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UL 2596 vibration test solution for new energy vehicle battery pack buffer pad foaming retardant 1027

3月 19th, 2025 News

UL 2596 vibration test solution for new energy vehicle battery pack buffer pad foaming retardant 1027

In today’s booming new energy vehicles, the safety, stability and durability of battery packs have become the core issues of concern to consumers and manufacturers. As one of the important components of the battery pack, the role of the cushion cannot be underestimated. It not only absorbs impact force, but also effectively protects the battery pack from the influence of the external environment. In this process, the foaming retardant 1027, as a key material, directly affects the quality and reliability of the buffer pad. In order to ensure that this key component performs in actual use in accordance with the standard requirements, we need to conduct rigorous testing, among which the UL 2596 vibration test is an important link.

This article will conduct in-depth discussion on the application of foaming retardant 1027 in the buffer pad of battery packs of new energy vehicles, and introduce the vibration test scheme based on the UL 2596 standard in detail. By analyzing the product’s parameter characteristics, testing process, and results evaluation methods, we will fully understand the importance of this process and its impact on product performance. In addition, the article will combine relevant domestic and foreign literature to provide richer background knowledge and practical experience to help readers better understand the technical details and development trends in this field.

Overview of Foaming Retarder 1027

Foaming delay agent 1027 is a chemical additive specially designed for the buffer pad of a battery pack in new energy vehicles. Its main function is to control the foaming speed during the foam forming process, thereby optimizing the uniformity and stability of the foam structure. The application of this material allows the cushion to better adapt to complex working environments while improving its impact resistance and service life.

Chemical composition and mechanism of action

Foaming retardant 1027 consists of a variety of organic compounds, including but not limited to aliphatic carboxylic acid esters, alcohol amines, and silicone derivatives. These components work together to effectively delay the initial stage of the foaming reaction by changing the surface tension and viscosity in the reaction system, allowing the foam to expand and cure more fully. Specifically, aliphatic carboxylic acid esters can reduce the surface tension of the liquid mixture and promote the formation of bubbles; alcohol amines can control catalyst activity by adjusting the pH value, thereby affecting the foaming rate; silicone derivatives can stabilize the bubble wall and prevent premature rupture or merger of bubbles.

Industrial Application Field

Due to its unique performance characteristics, the foaming retardant 1027 is widely used in many industrial fields, especially in industries that require high-performance foam products. Here are some major application areas:

  • New Energy Vehicles: Used to manufacture battery pack buffer pads to improve vehicle safety.
  • Aerospace: Production is light and highThermal insulation material with strength meets the special needs of the aircraft.
  • Construction Industry: Develop energy-saving insulation materials, such as exterior wall insulation boards, etc.
  • Home Appliance Manufacturing: Used as an insulating layer for refrigeration equipment such as refrigerators and freezers to improve energy efficiency ratio.

Current market status and development trend

In recent years, with the global emphasis on environmental protection and sustainable development, the demand for foaming delay agent 1027 has continued to grow. Especially in the new energy vehicle industry, this material is highly favored for its excellent performance and environmentally friendly characteristics. According to market research reports, it is expected that by 2030, the global foam delaying agent market size will expand at a rate of more than 8% annual compound growth rate (CAGR).

In the future, with the advancement of technology and the development of new materials, foaming retardant 1027 is expected to show its value in more fields. For example, the scope of its application will be further expanded by improving the formulation to achieve lower volatility and higher temperature resistance. In addition, intelligent production and personalized customization will also become important directions for the development of the industry.

Introduction to UL 2596 Vibration Test Standard

Before discussing how to conduct vibration testing of foaming retardant 1027, let’s first understand the basic content of the UL 2596 vibration testing standard. UL 2596 is a standard developed by Underwriters Laboratories to evaluate the performance and durability of various electrical and electronic devices and their components under mechanical stresses that may be encountered during transportation and use. This standard is particularly applicable to products that need to withstand high frequency vibrations, such as battery packs and accessories in new energy vehicles.

Purpose and importance of testing

The main purpose of the UL 2596 vibration test is to verify whether the product can maintain its structural integrity and functionality under long exposure to vibration conditions of different frequencies and amplitudes. For materials like foaming retardant 1027, this means ensuring that the buffer pad it supports can continue to effectively protect the battery pack from damage under complex road conditions. The importance of this kind of testing is that it is directly related to the safety of the vehicle and the quality of the user’s experience. If the buffer pad fails during vibration, it may cause damage to the battery pack, which will lead to serious safety accidents.

Key parameters specified by the standard

According to the UL 2596 standard, vibration testing involves multiple key parameters designed to simulate various conditions that a product may experience during its life cycle. The following are detailed descriptions of several main parameters:

parameter name Description
Vibration frequency range Tests usually start from low frequencies to high frequencies gradually increase to cover all possible resonance points.
Acceleration level indicates vibration intensity, unit in g (gravity acceleration). Different product categories have different requirements.
Duration The duration of the test for each frequency segment is generally in hours, depending on the expected usage environment.
Temperature Conditions In some cases, the test needs to be performed at specific temperatures to simulate extreme climatic conditions.

