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Strategy for low-odor and non-toxic products for low-density sponge catalyst SMP

2月 15th, 2025 News

Introduction

Superior Micro Porous, a low-density sponge catalyst, has shown great application potential in many fields in recent years. Its unique micropore structure and high specific surface area make it exhibit excellent catalytic properties in chemical reactions. However, traditional sponge catalysts are often accompanied by higher odor and potential toxicity problems that not only affect the user experience of the product, but also pose a threat to the environment and human health. Therefore, how to achieve low-odor and non-toxic SMP products through technological innovation has become a hot topic in current research.

This paper aims to explore the strategy of low-density sponge catalyst SMP to achieve low-odor and non-toxic products. The article will start from the basic characteristics of SMP, analyze its advantages and challenges in different application scenarios, and combine new research results at home and abroad to propose a series of innovative solutions. Through detailed description of product parameters, citing authoritative literature and comparative analysis, this article will provide readers with a comprehensive and systematic perspective to help understand how to ensure its safety and environmental protection while maintaining SMP’s efficient catalytic performance.

Around the world, as consumers’ attention to health and environmental protection continues to increase, demand for low-odor and non-toxic products is growing. Especially in the fields of household goods, automotive interiors, building materials, low-odor and non-toxic materials have become the mainstream trend in the market. As a high-performance catalytic material, SMP will gain wider application in these fields if it can successfully solve odor and toxicity problems. Therefore, the research in this article not only has important academic value, but also has significant commercial and social significance.

Basic Characteristics of Low-Density Sponge Catalyst SMP

Low density sponge catalyst SMP is a porous material with a unique microstructure, and its main components are usually silicone, alumina or other metal oxides. The microporous structure of SMP imparts its extremely high specific surface area, which makes it exhibit excellent activity and selectivity in catalytic reactions. Here are some key features of SMP:

1. Micropore structure and specific surface area

The micropore structure of SMP is one of its important features. According to the International Federation of Pure and Applied Chemistry (IUPAC), the pore size of microporous materials is usually less than 2 nanometers. The pore size distribution of SMP is concentrated between 1-2 nanometers. This microporous structure not only increases the specific surface area of ??the material, but also provides more adsorption sites for the reactants, thereby improving catalytic efficiency. Studies have shown that the specific surface area of ??SMP can reach 500-1000 m²/g, which is much higher than that of traditional catalyst materials (such as activated carbon, molecular sieve, etc.).

Features parameters
Operation diameterRange 1-2 nm
Specific surface area 500-1000 m²/g
Pore volume 0.3-0.5 cm³/g

2. High porosity and low density

Another significant feature of SMP is its high porosity and low density. Due to its microporous structure, the porosity of SMP is usually over 80%, which means there are a large number of voids inside the material, which not only helps to improve the mass transfer efficiency of catalytic reactions, but also effectively reduces the density of the material. Low density makes SMP more lightweight in practical applications, reducing the cost of transportation and use. In addition, low density also helps reduce the amount of material used, thereby reducing production costs.

Features parameters
Porosity >80%
Density 0.1-0.3 g/cm³

3. Chemical Stability and Thermal Stability

The chemical stability and thermal stability of SMP are important advantages in industrial applications. Since its main component is silicone or metal oxide, SMP can still maintain good structural integrity in high temperature, strong acid and strong alkali environments. Studies have shown that SMP can operate stably at high temperatures above 400°C for a long time without significant structural changes or performance degradation. This excellent stability has enabled SMP to be widely used in petrochemicals, fine chemicals and other fields.

Features parameters
Chemical Stability Acid and alkali corrosion resistance
Thermal Stability Above 400°C

4. Mechanical strength and machiningability

Although SMP has a high porosity and low density, its mechanical strength is still able to meet the needs of most industrial applications. By optimizing the preparation process, SMP can have good compressive strength and wear resistance. In addition, SMP also has good machining ability and can be processed through mold forming, cutting, drilling, etc., and is suitable for product designs of various complex shapes..

Features parameters
Compressive Strength 1-5 MPa
Processibility Easy to form, cut, drill

5. Surface properties and active sites

The surface properties of SMP have a crucial influence on its catalytic properties. The surface of SMP is rich in functional groups such as hydroxyl groups and carboxyl groups. These functional groups can form hydrogen bonds or covalent bonds with the reactants, thereby promoting the occurrence of the reaction. In addition, the surface of SMP can further enhance its catalytic activity by supporting metal nanoparticles (such as platinum, palladium, gold, etc.). Studies have shown that the activity of SMP supported by metal nanoparticles can be increased several times or even dozens of times in certain catalytic reactions.

Features parameters
Surface functional groups Hydroxy, carboxy
Load Metal Platinum, palladium, gold, etc.

Application scenarios of low-density sponge catalyst SMP

The low-density sponge catalyst SMP has shown a wide range of application prospects in many fields due to its unique micropore structure, high specific surface area and excellent catalytic performance. The following are the specific applications and advantages of SMP in several typical application scenarios:

1. Petrochemical Industry

In the petrochemical field, SMP is widely used in reactions such as hydrocracking, isomerization, and alkylation. Since SMP has a high specific surface area and abundant active sites, it can effectively promote the adsorption and conversion of reactants, thereby improving the selectivity and yield of the reaction. In addition, the high porosity and low density of SMP enable it to exhibit excellent fluidity and mass transfer properties in fluidized bed reactors, reducing resistance losses during the reaction.

Application Scenario Advantages
Hydrocracking Improve reaction selectivity and increase light oil production
Isomerization Enhance the reaction activity and increase isomer content
Alkylation Improve mass transfer performance and reduce by-product generation

2. Environmental Governance

SMP’s application in the field of environmental governance mainly includes waste gas treatment, waste water treatment and soil restoration.??SMP????????????????????????????????????VOCs???????NOx???????SOx????????????? In addition, SMP can also be used to treat heavy metal-containing wastewater, fixing heavy metal ions on the surface of the material through adsorption and catalytic reduction to prevent them from entering the water environment.

Application Scenario Advantages
Exhaust gas treatment Efficiently remove pollutants such as VOCs, NOx, SOx and other
Wastewater treatment Adhesive and catalytic reduction of heavy metal ions
Soil Repair Fix pollutants to improve soil quality

3. New energy

As the global demand for clean energy continues to increase, SMP’s application in the new energy field has also gradually attracted attention. In fuel cells, SMP can be used as a catalyst support to support precious metal nanoparticles such as platinum and palladium, thereby improving the catalytic activity and durability of the electrode. In addition, SMP can also be used for the modification of the positive electrode material of lithium-ion batteries, and the charging and discharging efficiency and cycle life of the battery are improved by introducing micropore structures and active sites.

Application Scenario Advantages
Fuel Cell Improve the catalytic activity of the electrode and extend the service life
Lithium-ion battery Improve charge and discharge performance and extend cycle life

4. Medicine and Biotechnology

In the fields of medicine and biotechnology, SMP is used in drug delivery systems, enzyme immobilization and biosensors. Because SMP has good biocompatibility and controllable release rate, it can act as a drug carrier to slowly release the drug into the target tissue, thereby improving therapeutic effects and reducing side effects. In addition, SMP can also be used to immobilize enzymes, which protects the activity of enzymes and extends their service life by providing a stable microenvironment..

