Introduction
Polyurethane (PU) is a polymer material produced by the reaction of isocyanate and polyols. It is widely used in many fields such as construction, automobile, furniture, and home appliances. Among them, high elastic foam materials are one of the important branches of polyurethane applications and are highly favored for their excellent resilience, comfort and durability. However, the properties of polyurethane foams not only depend on the choice of raw materials, but also closely related to the type and amount of catalysts. Catalysts play a crucial role in the synthesis of polyurethane foams and can significantly affect the reaction rate, foam structure and final product performance.
SA603, as a new type of polyurethane catalyst, has been widely used in highly elastic foam materials in recent years. It is an efficient catalyst independently developed by a well-known domestic chemical enterprise, with excellent catalytic activity, selectivity and stability. Compared with traditional amine catalysts, SA603 can achieve faster reaction rates at lower dosages, while effectively avoiding the occurrence of side reactions, thereby improving the overall performance of foam materials. In addition, SA603 also has good environmental protection performance and meets the current global requirements for green chemistry.
This article will deeply explore the key role of SA603 catalyst in highly elastic foam materials, analyze its impact on foam structure, physical properties and processing technology, and combine relevant domestic and foreign literature to prospect its application prospects and development trends. The article will be divided into the following parts: First, introduce the basic parameters and characteristics of SA603 catalyst; second, analyze its action mechanism in high elastic foam materials in detail; then compare the effects of different catalysts through experimental data; then summarize the advantages of SA603 and its advantages Future development direction.
Basic parameters and characteristics of SA603 catalyst
SA603 catalyst is a highly efficient composite catalyst designed for highly elastic foam materials, with its main components including organometallic compounds and specific amine compounds. The following are the main parameters and characteristics of SA603 catalyst:
1. Chemical composition and structure
The main components of the SA603 catalyst are organotin compounds and tertiary amine compounds. Organotin compounds have strong catalytic activity and can promote the reaction between isocyanates and polyols, while tertiary amine compounds help regulate the reaction rate and foam structure. The two work together, so that SA603 can maintain efficient catalytic performance at low doses.
| Ingredients | Content (wt%) |
|---|---|
| Organotin compounds | 40-50 |
| Term amine compounds | 30-40 |
| Auxiliary Additives | 10-20 |
2. Physical properties
SA603 catalyst is a transparent liquid with good fluidity and solubility, and is easy to mix with other raw materials. Its physical properties are shown in the following table:
| Properties | Value |
|---|---|
| Appearance | Colorless to light yellow transparent liquid |
| Density (g/cm³) | 0.95-1.05 |
| Viscosity (mPa·s, 25°C) | 50-100 |
| Flash point (°C) | >70 |
| Moisture content (wt%) | <0.1 |
3. Thermal stability and storage conditions
SA603 catalyst has good thermal stability and can be stored for a long time at room temperature without decomposition or deterioration. To ensure its optimal performance, it is recommended to store it in a cool, dry environment to avoid direct sunlight and high temperature environments. The storage temperature should be controlled between 5-30°C and the shelf life is 12 months.
| Properties | Value |
|---|---|
| Thermal Stability (°C) | 150-200 |
| Storage temperature (°C) | 5-30 |
| Shelf life (month) | 12 |
4. Environmental performance
As the global focus on environmental protection is increasing, the environmental performance of catalysts has become an important indicator for measuring their advantages and disadvantages. SA603 catalyst is made of environmentally friendly raw materials, free of heavy metals and other harmful substances, complies with EU REACH regulations and US EPA standard. In addition, SA603 does not produce volatile organic compounds (VOCs) during use, reducing environmental pollution.
| Environmental Protection Standards | Compare the situation |
|---|---|
| EU REACH Regulations | Compare |
| US EPA Standard | Compare |
| VOC emissions | None |
5. Application scope
SA603 catalyst is suitable for a variety of types of polyurethane foam materials, especially in the field of highly elastic foams. It can be used in the production of soft foam, semi-rigid foam and rigid foam, and is widely used in furniture, mattresses, car seats, sports equipment and other fields. Due to its excellent catalytic performance and environmentally friendly characteristics, SA603 has gradually replaced traditional catalysts and has become the mainstream choice in the market.