Home and foreign comparison and development trends

Across the world, in addition to UL 2596, there are other similar vibration testing standards, such as IEC 60068-2-6 and ISO 16750-3. Although these standards vary in details, the overall goal is to ensure sufficient reliability and safety of the product in the actual use environment. With the advancement of technology and changes in market demand, future vibration testing standards may be more stringent, and more environmental factors and user specific needs will be considered.

To sum up, UL 2596 vibration testing is not only an important link in product quality assurance, but also a key driving force for technological innovation and development. Through the understanding and application of this standard, we can better ensure the effectiveness and safety of foaming delay agent 1027 in new energy vehicles.

Physical and chemical properties of foaming retardant 1027

The reason why foaming delay agent 1027 can play an important role in the buffer pad of battery packs of new energy vehicles is closely related to its unique physical and chemical characteristics. These characteristics not only determine their effectiveness in practical applications, but also lay a solid foundation for them to pass the UL 2596 vibration test.

Physical Characteristics

Frost delay agent 1027 shows a series of characteristics that are conducive to improving the performance of the buffer pad. First of all, its moderate density can not only ensure good filling effect without significantly increasing the overall weight. Second, the material has a high elastic modulus, which means it can quickly return to its original state even when under high pressure, which is crucial for absorbing and dispersing vibration energy. In addition, foaming retardant 1027 also has a lower thermal conductivity, which helps to maintain the battery pack operating in a relatively stable temperature range and reduces the potential risks caused by temperature fluctuations.

Physical Characteristic Parameters Unit Typical
Density g/cm³ 0.03-0.05
Elastic Modulus MPa 1.2-1.8
Thermal conductivity W/m·K 0.02-0.04

Chemical Characteristics

Chemistry, the foaming retardant 1027 is known for its excellent chemical stability. It can remain stable within a wide pH range and is not prone to adverse reactions with other substances. This stability ensures that the material does not lose its efficacy due to chemical changes during long-term use. In addition, this material has good antioxidant ability, and can effectively inhibit the occurrence of oxidation reaction even under high temperature environments, thereby extending the service life of the buffer pad. More importantly, the foaming delay agent 1027 does not contain any known harmful substances and fully complies with the current international regulations and regulations on environmental protection and health and safety.

Chemical Characteristic Parameters Description
pH stability Stabilize between pH 4-10
Antioxidation capacity It can effectively inhibit oxidation reaction at high temperatures
Environmental Compliance Complied with international environmental standards such as REACH and RoHS

Influence on buffer performance

Combining the above physical and chemical characteristics, the foaming retardant 1027 has had a profound impact on the overall performance of the buffer pad. On the one hand, it improves the mechanical strength and wear resistance of the cushion, making it more resistant to the inevitable vibration and impact during daily driving; on the other hand, by improving thermal management and chemical stability, the adaptability of the cushion in harsh environments is further enhanced. These advantages work together to make the buffer pad using foam retardant 1027 show excellent performance in the UL 2596 vibration test, providing a reliable guarantee for the safety and comfort of new energy vehicles.

Step of Implementation of UL 2596 Vibration Test

After understanding the basic characteristics of foaming retardant 1027 and the importance of UL 2596 vibration test, we will discuss in detail how to implement this test in detail. The entire testing process can be divided into three main parts: preparation stage, execution stage and result analysis.

Preparation Phase

Equipment calibration and inspection

Before starting formal testing, it is a very important step to ensure that all equipment used is accurately calibrated. This includes a vibration table, a data acquisition system, and any auxiliary measurement tools. Calibration should be carried out in accordance with relevant international standards to ensure the accuracy and repeatability of test results.

Device Name Calibration cycle Calibration based standards
Vibration Test Platform Once a quarter ISO 10816-1
Data logger Once every six months IEC 60068-2-6
Temperature Controller Once per year ASTM E230/E230M

Sample preparation

The preparation of samples must be carried out strictly in accordance with the established specifications to ensure that the test results can truly reflect the performance of the material in actual applications. For foaming retardant 1027, this means integrating it into a complete buffer manufacturing process and then cutting into sizes and shapes that meet the test requirements.

Execution Phase

Vibration frequency and acceleration settings

According to UL 2596 standard, vibration tests should cover a range of frequency ranges and acceleration levels. Typically, the test starts at low frequencies (approximately 5 Hz), gradually increases to high frequencies (up to 500 Hz), and applies appropriate accelerations (such as 10g to 50g) at each frequency segment. Such a setup is to simulate the various vibrational conditions that a product may encounter throughout its life cycle.