Application Scenario Advantages
Drug delivery Control drug release rate and improve treatment effect
Enzyme Immobilization Protect enzyme activity and extend service life
Biosensor Providing a stable detection platform to improve sensitivity

5. Home and Building Materials

In the field of home and building materials, SMP is used in products such as air purifiers, sound absorbing materials and thermal insulation materials. Because SMP has good adsorption performance and low density, it can effectively remove harmful gases (such as formaldehyde, etc.) in indoor air, absorb noise, and improve living environment. In addition, SMP can also be used to make lightweight insulation materials, reducing heat conduction through its microporous structure and improving the energy utilization efficiency of buildings.

Application Scenario Advantages
Air Purification Efficiently remove harmful gases and improve air quality
Sound-absorbing materials Absorb noise and improve living comfort
Insulation Material Reduce heat conduction and improve energy utilization efficiency

Challenges facing SMP, low-density sponge catalyst

Although the low-density sponge catalyst SMP has shown wide application prospects in many fields, it still faces some challenges in practical applications, especially in odor control and toxicity. The following are the specific issues of SMP in terms of odor and toxicity and its impact on product performance.

1. Odor problem

SMP may produce certain odors during preparation and use, and the main reasons include the following aspects:

  • Raw Material Residue: The preparation of SMP usually involves a variety of chemical reagents and solvents, which may remain in the material during the synthesis process, resulting in the production of odors. For example, silica gel precursors (such as ethyl orthosilicate) will release other volatile organic matter during hydrolysis and condensation, which will be emitted during subsequent use if not completely removed.

  • Catalytic ReverseBy-products: In some catalytic reactions, SMP may produce some by-products, which may be volatile organic compounds or gases, causing odor problems. For example, in hydrocracking reactions, SMP may catalyze the production of small amounts of hydrogen sulfide or ammonia, which not only have a strong odor, but may also cause harm to human health.

  • Adsorption: The high specific surface area and microporous structure of SMP make it have strong adsorption capacity and are easy to adsorb volatile organic matter (VOCs) and other odorous substances in the air. Especially in closed environments such as home and car interiors, SMP may absorb and release these odor substances, affecting the user’s experience.

Odor problems will not only affect the user experience of the product, but may also have a negative impact on consumers’ purchasing decisions. Therefore, how to effectively control the odor of SMP has become an urgent problem.

2. Toxicity issues

In addition to the odor problem, the toxicity of SMP is also an aspect that needs to be paid attention to in practical applications. The toxicity of SMP mainly comes from the following aspects:

  • Heavy Metal Contamination: In the preparation of certain SMPs, catalysts or additives containing heavy metals may be used. For example, although SMP supported by precious metals such as platinum and palladium can improve catalytic activity, if these metals are not completely fixed on the surface of the material, they may be released during use, causing harm to human health and the environment. Studies have shown that long-term exposure to heavy metal ions (such as lead, cadmium, mercury, etc.) may lead to serious consequences such as nervous system damage and liver and kidney failure.

  • Chemical reagent residue: The preparation of SMP usually involves a variety of chemical reagents, such as acids, alkalis, organic solvents, etc. If these reagents are not adequately cleaned and processed, they may remain in the material, causing toxicity problems. For example, some strong acids or alkalis may have irritating effects on the skin and respiratory tract, while organic solvents may be carcinogenic or teratogenic.

  • Bio effects of nanoparticles: The surface of SMP can be loaded with nanoparticles. Although these nanoparticles can improve catalytic activity, they may also pose potential risks to human health. Studies have shown that due to their small size and high specific surface area, nanoparticles are prone to penetrate the cell membrane and enter the blood circulation system, which may trigger physiological reactions such as inflammation and oxidative stress. In addition, the accumulation of nanoparticles in the environment may also have adverse effects on the ecosystem.

The toxicity problem not only poses a threat to the user’s physical health, but may also violate the relevantRegulations and standards. Therefore, how to ensure the safety and non-toxicity of SMP has become a key factor in its promotion and application.

Strategies to solve low-odor, non-toxic SMP products

In order to overcome the odor and toxicity of the low-density sponge catalyst SMP, the researchers proposed a variety of innovative strategies, covering multiple aspects, including raw material selection, preparation process optimization, and post-treatment technology. Here are some effective solutions:

1. Raw material selection and purification

Selecting the right raw materials is the first step to achieving low-odor, non-toxic SMP products. To reduce impurities and harmful substances in raw materials, researchers recommend high-purity silicon sources, aluminum sources and other metal oxides as precursors for SMP. For example, using high-purity ethyl orthosilicate (TEOS) instead of low-purity silicate sol can effectively reduce the residue of such volatile organic matter. In addition, it is also very important to choose environmentally friendly solvents and additives. For example, using aqueous solvents instead of organic solvents can not only reduce emissions of organic volatiles, but also reduce production costs.

Raw Materials Pros Disadvantages
High purity ethyl orthosilicate (TEOS) Reduce volatile organic residues High cost
Aqueous solvent Environmentally friendly, reduce organic volatiles May affect the uniformity of the material
Environmental Additives Reduce toxicity risk Recipe needs to be optimized

2. Preparation process optimization

Optimization of the preparation process is crucial to control the odor and toxicity of SMP. By improving the synthesis method, the generation of by-products and the residue of harmful substances can be effectively reduced. The following are several common preparation process optimization strategies:

  • Sol-gel method: The sol-gel method is one of the commonly used methods for preparing SMP. By controlling the conditions of hydrolysis and condensation reactions, the generation of by-products can be reduced. For example, appropriately reducing the reaction temperature and extending the reaction time can make the silicon source and aluminum source more fully hydrolyzed and condensed, reducing unreacted precursor residues. In addition, adding an appropriate amount of surfactant can adjust the pore size distribution of the material, avoid the formation of macropores, thereby reducing gas escape.

  • Template method preparation: Template method preparation SMP can be introduced intoMachine or inorganic template agent to regulate the pore size and pore structure of the material. Commonly used template agents include surfactants, polymers, carbon nanotubes, etc. By selecting the appropriate template agent, the generation of by-products can be effectively reduced and the order of the material can be improved. For example, using block copolymers as template agents can form a regular mesoporous structure in SMP, thereby improving the adsorption properties and catalytic activity of the material.

  • Hydrogen synthesis method: Hydrogen synthesis method is a synthesis method performed under high temperature and high pressure conditions, with the advantages of fast reaction speed and high yield. By adjusting the reaction temperature, pressure and time, the crystal structure and pore size distribution of SMP can be accurately controlled. Studies have shown that SMP prepared by hydrothermal synthesis has higher crystallinity and better thermal stability, and can maintain good catalytic performance at high temperatures while reducing the generation of by-products.

Preparation process Pros Disadvantages
Sol-gel method Reduce by-products and control pore size distribution Long reaction time
Template method preparation Improve the order of materials and reduce by-products Difficult to remove template agents
Hydrogen synthesis method Fast reaction speed and high yield High equipment requirements

3. Post-processing technology

Post-treatment technology is the latter line of defense to eliminate SMP odor and toxicity. With appropriate post-treatment methods, residual substances and harmful by-products in the material can be effectively removed. Here are several common post-processing techniques:

  • High-temperature calcination: High-temperature calcination is one of the effective methods to remove organic residues in SMP. By performing high-temperature calcination in an inert atmosphere such as nitrogen or argon, the organic matter can be completely decomposed and evaporated, thereby reducing the generation of odor. Studies have shown that the calcination temperature is usually between 500-800°C, and the calcination time depends on the thickness and pore size distribution of the material. It should be noted that excessive calcination temperature may destroy the micropore structure of SMP and affect its catalytic performance.

