How to use low-odor catalyst DPA to optimize soft polyurethane foam production process: from raw material selection to finished product inspection

Catalog

Introduction
Overview of soft polyurethane foam
Introduction to DPA, a low-odor catalyst
Raw Material Selection
Production process optimization
Finished product inspection
Conclusion

1. Introduction

Soft polyurethane foam is widely used in furniture, automobiles, packaging and other fields. However, catalysts used in traditional production processes often produce irritating odors that affect the working environment and product quality. The emergence of the low-odor catalyst DPA provides a new way to solve this problem. This article will introduce in detail how to use DPA to optimize the production process of soft polyurethane foam, from raw material selection to finished product inspection, and comprehensively improve product quality.

2. Overview of soft polyurethane foam

Soft polyurethane foam is a material with high elasticity, good breathability and comfort. Its main components include polyols, isocyanates, catalysts, foaming agents and stabilizers. By adjusting the formulation and process parameters, foam products of different densities, hardness and resilience can be produced.

2.1 Main applications of soft polyurethane foam

Furniture: mattresses, sofas, seats
Car: Seats, headrests, armrests
Packaging: cushioning materials for precision instruments and electronic products

2.2 Production process of soft polyurethane foam

The production process of soft polyurethane foam mainly includes the following steps:

Raw Material Preparation
Mix
Foaming
Mature
Cutting
Finished product inspection

3. Introduction to DPA, a low-odor catalyst

Low odor catalyst DPA is a new type of organic amine catalyst with low volatility, low odor and high catalytic efficiency. Compared with traditional catalysts, DPA ensures catalytic effect while significantly reducing odor emissions during the production process and improving the working environment.

3.1 Main features of DPA

Low Volatility: Reduce odor emissions during production
High catalytic efficiency: shorten foaming time and improve production efficiency
Good stability: extend the shelf life and reduce raw material loss

3.2 Comparison between DPA and traditional catalysts

Features	DPA	Traditional catalyst
Volatility	Low	High
odor	Low	High
Catalytic Efficiency	High	Medium
Stability	High	Medium

4. Raw material selection

The selection of raw materials has an important influence on the performance and production process of soft polyurethane foam. The following are the selection criteria and suggestions for the main raw materials.

4.1 Polyol

Polyols are one of the main components of soft polyurethane foams, and their molecular weight and functionality directly affect the density and hardness of the foam.

parameters	Suggested Value
Molecular Weight	2000-6000
Stability	2-3
Hydroxynumber (mgKOH/g)	28-56

4.2 Isocyanate

Isocyanate is another major ingredient, and its type and amount affect the hardness and elasticity of the foam.

parameters	Suggested Value
Species	TDI, MDI
Doing (%)	40-60

4.3 Catalyst

The selection of catalyst directly affects the foaming rate and foam structure. As a low-odor catalyst, DPA has significant advantages.

parameters	Suggested Value
Species	DPA
Doing (%)	0.1-0.5

4.4 Foaming agent

The selection of foaming agent affects the density and breathability of the foam.

parameters	Suggested Value
Species	Water, physical foaming agent
Doing (%)	1-3

4.5 Stabilizer

The selection of stabilizer affects the uniformity and stability of the foam.

parameters	Suggested Value
Species	Silicon
Doing (%)	0.5-1.5

5. Production process optimization

Using the low-odor catalyst DPA to optimize the production process of soft polyurethane foam, you can start from the following aspects.

5.1 Mixed process optimization

The mixing process is one of the key steps in the production of soft polyurethane foam. Optimizing the mixing process can improve the uniformity of raw materials and reaction efficiency.

parameters	Suggested Value
Mixing speed (rpm)	1000-2000
Mixing time (s)	10-20
Temperature (℃)	20-30

5.2 Optimization of foaming process

The foaming process directly affects the structure and performance of the foam. Using DPA’s high catalytic efficiency can shorten foaming time and improve production efficiency.

parameters	Suggested Value
Foaming time (s)	60-120
Foaming temperature (℃)	30-40
Pressure (MPa)	0.1-0.2

5.3 Crafting process optimization

The maturation process is a key step after foam forming, affecting the final performance of the foam. Optimizing the maturation process can improve the stability and durability of the foam.

parameters	Suggested Value
Mature time (h)	24-48
Mature temperature (℃)	50-60
Humidity (%)	50-70

5.4 Cutting process optimization

The cutting process affects the dimensional accuracy and surface quality of the foam. Optimizing the cutting process can improve product yield and appearance quality.

parameters	Suggested Value
Cutting speed (m/min)	10-20
Cutting temperature (℃)	20-30
Tool Type	High-precision tool

6. Finished product inspection

Finished product inspection is an important part of ensuring the quality of soft polyurethane foam. The following are the main inspection items and recommended standards.

6.1 Physical performance inspection

Physical performance inspection includes indicators such as density, hardness, and resilience.

parameters	Suggested Standards
Density (kg/m³)	20-50
Hardness (N)	50-150
Resilience(%)	40-60

6.2 Chemical performance inspection

Chemical performance inspection includes indicators such as volatile organic compounds (VOC) content and formaldehyde content.

parameters	Suggested Standards
VOC content (mg/m³)	<100
Formaldehyde content (mg/kg)	<50

6.3 Environmental performance inspection

Environmental performance inspection includes indicators such as odor grade and durability.

parameters	Suggested Standards
Odor level	Level 1-2
Durability (times)	>10000

6.4 Appearance quality inspection

Appearance quality inspection includes indicators such as surface flatness and color uniformity.

parameters	Suggested Standards
Surface flatness (mm)	<1
Color uniformity	Alternate

7. Conclusion

By optimizing the production process of soft polyurethane foam using the low-odor catalyst DPA, it can significantly reduce odor emissions during the production process, improve the working environment, and improve the quality and production efficiency of the product. From raw material selection to finished product inspection, the optimization of each link has an important impact on the performance of the final product. I hope that the introduction of this article can provide valuable reference for relevant manufacturers and promote the sustainable development of the soft polyurethane foam industry.

Tag: How to optimize the production process of soft polyurethane foam using low-odor catalyst DPA: from raw material selection to finished product inspection

How to optimize the production process of soft polyurethane foam using low-odor catalyst DPA: from raw material selection to finished product inspection