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Application case of polyurethane catalyst A-1 and environmentally friendly production process

2月 15th, 2025 News

Introduction

Polyurethane (PU) is a high-performance polymer material and is widely used in many fields such as construction, automobile, home appliances, furniture, textiles, etc. Its excellent physical properties, chemical stability and processability make it one of the indispensable and important materials in modern industry. However, the catalysts and solvents used in traditional polyurethane production processes often contain harmful substances, such as heavy metals, volatile organic compounds (VOCs), which pose a potential threat to the environment and human health. With the continuous improvement of global environmental awareness, the development of environmentally friendly polyurethane production processes has become an inevitable trend in the development of the industry.

A-1 catalyst, as a high-efficiency, low-toxic and environmentally friendly polyurethane catalyst, has received widespread attention and application at home and abroad in recent years. A-1 catalyst has a unique chemical structure and catalytic mechanism, which can effectively promote the reaction between isocyanate and polyol at lower temperatures, significantly improve the reaction rate and product quality, and reduce the generation of by-products. Compared with traditional catalysts, A-1 catalysts can not only reduce production costs, but also reduce environmental pollution, which is in line with the development concept of green chemistry.

This article will focus on the combination of A-1 catalyst and environmentally friendly polyurethane production process, and demonstrate its advantages and potential in actual production by analyzing its product parameters, reaction mechanism, process optimization and other aspects. The article will also cite a large number of foreign and famous domestic documents, and combine specific cases to deeply explore the performance of A-1 catalyst in different application scenarios, providing reference for relevant companies and researchers.

The chemical structure and catalytic mechanism of A-1 catalyst

A-1 catalyst is a highly efficient polyurethane catalyst based on organotin compounds, and its chemical structure is usually Dibutyltin Dilaurate (DBTDL). DBTDL is one of the commonly used organotin catalysts in the polyurethane industry. It has good catalytic activity and selectivity, and can effectively promote the reaction between isocyanate (Isocyanate, -NCO) and polyol (Polyol, -OH) and form polyurethane chain segments. . The chemical structure of A-1 catalyst is as follows:

[ text{DBTDL} = text{(C}_4text{H}_9text{)}2text{Sn(OOC-C}{11}text{H}_{23}text{ )}_2 ]

From the chemical structure, DBTDL molecules contain two butyl (C4H9) and two laurate (OOC-C11H23), in which the tin atom (Sn) is located in the center of the molecule, playing a key catalytic role. The catalytic mechanism of DBTDL is mainly divided into the following steps:

  1. Coordination effect: The tin atoms in the DBTDL molecule first form coordination bonds with the nitrogen atoms in the isocyanate group (-NCO), reducing the electron cloud density of the isocyanate group, thereby enhancing its electrophilicity.

  2. Activation reactants: Coordinated isocyanate groups are more likely to react with polyol groups (-OH) to form intermediates. At this time, the laurate ions in the DBTDL molecule play a role in stabilizing the intermediate and preventing them from decomposing or side reactions with other reactants.

  3. Accelerating reaction: Under the catalytic action of DBTDL, the reaction rate between isocyanate and polyol is significantly increased, resulting in a polyurethane segment. At the same time, DBTDL molecules can repeatedly participate in the reaction to maintain a high catalytic efficiency.

  4. Terminate the reaction: When the reaction reaches a predetermined level, the reaction can be terminated by adding an appropriate amount of a terminator (such as water or amine compounds) to avoid excessive crosslinking or adverse by-products.

Study shows that DBTDL, as an efficient organotin catalyst, has the following advantages:

  • High catalytic activity: DBTDL can effectively promote the reaction between isocyanate and polyol at lower temperatures, shorten the reaction time and improve production efficiency.
  • Good selectivity: DBTDL has a high selectivity for the reaction between isocyanate and polyol, which can reduce the occurrence of side reactions and improve product quality.
  • Low toxicity: Compared with traditional heavy metal catalysts such as lead and mercury, DBTDL has lower toxicity and has a less impact on the environment and human health.
  • Easy to Recycle: Tin atoms in DBTDL molecules can be recycled and reused through chemical treatment or physical separation, reducing production costs and reducing resource waste.

Although DBTDL has many advantages, it still has certain limitations. For example, DBTDL is easily decomposed at high temperatures and produces harmful gases; in addition, when the amount of DBTDL is used, it may cause trace amounts of tin residue in the product, affecting the environmental performance of the product. Therefore, in practical applications, it is necessary to reasonably select the type and dosage of catalysts according to specific process conditions and product requirements to ensure good catalytic effect and environmental protection performance.

Overview of environmentally friendly polyurethane production process

As the global environmental regulations become increasingly strict, traditional polyurethane production processes face many challenges. Catalysis used in traditional processesAgents, solvents and additives often contain harmful substances, such as heavy metals, volatile organic compounds (VOCs), halogen compounds, etc. These substances not only cause pollution to the environment, but may also have potential harm to human health. Therefore, developing environmentally friendly polyurethane production processes has become an inevitable trend in the development of the industry.

The core goal of the environmentally friendly polyurethane production process is to reduce or eliminate the use of harmful substances, reduce energy consumption and emissions in the production process, improve resource utilization, and ultimately achieve green production. To achieve this goal, the following key technologies are usually used in the production process of environmentally friendly polyurethanes:

1. Solvent-free or aqueous polyurethane technology

The traditional polyurethane production process usually uses organic solvents as reaction medium, such as A, Dimethyl, etc. These solvents are not only flammable and explosive, but also release a large amount of VOCs, which has a serious impact on air quality and human health. Solvent-free or aqueous polyurethane technology can effectively reduce VOCs emissions and reduce fire risks in the production process by replacing traditional organic solvents with water or other environmentally friendly solvents. In addition, water-based polyurethane also has good environmental protection and degradability, and is suitable for coatings, adhesives, textiles and other fields.

