How to use delayed amine hard bubble catalyst to optimize hard bubble production process: from raw material selection to finished product inspection
Catalog
- Introduction
- Overview of hard bubble production process
- Properties of delayed amine hard bubble catalyst
- Raw Material Selection
- Production process optimization
- Finished product inspection
- Conclusion
1. Introduction
Rough polyurethane foam (referred to as hard foam) is widely used in construction, cold chain, automobile and home appliances due to its excellent thermal insulation performance, mechanical strength and lightweight properties. However, the production process of hard bubbles is complex and involves a variety of raw materials and reaction conditions, where the selection and use of catalysts have a crucial impact on product quality and production efficiency. As a new catalyst, the retardant amine hard bubble catalyst can significantly optimize the hard bubble production process due to its unique retardant reaction characteristics. This article will introduce in detail how to use delayed amine hard bubble catalysts to optimize the hard bubble production process from raw material selection to finished product inspection.
2. Overview of hard bubble production process
The production process of hard bubbles mainly includes the following steps:
- Raw material preparation: including polyols, isocyanates, catalysts, foaming agents, stabilizers, etc.
- Mix: Mix polyols, catalysts, foaming agents, stabilizers, etc. evenly.
- Reaction: React the mixed raw materials with isocyanate to form a foam.
- Mature: The foam is matured in the mold to form the final product.
- Finished product inspection: Inspection of the finished product in terms of physical properties, chemical properties, etc.
3. Characteristics of delayed amine hard bubble catalyst
The delayed amine hard bubble catalyst is a new type of catalyst with the following characteristics:
- Delayed reaction: Can delay the start time of the reaction and allow the raw materials to have a more sufficient mixing time.
- High-efficiency Catalysis: After the reaction begins, the reaction can be quickly catalyzed and the maturation time can be shortened.
- Good stability: Good stability during storage and use, and is not easy to decompose.
- Environmental: Low volatile organic compounds (VOC) emissions, meeting environmental protection requirements.
3.1 Parameters of delayed amine hard bubble catalyst
| parameter name | parameter value | Instructions |
|---|---|---|
| Appearance | Colorless transparent liquid | No impurities, high transparency |
| Density (g/cm³) | 1.05-1.10 | Moderate density, easy to mix |
| Viscosity (mPa·s) | 50-100 | Moderate viscosity, easy to flow |
| Flash point (?) | >100 | High flash point, high security |
| Storage Stability | >12 months | Long-term storage does not deteriorate |
| Reaction delay time | 10-30 seconds | Delay reaction time for easy mixing |
| Mature Time | 2-5 minutes | Rapid maturation to improve production efficiency |
4. Raw material selection
The selection of raw materials has a direct impact on the quality and performance of hard bubbles. The following are the key points for selecting main raw materials:
4.1 Polyol
Polyols are one of the main raw materials for hard foaming, and the following factors should be considered in their choice:
- Molecular weight: Molecular weight affects the hardness and elasticity of the foam.
- Functionality: Functionality affects the cross-linking density and mechanical strength of the foam.
- Viscosity: Viscosity affects mixing and flow properties.
4.2 Isocyanate
Isocyanate is another main raw material for hard foaming, and the following factors should be considered in the selection:
- NCO content: NCO content affects reaction speed and foam density.
- Viscosity: Viscosity affects mixing and flow properties.
- Reactive activity: Reactive activity affects the aging of foambetween.
4.3 Foaming agent
The following factors should be considered in the selection of foaming agents:
- Foaming efficiency: Foaming efficiency affects the density and thermal insulation properties of the foam.
- Environmentality: Choose a foaming agent with low GWP (global warming potential) to meet environmental protection requirements.
- Stability: The foaming agent has good stability during storage and use.
4.4 Stabilizer
The following factors should be considered in the selection of stabilizers:
- Foam Stability: Stabilizers can prevent foam from collapsing and shrinking.
- Compatibility: The stabilizer has good compatibility with other raw materials and does not affect the reaction.
4.5 Catalyst
The following factors should be considered in the selection of catalysts:
- Reaction delay time: Delay reaction time facilitates raw material mixing.
- Catalytic Efficiency: High catalytic efficiency and shorten maturation time.
- Stability: The catalyst has good stability during storage and use.
5. Production process optimization
Using delayed amine hard bubble catalyst to optimize the hard bubble production process, mainly including the following steps:
5.1 Raw material mixing
Raw material mixing is a key step in hard bubble production. The delayed reaction characteristics of the amine hard bubble catalyst allow the raw materials to have a more sufficient mixing time to ensure uniform mixing.
5.1.1 Hybrid Equipment
Select efficient mixing equipment, such as high-pressure foaming machines, to ensure that the raw materials are mixed evenly.
5.1.2 Mixing time
According to the delayed reaction time of the delayed amine hard bubble catalyst, adjust the mixing time to ensure that the raw materials are fully mixed.
5.2 Reaction control
Reaction control is the core step in hard bubble production. Retarding the efficient catalytic properties of amine hard bubble catalysts can shorten the maturation time and improve production efficiency.