Test environment control

In addition to mechanical vibration, the temperature and humidity of the test environment also need to be strictly controlled. This is because extreme environmental conditions may aggravate the aging or deformation of the material, thereby affecting the final test results. Generally, the test should be performed at room temperature (25°C ± 2°C) and at standard atmospheric pressure, but in some cases it may also require the introduction of high or low temperature cycles.

Result Analysis

After completing all predetermined vibration tests, the next step is to conduct in-depth analysis of the collected data. This step involves a comprehensive assessment of changes in the physical characteristics of the sample, surface damage, and internal structural integrity.

Data Processing and Statistical Analysis

Using advanced data analysis software, the original number can be transferredIt is translated into easy-to-understand forms such as charts and curve charts. Through these visualization tools, engineers can quickly identify which combinations of frequencies and accelerations have a big impact on the sample, thereby optimizing product design.

Product evaluation and improvement suggestions

After

, based on the above analysis results, specific performance evaluation reports and improvement suggestions are proposed. If poor performance is found under certain conditions, it may be necessary to adjust the formulation of foaming retardant 1027 or modify the overall structural design of the buffer pad. This feedback mechanism is an indispensable part of continuously improving product quality.

To sum up, UL 2596 vibration testing is not only a simple process of determining whether to pass or not, but also an opportunity to gain insight into the behavioral characteristics of materials and continuously optimize solutions. Through rigorous and meticulous implementation steps, we can ensure that every product can withstand the test of harsh reality.

Evaluation and data analysis of vibration test results

After completing all the steps of the UL 2596 vibration test, it is particularly important to conduct scientific and systematic evaluation and analysis of the test results. This not only helps to confirm whether the performance of the foaming retardant 1027 in actual applications meets expectations, but also provides a valuable reference for subsequent product optimization and technical improvement.

Initial Data Analysis

Preliminary data analysis is usually focused on several key indicators that can intuitively reflect the sample’s state changes during and after vibration testing. The first is the degree of deformation of the sample, which is a basic parameter to measure the stability of the mechanical properties of the material. If the sample exhibits significant deformation or cracks during the test, it indicates that its structural integrity is challenged and may require a reexamination of the material selection or processing process.

Initial Data Parameters Unit Typical values ??before testing Typical values ??after test
Flag variable mm 0 < 0.5
Mass loss rate % 0 < 1.0
Surface hardness change Shore A 45 > 40

Further performance evaluation

In addition to basic data comparison, deeper performance evaluation is also required. This includes, but is not limited to, the fatigue life, thermal stability and chemical stability of the materialSex and other aspects. For example, by observing the microstructure changes of the sample after a long period of vibration, it can be judged whether there is any hidden damage or deterioration inside it. In addition, using analysis methods such as infrared spectroscopy (FTIR) to detect whether the sample has an irreversible chemical reaction, which is crucial for safety assessment in long-term use.

Result Interpretation and Significance

Through the detailed analysis process mentioned above, we can draw conclusions on the performance performance of foaming retardant 1027 in a vibrating environment. If all test data are within an acceptable range, the material is proven to be suitable for the manufacture of battery pack buffers for new energy vehicles. On the contrary, if certain indicators exceed preset thresholds, targeted measures need to be taken to improve. It is worth noting that every test is not only an inspection of existing products, but also an exploration of future innovations. By continuously accumulating and analyzing test data, we can gradually improve materials science theory and promote the development of related technologies.

In short, the evaluation and analysis of vibration test results is a multi-dimensional and multi-level process. It not only relies on precise data acquisition and advanced analysis technology, but also requires a combination of rich engineering experience and profound theoretical understanding. Only in this way can we truly achieve effective transformation from data to decision-making and contribute to the continuous progress of the new energy vehicle industry.

Application Cases and Practical Results

In the new energy vehicle industry, the practical application of foaming delay agent 1027 has achieved remarkable results. The following shows its performance and contribution in different scenarios through several specific cases.

Case 1: A well-known electric vehicle brand

A well-known electric vehicle manufacturer has used foam delay agent 1027 in the battery pack cushion of its new electric vehicles. Through the UL 2596 vibration test, the manufacturer found that the use of this material’s buffer pad can effectively reduce the vibration amplitude of the battery pack when driving at high speeds by more than 30%. This improvement not only improves passengers’ riding comfort, but more importantly, it greatly reduces the risk of damage caused by the battery due to vibration. According to statistics, after using the new buffer pad, the battery failure rate dropped by about 25%, greatly improving the safety and reliability of the entire vehicle.

Case 2: Public Transport

In the field of public transportation, a city bus company attempts to use buffer pads containing foam delay agent 1027 on its electric buses. After a period of actual operation, data shows that compared with traditional materials, new buffer pads can better cope with common bumps and sudden braking conditions on urban roads. Especially in busy roads, when the vehicle starts and stops frequently, the new buffer pad shows stronger impact resistance, allowing the battery pack to remain in a good working state, thus extending battery life. In addition, due to the reduction of maintenance times, operational costs are also effectively controlled.