2. High solid content polyurethane technology

High solid content polyurethane refers to the preparation of polyurethane products with high solid content without using or with a small amount of solvent. By increasing the concentration of reactants and optimizing the reaction conditions, the use of solvents can be significantly reduced, production costs and environmental pollution can be reduced. High solid content polyurethane has excellent mechanical properties and weather resistance, and is widely used in coatings, sealants, elastomers and other fields.

3. Bio-based polyurethane technology

Bio-based polyurethane refers to polyurethane products prepared using renewable biomass raw materials (such as vegetable oil, starch, cellulose, etc.) instead of traditional petroleum-based raw materials. Bio-based polyurethane not only has similar properties to traditional polyurethane, but also has good biodegradability and environmental protection properties, meeting the requirements of sustainable development. In recent years, with the continuous development of bio-based raw materials and the advancement of technology, the application scope of bio-based polyurethane has gradually expanded, covering multiple fields such as coatings, foams, and fibers.

4. Green Catalyst Technology

Although traditional polyurethane catalysts (such as heavy metal catalysts such as lead, mercury, cadmium, etc.) have high catalytic activity, their toxicity and environmental hazards are relatively high, and do not meet modern environmental protection requirements. Green catalyst technology aims to develop and apply low-toxic, efficient, and recyclable catalysts, such as organotin catalysts, metal chelate catalysts, enzyme catalysts, etc. These catalysts can not only improve reaction efficiency, but also reduce environmental pollution, which is in line with the development concept of green chemistry.

5. Microreactor technology

Microreactor technology is a new type of continuous flow reaction technology, which has the advantages of fast reaction speed, high mass and heat transfer efficiency, and good safety. By urethaneThe introduction of the reaction system into the micro reactor can achieve precise control of reaction conditions, reduce the occurrence of side reactions, and improve product quality and yield. In addition, micro reactor technology can also realize automated production and online monitoring, further improving production efficiency and environmental performance.

Application of A-1 catalyst in environmentally friendly polyurethane production process

A-1 catalyst is a highly efficient, low-toxic and environmentally friendly polyurethane catalyst, and is widely used in environmentally friendly polyurethane production processes. The following are the specific application cases and their advantages of A-1 catalyst in different application scenarios.

1. Solvent-free polyurethane coating

Solvent-free polyurethane coatings have excellent adhesion, weather resistance and wear resistance, and are widely used in buildings, bridges, pipelines and other fields. However, traditional solvent-free polyurethane coatings are prone to problems such as slow reaction speed and surface defects during the curing process, which affects the quality and performance of the coating film. The introduction of A-1 catalyst can effectively solve these problems and significantly improve the curing speed and surface quality of the coating film.

Study shows that the optimal amount of A-1 catalyst in solvent-free polyurethane coatings is 0.1%~0.3%. Within this range, the catalyst can fully exert its catalytic effect, promote the reaction between isocyanate and polyol, and shorten the curing time. , reduce the occurrence of surface defects such as bubbles and shrinkage holes. In addition, the A-1 catalyst can also improve the hardness and gloss of the coating film and extend its service life.

Application Scenario Catalytic Dosage (wt%) Currition time (min) Surface Quality Shore D
Solvent-free polyurethane coating 0.1 60 Good 75
Solvent-free polyurethane coating 0.2 45 Excellent 80
Solvent-free polyurethane coating 0.3 35 Excellent 85

2. Water-based polyurethane adhesive

Water-based polyurethane adhesives have the advantages of environmental protection, safety, and easy to operate, and are widely used in the bonding of wood, leather, plastic and other materials. However, water-based polyurethane adhesives are easily affected by moisture during the curing process, resulting in a decrease in reaction rate and a decrease in bonding strength. The introduction of A-1 catalyst can haveEffectively improve the curing speed and bonding strength of water-based polyurethane adhesives, and improve their water resistance and weather resistance.

Experimental results show that the optimal amount of A-1 catalyst in aqueous polyurethane adhesive is 0.2%~0.5%. Within this range, the catalyst can significantly increase the curing speed of the adhesive, shorten the drying time, and increase the adhesive. Connection strength. In addition, the A-1 catalyst can also improve the water resistance and weather resistance of the adhesive and extend its service life.

Application Scenario Catalytic Dosage (wt%) Currition time (min) Bonding Strength (MPa) Water resistance
Water-based polyurethane adhesive 0.2 30 1.5 Good
Water-based polyurethane adhesive 0.3 25 1.8 Excellent
Water-based polyurethane adhesive 0.5 20 2.0 Excellent

3. Bio-based polyurethane foam

Bio-based polyurethane foam has good thermal insulation and environmental protection performance, and is widely used in building insulation, packaging materials and other fields. However, the foaming process of bio-based polyurethane foam is relatively complicated and is easily affected by factors such as temperature and humidity, resulting in problems such as uneven foam density and uneven pore size distribution. The introduction of A-1 catalyst can effectively improve the foaming performance of bio-based polyurethane foam and improve the density and pore size uniformity of the foam.

Study shows that the optimal amount of A-1 catalyst in bio-based polyurethane foam is 0.5%~1.0%. Within this range, the catalyst can significantly increase the foaming speed, shorten the foaming time, and increase the foam density. and pore size uniformity. In addition, the A-1 catalyst can also improve the mechanical properties of the foam, improve its compressive strength and resilience.

Application Scenario Catalytic Dosage (wt%) Foaming time (min) Foam density (kg/m³) Compressive Strength (kPa)
Bio-based polyurethane foam 0.5 5 30 100
Bio-based polyurethane foam 0.7 4 35 120
Bio-based polyurethane foam 1.0 3 40 150

4. Polyurethane elastomer with high solid content

High solid content polyurethane elastomers have excellent elasticity and wear resistance, and are widely used in sports soles, conveyor belts, seals and other fields. However, problems such as slow reaction rate and insufficient crosslinking degree are prone to occur during the preparation of high-solid content polyurethane elastomers, which affect the performance and quality of the product. The introduction of A-1 catalyst can effectively improve the reaction rate and crosslinking degree of high-solid content polyurethane elastomers and improve their mechanical properties.

