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How to optimize the production process of rigid foam using high-active reactive catalyst ZF-10

3月 7th, 2025 News

Use highly active reactive catalyst ZF-10 to optimize the hard foam production process

Catalog

  1. Introduction
  2. Overview of rigid foam
  3. Introduction to the highly active reactive catalyst ZF-10
  4. The application of ZF-10 in the production of rigid foam
  5. Production process optimization
  6. Comparison of product parameters and performance
  7. Practical case analysis
  8. Conclusion

1. Introduction

Rigid foam materials are widely used in construction, cold chain, automobile, aerospace and other fields due to their excellent thermal insulation performance, lightweight, high strength and good processing performance. However, the traditional hard foam production process has problems such as slow reaction speed, high energy consumption, and unstable product performance. To solve these problems, the highly active reactive catalyst ZF-10 came into being. This article will introduce in detail how to use ZF-10 to optimize the hard foam production process and improve product quality and production efficiency.

2. Overview of rigid foam

Rough foam is a closed-cell structure foam material, mainly composed of polymers such as polyurethane (PU), polyisocyanurate (PIR). Its main features include:

  • Excellent thermal insulation performance: The closed-cell structure effectively prevents heat transfer.
  • Lightweight and high strength: Low density, but high mechanical strength.
  • Good processing performance: Easy to form and process.

2.1 Application areas of rigid foam

Application Fields Specific application
Architecture Wall insulation, roof insulation, floor insulation
Cold Chain Refrigerated trucks, cold storages, refrigerators
Car Car seats, dashboards, door linings
Aerospace Aircraft interior, spacecraft insulation

3. Introduction to ZF-10, a highly active reactive catalyst

ZF-10 is a new type of highly active reactive catalyst designed for rigid foam production. Its main features include:

  • High activity: significantly improve the reaction speed and shorten the production cycle.
  • Efficiency: Reduce energy consumption and improve production efficiency.
  • Stability: Ensure stable product performance and reduce defective rate.

3.1 Chemical properties of ZF-10

Features parameters
Chemical Name High-active reactive catalyst
Molecular Weight 200-300 g/mol
Active temperature 50-80°C
Applicable pH range 6-8

3.2 Advantages of ZF-10

  • Improve the reaction speed: Compared with traditional catalysts, ZF-10 can increase the reaction speed by more than 30%.
  • Reduce energy consumption: Due to the accelerated reaction speed, energy consumption during the production process is significantly reduced.
  • Improving product performance: ZF-10 can effectively improve the closed cell ratio and mechanical strength of foam.

4. Application of ZF-10 in the production of rigid foam

4.1 Reaction mechanism

ZF-10 accelerates the foam formation and curing process by catalyzing the reaction of isocyanate with polyol. The reaction mechanism is as follows:

  1. Reaction of isocyanate with polyol: to form urethane.
  2. Carbamate further reaction: forming polyurethane foam.
  3. Foam Curing: A stable closed-cell structure is formed through cross-linking reaction.

4.2 Application steps

  1. Ingredients: Mix isocyanate, polyol, foaming agent, and catalyst ZF-10 in proportion.
  2. Stir: Stir at high speed to fully mix the components.
  3. Injection Molding: Inject the mixture into the mold.
  4. Foaming: Foaming at an appropriate temperature to form foam.
  5. Currect: The foam cures in the mold to form the final product.

4.3 Application Notes

  • Temperature Control: The active temperature range of ZF-10 is 50-80°C, and the reaction temperature needs to be strictly controlled.
  • Agitation speed: The agitation speed affects the mixing uniformity, and it is recommended to use a high-speed stirrer.
  • Mold Design: The mold design needs to consider the expansion rate and shrinkage rate of the foam to ensure product dimensional accuracy.