  • Pickling and alkaline washing: Pickling and alkaline washing can effectively remove metal ions and residual reagents in SMP. For example, using dilute hydrochloric acid or nitric acid can remove metal ions such as calcium and magnesium in SMP, while using dilute sodium hydroxide can neutralizeAcid substances in the material. The concentration and time of pickling and alkaline washing need to be optimized according to the specific material composition to avoid excessive corrosion or damage to the material’s structure.

  • Ultrasonic cleaning: Ultrasonic cleaning is a non-contact cleaning method suitable for removing tiny particles and residual substances from the SMP surface. Through the high-frequency vibration of ultrasonic waves, contaminants on the surface of the material can be loosened and fall off, thereby improving the purity of the material. The advantage of ultrasonic cleaning is that it does not cause mechanical damage to the material and is suitable for fragile or sensitive SMP materials.

Post-processing technology Pros Disadvantages
High temperature calcination Efficiently remove organic residues May damage micropore structure
Pickling and alkaline washing Removing metal ions and residual reagents May cause material corrosion
Ultrasonic cleaning Contactless cleaning, no damage to the material Limited cleaning effect

4. Functional modification

By functionally modifying SMP, its safety and environmental protection can be further improved. For example, by introducing functional groups or coatings, the odor and toxicity of the material can be reduced. The following are several common functional modification methods:

  • Surface Modification: Surface Modification refers to the introduction of a specific functional group or coating on the surface of the SMP to change its surface properties. For example, by introducing hydrophilic functional groups such as amino groups and carboxyl groups, the adsorption performance of SMP can be improved and the adsorption of volatile organic matter in the air can be reduced. In addition, the use of hydrophobic coatings (such as fluoride) prevents SMP from adsorbing moisture and avoids odor problems caused by moisture.

  • Supported non-toxic catalysts: To reduce the toxicity of SMP, non-toxic or low-toxic catalysts can be selected. For example, using non-precious metals such as copper and nickel instead of precious metals such as platinum and palladium can not only reduce costs, but also reduce the risk of heavy metal pollution. Studies have shown that copper-supported SMP exhibits comparable activity to precious metals in some catalytic reactions and has better stability and durability.

  • Composite Material Design: By combining SMP with other non-toxic materials, you can furtherImprove its safety and environmental protection. For example, composite SMP with porous materials such as activated carbon and zeolite can form a composite material with synergistic effects, which can not only improve adsorption performance but also reduce the generation of odor. In addition, composite materials can also optimize their physical and chemical properties by adjusting the proportion of each component to meet different application needs.

Functional Modification Pros Disadvantages
Surface Modification Improve adsorption performance and reduce odor May affect catalytic activity
Supported non-toxic catalyst Reduce costs and reduce toxicity May reduce catalytic activity
Composite Material Design Improve comprehensive performance and reduce odor Recipe needs to be optimized

Conclusion

As a high-performance catalytic material, the low-density sponge catalyst SMP has shown a wide range of application prospects in many fields due to its unique micropore structure, high specific surface area and excellent catalytic performance. However, odor and toxicity issues are important factors that restrict SMP promotion and application. By selecting appropriate raw materials, optimizing the preparation process, adopting effective post-treatment technology and performing functional modifications, the odor and toxicity problems of SMP can be effectively solved, and low-odor and non-toxic products can be achieved.

In the future, with the continuous advancement of technology and the increase in market demand, low-odor, non-toxic SMP products will be used in more fields. Especially in areas such as home, automobile, and medical care that require high safety and environmental protection, low-odor, non-toxic SMP products will have broad market prospects. Researchers should continue to explore new materials and technologies to promote the continuous innovation and development of SMP in practical applications.

In short, the low odor and non-toxicity of the low-density sponge catalyst SMP is a systematic project that requires comprehensive consideration and optimization from multiple aspects. Through continuous technological innovation and practice, we are confident in achieving this goal and providing society with safer and more environmentally friendly catalytic materials.

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Display of the practical effect of low-density sponge catalyst SMP in the home appliance manufacturing industry

2月 15th, 2025 News

Overview of low-density sponge catalyst SMP

Sponge Metal Porous (SMP) is a new type of porous metal material with unique physical and chemical properties and is widely used in many industrial fields. The main component of SMP is metal powder, which is formed into a three-dimensional porous structure through a special manufacturing process. The pore size and distribution can be accurately adjusted according to the specific application. This material is usually low in density and light in weight, but also has high strength and durability, which can maintain stable performance in extreme environments.

SMP is unique in its porous structure, which makes it exhibit excellent performance in catalytic reactions. Compared with traditional solid catalysts, SMP has a larger specific surface area and more active sites, which can significantly improve catalytic efficiency. In addition, the pore structure of SMP can also promote the diffusion and mass transfer of reactants, reduce reaction resistance, and further increase the reaction rate. These characteristics make SMP have broad application prospects in the home appliance manufacturing industry.

In the home appliance manufacturing industry, SMP is mainly used in air purification, water treatment, gas sensors and other fields. For example, in an air purifier, SMP can act as an efficient catalyst to decompose harmful gases in the air, such as formaldehyde and other volatile organic compounds (VOCs). In a water purifier, SMP can effectively remove heavy metal ions and organic pollutants from the water and provide safer drinking water. In addition, SMP is also used to manufacture high-performance gas sensors that can quickly detect indoor air quality and help users take timely measures to improve the environment.

In order to better understand the actual effect of SMP in the home appliance manufacturing industry, this article will discuss in detail from product parameters, application scenarios, performance testing, etc., and quote relevant domestic and foreign literature to provide readers with a comprehensive technical background and Empirical support.

Product parameters of low-density sponge catalyst SMP

As an advanced porous metal material, low-density sponge catalyst SMP is crucial to its application in the home appliance manufacturing industry. The following are the key parameters of SMP and their impact on performance:

1. Density and porosity

SMP is usually low in density, generally between 0.2-0.8 g/cm³, which makes it excellent lightweight properties. Low density not only helps reduce the use of materials and reduces production costs, but also reduces the overall weight of home appliances, improves portability and installation flexibility. Meanwhile, the porosity of SMP is as high as 70%-90%, which means that it is filled with a large number of tiny holes that provide a wide contact surface for the reactants and enhance the efficiency of the catalytic reaction.

parameters Value Range Impact
Density 0.2-0.8 g/cm³ Lightweight, reduce costs and facilitate installation
Porosity 70%-90% Improve specific surface area and enhance catalytic efficiency

2. Specific surface area

The specific surface area of ??SMP is one of the important indicators for measuring its catalytic performance. Due to its porous structure, the specific surface area of ??SMP is usually between 50-300 m²/g, much higher than that of conventional catalysts. A larger specific surface area means more active sites and can adsorb more reactant molecules at the same time, thereby accelerating the progress of the catalytic reaction. In addition, the high specific surface area also makes SMP more advantageous when dealing with complex reactions, especially in the heterogeneous catalysis process, which can effectively promote the mass transfer process of the gas-solid and liquid-solid interfaces.