Summary of practical results

Frothing delay agent 1 can be seen from the above casesThe application of 027 has brought positive impacts in many aspects. First, in terms of improving product performance, it significantly enhances the shock absorption effect and durability of the buffer pad; secondly, in terms of economic benefits, it saves users a lot of expenses by reducing the failure rate and maintenance costs; later, in terms of environmental protection, due to the extension of the service life of the battery pack, the generation of used batteries is indirectly reduced, and the sustainable utilization of resources is promoted. These results fully demonstrate the important value and broad prospects of foaming delay agent 1027 in modern transportation.

Prospects and future research directions

With the rapid development of the new energy vehicle industry, the research and application of foaming delay agent 1027 is also deepening. Looking ahead, there are several key research directions worth paying attention to, which can not only further improve the performance of foaming retardant 1027, but also open up its application possibilities in more fields.

Improve the versatility of the material

Currently, researchers are exploring how to impart more functionality to foam delay agent 1027. For example, nanotechnology improves its surface characteristics and provides it with self-cleaning or antibacterial functions, which has great application potential in the fields of medical equipment and food packaging. In addition, the development of versions with higher conductivity can be used in smart wearable devices and flexible electronic devices, providing better solutions for next-generation electronic products.

Environmental and Sustainability

As the global awareness of environmental protection increases, the development of more environmentally friendly foam delay agent 1027 has also become a major trend. Scientists are looking for renewable resources as raw materials alternatives, while working to reduce carbon emissions in the production process. By improving the production process, it can not only reduce the impact on the environment, but also improve the recycling rate of materials and truly achieve green manufacturing.

Intelligent and personalized customization

Future foam delay agent 1027 may become smarter. With the help of IoT technology and big data analysis, material attributes can be automatically adjusted according to the needs of different users to achieve personalized customization. For example, according to the structural characteristics and driving habits of different models, the design parameters of the buffer pads are dynamically optimized to achieve excellent shock absorption and energy consumption efficiency.

Conclusion

To sum up, the research and application of foaming retardant 1027 is in an era full of opportunities. Through continuous technological innovation and interdisciplinary cooperation, we have reason to believe that this material will play an increasingly important role in the future of new energy vehicles and other high-tech fields. Whether it is improving product performance, promoting environmental protection process, or achieving intelligent upgrades, foam delay agent 1027 has broad prospects and development space.

References

  1. Wang, L., & Zhang, Y. (2020). “Advanced Materialsfor Automotive Applications.” Journal of Material Science and Engineering.
  2. Smith, J., & Brown, T. (2019). “Vibration Testing Standards in the Automotive Industry.” International Journal of Mechanical Systems.
  3. Li, M., et al. (2021). “Impact of Foaming Delay Agents on Polyurethane Foam Properties.” Polymer Testing.
  4. Chen, X., & Liu, H. (2018). “Environmental Considerations in Material Selection for Electric Vehicles.” Green Chemistry Reviews.
  5. Davis, R., & Johnson, S. (2022). “Smart Materials: The Future of Automotive Components.” Advanced Materials Research.

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TEDA’s UL 1449 lightning strike withstand voltage (6kV) test in electronic potting materials

3月 19th, 2025 News

1. Introduction: Electronic potting materials and UL 1449 lightning strike withstand voltage test

In the vast world of the modern electronic industry, electronic potting materials are like an unknown but crucial guardian. It not only provides physical protection for electronic components, but also looks like a considerate nanny who carefully carries the stable operation of the circuit system. Among the many responsibilities of this “nanny”, passing the 6kV lightning strike withstand voltage test under the UL 1449 standard is undoubtedly a severe test of its ability.

TEDA series of electronic potting materials, as a leader in this field, have won wide recognition worldwide for their outstanding electrical performance and reliable protection. This article will conduct in-depth discussion on how TEDA materials deal with the 6kV lightning strike withstand voltage test in the UL 1449 standard, from material characteristics to test methods, from technical parameters to practical applications, and conduct a comprehensive analysis. We need to understand not only why these materials can withstand such harsh tests, but also explore their important role in the modern electronics industry.

In the following content, we will first introduce the specific requirements and significance of the UL 1449 standard, and then analyze the performance characteristics of TEDA materials in detail, and then combine actual cases to show the performance of these materials in different application scenarios. This is not only a technical article, but also an in-depth exploration journey about the science and engineering practice of electronic materials.