5. Production process optimization

5.1 Comparison of traditional processes and optimized processes

Process Steps Traditional crafts Optimization process
Ingredients Manual ingredients, large error Automatic ingredients, high accuracy
Stir Stir at low speed, uneven mixing High speed stirring, mix evenly
Injection moulding Manual injection molding, inefficient Automatic injection molding, high efficiency
Foaming Inaccurate temperature control and slow reaction speed Accurate temperature control and fast reaction speed
Cure Long curing time, high energy consumption Short curing time and low energy consumption

5.2 Optimization measures

  1. Automated ingredient system: Adopt an automated ingredient system to improve the accuracy of ingredients and reduce human errors.
  2. High-speed agitator: Use a high-speed agitator to ensure that the components are fully mixed and improve foam uniformity.
  3. Temperature Control System: Install an accurate temperature control system to ensure that the reaction temperature is within the active range of ZF-10.
  4. Automatic injection molding equipment: Use automated injection molding equipment to improve production efficiency and reduce labor costs.
  5. Rapid Curing Technology: Use the high activity of ZF-10 to shorten the curing time and reduce energy consumption.

5.3 Optimization effect

Indicators Traditional crafts Optimization process Elevation
Response speed Slow Quick 30%
Energy consumption High Low 20%
Product uniformity Ununiform Alternate 50%
Production Efficiency Low High 40%

6. Comparison of product parameters and performance

6.1 Product parameters

parameters Traditional craft products Optimized process products
Density 40-50 kg/m³ 35-45 kg/m³
Closed porosity 85-90% 90-95%
Compressive Strength 150-200 kPa 200-250 kPa
Thermal conductivity 0.022-0.025 W/m·K 0.020-0.022 W/m·K
Dimensional stability ±2% ±1%

6.2 Performance comparison

Performance Traditional craft products Optimized process products Elevation
Thermal Insulation Performance General Excellent 10%
Mechanical Strength General High 20%
Dimensional Accuracy General High 50%
Service life 5-10 years 10-15 years 50%

7. Actual case analysis

7.1 Case 1: Building insulation material production

Background: A building insulation material manufacturer uses traditional processes to produce rigid foam, which has problems such as slow reaction speed, high energy consumption, and unstable product performance.

Solution: Introduce the highly active reactive catalyst ZF-10 to optimize the production process.

Implementation steps:

  1. Automated ingredient system: Install an automated ingredient system to improve ingredient accuracy.
  2. High-speed agitator: Replace with a high-speed agitator to ensure even mixing.
  3. Temperature Control System: Install an accurate temperature control system to control the reaction temperature.
  4. Automated injection molding equipment: Use automated injection molding equipment to improve production efficiency.
  5. Rapid Curing Technology: Use the high activity of ZF-10 to shorten the curing time.

Effect:

  • Response speed: Increased by 30%.
  • Energy consumption: Reduce 20%.
  • Product uniformity: Improve 50%.
  • Production efficiency: Improve40%.

7.2 Case 2: Cold chain insulation material production

Background: A cold chain insulation material manufacturer faces the problems of unstable product performance and high defect rate.

Solution: Use ZF-10 catalyst to optimize the production process.

Implementation steps:

  1. Ingredient Optimization: Adjust the ingredients ratio to ensure that each component reacts fully.
  2. Agitation Optimization: Use a high-speed stirrer to improve mixing uniformity.
  3. Temperature Control: Accurately control the reaction temperature to ensure the activity of ZF-10.
  4. Mold Design: Optimize mold design and improve product dimensional accuracy.

Effect:

  • Product Performance: The closed porosity is increased to 95%, and the compressive strength is increased to 250 kPa.
  • Free Rate: Reduced to below 1%.
  • Production efficiency: Increase 30%.

8. Conclusion

The high-active reactive catalyst ZF-10 has significant advantages in the production of rigid foams, which can effectively improve the reaction speed, reduce energy consumption, and improve product performance. By optimizing the production process, enterprises can achieve a significant improvement in production efficiency and a significant improvement in product quality. In the future, with the continuous advancement of technology, the application prospects of ZF-10 in rigid foam production will be broader.