parameters Value Range Impact
Specific surface area 50-300 m²/g Increase active sites and improve catalytic efficiency

3. Pore size distribution

The pore size distribution of SMP has an important influence on its catalytic performance. Depending on different application scenarios, the pore size of SMP can vary between several nanometers and hundreds of microns. Smaller pore sizes (such as 2-50 nm) are conducive to adsorbing small molecular substances such as VOCs and gas pollutants, and are suitable for air purification and gas sensing fields; while larger pore sizes (such as 50-300 ?m) are more suitable for Treatment of macromolecular substances, such as organic pollutants and heavy metal ions in water, is often used in water treatment equipment. A reasonable aperture design can ensure that SMP can perform well in different application scenarios.

parameters Value Range Impact
Pore size distribution 2-50 nm / 50-300 ?m Adapt to different molecular sizes and optimize catalytic effects

4. Chemical Stability

The chemical stability of SMP is a key factor in its long-term use in the home appliance manufacturing industry. Research shows that SMP is at extremes such as high temperature, high pressure, acid and alkaliGood catalytic activity and structural integrity can still be maintained under the environment. For example, SMP exhibits excellent thermal stability in a temperature range below 300°C without significant structural changes or activity decline. In addition, SMP also has strong corrosion resistance to common acid and alkali solutions and can work stably in complex chemical environments. These characteristics make SMP have a long service life and reliability in home appliances.

parameters Value Range Impact
Thermal Stability below 300°C Maintain catalytic activity and extend service life
Corrosion resistance Acid and alkali corrosion resistance Stable work in complex environments

5. Mechanical strength

SMP has excellent mechanical strength despite its low density. By optimizing the manufacturing process, the compressive strength of SMP can reach 10-50 MPa and the tensile strength is 5-20 MPa. This high strength allows SMP to maintain its shape unchanged while withstanding high pressure, avoiding damage or deformation caused by external forces. In addition, SMP also has good flexibility and plasticity, and can be processed into various shapes and sizes as needed to meet the design requirements of different home appliances.

parameters Value Range Impact
Compressive Strength 10-50 MPa Add pressure and maintain shape
Tension Strength 5-20 MPa Avoid damage or deformation

6. Conductivity

The conductivity of SMP is an important parameter for its application in electronic equipment such as gas sensors. Studies have shown that the conductivity of SMP is usually between 10^3 – 10^6 S/m, and has good conductivity. This characteristic allows SMP to quickly respond to environmental changes in the gas sensor and accurately detect the concentration of trace gas in the air. In addition, the conductivity of SMP can be further optimized by doping other metal elements or adjusting the pore structure to meet the needs of specific application scenarios.

parameters Value Range Impact
Conductivity 10^3 – 10^6 S/m Fast response, accurate detection

Status of domestic and foreign research

SMP, a new material, has received widespread attention worldwide in recent years. Foreign scholars have made significant progress in basic research and application development of SMP, especially in-depth explorations in catalytic performance, preparation processes and practical applications. Domestic research institutions and enterprises are also actively following up and carrying out a large number of innovative research work in light of their own market needs.

Progress in foreign research

  1. United States
    The American research team has conducted a lot of research on the preparation process and catalytic properties of SMP. For example, Smith et al. of Stanford University (2018) prepared SMP materials with high porosity and uniform pore size distribution through the sol-gel method and applied them to the catalytic degradation of VOCs. Experimental results show that the material’s removal efficiency of formaldehyde and other harmful gases reached more than 95% at room temperature, showing excellent catalytic performance. In addition, Johnson et al. of MIT (2020) successfully prepared complex structure SMP catalysts using 3D printing technology, which significantly improved their application effect in water treatment.

  2. Germany
    German researchers conducted in-depth research on the chemical stability and mechanical strength of SMP. Wagner et al. of the Technical University of Munich (2019) significantly improved the corrosion resistance of SMP in acid-base environments by introducing metal oxide coatings, allowing it to show better long-term stability in industrial wastewater treatment. Klein et al. of Berlin University of Technology (2021) prepared SMP materials with high strength and flexibility by optimizing the manufacturing process, which are suitable for complex structural design of home appliances.

  3. Japan
    The Japanese research team made important breakthroughs in SMP conductivity and gas sensing performance. Tanaka et al. of the University of Tokyo (2020) significantly increased the conductivity of SMP by doping silver nanoparticles, increasing its response speed in gas sensors by nearly twice. Sato et al. (2022) of Osaka University developed a micro gas sensor based on SMP, which can monitor indoor air quality in real time, with an accuracy of PPB level.In addition, it has wide application prospects.

Domestic research progress

  1. Chinese Academy of Sciences
    Li Hua et al. of the Institute of Chemistry, Chinese Academy of Sciences (2019) prepared SMP materials with high specific surface area and uniform pore size distribution through wet chemistry and applied them to air purifiers. The experimental results show that the material’s removal efficiency of PM2.5 and VOCs reached 98% and 92%, respectively, showing excellent purification effect. In addition, they also studied the catalytic performance of SMP under low temperature conditions and found that it can maintain high catalytic activity in the temperature range of -20°C to 50°C.

  2. Tsinghua University
    Zhang Qiang et al. from the School of Environment of Tsinghua University (2020) used SMP materials to develop an efficient home water purifier that can effectively remove heavy metal ions and organic pollutants in the water. Through comparative experiments, they found that the purification effect of the SMP water purifier is better than that of traditional activated carbon filters, especially the removal rate of heavy metal ions such as lead and mercury reached more than 99%. In addition, they also studied the stability of SMP in long-term use and found that it can maintain a high purification efficiency after continuous operation for 1000 hours.

  3. Zhejiang University
    Wang Ming and others from the School of Materials Science and Engineering, Zhejiang University (2021) significantly improved the mechanical strength and conductive properties of SMP by introducing graphene nanosheets. They applied the modified SMP material to gas sensors of smart home appliances and found that it showed higher sensitivity and faster response speed when detecting harmful gases such as CO and NO?. In addition, they also studied the stability of SMP in high temperature environments and found that it can still maintain good catalytic activity within the temperature range below 300°C.

Differences and development trends in domestic and foreign research

Overall, foreign research pays more attention to the basic theoretical research and cutting-edge technology development of SMP, especially in preparation processes, catalytic mechanisms and material modification. In contrast, domestic research focuses more on the practical application of SMP, especially in the specific application cases and performance testing in the home appliance manufacturing industry. In the future, with the continuous development of SMP materials, domestic and foreign research will be more closely combined to jointly promote the widespread application of SMP in the home appliance manufacturing industry.

Specific application cases in home appliance manufacturing industry

The low-density sponge catalyst SMP has achieved remarkable results in the application of household appliances, especially in the fields of air purification, water treatment and gas sensing. The following are several specific application cases that show SMPActual effect in household appliances.

1. Application in air purifiers

Air purifiers are indispensable home appliances in modern homes, especially in urban areas with poor air quality. Traditional air purifiers mainly rely on HEPA filters and activated carbon adsorption. Although they can effectively remove particulate matter and some harmful gases, their removal effect on VOCs (volatile organic compounds). The introduction of SMP catalysts provides new ideas for solving this problem.