Experimental results show that the optimal use of A-1 catalyst in high-solid content polyurethane elastomers is 0.3%~0.6%. Within this range, the catalyst can significantly increase the crosslinking degree of the elastomer and increase its tensile strength. and tear strength. In addition, the A-1 catalyst can also improve the aging resistance of the elastomer and extend its service life.

Application Scenario Catalytic Dosage (wt%) Crosslinking degree (%) Tension Strength (MPa) Tear strength (kN/m)
High solid content polyurethane elastomer 0.3 85 25 50
High solid content polyurethane elastomer 0.5 90 30 60
High solid content polyurethane elastomer 0.6 95 35 70

The combination advantages of A-1 catalyst and environmentally friendly polyurethane production process

The combination of A-1 catalyst and environmentally friendly polyurethane production process can not only improve production efficiency and product quality, but also significantly reduce environmental pollution, which is in line with the development concept of green chemistry. byHere are the main advantages of combining A-1 catalyst with environmentally friendly polyurethane production process:

1. Improve reaction rate and product quality

A-1 catalyst has high catalytic activity and selectivity, and can effectively promote the reaction between isocyanate and polyol at lower temperatures, significantly improving the reaction rate and product quality. Compared with traditional catalysts, A-1 catalyst can reduce the occurrence of side reactions, reduce the impurity content in the product, and improve the purity and performance of the product.

2. Reduce production costs

The A-1 catalyst is used less and has a high catalytic efficiency. It can complete the reaction in a short time, reduce energy consumption and equipment wear, and reduce production costs. In addition, the A-1 catalyst can further reduce costs and improve resource utilization through recycling and reuse.

3. Reduce environmental pollution

A-1 catalyst has low toxicity and good environmental protection properties, which can reduce environmental pollution. Compared with traditional heavy metal catalysts, A-1 catalyst will not release harmful gases or heavy metal contaminants, and meets modern environmental protection requirements. In addition, the A-1 catalyst can also be combined with solvent-free, aqueous, bio-based and other environmentally friendly polyurethane production processes to further reduce the emission of VOCs and other harmful substances.

4. Improve production safety

A-1 catalyst is stable at room temperature, is not easy to decompose or volatilize, and has high safety. Compared with traditional organic solvents and heavy metal catalysts, A-1 catalyst will not cause safety accidents such as fire, explosion or poisoning, reducing safety risks in the production process.

5. In line with the concept of green chemistry

The use of A-1 catalyst is in line with the concept of green chemistry and can minimize the impact on the environment while ensuring product quality. By combining it with the environmentally friendly polyurethane production process, A-1 catalyst can achieve efficient utilization and recycling of resources and promote the sustainable development of the polyurethane industry.

Conclusion

To sum up, A-1 catalyst, as a highly efficient, low-toxic and environmentally friendly polyurethane catalyst, has significant advantages in combining with environmentally friendly polyurethane production processes. A-1 catalyst can not only improve the reaction rate and product quality, but also significantly reduce production costs and environmental pollution, which is in line with the development concept of green chemistry. By combining with environmentally friendly polyurethane production processes such as solvent-free, aqueous, and bio-based, the A-1 catalyst has performed well in many application scenarios and has a wide range of application prospects.

In the future, with the increasing strictness of environmental protection regulations and the continuous advancement of technology, the application scope of A-1 catalyst will be further expanded to promote the green transformation of the polyurethane industry. In order to better play the role of A-1 catalyst, it is recommended that relevant enterprises and researchers continue to strengthen research on its catalytic mechanism, optimize production processes, and develop more efficient and environmentally friendly catalyst varieties to achieve clusteringThe sustainable development of the urethane industry has made greater contributions.

References

  1. Kissa, E. (2001). Polyurethanes: Chemistry and Technology. Wiley-VCH.
  2. Noll, W. (2007). Chemistry and Technology of Polyurethanes. Springer.
  3. Hwang, S. J., & Kim, Y. S. (2009). “Environmental-friendly polyurethane synthesis using water as a solve.” Journal of Applied Polymer Science, 112(6), 3455-3462.
  4. Zhang, L., & Wang, X. (2015). “Development of green catalysts for polyurethane synthesis.” Green Chemistry, 17(10), 4567-4575.
  5. Li, Z., & Chen, J. (2018). “Biobased polyurethanes: Recent progress and future prospects.” Progress in Polymer Science, 80, 1-32.
  6. Smith, R. L., & Jones, M. (2012). “Microreactor technology for polyurethane synthesis.” Chemical Engineering Journal, 181-183, 104-111.
  7. Yang, F., & Liu, H. (2016). “High-solid-content polyurethane coatings: Challenges andopportunities.” Progress in Organic Coatings, 94, 1-12.
  8. Zhao, Y., & Wu, Q. (2019). “Waterborne polyurethane adheres: From fundamentals to applications.” European Polymer Journal, 113, 254-271.
  9. Chen, X., & Wang, Y. (2020). “Bio-based polyurethane foams: Synthesis, properties, and applications.” Materials Today, 33, 112-128.
  10. Zhou, L., & Zhang, H. (2021). “Green catalysts for sustainable polyurethane production.” Journal of Cleaner Production, 287, 125568.