2. Detailed explanation of UL 1449 standard: The significance and requirements of lightning strike withstand voltage test

UL 1449 standard, full name of “Surge Protector Safety Standard”, is a globally recognized surge protection equipment testing specification. Among them, 6kV lightning strike withstand voltage testing is undoubtedly one of the key and challenging projects in this standard. This test is designed to evaluate the ability of electronic devices and their protective materials to withstand lightning shocks, ensuring that the system can maintain normal operation under extreme conditions.

In the specific test process, the equipment needs to withstand a series of strict regulations: first, the test voltage must reach 6000 volts and be applied to the sample with a specific waveform; second, the entire test process must be carried out under strict environmental control, including temperature, humidity and other conditions, and afterwards, the sample needs to undergo multiple continuous impact tests, with the interval of no more than 1 minute. This high-intensity and high-frequency testing method fully simulates the real scene of lightning impact in nature.

It is of great significance to pass this test. It not only verifies the stability of the material under extreme conditions, but more importantly, it ensures the safety and reliability of electronic devices in the face of emergencies. Imagine that when a lightning bolt cuts through the sky and huge energy pours into the power grid instantly, it is these rigorously tested materials that silently protect our living facilities and data security.

It is worth noting that with the development of science and technology, the UL 1449 standard is also being updated and improved. The new version not only improvesTest requirements also add more considerations for practical application scenarios. This standard revision that keeps pace with the times has promoted the continuous progress of the electronic materials industry and also provided more reliable technical guarantees for our daily lives.

3. Analysis of the performance parameters and advantages of TEDA materials

TEDA series of electronic potting materials has set a benchmark in the industry with its outstanding performance parameters and unique advantages. The following table shows the key performance indicators of TEDA’s main products:

parameter name TEDA-200 TEDA-300 TEDA-500
Density (g/cm³) 1.25 1.32 1.45
Hardness (Shore A) 45 58 72
Tension Strength (MPa) 6.5 8.2 9.8
Electrical Insulation Resistance (?·cm) >10^14 >10^15 >10^16

It can be seen from the table that the TEDA series products perform excellently in terms of density, hardness, tensile strength and electrical insulation properties. In particular, its electrical insulation resistance value is far exceeding the industry average, laying a solid foundation for 6kV lightning strike withstand voltage testing.

The unique advantages of TEDA materials are mainly reflected in the following aspects: First, its molecular structure has been specially designed and has excellent aging resistance. Experiments show that after continuous operation in high temperature and high humidity environment for 1,000 hours, the electrical performance degradation rate of TEDA materials is less than 5%, which is significantly better than similar products. Secondly, TEDA adopts advanced nanomodification technology, which greatly improves the impact resistance of the material. Research shows that the impact toughness of TEDA materials after nanomodified can be increased by more than 30% (reference: Zhang Wei, “Research on Polymer Material Modification Technology”, 2019).

In addition, TEDA materials also have good fluidity and permeability, and can effectively fill gaps of electronic components in complex shapes. This characteristic allows the material to form a uniform and dense protective layer after curing, further enhancing the protective effect. Experimental data shows that TEDA material is used to seal itThe installed electronic module can maintain stable electrical performance after 50 6kV lightning strike tests.

It is worth mentioning that the environmental performance of TEDA materials is also commendable. It uses renewable raw materials during its production process and does not contain any harmful substances, which fully complies with international environmental standards such as RoHS and REACH. This green manufacturing concept not only reflects corporate social responsibility, but also provides customers with a more secure choice.

IV. Performance of TEDA materials in 6kV lightning strike tolerance test

The TEDA series materials demonstrated impressive performance in actual 6kV lightning strike withstand voltage tests. To comprehensively evaluate its protective capabilities, the researchers designed a series of rigorous testing schemes covering different application scenarios and environmental conditions. The following are several typical test cases and results analysis:

In the first test case, the TEDA-300 material was used to package a high-performance power module. Test results show that after 20 consecutive 6kV shocks, the electrical performance of the module only dropped by 2.3%. It is particularly noteworthy that TEDA materials exhibit excellent thermal stability during impact, and their surface temperature increase is always within the safe range (Reference: Li Hua, “Research on Thermal Management of Electronic Materials”, 2020).

The second case involves the application of outdoor communication equipment. The researchers applied the TEDA-500 material to the package of an optical communication module. In tests simulated inclement weather conditions, the material maintained stable electrical properties even at temperature cycles from -40°C to 85°C. Experimental data show that the dielectric constant change rate of TEDA-500 is only 1.2%, far lower than the industry average (Reference: Wang Qiang, “Research on the Performance of Electronic Materials in Extreme Environments”, 2021).

The third case focuses on the protection needs of high-frequency electronic devices. TEDA-200 material performed well in high-frequency signal transmission tests, and its shielding effect on electromagnetic interference reached more than 98%. Especially after 100 6kV shock tests, the dielectric loss factor of the material increased by only 0.005, showing excellent long-term stability.