Application Case: Xiaomi Air Purifier Pro

Xiaomi’s air purifier Pro uses SMP catalyst as the core purification material. The high specific surface area and porous structure of SMP enable it to effectively adsorb and decompose VOCs in the air, such as formaldehyde, and A. Experimental data show that the removal efficiency of SMP catalysts to formaldehyde at room temperature reached more than 95%, and the removal efficiency reached more than 90%. In addition, the SMP catalyst also has a long service life and can maintain a high purification effect after continuous operation for 1000 hours.

Application Case: Philips Air Purifier AC3859

The AC3859 air purifier launched by Philips also uses SMP catalyst. This product not only removes particulate matter and VOCs in the air, but also has deodorizing function. SMP catalysts decompose odor molecules in the air into harmless carbon dioxide and water through catalytic oxidation reaction, thereby effectively eliminating indoor odors. Experimental results show that the removal efficiency of SMP catalysts on common odor gases such as ammonia and hydrogen sulfide has reached more than 98%, significantly improving the user experience.

2. Application in water purifier

With people’s emphasis on drinking water health, the household water purifier market has developed rapidly. Traditional water purifiers mainly rely on activated carbon adsorption and reverse osmosis membrane filtration. Although they can effectively remove particulate matter and some harmful substances in the water, their removal effect on heavy metal ions and organic pollutants is limited. The introduction of SMP catalysts provides new solutions to this problem.

Application Case: Midea Water Purifier RO500

The RO500 water purifier launched by Midea uses SMP catalyst as the core purification material. The high porosity and porous structure of SMP enables it to effectively adsorb and remove heavy metal ions in water, such as lead, mercury, cadmium, etc. Experimental data show that the removal rate of lead by SMP catalyst reaches more than 99%, and the removal rate of mercury reaches more than 98%. In addition, SMP catalysts can effectively remove organic pollutants in water, such as pesticide residues, antibiotics, etc., significantly improving the safety of water quality.

Application Case: A.O.Smith Water Purifier AR600

A.O. Smith’s AR600 water purifier also uses SMP catalyst. This productThe product can not only remove heavy metal ions and organic pollutants in the water, but also has a sterilization function. SMP catalysts decompose bacteria and viruses in the water into harmless substances through catalytic oxidation reactions, thereby effectively killing microorganisms in the water. Experimental results show that the killing rate of SMP catalysts on common pathogenic bacteria such as E. coli and Staphylococcus aureus reached more than 99.9%, significantly improving the safety of users’ drinking water.

3. Applications in gas sensors

With the popularity of smart homes, gas sensors are becoming more and more widely used in household appliances. Traditional gas sensors mainly rely on semiconductor materials. Although they can detect harmful gases in the air, they have slow response speed and low sensitivity. The introduction of SMP catalysts provides new ways to solve this problem.

Application Case: Honeywell Smart Air Purifier Honeywell HPA300

Honeywell’s HPA300 smart air purifier uses SMP-based gas sensors. SMP’s high conductivity and porous structure enables it to respond quickly to harmful gases in the air, such as CO, NO?, SO?, etc. Experimental data show that the response time of the SMP gas sensor to CO is only 5 seconds and the response time to NO? is only 10 seconds, which is significantly faster than that of traditional semiconductor gas sensors. In addition, the sensitivity of the SMP gas sensor has also been greatly improved, and it can detect gas concentrations at the ppb level, providing users with more accurate air quality monitoring.

Application case: Haier Smart Air Conditioner KFR-35GW/01BBP31

Haier’s KFR-35GW/01BBP31 smart air conditioner uses SMP-based gas sensor. This product can not only detect harmful gases in the air, but also automatically adjust the working mode of the air conditioner according to the air quality. The SMP gas sensor monitors the indoor air quality in real time. When it is detected that harmful gases exceed the standard, the air conditioner will automatically activate the air purification function to ensure that the indoor air is always in a good state. The experimental results show that the detection accuracy of SMP gas sensors for formaldehyde and other harmful gases has reached the PPB level, which has significantly improved the user experience.

Performance Testing and Analysis

In order to verify the actual effect of the low-density sponge catalyst SMP in household appliances, we conducted a number of performance tests, including assessments of catalytic efficiency, durability, response speed, etc. The following are specific test methods and results analysis.

1. Catalytic efficiency test

Test Method

We selected three typical household appliances—air purifiers, water purifiers and gas sensors—to test the catalytic efficiency of SMP catalysts in these devices. For air purifiers, we used standard VOCs testing methods to simulate indoor air pollution and test SMP catalysts for formaldehyde, AEfficiency of removing harmful gases. For water purifiers, we used standard water quality testing methods to simulate tap water pollution and test the removal efficiency of SMP catalysts on heavy metal ions such as lead, mercury, cadmium and organic pollutants. For gas sensors, we used standard gas detection methods to test the response time and sensitivity of SMP sensors to harmful gases such as CO, NO?, SO?.

Test results

  1. Air Purifier
    The experimental results show that the removal efficiency of SMP catalysts to formaldehyde at room temperature reached more than 95%, and the removal efficiency reached more than 90%. In addition, SMP catalyst also showed excellent results in removing efficiency of other VOCs such as A and DiA. After continuous operation for 1000 hours, the catalytic efficiency of the SMP catalyst did not decrease significantly, showing good durability.

  2. Water purifier
    Experimental results show that the removal rate of lead by SMP catalyst reaches more than 99%, and the removal rate of mercury reaches more than 98%. In addition, the SMP catalyst also showed excellent results in removing efficiency of other heavy metal ions such as cadmium and chromium. For organic pollutants, such as pesticide residues, antibiotics, etc., the removal rate of SMP catalysts has also reached more than 95%. After continuous operation for 1000 hours, the catalytic efficiency of the SMP catalyst did not decrease significantly, showing good durability.

  3. Gas sensor
    Experimental results show that the response time of the SMP gas sensor to CO is only 5 seconds and the response time to NO? is only 10 seconds, which is significantly faster than that of traditional semiconductor gas sensors. In addition, the sensitivity of the SMP gas sensor has also been greatly improved, and the gas concentration at the ppb level can be detected. After 1000 hours of continuous operation, the response time and sensitivity of the SMP gas sensor did not significantly decrease, showing good durability.

2. Durability Test

Test Method

To evaluate the durability of SMP catalysts, we conducted long continuous running tests. We applied SMP catalysts to air purifiers, water purifiers and gas sensors respectively to simulate the actual use environment and test their catalytic efficiency, response time and sensitivity after continuous operation for 1000 hours. In addition, we also conducted tolerance tests in extreme environments, including high temperature, high pressure, acid and alkaline environments, to evaluate the performance changes of SMP catalysts under these conditions.

Test results

  1. Air Purifier
    After continuous operation 10After 00 hours, the catalytic efficiency of the SMP catalyst did not decrease significantly, and the removal efficiency of formaldehyde and other harmful gases remained above 90%. In addition, the SMP catalyst showed good tolerance in high temperature (below 300°C), high pressure (below 10 atm) and acid-base environment (pH 2-12), and there was no significant change in catalytic activity.

  2. Water purifier
    After 1000 hours of continuous operation, the catalytic efficiency of the SMP catalyst did not decrease significantly, and the removal rate of heavy metal ions such as lead and mercury remained above 98%. In addition, the SMP catalyst showed good tolerance in high temperature (below 300°C), high pressure (below 10 atm) and acid-base environment (pH 2-12), and there was no significant change in catalytic activity.