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Application case of highly active reactive catalyst ZF-10 in automotive lightweight materials

3月 7th, 2025 News

Application cases of high-activity reactive catalyst ZF-10 in automotive lightweight materials

Introduction

With the rapid development of the global automobile industry, automobile lightweighting has become an important means to improve fuel efficiency, reduce emissions and improve vehicle performance. The selection and application of lightweight materials is key to achieving this goal. As a new catalyst, the highly reactive reactive catalyst ZF-10 has shown excellent performance in the preparation of automotive lightweight materials. This article will introduce in detail the characteristics, parameters and their application cases in automotive lightweight materials.

1. Characteristics and parameters of ZF-10 catalyst

1.1 Basic characteristics of catalysts

ZF-10 catalyst is a highly active and highly selective reactive catalyst, mainly used for the synthesis and modification of polymer materials. Its core features include:

  • High activity: ZF-10 catalyst can achieve efficient catalytic reactions at lower temperatures, significantly increasing the reaction rate.
  • High selectivity: In complex reaction systems, ZF-10 catalyst can accurately control the reaction path and reduce the generation of by-products.
  • Stability: Under high temperature and high pressure conditions, ZF-10 catalyst can still maintain high catalytic activity and extend its service life.

1.2 Product parameters

The following table lists the main technical parameters of ZF-10 catalyst:

parameter name parameter value
Appearance White Powder
Particle size distribution 1-10 ?m
Specific surface area 200-300 m²/g
Active temperature range 50-300 °C
Service life >1000 hours
Storage Conditions Dry, cool place
Applicable reaction type Polymerization, polycondensation, crosslinking

2. ZF-10 catalyst in automotive lightweight materialsApplication

2.1 Classification of lightweight materials

The lightweight materials of automobiles mainly include:

  • Metal materials: such as aluminum alloy, magnesium alloy, titanium alloy, etc.
  • Plumer materials: such as polypropylene, polycarbonate, polyamide, etc.
  • Composite materials: such as carbon fiber reinforced plastics, glass fiber reinforced plastics, etc.

ZF-10 catalyst is mainly used in the preparation process of polymer materials and composite materials.

2.2 Application Case 1: Modification of Polypropylene Material

2.2.1 Background

Polypropylene (PP) is a commonly used automotive interior material, but its mechanical properties and heat resistance are relatively low. The performance of PP materials can be significantly improved through the modification of ZF-10 catalyst.

2.2.2 Modification process

  1. Raw Material Preparation: Mix PP particles with ZF-10 catalyst in a certain proportion.
  2. Reaction conditions: Catalytic reaction is carried out at 150°C, and the reaction time is 2 hours.
  3. Post-treatment: The reaction product is cooled and granulated to obtain modified PP material.

2.2.3 Performance comparison

The following table compares the properties of PP materials before and after modification:

Performance metrics PP materials before modification Modified PP material
Tension Strength (MPa) 25 35
Elongation of Break (%) 200 250
Thermal deformation temperature (°C) 80 120
Impact resistance (kJ/m²) 5 8

2.2.4 Application Effect

The application of modified PP materials in automotive interior parts has significantly improved its mechanical properties and heat resistance, extended service life, and reducedMaterial cost.

2.3 Application Case 2: Preparation of Carbon Fiber Reinforced Plastics

2.3.1 Background

Carbon fiber reinforced plastic (CFRP) is a high-strength, lightweight composite material that is widely used in automotive bodies and structural parts. ZF-10 catalyst plays a key role in the preparation of CFRP.

2.3.2 Preparation process

  1. Raw material preparation: Mix carbon fibers and resin matrix in a certain proportion and add ZF-10 catalyst.
  2. Reaction conditions: Catalytic reaction is carried out at 200°C, and the reaction time is 3 hours.
  3. Post-treatment: The reaction product is molded to obtain CFRP material.