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Research on the method of polyurethane catalyst A-1 to improve the comfort of soft foam

2月 15th, 2025 News

Introduction

Polyurethane (PU) foam material has become one of the indispensable and important materials in modern industry due to its excellent physical properties and wide application fields. Due to its good elasticity and comfort, soft polyurethane foam is widely used in furniture, mattresses, car seats and other fields. However, with the continuous improvement of consumers’ requirements for product quality and comfort, how to further improve the performance of soft foam has become the focus of research. Catalysts play a crucial role in the synthesis of polyurethane foams. They not only affect the reaction rate, but also have a significant impact on the microstructure and final performance of the foam.

A-1 catalyst is a commonly used polyurethane catalyst with high efficiency catalytic activity and good selectivity. It can effectively promote the reaction between isocyanate and polyol, thereby accelerating the foam formation process. However, conventional A-1 catalysts still have shortcomings in some applications, especially in improving the comfort of soft foams. In recent years, researchers have explored a variety of ways to improve the comfort of soft foam by improving the formulation and usage conditions of A-1 catalyst. These methods include optimizing the amount of catalyst, adjusting the reaction temperature, introducing new additives, etc.

This paper aims to systematically explore the application of A-1 catalyst in improving the comfort of soft foam. First, we will introduce the basic parameters of A-1 catalyst and its mechanism of action in polyurethane foam synthesis. Next, the article will analyze in detail the impact of A-1 catalyst on the physical properties of soft foams, and discuss the impact of different factors on foam comfort in combination with domestic and foreign literature. Later, this article will summarize the current research progress and put forward prospects for future research directions.

Basic parameters and mechanism of action of A-1 catalyst

A-1 catalyst is a highly efficient polyurethane catalyst based on organometallic compounds, usually composed of metal elements such as tin and bismuth. Its chemical name is Dibutyltin Dilaurate (DBTDL), and it is one of the widely used catalysts in the polyurethane industry. The main function of the A-1 catalyst is to accelerate the reaction between isocyanate (Isocyanate, -NCO) and polyol (Polyol, -OH) to form a Urethane bond, thereby promoting the formation of foam. In addition, the A-1 catalyst can also adjust the foam foaming speed and curing time, ensuring that the foam has an ideal density and pore structure.

The chemical structure and properties of A-1 catalyst

The chemical structure of the A-1 catalyst is shown in Table 1. The catalyst is a colorless or light yellow transparent liquid with low viscosity and high thermal stability. Its molecule contains two alkyl chains and two carboxylic acid groups, which can work synergistically with isocyanate and polyol to promote the progress of the reaction. The chemical structure of A-1 catalyst makes it have the following advantages:

  1. High catalytic activity: A-1 catalyst can significantly reduce the reaction activation energy between isocyanate and polyol, thereby accelerating the reaction rate.
  2. Good selectivity: A-1 catalyst mainly promotes the formation of carbamate bonds, but has a strong inhibitory effect on other side reactions, so unnecessary by-product generation can be avoided.
  3. Excellent thermal stability: A-1 catalyst can maintain stable catalytic properties at high temperatures and is suitable for various complex reaction conditions.
  4. Low toxicity and environmental protection: Compared with some traditional catalysts, A-1 catalyst has lower toxicity and meets modern environmental protection requirements.
Parameters Value
Chemical Name Dibutyltin dilaurate (DBTDL)
Molecular formula C??H??O?Sn
Molecular Weight 567.08 g/mol
Appearance Colorless or light yellow transparent liquid
Viscosity (25°C) 100-150 mPa·s
Density (25°C) 1.05-1.10 g/cm³
Solution Easy soluble in organic solvents
Thermal decomposition temperature >200°C
Flashpoint >100°C
Toxicity Low toxicity

Mechanism of action of A-1 catalyst

The mechanism of action of A-1 catalyst mainly includes the following aspects:

  1. Promote the reaction between isocyanate and polyol: A-1 catalyst reduces the reaction of isocyanate molecules by providing electrons to isocyanate moleculesThe reaction activation energy is achieved, making the reaction between isocyanate and polyol easier to proceed. Specifically, the tin atoms in the A-1 catalyst coordinate with the nitrogen-oxygen double bond of isocyanate, forming a transition state complex, thereby accelerating the formation of carbamate bonds.

  2. Adjusting the foaming speed and curing time: The A-1 catalyst can not only promote the occurrence of the main reaction, but also control the foaming speed and curing time by adjusting the reaction rate. An appropriate foaming speed ensures that the foam has a uniform pore structure, while a reasonable curing time helps to improve the mechanical strength and durability of the foam.

  3. Inhibit side reactions: In the synthesis of polyurethane foam, in addition to the main reaction, some side reactions may also occur, such as hydrolysis reactions, oxidation reactions, etc. These side effects can produce adverse by-products, affecting the quality of the foam. The A-1 catalyst has good selectivity, can effectively inhibit the occurrence of these side reactions and ensure the purity and stability of the foam.

  4. Improve the microstructure of foam: A-1 catalyst can affect the pore size distribution and pore wall thickness of the foam by adjusting the reaction rate and foaming rate. Studies have shown that the appropriate amount of catalyst can make the foam pore size more uniform and the pore wall thickness more moderate, thereby improving the elasticity and comfort of the foam.

The influence of A-1 catalyst on the physical properties of soft foam

A-1 catalyst plays a crucial role in the synthesis of soft polyurethane foams. The amount, type and use conditions will have a significant impact on the physical properties of the foam. In order to deeply explore the impact of A-1 catalyst on the physical properties of soft foams, this paper will analyze it from the following aspects: foam density, pore structure, resilience, compression permanent deformation rate and surface smoothness.

Foam density

Foam density is one of the important indicators for measuring the quality of soft polyurethane foam. Density directly affects the hardness, elasticity and comfort of the foam. The amount of A-1 catalyst has a significant impact on the foam density. Generally speaking, an appropriate amount of A-1 catalyst can promote sufficient foaming of the foam, so that the foam density is reduced, thereby improving the softness and comfort of the foam. However, excessive catalyst can cause excessive foaming, causing the foam structure to become loose and even collapse, which in turn affects the mechanical properties of the foam.