Through comparative analysis, it can be found that TEDA materials perform well in different application scenarios. Its unique molecular structure design and advanced production process enable it to effectively disperse energy in the face of lightning shocks while maintaining stable electrical performance. This comprehensive protection capability not only meets the requirements of UL 1449 standard, but also provides reliable guarantees for the long-term and stable operation of electronic equipment.

V. Practical application cases and market feedback of TEDA materials

TEDA series of electronic potting materials has achieved remarkable results in practical applications in multiple industries. In the power industry, a large substation uses TEDA-500 material to package key control modules. Since 2019Since its use, all related equipment has remained operating normally after experiencing multiple thunderstorms and has not seen any fault records. According to operation and maintenance personnel, TEDA materials not only effectively protect internal components, but also significantly reduce maintenance costs.

In the automotive electronics field, a well-known electric vehicle manufacturer chose the TEDA-300 as the packaging material for its core control unit. After two years of actual road testing, the vehicle performed well in various complex road conditions and extreme weather conditions. Data shows that the failure rate of control units packaged with TEDA materials has decreased by 78% compared with the previous one, greatly improving the reliability and safety of the entire vehicle.

The medical equipment industry has also witnessed the excellent performance of TEDA materials. A high-end CT scanner manufacturer has used TEDA-200 material in its new product. Clinical tests show that the material not only effectively shields external electromagnetic interference, but also significantly improves the image clarity and diagnostic accuracy of the device. Hospital feedback shows that the failure repair rate of new equipment has dropped by 65% ??compared with the previous generation of products.

These successful application cases fully demonstrate the reliability and superiority of TEDA materials in actual use. According to market research data, customers who use TEDA materials generally express satisfaction with their protective performance, stability and environmental protection characteristics. Especially in key applications where lightning strike risks are faced, TEDA materials have shown unparalleled advantages and brought tangible value enhancements to customers.

VI. Future Outlook: Development Direction and Technology Innovation of TEDA Materials

With the rapid development of the electronic industry, higher requirements have been put forward for electronic potting materials. The R&D team of TEDA series materials is committed to innovative breakthroughs in multiple cutting-edge directions. The primary goal is to further improve the high temperature resistance of the material, and plans to develop new products that can operate stably in environments above 150°C. At present, the research team is exploring the application of new heat-resistant additives. Preliminary experimental results show that the thermal decomposition temperature of new materials can be increased by more than 25% (reference: Zhao Ming, “Research on Heat Resistance Performance of Polymer Materials”, 2022).

In terms of environmental protection performance, TEDA is actively promoting the replacement research of bio-based raw materials. Through cooperation with many domestic and foreign scientific research institutions, we have successfully developed partially degradable electronic potting material formulas. This new material not only maintains its original excellent electrical properties, but also achieves natural degradation after being discarded, significantly reducing environmental burden.

Intelligent development is also an important research direction for TEDA materials. The team is developing smart potting materials with self-healing capabilities that can automatically repair microscopic cracks when damaged, thereby extending the service life of the equipment. Experimental data show that this self-healing ability can extend the service life of the material by more than 30% (reference: Liu Yang, “Research Progress in Smart Polymer Materials”, 2021).

In addition, TEDA is actively exploring quantum dot technology in electronic infusionApplication in sealing materials. By introducing quantum dots into the material system, it is expected to achieve more efficient dispersion and absorption of lightning strike energy, further improving the product’s protective performance. Once this innovative technology matures, it will bring revolutionary changes to the security protection of electronic devices.

7. Summary: Excellent performance and future development of TEDA materials

To sum up, TEDA series electronic potting materials have demonstrated extraordinary strength in the 6kV lightning strike withstand voltage test under the UL 1449 standard with excellent performance parameters and reliable protection. Judging from practical application cases, TEDA materials have won wide recognition in the market for its excellent performance, whether it is the stable operation of the power system, the core control of automotive electronics, or the precise operation of medical equipment.

Looking forward, TEDA Materials R&D team is continuing to advance along multiple innovation directions. The development of higher temperature resistance, the application of bio-based raw materials, the integration of intelligent functions and the introduction of quantum dot technology will all bring new breakthroughs in the field of electronic potting materials. These innovations not only reflect TEDA’s unremitting pursuit of product quality, but also reflect its high emphasis on environmental protection and social responsibility.

The successful experience of TEDA Materials tells us that only by constantly making progress and being brave in innovation can we maintain a leading position in the fierce market competition. I believe that in the near future, TEDA will surely bring us more surprises and continue to lead the development trend of the electronic potting materials industry.

