Use highly active reactive catalyst ZF-10 to optimize the hard foam production process
Catalog
- Introduction
- Overview of rigid foam
- Introduction to the highly active reactive catalyst ZF-10
- The application of ZF-10 in the production of rigid foam
- Production process optimization
- Comparison of product parameters and performance
- Practical case analysis
- Conclusion
1. Introduction
Rigid foam materials are widely used in construction, cold chain, automobile, aerospace and other fields due to their excellent thermal insulation performance, lightweight, high strength and good processing performance. However, the traditional hard foam production process has problems such as slow reaction speed, high energy consumption, and unstable product performance. To solve these problems, the highly active reactive catalyst ZF-10 came into being. This article will introduce in detail how to use ZF-10 to optimize the hard foam production process and improve product quality and production efficiency.
2. Overview of rigid foam
Rough foam is a closed-cell structure foam material, mainly composed of polymers such as polyurethane (PU), polyisocyanurate (PIR). Its main features include:
- Excellent thermal insulation performance: The closed-cell structure effectively prevents heat transfer.
- Lightweight and high strength: Low density, but high mechanical strength.
- Good processing performance: Easy to form and process.
2.1 Application areas of rigid foam
| Application Fields | Specific application |
|---|---|
| Architecture | Wall insulation, roof insulation, floor insulation |
| Cold Chain | Refrigerated trucks, cold storages, refrigerators |
| Car | Car seats, dashboards, door linings |
| Aerospace | Aircraft interior, spacecraft insulation |
3. Introduction to ZF-10, a highly active reactive catalyst
ZF-10 is a new type of highly active reactive catalyst designed for rigid foam production. Its main features include:
- High activity: significantly improve the reaction speed and shorten the production cycle.
- Efficiency: Reduce energy consumption and improve production efficiency.
- Stability: Ensure stable product performance and reduce defective rate.
3.1 Chemical properties of ZF-10
| Features | parameters |
|---|---|
| Chemical Name | High-active reactive catalyst |
| Molecular Weight | 200-300 g/mol |
| Active temperature | 50-80°C |
| Applicable pH range | 6-8 |
3.2 Advantages of ZF-10
- Improve the reaction speed: Compared with traditional catalysts, ZF-10 can increase the reaction speed by more than 30%.
- Reduce energy consumption: Due to the accelerated reaction speed, energy consumption during the production process is significantly reduced.
- Improving product performance: ZF-10 can effectively improve the closed cell ratio and mechanical strength of foam.
4. Application of ZF-10 in the production of rigid foam
4.1 Reaction mechanism
ZF-10 accelerates the foam formation and curing process by catalyzing the reaction of isocyanate with polyol. The reaction mechanism is as follows:
- Reaction of isocyanate with polyol: to form urethane.
- Carbamate further reaction: forming polyurethane foam.
- Foam Curing: A stable closed-cell structure is formed through cross-linking reaction.
4.2 Application steps
- Ingredients: Mix isocyanate, polyol, foaming agent, and catalyst ZF-10 in proportion.
- Stir: Stir at high speed to fully mix the components.
- Injection Molding: Inject the mixture into the mold.
- Foaming: Foaming at an appropriate temperature to form foam.
- Currect: The foam cures in the mold to form the final product.
4.3 Application Notes
- Temperature Control: The active temperature range of ZF-10 is 50-80°C, and the reaction temperature needs to be strictly controlled.
- Agitation speed: The agitation speed affects the mixing uniformity, and it is recommended to use a high-speed stirrer.
- Mold Design: The mold design needs to consider the expansion rate and shrinkage rate of the foam to ensure product dimensional accuracy.
5. Production process optimization
5.1 Comparison of traditional processes and optimized processes
| Process Steps | Traditional crafts | Optimization process |
|---|---|---|
| Ingredients | Manual ingredients, large error | Automatic ingredients, high accuracy |
| Stir | Stir at low speed, uneven mixing | High speed stirring, mix evenly |
| Injection moulding | Manual injection molding, inefficient | Automatic injection molding, high efficiency |
| Foaming | Inaccurate temperature control and slow reaction speed | Accurate temperature control and fast reaction speed |
| Cure | Long curing time, high energy consumption | Short curing time and low energy consumption |
5.2 Optimization measures
- Automated ingredient system: Adopt an automated ingredient system to improve the accuracy of ingredients and reduce human errors.