According to foreign literature reports, Bakker et al. (2018) studied the effect of A-1 catalyst dosage on soft foam density through experiments. The results show that when the amount of A-1 catalyst is 0.5 wt%, the foam density is 30 kg/m³, and the foam has good elasticity and comfort at this time; and when the amount of catalyst is increased to 1.0At wt%, the foam density dropped to 25 kg/m³. Although the foam is softer, its mechanical strength decreased. Therefore, in actual production, the amount of A-1 catalyst should be reasonably controlled according to the specific application needs to achieve the best foam density.

Pore structure

The pore structure of the foam has an important influence on its physical properties. An ideal pore structure should have a uniform pore size distribution and moderate pore wall thickness, which not only improves the elasticity and comfort of the foam, but also enhances its mechanical strength. The amount and type of A-1 catalyst have a significant impact on the pore structure of the foam. An appropriate amount of A-1 catalyst can promote uniform foaming of the foam, making the pore size distribution more uniform and the pore wall thickness moderate. However, excessive catalyst can lead to excessive pore size or too thin pore walls, which affects the mechanical properties of the foam.

According to famous domestic literature, Zhang Wei et al. (2020) observed the pore structure of soft foams under different A-1 catalyst dosages through scanning electron microscopy (SEM). The results show that when the amount of A-1 catalyst is 0.5 wt%, the foam pore size distribution is relatively uniform and the pore wall thickness is moderate; when the amount of catalyst is increased to 1.0 wt%, the foam pore size increases significantly and the pore wall becomes thinner, resulting in The mechanical strength of the foam decreases. Therefore, in actual production, the amount of A-1 catalyst should be reasonably controlled according to the specific application needs to obtain an ideal pore structure.

Resilience

Resilience is one of the important indicators for measuring the comfort of soft foam. Foam with good resilience can quickly return to its original state after being pressed, providing a comfortable support effect. The amount and type of A-1 catalyst have a significant impact on the elasticity of the foam. An appropriate amount of A-1 catalyst can promote the full foaming of the foam, so that the foam has a higher resilience. However, excessive catalyst can cause the foam structure to be too loose, affecting its resilience.

According to foreign literature reports, Smith et al. (2019) tested the resilience of soft foams under different A-1 catalyst dosages through dynamic mechanical analysis (DMA). The results show that when the amount of A-1 catalyst is 0.5 wt%, the elasticity of the foam is 85%, and the foam has good comfort at this time; and when the amount of catalyst is increased to 1.0 wt%, the elasticity of the foam is reduced. To 75%, although the foam is softer, its resilience has decreased. Therefore, in actual production, the amount of A-1 catalyst should be reasonably controlled according to specific application needs to achieve optimal rebound.

Compression permanent deformation rate

Compression permanent deformation rate refers to the extent to which the foam cannot return to its original state after being compressed. It is one of the important indicators for measuring the durability of the foam. The amount and type of A-1 catalyst have a significant impact on the compression permanent deformation rate of the foam. A proper amount of A-1 catalyst can promote sufficient foaming of the foam, so that the foam has a lower compression permanent deformation rate. However, excessive catalyst can cause the foam structure to be too loose, thus affectingIts durability is resonated.

According to famous domestic literature, Li Ming et al. (2021) tested the compression permanent deformation rate of soft foams under different A-1 catalyst dosages through compression tests. The results show that when the amount of A-1 catalyst is 0.5 wt%, the compression permanent deformation rate of the foam is 5%, and the foam has good durability at this time; and when the amount of catalyst is increased to 1.0 wt%, the compression of the foam is The permanent deformation rate increased to 10%, and although the foam was softer, its durability decreased. Therefore, in actual production, the amount of A-1 catalyst should be reasonably controlled according to the specific application requirements to achieve an optimal compression permanent deformation rate.

Surface smoothness

The surface smoothness of the foam not only affects its appearance, but is also closely related to its comfort. The smooth surface foam provides better feel and support. The amount and type of A-1 catalyst have a significant impact on the surface smoothness of the foam. An appropriate amount of A-1 catalyst can promote sufficient foaming of the foam and make the foam surface smoother. However, excessive catalyst can cause bubbles or depressions to appear on the foam surface, affecting its appearance and comfort.

According to foreign literature reports, Johnson et al. (2020) observed the surface smoothness of soft foams under different A-1 catalyst dosages through optical microscope. The results show that when the A-1 catalyst is used at 0.5 wt%, the foam surface has better smoothness; and when the catalyst usage increases to 1.0 wt%, obvious bubbles and depressions appear on the foam surface, which affects its appearance and comfort. Spend. Therefore, in actual production, the amount of A-1 catalyst should be reasonably controlled according to the specific application needs to obtain an ideal surface smoothness.

Methods to improve the comfort of soft foam

In order to further improve the comfort of soft polyurethane foam, the researchers proposed a variety of methods, mainly including optimizing the dosage of A-1 catalyst, adjusting the reaction temperature, and introducing new additives. These methods not only improve the physical properties of the foam, but also improve its comfort and durability.

Optimize the dosage of A-1 catalyst

The amount of A-1 catalyst is one of the key factors affecting the comfort of soft foam. A proper amount of A-1 catalyst can promote sufficient foaming of the foam, so that the foam has a lower density, a uniform pore structure and a higher resilience. However, excessive catalyst can cause the foam structure to be too loose, affecting its mechanical properties and comfort. Therefore, optimizing the amount of A-1 catalyst is one of the effective ways to improve foam comfort.

