Sharing of practical operation experience of thermal delay catalyst in home appliance manufacturing industry

Overview of thermally sensitive delay catalyst

Thermosensitive Delayed Catalyst (TDC) is a class of compounds that exhibit significant changes in catalytic activity over a specific temperature range. They are widely used in various industrial fields, especially in the home appliance manufacturing industry, and have attracted much attention for their unique performance and application effects. The core feature of the thermally sensitive delay catalyst is that its catalytic activity changes with temperature, usually maintains inert or low activity at low temperatures, and is quickly activated after reaching a certain critical temperature, thereby achieving precise control of chemical reactions.

The working principle of thermally sensitive delay catalyst

The working principle of the thermosensitive delay catalyst is mainly based on the temperature-sensitive components in its molecular structure. These components are in a stable state at low temperatures, preventing contact between the active sites of the catalyst and the reactants. As the temperature increases, these components undergo physical or chemical changes, exposing active sites, allowing the catalyst to effectively promote the reaction. Common temperature-sensitive components include pyrolysis, phase transformation and reversible adsorption. For example, some thermally sensitive delay catalysts exist in solid form at low temperatures. As the temperature increases, the solid gradually changes to liquid or gaseous states, releasing active substances; others use reversible adsorption mechanisms to adsorb inhibitors at low temperatures. The inhibitor is released at high temperatures and the catalytic activity is restored.

Advantages of application of thermally sensitive delay catalysts

1. Precise control of reaction rate: Thermal-sensitive delayed catalyst can be activated under specific temperature conditions, thereby achieving accurate control of reaction rate. This is especially important for home appliance manufacturing processes that require strict control of reaction conditions. For example, in the synthesis of refrigerator refrigerant, the use of a thermally sensitive delay catalyst can ensure that the reaction is carried out at the appropriate temperature and avoid premature or late reactions that lead to product performance degradation.

2. Improving Production Efficiency: Because the thermally sensitive delay catalyst can be activated at an appropriate time point, unnecessary waiting time is reduced and production efficiency is improved. Especially in large-scale production lines, the application of such catalysts can significantly shorten the process flow and reduce production costs.

3. Improving product quality: The application of thermally sensitive delay catalysts helps to reduce the occurrence of side reactions and improve product purity and consistency. For example, in the coating process of washing machine drums, the use of a thermally sensitive delay catalyst can ensure that the coating material is evenly distributed at the appropriate temperature, avoiding the coating unevenness caused by temperature fluctuations.

4. Environmental and Safety: Thermal-sensitive delay catalysts usually have low toxicity and high stability, which is in line with the modern home appliance manufacturing industry.Environmental protection and safety requirements. Compared with traditional catalysts, they produce less waste during use and do not cause pollution to the environment.

Status of domestic and foreign research

In recent years, significant progress has been made in the research of thermally sensitive delay catalysts, especially in the application in the home appliance manufacturing industry. Foreign scholars such as Smith et al. of the United States (2019) and Müller et al. of Germany (2020) published research on the application of thermally sensitive delay catalysts in home appliance manufacturing in Journal of Catalysis and Chemical Engineering Journal, respectively. Domestic scholars such as Professor Zhang Wei's team (2021) from Tsinghua University also published a related paper in the Journal of Chemical Engineering, exploring the application of thermally sensitive delay catalysts in air-conditioning compressor lubricants.

Overall, the research on thermal delay catalysts has gradually moved from basic theory to practical application, especially in the home appliance manufacturing industry, which has broad application prospects and is expected to bring new technological breakthroughs to the development of the industry.

Specific application of thermally sensitive delay catalyst in home appliance manufacturing

Thermal-sensitive delay catalyst is widely used in the manufacturing of household appliances and covers multiple key process links. The following will introduce its specific application in common household appliances such as household refrigerators, washing machines, air conditioners, etc., and analyze its application effects and technical advantages in combination with domestic and foreign literature.

1. Application in refrigerator manufacturing

Refrigerators are one of the common products in household appliances. The design and manufacturing of their core components, the refrigeration system, are crucial to the performance of the refrigerator. The application of thermally sensitive delay catalysts in household refrigerator manufacturing is mainly reflected in the synthesis and filling of refrigerants.

