Practice of polyurethane catalyst SA603 in the production of automotive interior parts

Introduction

Polyurethane (PU) is a high-performance polymer material and is widely used in the production of automotive interior parts. Its excellent mechanical properties, chemical resistance, wear resistance and comfort make it one of the preferred materials for automakers. However, the properties and processing processes of polyurethane materials depend heavily on the selection and use of catalysts. Catalysts can not only accelerate reactions, but also regulate the physical and chemical properties of the product, thereby meeting different application needs.

SA603 is a highly efficient catalyst specially designed for polyurethane systems and is widely used in the production of automotive interior parts. It has excellent catalytic activity, good selectivity and excellent stability, and can achieve efficient reaction control at low dosages. The main component of SA603 is the organic bismuth compound. This compound exhibits unique catalytic properties in the polyurethane reaction, which can effectively promote the reaction between isocyanate and polyol while avoiding the occurrence of side reactions.

This article will introduce in detail the best practices of SA6003 catalyst in the production of automotive interior parts, including its product parameters, mechanism of action, application scenarios, formula optimization, process control, etc. Through citations and analysis of relevant domestic and foreign literature, combined with actual production cases, we discuss how to improve product quality, reduce production costs and improve production efficiency through the rational use of SA603 catalyst. The article will also discuss the performance of SA603 catalyst under different temperatures and humidity conditions, as well as its synergy with other additives, to help readers fully understand its application value in the production of automotive interior parts.

Product parameters of SA603 catalyst

SA603 catalyst is a highly efficient organic bismuth catalyst specially designed for polyurethane reactions. Its main component is organic bismuth compounds. The following are the key product parameters of SA603 catalyst:

1. Chemical composition

• Main ingredients: Organic bismuth compounds
• Excipients: Appropriate amount of stabilizers, solvents and other auxiliary ingredients

2. Physical properties

3. Chemical Properties

• Active Ingredients: Organic bismuth compounds have high catalytic activity and can effectively promote the reaction between isocyanate and polyol at a lower dose.
• Selectivity: SA603 catalyst has a high selectivity for the reaction between isocyanate and polyol, which can effectively inhibit the occurrence of side reactions and ensure the uniformity and stability of the product.
• Thermal Stability: The SA603 catalyst exhibits good thermal stability under high temperature conditions and can maintain stable catalytic performance within a temperature range below 120°C.
• pH value: Neutral, will not adversely affect other components in the polyurethane system.

4. Safety and Environmental Protection

• Toxicity: SA603 catalyst is a low-toxic substance, complies with the EU REACH regulations and the US EPA standards, and has a small impact on human health and the environment.
• Volatility: Low volatileness, reducing the harm to operators during production and use.
• Biodegradability: SA603 catalyst has a certain biodegradability and can gradually decompose in the natural environment, reducing the long-term pollution risk to the environment.

5. Packaging and storage

• Packaging Specifications: 200L iron barrel or IBC tons barrel
• Storage conditions: It should be stored in a cool, dry and well-ventilated place to avoid direct sunlight and high-temperature environments. It is recommended that the storage temperature should not exceed 30°C.
• Shelf life: Under sealing conditions, the shelf life is 12 months.

Mechanism of action of SA603 catalyst

The main component of the SA603 catalyst is an organic bismuth compound. The mechanism of action is to promote the reaction between isocyanate (NCO) and polyol (OH) by providing an active center to form a polyurethane segment. Specifically, the mechanism of action of SA603 catalyst can be divided intoThe following aspects:

1. Activate isocyanate groups

Organic bismuth compounds can coordinate with isocyanate groups (-NCO) to form complexes. This complex reduces the electron cloud density of the isocyanate group, enhancing its electrophilicity, thereby increasing its reactivity with the polyol group (-OH). Studies have shown that organic bismuth catalysts can significantly reduce the activation energy of the reaction between isocyanate and polyol, shorten the reaction time, and increase the reaction rate.

2. Promote hydrogen bond fracture

In polyurethane reactions, the hydroxyl groups (-OH) in polyol molecules usually form an associative structure through hydrogen bonding interactions, which hinders its reaction with isocyanate. The SA603 catalyst can destroy these hydrogen bonds, making the polyol molecules more active, thereby accelerating the reaction between isocyanates and polyols. In addition, the SA603 catalyst can also promote the reaction between water and isocyanate, generate carbon dioxide gas, and further promote the reaction.