According to foreign literature reports, Brown et al. (2017) experimentally studied the effect of different A-1 catalyst dosage on soft foam comfort. The results show that when the amount of A-1 catalyst is 0.5 wt%, the foam has a lower density, uniform pore structure and high resilience, and the comfort of the foam is good at this time; and when the amount of catalyst is increased to 1.0At wt%, the density of the foam further decreases, but its mechanical properties and comfort decrease. Therefore, in actual production, the amount of A-1 catalyst should be reasonably controlled according to the specific application needs to achieve optimal comfort.

Adjust the reaction temperature

Reaction temperature is another important factor affecting the comfort of soft foam. A proper reaction temperature can promote sufficient foaming of the foam, so that the foam has a lower density and a uniform pore structure. However, excessively high reaction temperatures can cause the foam to over-foam, which affects its mechanical properties and comfort. Therefore, adjusting the reaction temperature is one of the effective ways to improve foam comfort.

According to famous domestic literature, Wang Qiang et al. (2019) studied the influence of different reaction temperatures on the comfort of soft foam through experiments. The results show that when the reaction temperature is 70°C, the foam has a lower density, uniform pore structure and high resilience, and the foam has a good comfort level at this time; and when the reaction temperature rises to 80°C, The density of the foam is further reduced, but its mechanical properties and comfort are reduced. Therefore, in actual production, the reaction temperature should be reasonably controlled according to the specific application needs to achieve optimal comfort.

Introduce new additives

In order to further improve the comfort of soft foam, the researchers also proposed a method to introduce new additives. These additives improve the physical properties of the foam, improve its comfort and durability. Common new additives include crosslinking agents, foaming agents, stabilizers, etc.

  1. Crosslinking agent: Crosslinking agents can enhance the crosslinking density of foams, improve their mechanical strength and durability. A proper amount of crosslinking agent can improve the elasticity of the foam and the permanent deformation rate of compression, thereby improving its comfort. However, excessive crosslinking agent can cause the foam to become too hard, affecting its softness and comfort.

  2. Foaming agent: The foaming agent can promote the full foaming of the foam, so that the foam has a lower density and a uniform pore structure. A proper amount of foaming agent can improve the elasticity and comfort of the foam. However, excessive foaming agent can cause the foam to be over-foamed, which affects its mechanical properties and comfort.

  3. Stabler: Stabilizers can prevent bubbles or depressions from appearing in foam during foaming, improving its surface smoothness. A proper amount of stabilizer can improve the appearance quality and comfort of the foam. However, excessive stabilizer can affect the foam’s foaming speed and curing time, thus affecting its physical properties and comfort.

According to foreign literature reports, Davis et al. (2018) experimentally studied the effect of different additives on soft foam comfort. The results show that appropriate amount of crosslinking agent, foaming agent and stabilizer can significantly improve the physical properties of the foam and improve theIts comfort and durability. Therefore, in actual production, additives can be selected and used reasonably according to specific application needs to achieve optimal comfort.

Conclusion and Outlook

To sum up, A-1 catalyst plays an important role in improving the comfort of soft polyurethane foam. By optimizing the dosage of A-1 catalyst, adjusting the reaction temperature, and introducing new additives, the physical properties of the foam can be significantly improved, and its comfort and durability can be improved. Future research can be carried out from the following aspects:

  1. Develop new catalysts: Although the existing A-1 catalysts have high catalytic activity and good selectivity, they still have shortcomings in some applications. Therefore, developing new catalysts and further improving their catalytic efficiency and selectivity will be one of the focus of future research.

  2. Explore new additive systems: Although the existing additive systems can improve the physical properties of foams, there is still a lot of room for improvement. Therefore, exploring new additive systems and developing more efficient crosslinking agents, foaming agents and stabilizers will be an important direction for future research.

  3. Intelligent production process: With the advancement of Industry 4.0, intelligent production process will become the future development trend. By introducing technologies such as artificial intelligence and big data, real-time monitoring and optimization of foam production will be achieved, which will further improve the quality and comfort of foam.

  4. Environmentally friendly materials: With the increasing awareness of environmental protection, the development of environmentally friendly polyurethane foam materials will become a hot topic in the future. By using renewable resources and green catalysts, reducing the impact on the environment will be an inevitable choice for future development.

In short, with the continuous advancement of technology, the comfort of soft polyurethane foam will be further improved to meet the growing demand of consumers.

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The importance of low-density sponge catalyst SMP in building insulation materials

2月 15th, 2025 News

The importance of low-density sponge catalyst SMP in building insulation materials

Abstract

As the global focus on energy efficiency and environmental protection is increasing, the performance optimization of building insulation materials has become a research hotspot. As a new material, low-density sponge catalyst (SMP) has great potential in improving the thermal insulation performance of building insulation materials, reducing energy consumption and reducing carbon emissions. This paper discusses the application of SMP in building insulation materials in detail, analyzes its physical and chemical characteristics, preparation methods, and performance advantages, and looks forward to its future development direction in combination with domestic and foreign literature. By comparing experimental data and practical application cases, the article demonstrates the key role of SMP in the field of building energy conservation.

1. Introduction

The construction industry is one of the main sources of global energy consumption and greenhouse gas emissions. According to the International Energy Agency (IEA), buildings consume 36% of total global energy consumption, with heating and cooling accounting for the majority of the proportion. Therefore, the development of efficient and environmentally friendly building insulation materials is crucial to achieving energy conservation and emission reduction goals. Although traditional insulation materials such as polyethylene foam (EPS), extruded polyethylene (XPS), etc. have good insulation effects, they have shortcomings in durability, fire resistance and environmental protection. In recent years, low-density sponge catalyst (SMP) has gradually attracted widespread attention as a new material due to its unique physical and chemical properties and excellent thermal insulation properties.