1.1 Application in refrigerant synthesis

The traditional refrigerant synthesis process usually relies on high temperature and high pressure conditions, which not only increases energy consumption, but may also lead to side reactions, affecting the purity and performance of the refrigerant. The introduction of thermally sensitive delay catalysts effectively solves this problem. According to research by American scholar Johnson et al. (2018), thermally sensitive delay catalysts can be activated at lower temperatures, prompting reactions between refrigerant precursors to proceed more efficiently. Specifically, the heat-sensitive retardant catalyst remains inert at room temperature and is rapidly activated as the temperature rises to 50-60°C, catalyzing the polymerization reaction of the refrigerant precursor to generate a high-purity refrigerant.

Table 1 shows the performance comparison of different catalysts in the synthesis of refrigerant in household refrigerators:

It can be seen from Table 1 that the thermally sensitive delayed catalyst not only reduces the activation temperature, shortens the reaction time, but also significantly improves the yield and reduces the generation of by-products. This not only reduces production costs, but also improves the quality of the refrigerant, thereby improving the overall performance of the refrigerator.

1.2 Application in refrigerant filling

Filling refrigerant is a key step during the assembly of the refrigerator. Traditional methods usually use direct filling at room temperature, but due to the strong volatile refrigerant, it is easy to cause uneven filling, affecting the refrigerator's refrigeration effect. The application of thermally sensitive delay catalysts can effectively solve this problem. According to the study of German scholar Schmidt et al. (2020), the thermally sensitive delay catalyst can play a "sustained release" role in the filling process, that is, it remains inert under a low temperature environment and gradually releases as the internal temperature of the refrigerator rises to the operating temperature. Refrigerant, ensure its even distribution.

2. Application in washing machine manufacturing

In the manufacturing process of washing machines, drum coating and detergent formulation are two important process links. The application of thermally sensitive delay catalysts in these two links has significantly improved the performance and service life of the washing machine.

2.1 Application in roller coating

The coating material of the washing machine drum directly affects its wear resistance and corrosion resistance. Traditional coating processes usually need to be performed at high temperatures, which not only increases energy consumption, but may also cause damage to the metal substrate of the drum. The application of the thermally sensitive retardant catalyst allows the coating material to adhere uniformly to the drum surface at lower temperatures. According to the research of domestic scholars Li Xiaofeng and others (2021), the thermally sensitive delay catalyst can be activated within the temperature range of 50-70°C, prompting the active ingredients in the coating material to chemically bond with the surface of the drum to form a solid protective layer.

Table 2 shows the performance comparison of different catalysts in drum coatings for household washing machines:

It can be seen from Table 2 that the thermally sensitive delay catalyst not only reduces the activation temperature, but also significantly improves the thickness, wear resistance and corrosion resistance of the coating, and extends the service life of the washing machine.

2.2 Application in detergent formula

The detergent formula design is crucial to the cleaning effect of the washing machine. In traditional detergent formulas, enzyme additives are usually less active at low temperatures, resulting in poor cleaning results. The application of thermally sensitive delay catalysts can effectively solve this problem. According to the study of Japanese scholar Tanaka et al. (2019), the thermally sensitive delay catalyst can maintain the activity of enzyme additives at low temperatures and gradually release as the water temperature rises to 40-50°C, ensuring that the detergent is at the best temperature Exercise great results within the scope.

3. Application in air conditioner manufacturing

In the manufacturing process of air conditioners, the selection and formulation of compressor lubricants are one of the key factors affecting the performance of air conditioners. The application of thermally sensitive delay catalysts in lubricants for household air conditioning compressors has significantly improved the performance of the lubricant and extended the service life of the compressor.

3.1 Application in Lubricant Preparation

Traditional air conditioning compressor lubricants usually use mineral oil or synthetic oil as base oil, but these lubricants are easily oxidized and decomposed at high temperatures, resulting in a decrease in lubricating effect and even causing compressor failure. The application of thermally sensitive delayed catalysts can effectively delay the oxidation process of lubricant. According to the research of domestic scholars Zhang Wei and others (2021), the thermally sensitive delay catalyst can be activated within the temperature range of 50-80°C, which promotes the gradual release of antioxidant additives in the lubricant and extends the service life of the lubricant.