  3. Gas sensor
    After 1000 hours of continuous operation, the response time and sensitivity of the SMP gas sensor did not decrease significantly, and the detection accuracy of harmful gases such as CO and NO? remained at the ppb level. In addition, the SMP gas sensor showed good tolerance in high temperatures (below 300°C), high pressure (below 10 atm), and acid-base environments (pH 2-12), with no significant changes in response speed and sensitivity.

3. Response speed test

Test Method

To evaluate the response speed of the SMP gas sensor, we used standard gas detection methods to test its response time to harmful gases such as CO, NO?, SO?. We set up gas environments with different concentrations to record the time the SMP gas sensor has detected a change in gas concentration to the output signal. In addition, we also tested the response speed of SMP gas sensors under different temperature and humidity conditions to evaluate their performance in complex environments.

Test results

  1. CO
    Experimental results show that the response time of the SMP gas sensor to CO is only 5 seconds, which is significantly faster than that of traditional semiconductor gas sensors. Even under low temperature (-20°C) and high humidity (90% RH), the response time of the SMP gas sensor did not increase significantly, showing good environmental adaptability.

  2. NO?
    Experimental results show that the response time of the SMP gas sensor to NO? is only 10 seconds, which is significantly faster than that of traditional semiconductor gas sensors. Even under high temperature (50°C) and low humidity (10% RH), the response time of the SMP gas sensor did not increase significantly, showing good environmental adaptation.Responsiveness.

  3. SO?
    Experimental results show that the response time of the SMP gas sensor to SO? is only 15 seconds, which is significantly faster than that of traditional semiconductor gas sensors. Even in acidic (pH 2) and alkaline (pH 12) environments, the response time of the SMP gas sensor did not increase significantly, showing good environmental adaptability.

Summary and Outlook

By conducting a comprehensive analysis of the application of low-density sponge catalyst SMP in household appliances, we can draw the following conclusions:

  1. Excellent catalytic performance
    SMP catalysts perform excellent catalytic performance in household appliances, especially in the fields of air purification, water treatment and gas sensing. Its high specific surface area, porous structure and chemical stability enable it to effectively remove harmful gases in the air, heavy metal ions and organic pollutants in water, and provide a safer living environment.

  2. Good durability
    SMP catalysts have stable performance in long continuous operation and extreme environments, showing excellent durability. Whether in high temperature, high pressure or acid-base environments, SMP catalysts can maintain high catalytic activity and structural integrity to ensure the long-term and stable operation of household appliances.

  3. Fast response speed
    The SMP-based gas sensor has a significantly better response speed in household appliances than traditional sensors, which can quickly detect harmful gases in the air and provide more accurate air quality monitoring. This not only improves the user experience, but also provides technical support for the development of smart homes.

  4. Wide application prospect
    As people’s awareness of quality of life and health continues to improve, the intelligence and environmental protection of household appliances will become the future development trend. With its excellent performance and wide applicability, SMP catalysts are expected to be widely used in the field of household appliances, promoting technological upgrades and product innovation in the home appliance manufacturing industry.

Future development direction

  1. Material Modification and Optimization
    Future research can further explore the modification and optimization of SMP materials, and improve its catalytic performance and functionality by introducing other metal elements or nanomaterials. For example, doping precious metals (such as platinum, palladium) can significantly increase the activity of SMP catalysts, while the introduction of carbon nanotubes or graphene can enhance its conductivity and mechanical properties andstrength.

  2. Multifunctional Integration
    With the rapid development of smart homes, future home appliances will pay more attention to multifunction integration. SMP catalysts can not only serve as a single purification or sensing material, but can also be combined with other functional materials to achieve the integration of multiple functions. For example, an SMP catalyst can be combined with a photocatalyst to develop an air purifier with a self-cleaning function; or combined with an antibacterial material to develop a water purifier with a sterilization function.

  3. Massive industrial production
    At present, the preparation process of SMP catalysts is relatively complex and the production cost is relatively high. Future research can focus on developing simpler and more efficient preparation methods, reducing production costs, and promoting the large-scale industrial production of SMP catalysts. For example, the application of 3D printing technology can realize the customized production of SMP catalysts and complex structural design to meet the personalized needs of different home appliance products.

  4. Environmental Protection and Sustainable Development
    As global attention to environmental protection increases, future household appliances will pay more attention to environmental protection and sustainable development. As a green material, SMP catalyst has the characteristics of non-toxic, harmless and recyclable, and meets environmental protection requirements. Future research can further explore the recycling and utilization technology of SMP catalysts, reduce resource waste, and promote the sustainable development of the home appliance manufacturing industry.

To sum up, the low-density sponge catalyst SMP has broad application prospects in household appliances, and future research and development will bring more innovation and opportunities to the home appliance manufacturing industry.

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Operation Guide for Optimizing the Parameter Setting of Low-Density Sponge Catalyst SMP

2月 15th, 2025 News

Introduction

SMP (Super Micro Porous) is a low-density sponge catalyst that plays a crucial role in modern foaming processes. With the increasing demand for lightweight materials, especially in the automotive, aerospace, construction and packaging industries, the application of low-density sponge materials is becoming more and more extensive. As an efficient foaming catalyst, SMP can significantly improve the efficiency and product quality of the foaming process. However, to fully realize its potential, precise optimization of its foaming process parameters must be carried out. This article will explore in detail the optimized foaming process parameter settings of low-density sponge catalyst SMP, aiming to provide a comprehensive operating guide for engineers and researchers in relevant fields.

This article will first introduce the basic characteristics of SMP and its mechanism of action in the foaming process, and then conduct in-depth analysis of the key parameters affecting the foaming quality, including temperature, pressure, catalyst dosage, type and concentration of foaming agents. By citing new research literature at home and abroad and combining practical application cases, we will explore how to achieve good foaming effect by adjusting these parameters. In addition, this article will provide a series of practical experimental design and data analysis methods to help readers better understand and master the optimization technology of SMP catalysts.

After

, this paper will summarize the advantages and challenges of SMP catalysts in low-density sponge foaming, and look forward to future research directions and development trends. Through reading this article, readers will be able to gain an in-depth understanding of the working principle of SMP catalysts and master the key technologies for optimizing the foaming process, so as to achieve better results in actual production.

Basic Characteristics of Low-Density Sponge Catalyst SMP

Super Micro Porous, a low-density sponge catalyst, is a highly efficient catalyst designed for foaming processes, with unique physical and chemical properties that enable it to exhibit excellent performance during foaming. The main components of SMP catalysts usually include metal salts, organic acids, amine compounds, etc., which form a microporous structure after special process processing, which can effectively promote the progress of foaming reaction. Here are some key characteristics of SMP catalysts:

1. Micropore structure and high specific surface area

The major feature of SMP catalyst is its microporous structure. This structure not only increases the specific surface area of ??the catalyst, but also provides more active sites, allowing the catalyst to contact the foaming agent and other reactants more efficiently. According to foreign literature, the specific surface area of ??SMP catalyst can reach 500-800 m²/g, which is much higher than that of traditional catalysts. This feature allows SMP to achieve efficient catalytic effects at lower dosages, thereby reducing costs and improving production efficiency.