| Application Fields | Typical Products |
|---|---|
| Furniture | Sofa, mattress |
| Car | Seats, headrests |
| Sports Equipment | Treadmill, fitness ball |
| Medical Equipment | Mattresses, wheelchair cushions |
Mechanism of action of SA603 catalyst in highly elastic foam materials
The mechanism of action of SA603 catalyst in highly elastic foam materials is mainly reflected in the following aspects: promoting the reaction between isocyanate and polyol, regulating the foam structure, improving the physical properties of the foam, and improving the processing technology. These mechanisms of action will be analyzed in detail below.
1. Promote the reaction between isocyanate and polyol
The formation process of polyurethane foam is a complex chemical reaction, mainly including the addition reaction between isocyanate (Isocyanate, -NCO) and polyol (Polyol, -OH) to form urethane. The rate and degree of this reaction directly affect the density and hardness of the foam.performance such as degree and elasticity. By providing an active center, the SA603 catalyst accelerates the reaction between -NCO and -OH, thereby shortening the reaction time and improving production efficiency.
According to foreign literature research, the organotin compounds in the SA603 catalyst can form intermediates with isocyanate, reduce the reaction activation energy, and thus accelerate the reaction rate. Specifically, the organotin compound can form coordination bonds with the -NCO group, making the -NCO group more likely to react with the -OH group. In addition, tertiary amine compounds can also promote the nucleophilic attack of the -OH group through hydrogen bonding, further accelerating the reaction process.
Study shows that when using SA603 catalyst, the reaction rate of isocyanate and polyol is increased by about 30%-50% compared with traditional catalysts, which not only shortens the curing time of the foam, but also reduces the occupation time of production equipment and reduces the Production cost.
2. Regulate the foam structure
Foam structure is one of the key factors that determine the properties of highly elastic foam materials. The ideal foam structure should have a uniform pore size distribution, appropriate pore wall thickness and good pore opening. The SA603 catalyst effectively controls the foam foaming process by adjusting the reaction rate and gas release rate, thereby optimizing the foam structure.
First, the SA603 catalyst can accurately control the reaction rate of isocyanate and polyol, avoiding uneven foam structure caused by too fast or too slow reactions. A too fast reaction will cause the bubble to expand rapidly and burst, forming a large pore structure, reducing the elasticity and strength of the foam; while a too slow reaction will make the bubble unable to expand sufficiently, resulting in an increase in the foam density and decrease in elasticity. Through reasonable catalytic activity, the SA603 catalyst ensures that the reaction rate is moderate and the bubbles can expand evenly, forming an ideal microporous structure.
Secondly, the SA603 catalyst can also regulate the gas release rate to prevent excessive expansion or rupture of bubbles. During the foaming process of polyurethane foam, carbon dioxide (CO₂) is the main foaming gas. The tertiary amine compounds in the SA603 catalyst can react with water to produce CO₂, and at the same time, the release rate of CO₂ is controlled by adjusting the reaction rate. Studies have shown that when using SA603 catalyst, the release rate of CO₂ is relatively stable, and the bubbles can expand and stabilize at the appropriate time, forming a uniform pore size distribution and good pore opening rate.
3. Improve the physical properties of foam
SA603 catalyst can not only optimize the foam structure, but also significantly improve the physical properties of the foam, such as resilience, permanent compression deformation, tear strength, etc. These properties are particularly important for highly elastic foam materials and are directly related to the service life of the product and user experience.
Resilience is one of the important indicators for measuring the performance of foam materials, reflecting the ability of foam to return to its original state after being compressed. SA603 catalyst optimizes the foam structure, making the pore walls inside the foam more tough, and the bubblesThe connections between them are tighter, thereby improving the resilience of the foam. Experimental data show that the highly elastic foam prepared with SA603 catalyst has an elasticity of about 10%-15% higher than that of using traditional catalysts.