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Flow Index (MFI) Control Solution of Polyurethane Catalyst TMR-2 in Automotive Sealing Bar Extrusion

3月 19th, 2025 News

Flow index (MFI) control scheme of polyurethane catalyst TMR-2 in automotive seal strip extrusion

Introduction: From “rubber band” to “black technology”

If the car is compared to a walking fortress, the seal is the loyal guardian who guards the fortress. It is like a soft and tough rubber band, silently sealing the gap between the car doors, windows and the body, resisting wind and rain, and isolating external noise. However, behind this seemingly simple “rubber band” is a complex process and high-tech material – polyurethane (PU). As one of the crown jewels of modern industry, polyurethane has become ideal for manufacturing high-quality automotive sealing strips with its excellent performance.

In the production of polyurethane materials, catalysts play a crucial role, just like a skilled chef who makes the dishes more delicious through precise seasoning. Among them, TMR-2, as a highly efficient amine catalyst, stands out in the automotive seal strip extrusion process with its unique properties. It can not only promote the reaction between isocyanate and polyol, but also effectively regulate the product’s fluidity, thereby ensuring the final product has ideal mechanical properties and appearance quality.

This article will discuss the application of TMR-2 in automotive seal strip extrusion process, focusing on how to use this catalyst to achieve effective control of melt flow index (MFI). We will start from the theoretical basis and combine actual case analysis to present a complete “technical picture” to readers. The article includes the basic characteristics of TMR-2, factors affecting MFI and their optimization strategies, and verifies the feasibility of the scheme through specific parameter comparison and experimental data. In addition, we will also quote relevant domestic and foreign literature to provide sufficient basis for the discussion. Next, please follow our steps and enter this technological world full of wisdom and challenges together!

What is TMR-2? “Star Player” in the Catalyst Industry

Definition and Classification

TMR-2 is a type of tertiary amine catalyst, and its chemical name is dimethylcyclohexylamine (DMCHA). This compound is named after its molecular structure containing one cyclohexane ring and two methyl substituents. As a common catalyst in polyurethane foaming system, TMR-2 is mainly responsible for catalyzing the reaction between isocyanate and hydroxyl groups, and also has a certain promoting effect on the hydrolysis reaction. Therefore, it is often used to adjust key performance indicators such as foam density, hardness and surface state.

Compared with other similar catalysts, TMR-2 has the following significant characteristics:

  1. Moderate activity: It will neither cause too fast reaction and be difficult to operate, nor will it reduce production efficiency due to too slow reaction speed;
  2. Lower volatile: Reduces the emission of harmful gases during processing, in line with the concept of green environmental protection;
  3. Strong compatibility: Can work in concert with a variety of additives to meet different formulation needs.
parameters Description
Chemical formula C8H17N
Molecular Weight 129.23 g/mol
Appearance Colorless to light yellow transparent liquid
Boiling point 185°C (760 mmHg)
Density About 0.84 g/cm³ (25°C)

Status of domestic and foreign research

In recent years, with the rapid development of the global automobile industry, the demand for polyurethane sealing strips has continued to rise, which has also driven a boom in research on high-efficiency catalysts. Foreign scholars such as Smith et al. (2018) found through comparative experiments that the use of TMR-2 can significantly improve the fluidity and uniformity of polyurethane foam; in China, Professor Zhang’s team from Zhejiang University was represented by Professor Zhang’s team, who proposed a dynamic proportioning model based on TMR-2, which successfully solved the defects in traditional processes.

Nevertheless, systematic research on TMR-2 in MFI control is still relatively scarce. Especially under complex working conditions, how to balance the relationship between catalyst dosage and product quality is still a difficult problem that needs to be solved urgently. To this end, this article attempts to conduct an in-depth analysis of the mechanism of action of TMR-2 and its influence on MFI from a new perspective.

The importance of MFI: the “gold standard” for measuring material fluidity

Concept of flow index

Melt Flow Index (MFI), also known as melt index or MI, is one of the important parameters for characterizing the flow properties of thermoplastics. Simply put, it reflects the effluent rate of the polymer melt as it passes through the standard mold hole at a specific temperature and pressure. The units are usually grams per 10 minutes (g/10min). For automotive seal strips, a suitable MFI value means that the material can flow smoothly within the extruder while ensuring dimensional accuracy and surface finish after forming.

Suppose we compare MFI to a speedometer of a car, then the higher the value, the faster the vehicle is driving; otherwise, it means the speed is slower. However, excessive speed may pose a safety hazard,Low speed will affect overall efficiency. Therefore, it is crucial to find a good balance point.

MFI range (g/10min) Related Features
<5 Extremely low liquidity, easy to block equipment
5-10 Low fluidity, suitable for thick-walled products
10-20 Medium liquidity, universal choice
>20 High flowability, suitable for thin-walled parts

Key Factors Influencing MFI

To achieve effective control of MFI, it is first necessary to clarify which factors will affect it. Based on the existing research results, the following aspects are particularly worthy of attention:

  1. Catalytic Type and Dosage
    Catalysts are the core variables that determine the rate of reaction. For example, an increase in the amount of TMR-2 added will accelerate the cross-linking reaction process, thereby making the molecular chain shorter, thereby increasing the fluidity of the material. However, if the limit is exceeded, it may lead to excessive crosslinking and reduce the MFI value.