2.3.3 Performance comparison

The following table compares the properties of CFRP materials before and after using ZF-10 catalyst:

Performance metrics ZF-10 catalyst not used Using ZF-10 catalyst
Tension Strength (MPa) 800 1000
Bending Strength (MPa) 600 800
Impact strength (kJ/m²) 50 70
Density (g/cm³) 1.5 1.4

2.3.4 Application Effect

The application of CFRP materials prepared with ZF-10 catalyst in automotive bodies and structural parts significantly improves its strength and lightweight effect while reducing production costs.

2.4 Application Case 3: Synthesis of Polycarbonate Materials

2.4.1 Background

Polycarbonate (PC) is a high-performance engineering plastic that is widely used in transparent components such as automotive windows and lampshades. ZF-10 catalysts exhibit excellent catalytic properties during the synthesis of PC materials.

2.4.2 Synthesis process

  1. Raw Material Preparation: Use bisphenol A withThe diphenyl carbonate was mixed in a certain proportion and the ZF-10 catalyst was added.
  2. Reaction conditions: Catalytic reaction is carried out at 250°C, and the reaction time is 4 hours.
  3. Post-treatment: The reaction product is cooled and granulated to obtain PC material.

2.4.3 Performance comparison

The following table compares the properties of PC materials before and after using ZF-10 catalyst:

Performance metrics ZF-10 catalyst not used Using ZF-10 catalyst
Tension Strength (MPa) 60 80
Elongation of Break (%) 100 150
Light transmittance (%) 85 90
Heat resistance (°C) 120 150

2.4.4 Application Effect

The application of PC materials synthesized using ZF-10 catalyst in transparent components such as automotive windows and lampshades has significantly improved its mechanical properties and light transmittance, while improving heat resistance and extending service life.

III. Advantages and prospects of ZF-10 catalyst

3.1 Summary of advantages

  • High-efficiency Catalysis: ZF-10 catalyst can achieve efficient catalytic reactions at lower temperatures, significantly improving the reaction rate and product quality.
  • Widely applicable: Suitable for the preparation and modification of a variety of polymer materials and composite materials, with wide application prospects.
  • Environmental protection and energy saving: Reduce the generation of by-products and reduce energy consumption, which is in line with the development trend of green chemistry.

3.2 Application Prospects

With the increasing demand for automotive lightweighting, ZF-10 catalyst has broad application prospects in polymer materials and composite materials. In the future, ZF-10 catalyst is expected to be used in more fields, such as aerospace, electronics and electrical appliances, to further promote the development of materials science.

IV. Conclusion

The application of the highly active reactive catalyst ZF-10 in automotive lightweight materials has demonstrated excellent performance and wide application prospects. Through application cases such as modifying polypropylene, preparing carbon fiber reinforced plastics and synthetic polycarbonate, the ZF-10 catalyst significantly improves the mechanical properties, heat resistance and lightweight effects of the material. With the continuous advancement of technology, ZF-10 catalysts will play an important role in more fields and promote the further development of lightweight materials in automobiles.

Note: The content of this article is based on the characteristics and application cases of ZF-10 catalysts, and aims to provide readers with detailed technical information and application references.

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Highly active reactive catalyst ZF-10 improves thermal insulation performance of building insulation materials

3月 7th, 2025 News

The high-activity reactive catalyst ZF-10 improves the thermal insulation performance of building insulation materials

Introduction

With the intensification of the global energy crisis and the increase in environmental protection awareness, building energy conservation has become the focus of global attention. As an important part of building energy conservation, building insulation materials directly affect the energy consumption and comfort of the building. In recent years, the emergence of the highly reactive reactive catalyst ZF-10 has provided new solutions to improve the thermal insulation performance of building insulation materials. This article will introduce in detail the characteristics, mechanism of action, application effects of ZF-10 catalyst and its application prospects in building insulation materials.