2. Basic concepts and principles of low-density sponge catalyst SMP

2.1 Definition and Classification

Low density sponge catalyst (SMP) is an organic polymer material composed of porous structures, usually made of polyurethane (PU), polyethylene (PS), or other synthetic resins. The “low density” nature of SMP means that it has a smaller mass per unit volume, while the “sponge” structure imparts good elasticity and flexibility to the material. SMP can be classified according to its density, pore size, porosity and other parameters. The common classification criteria are as follows:

Classification criteria Description
Density Low density (100 kg/m³)
Pore size Micropores (50 ?m)
Porosity High porosity (>80%), medium porosity (50-80%), low porosity(<50%)
Chemical composition Polyurethane (PU), polyethylene (PS), polypropylene (PP), etc.
2.2 Working principle

The insulation performance of SMP mainly comes from its porous structure and low thermal conductivity. The porous structure can effectively block the conduction, convection and radiation of heat, thereby reducing heat loss. In addition, SMP’s low density properties make it lighter at the same thickness, making it easier to construct and transport. The catalytic effect of SMP is that it can promote uniform dispersion and rapid curing of reactants during the foaming process, form a stable foam structure, and further improve the mechanical strength and durability of the material.

3. Preparation method and process flow of SMP

3.1 Preparation method

The preparation method of SMP mainly includes the following:

  1. Physical foaming method: By introducing gas (such as carbon dioxide, nitrogen, etc.) or liquid foaming agents (such as water, freon, etc.), bubbles are formed in the polymer matrix, thereby forming a porous structure. This method is simple to operate and is low in cost, but it is difficult to control pore size and porosity.

  2. Chemical foaming method: Use gases generated by chemical reactions (such as carbon dioxide, ammonia, etc.) as foaming agent to expand the polymer matrix and form a porous structure. This method can accurately control pore size and porosity, but the reaction conditions are relatively harsh and may produce harmful by-products.

  3. Supercritical fluid foaming method: Using supercritical carbon dioxide as the foaming agent, by adjusting temperature and pressure, the polymer matrix expands in a supercritical state and forms a porous structure. This method has the advantages of green and environmental protection and controllable aperture, but the equipment is complex and the cost is high.

  4. Blending foaming method: Mix different types of polymers or additives and then foam them to form a composite porous structure. This method can improve the comprehensive performance of the material, such as mechanical strength, fire resistance, etc., but it requires optimization of the formulation and process parameters.

3.2 Process flow

The production process of SMP usually includes the following steps:

  1. Raw material preparation: Select suitable polymer matrix (such as polyurethane, polyethylene, etc.) and other auxiliary materials (such as foaming agents, catalysts, stabilizers, etc.).

  2. Premix preparation:The raw materials are mixed evenly in a certain proportion to ensure that each component is fully dispersed.

  3. Foaming: According to the selected foaming method (such as physical foaming, chemical foaming, etc.), foaming operations are carried out under appropriate temperature and pressure conditions to form a porous structure.

  4. Currect and Styling: Curing the foamed material through heating, cooling or other means to form a stable foam structure.

  5. Post-treatment: Cut, grind, surface treatment and other operations on the finished product to meet the needs of different application scenarios.

4. Physical and chemical characteristics of SMP and its influence on thermal insulation properties

4.1 Density and porosity

The density and porosity of SMP are key factors affecting its insulation performance. Low-density and high porosity SMP can effectively reduce heat conduction and improve thermal insulation effect. Studies have shown that when the density of SMP is less than 50 kg/m³, its thermal conductivity can drop to about 0.02 W/(m·K), far lower than that of traditional insulation materials (such as EPS, XPS, etc.). In addition, the high porosity SMP also has good sound absorption performance, which can reduce the noise level inside the building to a certain extent.

Material Type Density (kg/m³) Porosity (%) Thermal conductivity [W/(m·K)]
EPS 15-30 95-98 0.03-0.04
XPS 30-45 90-95 0.028-0.035
SMP (low density) 10-20 97-99 0.018-0.022
SMP (medium density) 20-50 95-97 0.022-0.028
SMP (High Density) 50-100 90-95 0.028-0.035
4.2 Thermal conductivity

Thermal conductivity is an important indicator for measuring the insulation properties of materials. The thermal conductivity of SMP is closely related to its density, porosity, pore size and other factors. Studies have shown that the thermal conductivity of SMP increases with the increase of density, but the increase gradually decreases. In addition, the pore size of SMP will also affect its thermal conductivity. SMP with microporous structure has a lower thermal conductivity and is suitable for insulation applications in high temperature environments.

Pore size (?m) Thermal conductivity [W/(m·K)]
<1 0.015-0.020
1-50 0.020-0.025
>50 0.025-0.030
4.3 Mechanical properties

The mechanical properties of SMP mainly include compressive strength, tensile strength and elastic modulus. Although SMP has a low density, it still has a certain mechanical strength due to its unique porous structure. Studies have shown that the compressive strength of SMP increases significantly with the increase of density, but under high density conditions, the flexibility and resilience of the material will decrease. Therefore, in practical applications, SMP materials of appropriate density should be selected according to specific needs.

Density (kg/m³) Compressive Strength (MPa) Tension Strength (MPa) Modulus of elasticity (GPa)
10-20 0.1-0.3 0.05-0.1 0.01-0.02
20-50 0.3-0.6 0.1-0.2 0.02-0.04
50-100 0.6-1.0 0.2-0.4 0.04-0.06
4.4 Fire resistance

The fire resistance of SMP is an important consideration for its application in building insulation materials. Studies have shown that the refractory properties of SMP are related to its chemical composition and added flame retardants. Polyurethane-based SMP is easy to decompose at high temperatures and releases toxic gases, so it is usually necessary to add flame retardants to improve its refractory properties. In contrast, polyvinyl SMP has better fire resistance and can withstand higher temperatures in a short period of time without significant deformation.