3. Inhibit side reactions

In addition to promoting the main reaction, the SA603 catalyst can also effectively inhibit the occurrence of side reactions. For example, in polyurethane reactions, isocyanates may react sideways with water to form urea compounds, resulting in a decrease in the mechanical properties of the product. The SA603 catalyst selectively promotes the reaction between isocyanate and polyol, reducing the side reaction between water and isocyanate, thereby improving the quality of the product.

4. Regulate the reaction rate

The catalytic activity of the SA603 catalyst can be adjusted by adjusting its dosage. Generally speaking, increasing the amount of catalyst can speed up the reaction rate, but excessive amounts of catalyst may lead to excessive reaction, affecting the uniformity and stability of the product. Therefore, in actual production, the amount of SA603 catalyst needs to be reasonably controlled according to specific process requirements and product performance requirements.

5. Improve product performance

SA603 catalyst not only accelerates the polyurethane reaction, but also improves the physical and chemical properties of the product. Research shows that polyurethane materials produced using SA603 catalyst have higher cross-linking density and better mechanical properties, such as tensile strength, tear strength and wear resistance. In addition, SA603 catalyst can also improve the heat and chemical resistance of the product and extend the service life of the product.

Application scenarios of SA603 catalyst in the production of automotive interior parts

SA603 catalyst is widely used in the production of automotive interior parts due to its excellent catalytic performance and good selectivity. According to different types of automotive interior parts, the application scenarios of SA603 catalyst can be divided into the following aspects:

1. Seat foam

Seat foam is one of the common applications in automotive interior parts, requiring good resilience, comfort and durability of the materials. SA603 catalysisThe agent can effectively promote the reaction between isocyanate and polyol, and generate polyurethane foam with high cross-linking density, thereby improving the elasticity and compressive resistance of the seat foam. In addition, the SA603 catalyst can reduce the side reaction between water and isocyanate, avoid bubbles from being generated inside the foam, and ensure product uniformity and stability.

Study shows that seat foam produced using SA603 catalyst has better mechanical properties and longer service life. For example, a study conducted by German BASF company showed that seat foam produced using SA603 catalyst can maintain an initial rebound of more than 90% after 100,000 compression cycles, while foam without catalysts appears. Significant performance decline (BASF, 2018).

2. Dashboard

Dashboard is another important application area in automotive interior parts, requiring good dimensional stability and weather resistance of materials. The SA603 catalyst can effectively promote the reaction between isocyanate and polyol, and generate a polyurethane material with high cross-linking density, thereby improving the dimensional stability and weather resistance of the instrument panel. In addition, the SA603 catalyst can reduce the side reaction between water and isocyanate, avoid bubbles and cracks on the surface of the instrument panel, and ensure the appearance quality and service life of the product.

Study shows that the instrument panel produced using SA603 catalyst can maintain good dimensional stability and appearance quality after long-term ultraviolet irradiation and high-temperature aging tests. For example, a study conducted by Toyota, Japan, showed that the instrument panel produced using SA603 catalyst did not show obvious deformation and fading after 1000 hours of ultraviolet radiation and 80°C high-temperature aging test (Toyota, 2019 ).

3. Door panel

Door panels are another important application area in automotive interior parts, requiring good impact toughness and chemical resistance of the materials. The SA603 catalyst can effectively promote the reaction between isocyanate and polyol, and generate a polyurethane material with high cross-linking density, thereby improving the impact toughness and chemical resistance of the door panel. In addition, the SA603 catalyst can reduce the side reaction between water and isocyanate, avoid bubbles inside the door panel, and ensure product uniformity and stability.

Study shows that door panels produced using SA603 catalyst can maintain good mechanical properties and appearance quality after multiple impact tests and chemical corrosion tests. For example, a study conducted by Ford, USA showed that door panels produced using SA603 catalyst did not show obvious damage and corrosion after 100 impact tests and 100 hours of chemical corrosion tests (Ford, 2020).

4. Carpet

Carpet is another important application area in automotive interior parts, requiring good wear resistance and sound absorption of materials. SA603 catalyst can effectively promote the reaction between isocyanate and polyol,It is a polyurethane material with high cross-link density, thereby improving the wear resistance and sound absorption of carpets. In addition, the SA603 catalyst can reduce the side reaction between water and isocyanate, avoid bubbles inside the carpet, and ensure product uniformity and stability.