5.2.1 Reaction temperature
Control the reaction temperature within the appropriate range, usually 20-40°C to ensure smooth progress of the reaction.
5.2.2 Reaction pressure
Control the reaction pressure within the appropriate range, usually 0.1-0.3MPa, to ensure uniform foaming of the foam.
5.3 Cultivation process
The maturation process is the latter step in hard bubble production. The rapid maturation characteristics of delayed amine hard bubble catalyst can shorten the maturation time and improve production efficiency.
5.3.1 Craving temperature
Control the maturation temperature within the appropriate range, usually 40-60°C to ensure that the foam is fully matured.
5.3.2 Crafting time
According to the maturation time of the delayed amine hard bubble catalyst, adjust the maturation time to ensure that the foam is fully matured.
5.4 Process parameter optimization
Through experimental and data analysis, process parameters are optimized, production efficiency and product quality are improved.
5.4.1 Experimental Design
Design orthogonal experiments to examine the impact of different process parameters on product quality.
5.4.2 Data Analysis
Through data analysis, the best process parameters are determined, such as mixing time, reaction temperature, maturation time, etc.
6. Finished product inspection
Finished product inspection is the next step in hard bubble production to ensure that the product quality meets the requirements. The following are the main items for finished product inspection:
6.1 Physical performance inspection
6.1.1 Density
Density is an important physical performance indicator of hard bubbles, affecting the thermal insulation performance and mechanical strength of the foam.
| Density range (kg/m³) | Instructions |
|---|---|
| 30-50 | Low-density foam, suitable for lightweight thermal insulation materials |
| 50-80 | Medium density foam, suitable for general thermal insulation materials |
| 80-120 | High-density foam, suitable for high-strength thermal insulation materials |
6.1.2 Compression Strength
Compression strength is an important mechanical performance indicator of hard bubbles, affecting the bearing capacity of the foam.
| Compression Strength Range (kPa) | Instructions |
|---|---|
| 100-200 | Low compression strength, suitable for lightweight thermal insulation materials |
| 200-400 | Medium compression strength, suitable for general thermal insulation materials |
| 400-600 | High compression strength, suitable for high-strength thermal insulation materials |
6.1.3 Thermal conductivity
Thermal conductivity is an important thermal insulation indicator for hard bubbles, affecting the thermal insulation effect of foam.
| Thermal conductivity range (W/m·K) | Instructions |
|---|---|
| 0.020-0.025 | Low thermal conductivity, suitable for high-efficiency thermal insulation materials |
| 0.025-0.030 | The thermal conductivity in the medium, suitable for general heat insulation materials |
| 0.030-0.035 | High thermal conductivity, suitable for ordinary thermal insulation materials |
6.2 Chemical performance inspection
6.2.1 Chemical resistance
Chemical resistance is an important chemical performance indicator for hard bubbles and affects the service life of the bubbles.
| Chemical resistance level | Instructions |
|---|---|
| Outstanding | Good acid and alkali resistance and solvent resistance |
| Good | Good acid and alkali resistance and solvent resistance |
| in | Acoustic alkali and solvent resistance are generally |
| Poor | Poor acid and alkali resistance and solvent resistance |
6.2.2 Aging resistance
Aging resistance is an important chemical performance indicator for hard bubbles, which affects the service life of the bubbles.
| Aging resistance level | Instructions |
|---|---|
| Outstanding | Good resistance to ultraviolet rays and humidity and heat resistance |
| Good | Good resistance to ultraviolet rays and humidity and heat resistance |
| in | Ultraviolet resistance and humidity resistance are average |
| Poor | Purple-resistantPoor external and heat resistance |
6.3 Appearance inspection
Appearance inspection is an important step in hard bubble production to ensure that the product appearance meets the requirements.
6.3.1 Surface flatness
Surface flatness is an important appearance indicator for hard bubbles and affects the appearance quality of the product.
| Surface flatness level | Instructions |
|---|---|
| Outstanding | The surface is flat, without any unevenness |
| Good | The surface is flat, slightly uneven |
| in | The surface is uneven and obviously uneven |
| Poor | The surface is seriously uneven and has obvious unevenness |
6.3.2 Color uniformity
Color uniformity is an important appearance indicator for hard bubbles and affects the appearance quality of the product.
| Color uniformity level | Instructions |
|---|---|
| Outstanding | Even color, no color difference |
| Good | The color is relatively uniform, with a slight color difference |
| in | The color is uneven, and the color difference is obvious |
| Poor | The color is seriously uneven and the color difference is obvious |
7. Conclusion
Using delayed amine hard bubble catalyst to optimize the hard bubble production process can significantly improve production efficiency and product quality. By rationally selecting raw materials, optimizing production processes and strict finished product inspection, high-performance rigid polyurethane foam can be produced to meet the needs of different application fields. The delayed reaction characteristics and efficient catalytic properties of the delayed amine hard bubble catalyst make it an ideal choice for hard bubble production. In the future, with the continuous advancement of technology, delayed amine hard bubble catalysts will play a greater role in hard bubble production and promote the development of the hard bubble industry.
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