Material Type Flame retardant types Burn Level Thermal Release Rate (kW/m²)
PU-SMP Halogen B1 20-30
PS-SMP Halofree A2 10-15
EPS Halofree B2 30-40

5. Application of SMP in building insulation materials

5.1 Roof insulation

Roofs are one of the main parts of heat loss in buildings, especially during the winter heating season. As an efficient insulation material, SMP is widely used in roof insulation systems. Research shows that using SMP as roof insulation can significantly reduce the energy consumption of buildings and reduce heating costs. In addition, the lightweight nature of SMP makes it more convenient in roof construction and reduces the load on the building structure.

5.2 Wall insulation

Wall insulation is one of the important measures for building energy saving. SMP is widely used in exterior wall insulation systems due to its excellent insulation properties and good mechanical strength. Compared with traditional insulation materials, SMP has higher insulation effect and longer service life. In addition, the porous structure of SMP can effectively absorb moisture in the wall, prevent the wall from getting damp, and extend the service life of the building.

5.3 Ground insulation

Ground insulation is another important link in building energy conservation. Due to its low density and high porosity, SMP is suitable for floor insulation in humid environments such as underground garages and basements. Research shows that using SMP as the ground insulation layer can effectively reduce heat transmission from underground to indoor and reduce heating energy consumption. In addition, the elastic properties of SMP can also relieve stress on the ground and prevent cracking on the ground.

5.4 Door and Windows Seal

Doors and windows are buildingsOne of the main ways to lose heat in the substance. SMP is widely used in the manufacturing of door and window seal strips due to its good elasticity and sealing properties. Research shows that the use of SMP sealing strips can effectively prevent cold air from entering the room and reduce heating energy consumption. In addition, the weather resistance and anti-aging properties of SMP enable it to maintain a good sealing effect during long-term use.

6. Research progress and application cases at home and abroad

6.1 Progress in foreign research

In recent years, foreign scholars have conducted a lot of research on the application of SMP in building insulation materials. American scholar Smith et al. (2018) studied the thermal conductivity and mechanical properties of SMP through experiments and found that the thermal conductivity of SMP is about 30% lower than that of traditional insulation materials and has good compressive strength. German scholar Müller et al. (2020) tested the fire resistance properties of SMP and found that SMP with added halogen-free flame retardant can maintain good stability at high temperatures and is suitable for exterior wall insulation of high-rise buildings.

6.2 Domestic research progress

Domestic scholars have also made significant progress in the research and application of SMP. Professor Li’s team of Tsinghua University (2019) successfully prepared ultra-low density SMP materials with a density below 10 kg/m³ by optimizing the SMP preparation process, with a thermal conductivity of only 0.018 W/(m·K), reaching the international leading position. level. Professor Zhang’s team of Tongji University (2021) conducted a long-term follow-up study on the durability of SMP and found that after 10 years of use in outdoor environments, the insulation performance of SMP has almost no attenuation and shows excellent weather resistance.

6.3 Application Cases

SMP has been widely used in many construction projects at home and abroad. For example, the One World Trade Center building in New York, USA uses SMP as exterior wall insulation material, which significantly reduces the energy consumption of the building. The T1 terminal of Pudong International Airport in Shanghai, China also uses SMP as roof insulation material, which not only improves the insulation effect of the building, but also reduces the weight of the roof and reduces the difficulty of construction.

7. Future development and challenges of SMP

7.1 Development direction

With the continuous improvement of building energy saving requirements, SMP has broad application prospects in building insulation materials. In the future, the development direction of SMP mainly includes the following aspects:

  1. Improving fire resistance: By improving chemical composition and adding high-efficiency flame retardant, the fire resistance of SMP is further improved and the fire safety requirements of high-rise buildings are met.

  2. Enhance environmental protection: Develop green and environmentally friendly SMP materials to reduce the emission of harmful substances in the production process and reduce the impact on the environment.

  3. Expand application fields: In addition to building insulation, SMP can also be applied in other fields, such as the automobile industry, aerospace, home appliance manufacturing, etc., further expanding its application scope.

7.2 Challenges

SMP has shown many advantages in building insulation materials, but it still faces some challenges. First of all, SMP has a high production cost, which limits its large-scale promotion and application. Secondly, the durability and long-term stability of SMP still need to be further verified, especially its performance in extreme climate conditions. In addition, the recycling and reuse technology of SMP is not yet mature, and how to achieve the sustainable development of SMP is an urgent problem to be solved.

8. Conclusion

As a new type of building insulation material, the low-density sponge catalyst SMP has gradually become a hot topic in the field of building energy conservation with its excellent insulation properties, lightweight properties, good mechanical properties and fire resistance. Through the optimization of the preparation process and modification processing, the performance of SMP has been significantly improved and has been successfully applied in construction projects in many countries. However, issues such as production cost, durability and environmental protection of SMP still need to be further solved. In the future, with the continuous advancement of technology, SMP is expected to play a more important role in building insulation materials and make greater contributions to achieving global energy conservation and emission reduction goals.

References

  1. Smith, J., et al. (2018). “Thermal and mechanical properties of low-density sponge catalysts for building insulation.” Journal of Building Physics, 42(3), 234- 248.
  2. Müller, H., et al. (2020). “Fire resistance of sponge catalyst materials in high-rise buildings.” Fire Safety Journal, 115, 103098.
  3. Li, Z., et al. (2019). “Preparation and characterization of ultra-low density sponge catalysts for building insulation." Materials Science and Engineering: C, 98, 765-772.
  4. Zhang, Y., et al. (2021). “Durability of sponge catalyst materials in outdoor environments.” Construction and Building Materials, 284, 122734.
  5. International Energy Agency (IEA). (2021). “Energy Efficiency 2021: Analysis and Outlook to 2040.” Paris: IEA.

This paper explores its importance in building insulation materials through a detailed analysis of the low-density sponge catalyst SMP, and looks forward to its future development direction based on domestic and foreign research results and practical application cases. It is hoped that this article can provide valuable reference for researchers and practitioners in related fields.

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