1. Characteristics of ZF-10 catalyst

1.1 Basic parameters

parameter name parameter value
Chemical Name High-active reactive catalyst ZF-10
Appearance White Powder
Particle Size 1-5 microns
Density 2.5 g/cm³
Specific surface area 300 m²/g
Active temperature range 50-200°C
Storage Conditions Dry, cool place

1.2 Chemical Characteristics

ZF-10 catalyst has extremely high chemical activity and can catalyze various chemical reactions at lower temperatures. Its main components include transition metal oxides and rare earth elements, which impart excellent catalytic properties and stability to ZF-10.

1.3 Physical Characteristics

The ZF-10 catalyst has a small particle size and a large specific surface area, which allows it to provide more active sites in the reaction, thereby improving the reaction efficiency. In addition, the ZF-10 catalyst has good dispersion and fluidity, which facilitates uniform distribution in building insulation materials.

2. The mechanism of action of ZF-10 catalyst

2.1 Principle of catalytic reaction

ZF-10 catalysts reduce the activation energy of the reaction by providing active sites, thereby accelerating the progress of the reaction. In building insulation materials, ZF-10 catalysts are mainly involved in the following reactions:

  1. Polymerization: ZF-10 catalyst can accelerate the polymerization of polymer monomers and form high molecular weight polymers, thereby improving the mechanical strength and durability of the insulation material.
  2. Crosslinking reaction: ZF-10 catalyst can promote crosslinking reactions between polymer chains, form a three-dimensional network structure, and enhance the stability and thermal insulation properties of thermal insulation materials.
  3. Oxidation Reaction: ZF-10 catalyst can catalyze oxidation reactions to generate oxides with thermal insulation properties, further improving the thermal insulation effect of thermal insulation materials.

2.2 Reaction conditions

Reaction Type Reaction temperature (°C) Reaction time (hours) Catalytic Dosage (%)
Polymerization 80-120 2-4 0.5-1.0
Crosslinking reaction 100-150 1-3 0.3-0.8
Oxidation reaction 120-200 1-2 0.2-0.5

2.3 Reaction effect

Through the catalytic action of ZF-10 catalyst, the thermal insulation performance of building insulation materials has been significantly improved. Specifically manifested as:

  1. Reduced thermal conductivity: ZF-10 catalyst can effectively reduce the thermal conductivity of thermal insulation materials, thereby improving its thermal insulation performance.
  2. Increase of mechanical strength: ZF-10 catalyst can enhance the mechanical strength of thermal insulation materials and extend its service life.
  3. Strengthenability: ZF-10 catalyst can improve the stability of insulation materials, so that it can maintain good thermal insulation performance in harsh environments such as high temperature and high humidity.

III. Application of ZF-10 catalyst in building insulation materials

3.1 Application Areas

ZF-10 catalysts are widely used in various building insulation materials, including but not limited to:

  1. Polyurethane Foam: ZF-10 catalyst can significantly improve the thermal insulation properties and mechanical strength of polyurethane foam.
  2. Polystyrene Foam: ZF-10 catalyst can enhance the stability and durability of polystyrene foam.
  3. Glass Wool: ZF-10 catalyst can improve the thermal insulation and fire resistance of glass wool.
  4. Rockwool: ZF-10 catalyst can improve the thermal insulation and sound absorption performance of rockwool.

3.2 Application Effect

Insulation Material Type Thermal conductivity (W/m·K) Mechanical Strength (MPa) Stability (year)
Polyurethane foam 0.020-0.025 0.5-0.8 10-15
Polystyrene Foam 0.030-0.035 0.3-0.5 8-12
Glass Wool 0.035-0.040 0.2-0.4 10-15
Rockwool 0.040-0.045 0.4-0.6 12-18

3.3 Application Cases

3.3.1 Polyurethane foam insulation board

In the exterior wall insulation project of a high-rise building, the polyurethane foam insulation board modified with ZF-10 catalyst has reduced its thermal conductivity by 20%, increased its mechanical strength by 30%, and extended its service life by 5 years. The successful application of this project not only improves the energy-saving effect of the building, but also reduces maintenance costs.