- High-speed agitator: Use a high-speed agitator to ensure that the components are fully mixed and improve foam uniformity.
- Temperature Control System: Install an accurate temperature control system to ensure that the reaction temperature is within the active range of ZF-10.
- Automatic injection molding equipment: Use automated injection molding equipment to improve production efficiency and reduce labor costs.
- Rapid Curing Technology: Use the high activity of ZF-10 to shorten the curing time and reduce energy consumption.
5.3 Optimization effect
| Indicators | Traditional crafts | Optimization process | Elevation |
|---|---|---|---|
| Response speed | Slow | Quick | 30% |
| Energy consumption | High | Low | 20% |
| Product uniformity | Ununiform | Alternate | 50% |
| Production Efficiency | Low | High | 40% |
6. Comparison of product parameters and performance
6.1 Product parameters
| parameters | Traditional craft products | Optimized process products |
|---|---|---|
| Density | 40-50 kg/m³ | 35-45 kg/m³ |
| Closed porosity | 85-90% | 90-95% |
| Compressive Strength | 150-200 kPa | 200-250 kPa |
| Thermal conductivity | 0.022-0.025 W/m·K | 0.020-0.022 W/m·K |
| Dimensional stability | ±2% | ±1% |
6.2 Performance comparison
| Performance | Traditional craft products | Optimized process products | Elevation |
|---|---|---|---|
| Thermal Insulation Performance | General | Excellent | 10% |
| Mechanical Strength | General | High | 20% |
| Dimensional Accuracy | General | High | 50% |
| Service life | 5-10 years | 10-15 years | 50% |
7. Actual case analysis
7.1 Case 1: Building insulation material production
Background: A building insulation material manufacturer uses traditional processes to produce rigid foam, which has problems such as slow reaction speed, high energy consumption, and unstable product performance.
Solution: Introduce the highly active reactive catalyst ZF-10 to optimize the production process.
Implementation steps:
- Automated ingredient system: Install an automated ingredient system to improve ingredient accuracy.
- High-speed agitator: Replace with a high-speed agitator to ensure even mixing.
- Temperature Control System: Install an accurate temperature control system to control the reaction temperature.
- Automated injection molding equipment: Use automated injection molding equipment to improve production efficiency.
- Rapid Curing Technology: Use the high activity of ZF-10 to shorten the curing time.
Effect:
- Response speed: Increased by 30%.
- Energy consumption: Reduce 20%.
- Product uniformity: Improve 50%.
- Production efficiency: Improve40%.
7.2 Case 2: Cold chain insulation material production
Background: A cold chain insulation material manufacturer faces the problems of unstable product performance and high defect rate.
Solution: Use ZF-10 catalyst to optimize the production process.
Implementation steps:
- Ingredient Optimization: Adjust the ingredients ratio to ensure that each component reacts fully.
- Agitation Optimization: Use a high-speed stirrer to improve mixing uniformity.
- Temperature Control: Accurately control the reaction temperature to ensure the activity of ZF-10.
- Mold Design: Optimize mold design and improve product dimensional accuracy.
Effect:
- Product Performance: The closed porosity is increased to 95%, and the compressive strength is increased to 250 kPa.
- Free Rate: Reduced to below 1%.
- Production efficiency: Increase 30%.
8. Conclusion
The high-active reactive catalyst ZF-10 has significant advantages in the production of rigid foams, which can effectively improve the reaction speed, reduce energy consumption, and improve product performance. By optimizing the production process, enterprises can achieve a significant improvement in production efficiency and a significant improvement in product quality. In the future, with the continuous advancement of technology, the application prospects of ZF-10 in rigid foam production will be broader.
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