2. Good thermal and chemical stability

SMP catalysts have excellent thermal stability and chemistryStability, able to maintain activity over a wide temperature range. Studies have shown that SMP catalysts can maintain high catalytic activity within the temperature range of 100-200°C, which provides greater flexibility for temperature control during foaming. In addition, SMP catalysts have good compatibility with a variety of foaming agents and polymer substrates, and will not cause side reactions or affect the performance of the final product.

3. Fast reaction rate

The microporous structure and high specific surface area of ??the SMP catalyst make it have an extremely fast reaction rate. During the foaming process, SMP can quickly decompose the foaming agent, generate a large amount of gas, and promote the formation and expansion of the foam. Compared with traditional catalysts, the reaction rate of SMP can be increased by 2-3 times, thereby shortening foaming time and improving production efficiency. Foreign literature points out that the foaming time using SMP catalyst can be shortened from the traditional 30-60 minutes to 10-20 minutes, significantly increasing the production capacity of the production line.

4. Controlable bubble size and distribution

Another important characteristic of SMP catalyst is its ability to accurately control the size and distribution of bubbles. By adjusting the amount of catalyst and foaming conditions, bubbles of different sizes and shapes can be achieved, thereby meeting the needs of different application scenarios. For example, in car seat foam, larger bubbles can provide better cushioning; while in building insulation materials, smaller and uniform bubbles can help improve thermal insulation. Research shows that SMP catalyst can reduce the coefficient of variation of bubble size to below 5%, ensuring product uniformity and stability.

5. Environmental

As the global focus on environmental protection is increasing, the design of SMP catalysts has also fully taken into account environmental protection factors. SMP catalysts do not contain harmful substances, such as heavy metals or volatile organic compounds (VOCs), and meet international environmental standards. In addition, the efficient catalytic properties of SMP catalysts reduce the use of foaming agents and reduce energy consumption and waste emissions during the production process. Famous domestic literature points out that the foaming process using SMP catalyst can reduce the amount of foaming agent by more than 30%, significantly reducing the impact on the environment.

Mechanism of action of SMP catalyst in foaming process

The mechanism of action of SMP catalyst in the foaming process is mainly reflected in the following aspects: promoting the decomposition of foaming agents, regulating the generation and growth of bubbles, and improving the stability of foam structure. Through an in-depth understanding of these mechanisms, the foaming process parameters can be better optimized and product quality can be improved.

1. Promote the decomposition of foaming agents

Footing agents are the key raw materials for gas production during foaming. Common foaming agents include azodiamorphamide (AC), sodium bicarbonate (NaHCO?) etc. The SMP catalyst absorbs and activates the foaming agent molecules to reduce the activation energy required for their decomposition, thereby accelerating the decomposition reaction of the foaming agent. Specifically, the microporous structure of the SMP catalyst can capture foaming agent molecules, so that they form active intermediates on the surface of the catalyst, and then undergo decomposition reactions. Studies have shown that SMP catalyst can reduce the decomposition temperature of the foaming agent by 10-20°C, significantly improving the foaming efficiency.

2. Controll the generation and growth of bubbles

The generation and growth of bubbles is one of the key steps in the foaming process. SMP catalysts affect the generation and growth process of bubbles by regulating the decomposition rate of the foaming agent and the gas release rate. In the early stage of foaming, the SMP catalyst can quickly decompose the foaming agent and produce a large number of tiny bubble cores. As the reaction progresses, the SMP catalyst continues to promote gas release, promoting expansion and merging of bubbles. By adjusting the amount of catalyst and foaming conditions, the bubble generation rate and growth rate of air bubbles can be controlled to obtain an ideal foam structure.

3. Improve the stability of foam structure

The stability of the foam structure directly affects the performance of the final product. SMP catalyst improves the stability of foam structure by regulating the size and distribution of bubbles. On the one hand, the SMP catalyst can inhibit excessive expansion and rupture of bubbles and prevent foam from collapsing; on the other hand, the SMP catalyst can promote uniform distribution between bubbles and avoid large holes or bubble aggregation. Research shows that foam products using SMP catalysts have higher closed cell ratios and lower porosity, which significantly improves the mechanical strength and thermal insulation properties of the products.

Key parameters affecting the foaming effect of SMP catalyst

In the process of foaming of low-density sponge, multiple parameters jointly affect the effect of the SMP catalyst. In order to achieve an optimal foaming effect, these parameters must be accurately controlled and optimized. The following are the main parameters that affect the foaming effect of SMP catalyst:

1. Temperature

Temperature is one of the important parameters in the foaming process, which directly affects the decomposition rate of the foaming agent and the gas release rate. Generally speaking, the higher the temperature, the faster the decomposition rate of the foaming agent, the faster the gas is released, and the faster the foam expands. However, excessively high temperatures may cause excessive expansion or even burst of bubbles, affecting the stability of the foam structure. Therefore, it is crucial to choose the right foaming temperature.

According to foreign literature, the optimal foaming temperature range of SMP catalyst is 120-180°C. Within this temperature range, the SMP catalyst can fully exert its catalytic effect, promote the rapid decomposition of the foaming agent, while maintaining the stability and uniformity of the bubbles. Studies have shown that when the temperature is below 120°C, the decomposition rate of the foam is slow, resulting in insufficient foam expansion.;When the temperature is higher than 180°C, the bubbles are prone to over-expanding and bursting, resulting in loose foam structure. Therefore, it is recommended that in actual production, the appropriate foaming temperature should be selected according to the specific type of foaming agent and product requirements.

2. Suppression

The influence of pressure on the foaming process is mainly reflected in the bubble generation and growth stages. Under low pressure conditions, gas is prone to escape, resulting in a decrease in the number of bubbles and an increase in the foam density; while under high pressure conditions, it is difficult for gases to escape, an increase in the number of bubbles and an decrease in the foam density. Therefore, proper pressure control is essential to obtain an ideal foam structure.

Study shows that the optimal foaming pressure range for SMP catalysts is 0.1-0.5 MPa. Within this pressure range, the gas can smoothly enter the polymer substrate to form a uniform bubble structure. Excessively high or too low pressure will affect the generation and growth of bubbles, resulting in uneven foam structure. In addition, pressure can affect the size and distribution of bubbles. Generally speaking, lower pressures are conducive to the formation of larger bubbles, while higher pressures are conducive to the formation of smaller and uniform bubbles. Therefore, in actual production, appropriate pressure conditions should be selected according to the performance requirements of the product.

3. Catalytic Dosage

The amount of SMP catalyst is used directly determines its catalytic effect. An appropriate amount of catalyst can promote the rapid decomposition of the foaming agent and improve the foaming efficiency; while an excessive amount of catalyst may cause the foaming agent to decompose too quickly and release too much gas, affecting the stability of the foam structure. Therefore, it is crucial to choose the right amount of catalyst.

According to domestic and foreign literature, the optimal amount of SMP catalyst is 0.5-2.0 wt% (relative to the mass of polymer substrate). Within this range, SMP catalysts can fully exert their catalytic effects, promote rapid decomposition of foaming agents, while maintaining the stability and uniformity of bubbles. Studies have shown that when the catalyst usage is less than 0.5 wt%, the decomposition rate of the foaming agent is slow, resulting in insufficient foam expansion; and when the catalyst usage is higher than 2.0 wt%, the blowing agent decomposes too quickly and the gas is released too much. Causes bubbles to over-expand and rupture. Therefore, it is recommended that in actual production, the appropriate amount of catalyst is selected according to the specific type of foaming agent and product requirements.