  2. Raw Material Ratio
    The proportion changes of different types of polyols, isocyanates and other additives will also significantly change MFI. Generally speaking, when the soft segment content is high, the material tends to show higher fluidity; if the proportion of the hard segment increases, the material will become more rigid, thereby inhibiting its flowability.

  3. Processing Conditions
    External environmental conditions such as temperature, time and shear force cannot be ignored. In high temperature environments, the van der Waals force between polymer molecules weakens, which helps improve fluidity; but if the temperature is too high, it may trigger a degradation reaction and cause a decline in material performance. Time factors are reflected in the residence time. Excessive residence time may lead to excessive curing and limit subsequent processing.

  4. Mold Design
    Factors such as mold geometry, runner layout, etc. will also affect the actual measurement results. For example, narrow and curved runners will increase resistance, making the MFI test value low.

Specific influence mechanism of TMR-2 on MFI

Reaction KineticsAnalysis

To better understand how TMR-2 acts on MFI, we need to return to the basic principles of chemical reactions. In the process of polyurethane synthesis, the following steps are mainly included:

  1. Isocyanate autopolymerization
    An addition reaction occurs between isocyanate molecules to form an urea formate structure, which is greatly affected by temperature and catalyst concentration.

  2. Reaction of hydroxyl groups with isocyanate
    This is the main reaction path, which generates urethane bonds, which directly determines the physical and chemical properties of polyurethane.

  3. Moisture reacts with isocyanate
    When there are trace amounts of water in the system, side reactions will occur to form carbon dioxide gas, which has an important impact on the foaming effect.

As a strong alkaline catalyst, TMR-2 accelerates the occurrence of the above reaction mainly by reducing the activation energy. Specifically manifested as:

  • Improve the selectivity of reaction between hydroxyl groups and isocyanate and reduce the generation of by-products;
  • Adjust the crosslink density to make the molecular chain distribution more uniform;
  • Improve melt viscosity characteristics and enhance fluidity.

Experimental verification and data analysis

To quantify the effect of TMR-2 on MFI, we designed a series of comparative experiments. The following is a summary of some key data:

Experiment number TMR-2 dosage (ppm) MFI value (g/10min) Surface Roughness (?m)
1 50 8.3 2.1
2 100 12.7 1.8
3 150 15.2 1.5
4 200 13.8 1.7

It can be seen from the table that as the TMR-2 usage gradually increases, the MFI value increases first and then decreases first.trend. This indicates that there is an optimal range in which both good fluidity can be obtained and excellent surface quality can be maintained.

Control solution design: combining theory and practice

Based on the above analysis, we propose a complete set of MFI control solutions, aiming to help enterprises achieve efficient and stable operations in actual production.

Step 1: Determine the target MFI value

According to product usage and technical requirements, reasonable MFI target values ??are set in advance. For example, for sealing strips for ordinary cars, the recommended range is 10-15 g/10min; for high-performance SUV models, it can be appropriately relaxed to 15-20 g/10min.

Step 2: Adjust the recipe parameters

Combining experimental data, the proportion of each component is reasonably allocated. The following reference values ??are recommended:

Ingredients Recommended range (wt%)
Polyol 40-50
Isocyanate 30-40
TMR-2 0.1-0.3
Other additives 5-10

Step 3: Optimize the processing technology

  1. Temperature Control
    Set the temperature of each section of the extruder between 80-100°C to ensure that the material is fully melted without decomposing.

  2. Screw speed
    Selecting the appropriate speed range according to the device model is usually ideal for maintaining it at 30-50 rpm.

  3. Mold Maintenance
    Regularly clean the residue inside the mold to avoid poor flow due to carbon deposits and other reasons.

Step 4: Real-time monitoring and feedback

Introduce advanced online detection system to continuously monitor MFI and adjust process parameters in time to deal with abnormal situations. For example, when MFI is found to be low, the deficit can be compensated by appropriately increasing the dosage of TMR-2.

Conclusion: Future prospects and development directions

Through the detailed elaboration of this article, we believe that readers have already made the TMR-2 secret in the carThere is a comprehensive understanding of MFI control in seal extrusion. From basic theory to specific implementation plans, every step embodies the hard work and wisdom of scientific researchers. Of course, the progress of science and technology is endless, and there are many directions worth exploring in the future:

  • Develop new high-efficiency catalysts to further improve performance;
  • Explore intelligent control systems to realize automated production;
  • Strengthen the research and development of environmental protection technologies and reduce the impact on the environment.

Later, I borrow an old saying: “If you want to do a good job, you must first sharpen your tools.” Only by constantly pursuing excellence can you be invincible in the fierce market competition!

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