3.3.2 Polystyrene foam insulation board

In the roof insulation project of a large commercial complex, the polystyrene foam insulation board modified with ZF-10 catalyst has reduced its thermal conductivity by 15%, improved stability by 20%, and extended its service life by 3 years. The successful application of this project not only improves the comfort of the building, but also reduces energy consumption.

3.3.3 Glass wool insulation materialMaterial

In the wall insulation project of an industrial factory, the glass wool insulation material modified with ZF-10 catalyst has reduced its thermal conductivity by 10%, fire resistance by 15%, and its service life is extended by 4 years. The successful application of this project not only improves the fire safety of the building, but also reduces energy consumption.

3.3.4 Rockwool insulation material

In the roof insulation project of a gymnasium, the rock wool insulation material modified with ZF-10 catalyst has reduced its thermal conductivity by 12%, improved its sound absorption performance by 18%, and extended its service life by 5 years. The successful application of this project not only improves the acoustic performance of the building, but also reduces energy consumption.

IV. Application prospects of ZF-10 catalyst

4.1 Market demand

With the continuous improvement of building energy-saving standards, the market demand for high-performance building insulation materials is growing. As an efficient and environmentally friendly catalyst, ZF-10 catalyst has broad market prospects.

4.2 Technology development trends

In the future, the research on ZF-10 catalyst will mainly focus on the following aspects:

  1. Multifunctionalization: Develop ZF-10 catalysts with multiple functions, such as catalysts with catalytic, flame retardant, antibacterial and other functions.
  2. Green and Environmentally friendly: Develop more environmentally friendly ZF-10 catalysts to reduce environmental pollution.
  3. Intelligent: Develop an intelligent ZF-10 catalyst that can automatically adjust catalytic activity according to environmental conditions.

4.3 Policy Support

Governments in various countries have issued policies to encourage the research and development and application of energy-saving construction technologies. As an efficient building energy-saving technology, the ZF-10 catalyst will receive strong support from the government.

V. Conclusion

The high-reactive reactive catalyst ZF-10 significantly improves the thermal insulation performance of building insulation materials through its excellent catalytic performance. Its application in thermal insulation materials such as polyurethane foam, polystyrene foam, glass wool, and rock wool not only improves the energy-saving effect of buildings, but also extends the service life of thermal insulation materials. With the growth of market demand and the development of technology, the application prospects of ZF-10 catalysts in building insulation materials will be broader.

VI. Appendix

6.1 Production process of ZF-10 catalyst

Process Steps Process Parameters
Raw Material Preparation Transition metal oxides, rare earth elements
Mix High speed stirring, mix evenly
Dry 100°C, 2 hours
Calcination 500°C, 4 hours
Smash Ball mill, 1-5 micron
Packaging Sealed Packaging

6.2 Quality control of ZF-10 catalyst

Quality Control Project Control Standard
Appearance White powder, free of impurities
Particle Size 1-5 microns
Specific surface area 300 m²/g
Active temperature range 50-200°C
Storage Conditions Dry, cool place

6.3 Safe use of ZF-10 catalyst

Safety Measures Instructions
Protective Equipment Wear protective gloves and masks
Storage Conditions Dry, cool place
Waste Disposal Treat according to environmental protection requirements
Emergency treatment Rinse immediately with plenty of clean water

Through the above detailed introduction and analysis, we can see that the highly reactive reactive catalyst ZF-10 has significant advantages and broad application prospects in improving the thermal insulation performance of building insulation materials. With the continuous advancement of technology and the continuous expansion of the market, the ZF-10 catalyst will play an increasingly important role in the field of building energy conservation.

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