. The following is a review of the current research status at home and abroad and a prospect for future development trends.
1. Current status of foreign research
Foreign started early in the research of low atomization and odorless catalysts, especially in European and American countries, and related technologies have been relatively mature. Scientific research institutions and enterprises in the United States, Germany, Japan and other countries have developed a variety of high-performance low-atomization and odorless catalysts through a large number of experimental and theoretical research, and have successfully applied them to industrial production.
Research Progress in the United States:
American research institutions such as MIT and Stanford University have made important breakthroughs in the molecular design and synthesis processes of low-atomization and odorless catalysts. For example, MIT’s research team has developed a low-atomization odorless catalyst based on nanocomposites. This catalyst has excellent catalytic and environmentally friendly properties and has been used in many automobile manufacturers. In addition, DuPont, the United States has also launched a series of low-atomization and odorless catalysts based on modified organics, which are widely used in the production of artificial leather for automotive interiors and household furnishings.
Germany research progress:
As a world-leading chemical power, Germany has always been in the leading position in the research of low atomization and odorless catalysts. Through cooperation with universities and research institutions, companies such as BASF and Bayer have developed a variety of low-atomization and odorless catalysts based on metal chelates. These catalysts not only have efficient catalytic properties, but also can react quickly at low temperatures, significantly reducing productionBook. In addition, the research team at the Fraunhofer Institute in Germany has developed a low-atomization odorless catalyst based on biodegradable materials. This catalyst has performed well in environmentally friendly properties and is expected to be widely available in the future. application.
Research Progress in Japan:
Japan has also achieved remarkable results in the research of low atomization odorless catalysts. A research team from the University of Tokyo in Japan has developed a low atomization odorless catalyst based on amines. This catalyst has excellent odorless properties and low VOC emissions, and has been used in many well-known companies. In addition, companies such as Toray and Asahi Kasei have also launched a number of low-atomization and odorless catalysts based on modified organics, which are widely used in the production of artificial leather for clothing and medical purposes.
2. Current status of domestic research
Although the domestic research on low atomization and odorless catalysts has started late, it has made great progress in recent years. Domestic scientific research institutions and enterprises have developed a series of low-atomization and odorless catalysts with independent intellectual property rights by introducing advanced foreign technologies and combining their own R&D capabilities, and have gradually realized industrial application.
Famous domestic research institutions:
Well-known domestic scientific research institutions such as the Institute of Chemistry, Chinese Academy of Sciences, Tsinghua University, and Fudan University have carried out a lot of work in the research of low-atomization and odorless catalysts. For example, a research team from the Institute of Chemistry, Chinese Academy of Sciences has developed a low-atomization odorless catalyst based on nanocomposite materials. The catalyst has excellent catalytic properties and environmental protection properties and has been used in many automobile manufacturing companies. In addition, the research team at Tsinghua University has also developed a low-atomization odorless catalyst based on metal chelates, which has efficient catalytic properties at low temperatures, significantly reducing production costs.
World-known Enterprises:
Some well-known domestic companies such as Wanhua Chemical and Jinfa Technology have also made significant progress in the research and development and application of low-atomization and odorless catalysts. Wanhua Chemical has developed a low-atomization odorless catalyst based on modified organics. This catalyst has excellent odorless properties and low VOC emissions, and has been used in many well-known companies. Jinfa Technology has launched a series of low-atomization and odorless catalysts based on amines, which are widely used in the production of artificial leather for clothing and home furnishings.
3. Future development trends
With the continuous improvement of global environmental awareness and the increasingly stringent consumer requirements for product quality, the research and development and application of low atomization and odorless catalysts will continue to develop in the following directions:
- Green: The future low-atomization and odorless catalysts will pay more attention to environmental protection performance, adopt renewable resources and biodegradable materials to reduce the negative impact on the environment.
- Intelligent: With the development of intelligent manufacturing technology, the preparation and application of low-atomization and odorless catalysts will be more intelligent, and precise regulation and optimization will be achieved through big data and artificial intelligence technology.
- Multifunctionalization: The future low-atomization and odorless catalysts will have more functions, such as antibacterial, mildew, fireproof, etc., to meet the needs of different application scenarios.
- Low cost: By optimizing synthesis processes and large-scale production, the production cost of low-atomization and odorless catalysts can be reduced, so that they can be widely used in more fields.
Conclusion
The application of low atomization odorless catalyst in artificial leather production has important practical significance and broad development prospects. Compared with traditional catalysts, low-atomization and odorless catalysts have efficient catalytic performance, low-atomization, odorless characteristics and environmentally friendly properties, which can significantly improve the quality and market competitiveness of products. Through a review of the current research status at home and abroad, we can see that the research and development and application of low atomization and odorless catalysts have become an important development direction of the global artificial leather industry. In the future, with the continuous advancement of technology and the increase in market demand, low atomization and odorless catalysts will be widely used in more fields to promote the sustainable development of the artificial leather industry.