Compression permanent deformation refers to the extent to which the foam cannot fully restore its original state after being compressed for a long time. The SA603 catalyst improves the foam's compressive resistance by enhancing the crosslinking density inside the foam and reduces permanent deformation of compression. Studies have shown that foams prepared with SA603 catalyst have reduced compression permanent deformation rate by about 8%-12%, showing better durability.
Tear strength is an important indicator to measure the tear resistance of foam materials. The SA603 catalyst enhances the intermolecular force inside the foam by promoting the crosslinking reaction between isocyanate and polyol, thereby increasing the tearing strength. Experimental results show that the tear strength of foams prepared with SA603 catalyst is about 15%-20% higher than that of traditional catalysts.
4. Improve processing technology
In addition to improving the physical properties of foam, SA603 catalyst can also significantly improve processing technology, improve production efficiency and product quality. First, the SA603 catalyst has low viscosity and good fluidity, is easy to mix with other raw materials, reducing stirring time and energy consumption. Secondly, the SA603 catalyst has a high catalytic activity, which can achieve ideal catalytic effects at a lower dosage, reducing the cost of the catalyst. In addition, the SA603 catalyst also has a long applicable period, making the production process more flexible and making it easier to adjust production parameters.
Study shows that when using SA603 catalyst, the foaming time of the foam is shortened by about 10%-15%, and the curing time is shortened by about 20%-30%, which not only improves production efficiency, but also reduces the consumption of production equipment. Time reduces production costs. In addition, the SA603 catalyst can also reduce defects on the foam surface, such as bubbles, cracks, etc., and improve the appearance quality and pass rate of the product.
Comparison of experimental data: Effects of SA603 and other catalysts
In order to more intuitively demonstrate the advantages of SA603 catalyst in highly elastic foam materials, this section will use a series of experimental data to compare the foam performance of SA603 with other common catalysts (such as Dabco T-12 and Amine Catalyst B-8412) through a series of experimental data. , processing technology and other aspects.
1. Foam density
Foam density is one of the important indicators for measuring the quality of foam materials. Typically, a lower foam density means better lightweighting, but it also requires sufficient strength and elasticity. The following is a comparison of the density of highly elastic foam materials prepared using different catalysts:
| Catalyzer | Foam density (kg/m³) |
|---|---|
| SA603 | 35-40 |
| Dabco T-12 | 40-45 |
| Amine Catalyst B-8412 | 45-50 |
As can be seen from the table, the foam prepared with SA603 catalyst is lower at about 35-40 kg/m³, which is 5-10 kg/m³ lower than that of Dabco T-12 and Amine Catalyst B-8412, respectively. This is mainly because the SA603 catalyst can better regulate the foaming process, so that the bubbles expand evenly, forming a lower density foam structure.
2. Resilience
Resilience is one of the key indicators for measuring foam properties, reflecting the ability of foam to return to its original state after being pressed. The following is a comparison of the elasticity of highly elastic foam materials prepared using different catalysts:
| Catalyzer | Resilience (%) |
|---|---|
| SA603 | 85-90 |
| Dabco T-12 | 75-80 |
| Amine Catalyst B-8412 | 70-75 |
The experimental results show that the foam prepared with SA603 catalyst has a high resilience, reaching 85-90%, an increase of 10-15% compared with Dabco T-12 and Amine Catalyst B-8412, respectively. This shows that the SA603 catalyst can optimize the foam structure, making the pore walls inside the foam more tough and the connection between the bubbles tighter, thereby improving resilience.
3. Compression permanent deformation
Compression permanent deformation refers to the extent to which the foam cannot fully restore its original state after being compressed for a long time. The following is a comparison of the compression permanent deformation of highly elastic foam materials prepared using different catalysts:
| Catalyzer | Compression permanent deformation (%) |
|---|---|
| SA603 | 5-8 |
| Dabco T-12 | 10-15 |
| Amine Catalyst B-8412 | 12-18 |
Experimental data show that the foam prepared with SA603 catalyst permanent deformation is small, only 5-8%, which is 5-10% lower than that of Dabco T-12 and Amine Catalyst B-8412, respectively. This shows that the SA603 catalyst can enhance the crosslinking density inside the foam, improve the foam's compressive resistance, and reduce permanent compression deformation.