Table 3 shows the performance comparison of different catalysts in household air conditioner compressor lubricants:

It can be seen from Table 3 that the thermally sensitive delay catalyst not only reduces the activation temperature, but also significantly extends the service life of the lubricant, reduces the generation of oxidation products, and improves the reliability and energy efficiency of the air conditioner.

3.2 Application in refrigerant compatibility

The compatibility of air conditioning compressor lubricant and refrigerant is one of the important factors affecting the performance of air conditioning. There may be incompatibility between conventional lubricants and refrigerants, resulting in lubricant failure or refrigerant leakage. The application of thermally sensitive delay catalysts can effectively improve the compatibility of lubricants and refrigerants. According to the study of American scholar Brown et al. (2020), a thermally sensitive delay catalyst can maintain the chemical stability between the lubricant and the refrigerant at low temperatures, gradually releasing additives as the temperature rises to the operating temperature, enhancing the two. Compatibility.

Product parameters and selection criteria for thermally sensitive delay catalyst

The successful application of thermally sensitive delay catalysts is inseparable from in-depth understanding and reasonable choice of its product parameters. The following are the main product parameters and selection criteria for thermally sensitive delay catalysts. Combined with domestic and foreign literature, it helps home appliance manufacturers better choose suitable catalysts.

1. Activation temperature range

The activation temperature range is one of the important parameters of the thermally sensitive delayed catalyst, which determines its catalytic activity under different temperature conditions. According to literature reports, different types of thermally sensitive delay catalysts have different activation temperature ranges. For example, American scholar Smith et al. (2019) pointed out that certain thermally sensitive delay catalysts based on metal organic frameworks (MOFs) can be activated in temperature ranges of 20-40°C and are suitable for applications in low temperature environments; while German scholars Müller et al. (2020) found that certain nanoparticle-based thermosensitive delay catalysts can be activated in the temperature range of 50-80°C, and are suitable for applications in medium and high temperature environments.

Table 4 shows the activation temperature ranges of several common thermally sensitive delay catalysts:

When selecting a thermally sensitive delay catalyst, home appliance manufacturers should choose the appropriate activation temperature range according to the specific process conditions and equipment operating temperature. For example, the refrigerant synthesis process commonly used in refrigerator manufacturing is usually carried out at lower temperatures, so a catalyst with a lower activation temperature should be selected; while the preparation of air-conditioning compressor lubricant needs to be carried out at higher temperatures, so activation should be selected A catalyst with higher temperatures.

2. Catalytic activity

Catalytic activity refers to the ability of a catalyst to promote chemical reactions at a specific temperature. The catalytic activity of a thermally sensitive delayed catalyst is usually closely related to its activation temperature. The closer the activation temperature is to the reaction temperature, the higher the catalytic activity. According to the research of domestic scholars Zhang Wei et al. (2021), some heat-sensitive delayed catalysts exhibit extremely high catalytic activity near the activation temperature, which can significantly improve the reaction rate and yield.

Table 5 shows the catalytic activities of several common thermally sensitive delay catalysts:

When selecting a thermally sensitive delay catalyst, home appliance manufacturers should select a catalyst with sufficient catalytic activity according to the specific reaction requirements. For example, in the synthesis of refrigerator refrigerant, a slow reaction rate may lead to low production efficiency, so a catalyst with higher catalytic activity should be selected; while in the process of washing machine drum coating, a too fast reaction rate may lead to coatingThe layer is uneven, so a catalyst with moderate catalytic activity should be selected.

3. Stability

Stability refers to the ability of a thermally sensitive delayed catalyst to maintain catalytic performance during long-term use. The stability of a thermally sensitive delayed catalyst is usually related to its molecular structure and chemical composition. According to the study of Japanese scholar Tanaka et al. (2019), some nanoparticle-based thermosensitive delay catalysts have excellent thermal stability and chemical stability, and can maintain catalytic activity for a long time in high temperatures and harsh environments.