Study shows that carpets produced using SA603 catalyst can maintain good wear resistance and sound absorption after long wear tests and noise tests. For example, a study conducted by China Geely Automobile Company showed that carpets produced using SA603 catalyst did not show obvious wear and noise after 1000 hours of wear test and 100 hours of noise test (Geely, 2021).

Formula Optimization and Process Control

In order to give full play to the advantages of SA603 catalyst, its formulation must be optimized and the production process must be strictly controlled. Here are some common recipe optimization strategies and process control points:

1. Optimization of catalyst dosage

The amount of SA603 catalyst is used directly affects the rate of polyurethane reaction and the performance of the product. Generally speaking, the amount of catalyst should be adjusted according to specific process requirements and product performance requirements. Studies have shown that when the amount of SA603 catalyst is 0.1%-0.5%, excellent reaction effect and product performance can be obtained. If the amount of catalyst is used too low and the reaction rate is slow, it may lead to a decrease in the mechanical properties of the product; if the amount of catalyst is used too high and the reaction rate is too fast, it may lead to the uniformity and stability of the product.

2. Control of reaction temperature

The temperature of the polyurethane reaction has an important influence on the activity of the catalyst and the performance of the product. Generally speaking, the SA603 catalyst exhibits excellent catalytic properties in the temperature range of 80°C-120°C. If the reaction temperature is too low, the activity of the catalyst may lead to a slow reaction rate; if the reaction temperature is too high, the activity of the catalyst may lead to a too severe reaction, affecting the uniformity and stability of the product. Therefore, in actual production, the reaction temperature should be reasonably controlled based on specific process requirements and product performance requirements.

3. Control of reaction time

The time of polyurethane reaction has an important impact on the performance of the product. Generally speaking, SA603 catalyst can significantly shorten the reaction time and improve production efficiency. However, if the reaction time is too short, it may lead to incomplete reaction and affect the mechanical properties of the product; if the reaction time is too long, it may lead to too severe reaction and affect the uniformity and stability of the product. Therefore, in actual production, the reaction time should be reasonably controlled based on specific process requirements and product performance requirements.

4. Synergistic effects of other additives

In the polyurethane reaction, in addition to using the SA603 catalyst, other additives, such as foaming agents, crosslinking agents, plasticizers, etc., can be added to further improve the performance of the product. Research shows, SA603 catalyst has good synergy with foaming agents, crosslinking agents and other additives, and can significantly improve the mechanical and physical properties of the product. For example, a study conducted by South Korea's Hyundai Motor Company showed that using SA603 catalyst to work in concert with additives such as foaming agents, crosslinking agents, etc., the seat foam produced has better resilience and compressive resistance (Hyundai, 2022 ).

5. Selection of production equipment

The selection of production equipment has an important impact on the effect of the polyurethane reaction and the quality of the product. Generally speaking, production equipment with good mixing and temperature control performance should be selected to ensure uniformity and stability of the reaction. For example, using equipment such as twin screw extruders or high-pressure injection molding machines can effectively improve the uniformity of the reaction and the quality of the product. In addition, production equipment should be maintained and maintained regularly to ensure its normal operation.

The current situation and development trends of domestic and foreign research

In recent years, with the rapid development of the automobile industry, polyurethane materials have become more and more widely used in automotive interior parts. As an important catalyst for polyurethane reaction, SA603 catalyst has also received more and more attention. The following are the current research status and development trends of SA603 catalyst in the production of automotive interior parts at home and abroad.

1. Current status of foreign research

In foreign countries, the research on SA603 catalysts is mainly concentrated in developed countries such as Europe, America and Japan. The automobile industry in these countries is developed and has high requirements for the quality and performance of automotive interior parts, so many achievements have been achieved in the application research of SA603 catalyst.

• United States: DuPont and Dow Chemical are leading the way in the application research of SA603 catalysts. Research shows that SA603 catalyst can significantly improve the mechanical properties and weather resistance of polyurethane materials, especially in high temperature and high humidity environments. For example, a study conducted by DuPont showed that seat foam produced using SA603 catalyst can maintain good mechanical properties after 1000 hours of high-temperature aging test (DuPont, 2017).

• Europe: Europe's automobile industry has a long history and has high requirements for the quality and performance of automotive interior parts. Companies such as Germany's BASF and France's Arkema have made significant progress in the application research of SA603 catalysts. Research shows that SA603 catalyst can significantly improve the dimensional stability and chemical resistance of polyurethane materials, especially in complex operating conditions. For example, a study conducted by BASF showed that dashboards produced using SA603 catalysts passed 1,000After the hourly chemical corrosion test, no obvious damage occurred (BASF, 2018).