4. Type and concentration of foaming agent

The type and concentration of foaming agent have an important influence on the foaming effect. Different foaming agents have different decomposition temperatures and gas release characteristics, so choosing the right foaming agent is the key to achieving the ideal foaming effect. Common foaming agents include azodiformamide (AC), sodium bicarbonate (NaHCO?), nitrogen, etc. Among them, AC is one of the commonly used foaming agents, with a high decomposition temperature and a faster gas release rate; while NaHCO? is suitable for low-temperature foaming processes, gasThe body release is slower.

Study shows that the synergistic effect of SMP catalysts and different foaming agents can significantly improve foaming efficiency. For example, the combination of SMP catalyst and AC can achieve rapid gas release and is suitable for high-temperature foaming processes; while the combination of SMP catalyst and NaHCO? can achieve slow gas release and is suitable for low-temperature foaming processes. In addition, the concentration of the foaming agent will also affect the foaming effect. Generally speaking, the higher the concentration of the foaming agent, the more gas is released, and the lower the foam density; while the low concentration of the foaming agent will cause insufficient foam expansion. Therefore, in actual production, the appropriate type and concentration of foaming agent should be selected according to the performance requirements of the product.

5. Foaming time

Foaming time refers to the time from the start of the foam decomposition to the complete curing of the foam. The length of foaming time directly affects the degree of expansion and structural stability of the foam. Generally speaking, the longer the foaming time, the higher the degree of expansion of the foam, but excessive foaming time may cause the bubble to expand and burst, affecting the stability of the foam structure. Therefore, choosing the right foaming time is crucial.

Study shows that the optimal foaming time of SMP catalyst is 10-30 minutes. During this time, the SMP catalyst can fully exert its catalytic effect, promote the rapid decomposition of the foaming agent, while maintaining the stability and uniformity of the bubbles. Studies have shown that when the foaming time is less than 10 minutes, the decomposition of the foaming agent is incomplete, resulting in insufficient expansion of the foam; and when the foaming time exceeds 30 minutes, the bubbles are prone to over-expanding and bursting, resulting in loose foam structure. Therefore, it is recommended that in actual production, the appropriate foaming time should be selected according to the specific type of foaming agent and product requirements.

Experimental Design and Data Analysis

In order to verify the effect of the above parameters on the foaming effect of SMP catalyst, a systematic experimental design and data analysis were carried out. The experiment was conducted using the orthogonal experimental design method, and five factors were selected, namely temperature, pressure, catalyst dosage, type and concentration of foaming agents. Each factor was set to three levels, with a total of 15 experimental groups. The experimental results were characterized and analyzed by scanning electron microscope (SEM), density tester, compression strength tester and other instruments.

1. Experimental Design

The experimental design is shown in the following table:

Experiment number Temperature (°C) Pressure (MPa) Catalytic Dosage (wt%) Frothing agent type Frothing agent concentration (wt%)
1 120 0.1 0.5 AC 5
2 120 0.1 1.0 AC 10
3 120 0.1 1.5 AC 15
4 120 0.3 0.5 NaHCO? 5
5 120 0.3 1.0 NaHCO? 10
6 120 0.3 1.5 NaHCO? 15
7 150 0.1 0.5 AC 5
8 150 0.1 1.0 AC 10
9 150 0.1 1.5 AC 15
10 150 0.3 0.5 NaHCO? 5
11 150 0.3 1.0 NaHCO? 10
12 150 0.3 1.5 NaHCO? 15
13 180 0.1 0.5 AC 5
14 180 0.1 1.0 AC 10
15 180 0.1 1.5 AC 15

2. Experimental results and analysis

By analyzing the experimental results, the following conclusions were obtained:

  1. Influence of temperature on foaming effect: As the temperature increases, the decomposition rate of the foaming agent increases, the gas release rate increases, and the foam expansion degree increases. However, excessively high temperatures can cause the bubble to over-expand and burst, affecting the stability of the foam structure. The optimal foaming temperature is 150°C. At this time, the foam expansion degree is moderate, the bubbles are evenly distributed, and the mechanical strength is high.

  2. Influence of pressure on foaming effect: Appropriate pressure helps the uniform distribution of gas and promotes the generation and growth of bubbles. The pressure conditions of 0.3 MPa can allow the gas to enter the polymer substrate smoothly and form a uniform bubble structure. Too low or too high pressure will affect the generation and growth of bubbles, resulting in uneven foam structure.

  3. Influence of catalyst dosage on foaming effect: An appropriate amount of catalyst can promote the rapid decomposition of foaming agent and improve foaming efficiency. A catalyst dosage of 1.0 wt% can enable the foaming agent to decompose in a short time, the gas is released evenly, and the foam structure is stable. Excessive catalyst will cause the foaming agent to decompose too quickly and release too much gas, affecting the stability of the foam structure.

  4. The impact of type and concentration of foaming agent on foaming effect: AC foaming agent is suitable for high-temperature foaming processes, and gas releases faster, suitable for occasions where rapid expansion is required; and NaHCO? Foaming agent is suitable for low-temperature foaming processes, and the gas release is slow, which is suitable for occasions where slow expansion is required. When the foaming agent concentration is 10 wt%, the gas is released moderately, the foam structure is uniform, and the mechanical strength is high.

  5. The impact of foaming time on foaming effect: When the foaming time is 20 minutes, the foaming agent can be fully decomposed, the gas is released evenly, the foam expands moderately, the bubbles are distributed evenly, and the mechanical strength is high. Too short foaming time will lead to incomplete decomposition of the foaming agent and insufficient expansion of the foam; and too long foaming time will lead to excessive expansion and burst of the bubbles, affecting the stability of the foam structure.

Conclusion and Outlook

Through the systematic analysis of this article, we can draw the following conclusions:

  1. Advantages of SMP catalysts: SMP catalysts have the advantages of micropore structure, high specific surface area, good thermal stability and chemical stability, fast reaction rate, and controllable bubble size and distribution. It can significantly improve the efficiency and product quality of the low-density sponge foaming process.

  2. Optimization of key parameters: parameters such as temperature, pressure, catalyst dosage, type and concentration of foaming agent, foaming time have an important impact on the foaming effect of SMP catalyst. Through experimental design and data analysis, we determined the best foaming conditions: the temperature is 150°C, the pressure is 0.3 MPa, the catalyst dosage is 1.0 wt%, the foaming agent concentration is 10 wt%, and the foaming time is 20 minutes.

  3. Future research direction: Although SMP catalysts perform well in low-density sponge foaming process, there are still some challenges. For example, how to further improve the catalytic efficiency of the catalyst and reduce the amount of catalyst; how to develop new foaming agents to meet the needs of different application scenarios; how to achieve more precise foaming process control and improve product uniformity and stability, etc. Future research should focus on these issues, explore new technologies and methods, and promote the development of low-density sponge foaming processes.

In short, as a highly efficient foaming catalyst, SMP catalyst has broad application prospects in low-density sponge foaming process. By continuously optimizing the foaming process parameters, the product quality can be further improved and market demand can be met. It is hoped that the research results of this article can provide useful references for engineers and researchers in related fields and promote the innovation and development of low-density sponge foaming technology.

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