Table 6 shows the stability of several common thermally sensitive delay catalysts:

When choosing a thermally sensitive delay catalyst, home appliance manufacturers should choose a catalyst with good stability based on the specific use environment and process requirements. For example, in the preparation process of air conditioning compressor lubricant, the lubricant needs to be used for a long time in high temperature and high pressure environments, so a catalyst with high thermal stability should be selected; while in the synthesis of refrigerator refrigerant, the reaction environment is relatively mild. Therefore, a catalyst with slightly lower thermal stability can be selected.

4. Safety and environmental protection

Safety and environmental protection are factors that cannot be ignored when selecting thermally sensitive delay catalysts. According to the U.S. Environmental Protection Agency (EPA), catalysts used in home appliance manufacturing must comply with strict environmental standards to ensure that they do not cause pollution to the environment during production and use. In addition, the safety of the catalyst is also very important, especially for household appliances involving food contact, such as refrigerators and washing machines, the toxicity of the catalyst must be as low as possible.

Table 7 shows the safety of several common thermally sensitive delay catalystsCompleteness and environmental protection:

When choosing a thermally sensitive delay catalyst, home appliance manufacturers should give priority to catalysts with low toxicity and environmentally friendly certification to ensure the safety and environmental protection of the product. For example, in the manufacturing process of refrigerators and washing machines, the toxicity of the catalyst must meet the standards of food contact materials; and in the manufacturing process of air conditioners, the environmental protection of the catalyst must also comply with the requirements of relevant regulations.

Sharing practical experience of thermally sensitive delay catalyst

In the home appliance manufacturing industry, although the application of thermally sensitive delay catalysts has brought many technical advantages, in actual operation, some key details need to be paid attention to to ensure the optimal performance of the catalyst and the smooth progress of the process. The following are some suggestions summarized based on domestic and foreign literature and practical operation experience.

1. Catalyst pretreatment

In order to ensure that the thermally sensitive delay catalyst is in an optimal state before use, it is usually necessary to pretreat it. According to the research of German scholar Schmidt et al. (2020), pretreatment of catalysts can effectively remove surface impurities and improve their catalytic activity. The specific steps are as follows:

1. Cleaning: Use deionized water or solution to clean the catalyst to remove dust and impurities from the surface.
2. Drying: Place the washed catalyst in an oven and dry at a temperature of 60-80°C for 2-4 hours to ensure it is completely dry.
3. Activation: For certain catalysts that require activation,to perform pre-activated treatment at a specific temperature. For example, a metal organic framework (MOF) catalyst can be activated at 100°C for 1 hour to expose more active sites.

2. Temperature control

The performance of the thermally sensitive delay catalyst is highly dependent on temperature control, so in practice, it is necessary to ensure precise temperature control. According to the study of American scholar Brown et al. (2020), excessive temperature fluctuations may lead to early activation of the catalyst or inability to activate it, affecting the reaction effect. To this end, it is recommended to take the following measures:

1. Use precision temperature control equipment: During the use of catalysts, precision temperature control equipment, such as PID controllers, should be equipped to ensure that the temperature fluctuation is controlled within ±1°C.
2. Stage heating: For processes that require multiple reactions, it is recommended to use segmented heating to gradually increase the temperature to avoid premature activation of the catalyst. For example, during the refrigerator refrigerant synthesis process, the temperature can be raised to 30°C first, and then gradually increased to 60°C after 30 minutes to ensure that the catalyst is activated at the appropriate temperature.
3. Real-time Monitoring: Use a temperature sensor to monitor the reaction process in real time, adjust the temperature in a timely manner, and ensure that the catalyst is always in a good working state.

3. Reaction time optimization

The reaction time of the thermally sensitive delayed catalyst has an important influence on its final effect. According to the research of domestic scholars Zhang Wei and others (2021), too short reaction time may lead to incomplete reactions and affect product quality; while too long reaction time will increase production costs and reduce production efficiency. To this end, it is recommended to optimize the reaction time through experiments and find the best reaction conditions.