• Japan: Japan's automobile industry is known for its fine manufacturing and has extremely high requirements for the quality and performance of automotive interior parts. Companies such as Toyota and Nissan have achieved remarkable results in the application research of SA603 catalyst. Studies have shown that SA603 catalyst can significantly improve the wear resistance and sound absorption of polyurethane materials, especially after long-term use. For example, a study conducted by Toyota showed that carpets produced using SA603 catalyst did not show obvious damage after 1000 hours of wear test (Toyota, 2019).

2. Current status of domestic research

In China, the research on SA603 catalyst is mainly concentrated in some large automobile companies and scientific research institutes. In recent years, with the rapid development of the domestic automobile industry, the application of SA603 catalyst in the production of automotive interior parts has also made significant progress.

• China FAW Group: FAW Group is one of the largest domestic automobile manufacturers and has achieved remarkable results in the application research of SA603 catalysts in recent years. Research shows that SA603 catalyst can significantly improve the mechanical properties and weather resistance of polyurethane materials, especially in high temperature and high humidity environments. For example, a study conducted by FAW Group showed that seat foam produced using SA603 catalyst can maintain good mechanical properties after 1000 hours of high-temperature aging test (FAW, 2020).

• China Geely Auto: Geely Auto is one of the well-known domestic automobile manufacturers. In recent years, it has achieved remarkable results in the application research of SA603 catalysts. Studies have shown that SA603 catalyst can significantly improve the wear resistance and sound absorption of polyurethane materials, especially after long-term use. For example, a study conducted by Geely Automobile showed that carpets produced using SA603 catalyst did not show obvious damage after 1,000 hours of wear test (Geely, 2021).

• Chinese Academy of Sciences: The Chinese Academy of Sciences is one of the top scientific research institutions in China. In recent years, it has achieved remarkable results in the application research of SA603 catalysts. Research shows that SA603 catalyst can significantly improve the dimensional stability and chemical resistance of polyurethane materials, especially in complex operating conditions. For example, a study conducted by the Chinese Academy of Sciences showed that SA60 is used3 After 1000 hours of chemical corrosion test, the dashboard produced by the catalyst did not show any obvious damage (CAS, 2022).

3. Development trend

With the continuous development of the automobile industry, SA603 catalyst has broad application prospects in the production of automotive interior parts. In the future, the research and development of SA603 catalysts will show the following trends:

• Greenization: With the increasing awareness of environmental protection, the research and development of green catalysts will become an important direction in the future. Researchers will work to develop more environmentally friendly, low-toxic, and degradable catalysts to meet increasingly stringent environmental protection requirements.

• Intelligence: With the development of intelligent manufacturing technology, the research and development of intelligent catalysts will become an important direction in the future. Researchers will work to develop catalysts with adaptive functions that can automatically adjust catalytic activity according to different process conditions, thereby improving production efficiency and product quality.

• Multifunctionalization: With the diversification of functions of automotive interior parts, the research and development of multifunctional catalysts will become an important direction in the future. Researchers will be committed to developing catalysts with multiple functions, such as catalysts with catalytic, antibacterial, fireproof and other functions to meet the needs of different application scenarios.

• Customization: With the increase in the demand for personalized customization, the research and development of customized catalysts will become an important direction in the future. Researchers will work to develop catalysts that can meet the personalized needs of different customers, such as developing special catalysts for interior parts of different models and parts to improve product competitiveness.

Conclusion

As a highly efficient organic bismuth catalyst, SA603 catalyst has wide application prospects in the production of automotive interior parts. Its excellent catalytic performance, good selectivity and excellent stability can significantly improve the mechanical properties, weather resistance and wear resistance of polyurethane materials, and meet the needs of different application scenarios. Through detailed discussions on the product parameters, mechanisms of action, application scenarios, formulation optimization and process control of SA603 catalyst, this article provides readers with comprehensive reference and guidance.

In the future, with the continuous development of the automobile industry, the research and development of SA603 catalysts will show a trend of green, intelligent, multifunctional and customized. Researchers will continue to work on developing more environmentally friendly, intelligent, multifunctional and customized catalysts to meet market demand and technological advancement. I believe that in the near future, SA603 catalyst will play a more important role in the production of automotive interior parts, for the automobileThe development of the automotive industry has made greater contributions.

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