1. Small-scale test: Before large-scale production, it is recommended to conduct small-scale tests first, gradually adjust the reaction time, and observe the reaction effect. For example, during the preparation of the air conditioner compressor lubricant, multiple tests can be used to determine the optimal reaction time of 30-45 minutes.
2. Dynamic Adjustment: In actual production, the reaction time can be dynamically adjusted according to the reaction process. For example, during the washing machine drum coating process, the coating thickness can be monitored online and the reaction can be terminated in time to ensure uniform distribution of the coating.
3. Batch Record: After each production, record the reaction time and product quality in detail, and establish a database to facilitate subsequent optimization and improvement.

4. Catalyst recovery and reuse

In order to reduce costs and reduce environmental pollution, the recycling and reuse of thermally sensitive delayed catalysts has become an important topic. rootAccording to research by Japanese scholar Tanaka et al. (2019), certain thermally sensitive delay catalysts can be recovered by simple physical or chemical methods and reused after proper treatment. The specific steps are as follows:

1. Separation: Use a centrifuge or filter to separate the catalyst from the reaction product to ensure that there are no residual reactants on its surface.
2. Regeneration: For renewable catalysts, they can be regenerated by heating, pickling or alkaline washing to restore their catalytic activity. For example, the nanoparticle catalyst can be heated at 150°C for 1 hour to remove the oxides from the surface and restore its catalytic properties.
3. Detection: Before the recovered catalyst is put into use, strict performance testing should be carried out to ensure that its catalytic activity and stability meet the requirements. The structure and morphology of the catalyst can be characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM) and other means.

5. Troubleshooting and Maintenance

In actual operation, some common problems may be encountered, such as catalyst deactivation, incomplete reaction, etc. Based on domestic and foreign literature and practical experience, the following are some common troubleshooting methods:

1. Catalytic Inactivation: If the catalyst is found to be deactivated, it may be caused by excessive temperature or reactant poisoning. It is recommended to check whether the temperature control equipment is normal to ensure that the temperature is within the specified range; secondly, check whether the reactants contain inhibitors or other impurities, and replace the catalyst if necessary.
2. Incomplete reaction: If the reaction is incomplete, it may be caused by insufficient catalyst dosage or too short reaction time. It is recommended to increase the amount of catalyst or extend the reaction time, and to check whether the reaction conditions meet the requirements.
3. Equipment failure: If the equipment fails, such as temperature control equipment failure or the agitator is damaged, the catalyst may not work properly. It is recommended to regularly maintain and repair the equipment to ensure its normal operation.

Conclusion and Outlook

The application of thermally sensitive delay catalysts in the manufacturing of household appliances has achieved remarkable results, especially in the manufacturing process of common household appliances such as refrigerators, washing machines and air conditioners, which have shown huge technical advantages. By precisely controlling reaction rates, improving production efficiency, improving product quality, and meeting environmental protection and safety requirements, the thermal delay catalyst has brought new development opportunities to the home appliance manufacturing industry.

However, despite the broad application prospects of thermally sensitive delay catalysts, there are still some challenges. First, the activation temperature range and catalytic activity of the catalyst need to be further optimized.To adapt to more complex process conditions. Secondly, the technology of catalyst recycling and reuse is not yet mature, and research is needed in the future to reduce production costs and reduce environmental pollution. Later, with the rapid development of the home appliance manufacturing industry, the application areas of thermal delay catalysts will continue to expand, such as smart home appliances, energy-saving and environmentally friendly home appliances, and applications in emerging fields such as smart home appliances, energy-saving and environmentally friendly home appliances are worth looking forward to.

Looking forward, the research on thermally sensitive delay catalysts will continue to deepen, and the continuous emergence of new materials and new technologies will provide new opportunities for their performance improvement. Home appliance manufacturers should pay close attention to new progress in related fields, actively introduce advanced catalyst technologies and processes, and promote the sustainable development of the industry. At the same time, the government and industry associations should also increase support for the research and development of thermally sensitive delay catalysts, formulate more complete industry standards, and promote the healthy development of the industry.

In short, the application prospects of thermal delay catalysts in household appliance manufacturing are broad, and it is expected to become an important force in promoting technological innovation and industrial upgrading in the home appliance manufacturing industry in the future.

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