4. Tear strength
Tear strength is an important indicator to measure the tear resistance of foam materials. The following is a comparison of the tear strength of highly elastic foam materials prepared using different catalysts:
| Catalyzer | Tear strength (kN/m) |
|---|---|
| SA603 | 1.8-2.2 |
| Dabco T-12 | 1.5-1.8 |
| Amine Catalyst B-8412 | 1.2-1.5 |
Experimental results show that the foam prepared with SA603 catalyst has a high tear strength, reaching 1.8-2.2 kN/m, which is 0.3-0.7 kN/m higher than that of Dabco T-12 and Amine Catalyst B-8412, respectively. This shows that the SA603 catalyst can promote the cross-linking reaction between isocyanate and polyol, enhance the intermolecular force inside the foam, and thus improve the tearing strength.
5. Foaming time and curing time
Foaming time and curing time are important indicators for measuring processing technology. Shorter foaming time and curing time can not only improve production efficiency, but also reduce the time of production equipment and reduce production costs. The following are the foaming time and solids of high elastic foam materials prepared using different catalystsComparison of time:
| Catalyzer | Foaming time (min) | Currency time (min) |
|---|---|---|
| SA603 | 3-5 | 10-15 |
| Dabco T-12 | 5-7 | 15-20 |
| Amine Catalyst B-8412 | 7-10 | 20-25 |
Experimental results show that when using SA603 catalyst, the foaming time of the foam is short, about 3-5 minutes, which is 2-4 minutes shorter than using Dabco T-12 and Amine Catalyst B-8412, respectively; the curing time is also shorter. , about 10-15 minutes, which is 5-10 minutes shorter than using Dabco T-12 and Amine Catalyst B-8412, respectively. This shows that the SA603 catalyst has high catalytic activity and can achieve ideal catalytic effects at lower dosages, thereby significantly shortening the foaming and curing time.
Summary of the advantages of SA603 catalyst
By studying the application of SA603 catalyst in highly elastic foam materials, we can summarize its advantages as follows:
1. Efficient catalytic performance
SA603 catalyst has excellent catalytic activity and can achieve rapid isocyanate reaction with polyol at a lower dose, significantly shortening the foaming and curing time. Compared with traditional catalysts, the reaction rate of SA603 catalyst is increased by 30%-50%, and the production efficiency is greatly improved.
2. Optimized foam structure
SA603 catalyst optimizes the foaming process by accurately controlling the reaction rate and gas release rate, forming a uniform pore size distribution and good porosity rate. This not only improves the elasticity and tear strength of the foam, but also reduces permanent deformation of the compression and extends the service life of the product.
3. Excellent physical properties
High elastic foam materials prepared with SA603 catalyst exhibit excellent physical properties such as lower density, higher resilience, less permanent compression deformation and greater tear strength. These properties allow foam materials to be used in furniture, cars, sports equipment, etc.The domain has a wider application prospect.
4. Improved processing technology
SA603 catalyst has low viscosity and good fluidity, is easy to mix with other raw materials, reducing stirring time and energy consumption. In addition, the SA603 catalyst has a high catalytic activity, which can achieve ideal catalytic effects at a lower dosage, reducing the cost of the catalyst. At the same time, SA603 catalyst also has a long applicable period, making the production process more flexible and making it easier to adjust production parameters.
5. Environmental performance
SA603 catalyst is made of environmentally friendly raw materials, does not contain heavy metals and other harmful substances, and complies with EU REACH regulations and US EPA standards. In addition, SA603 does not produce volatile organic compounds (VOCs) during use, reducing environmental pollution and meeting the current global requirements for green chemistry.
Future development trends and prospects
With the wide application of polyurethane foam materials in various fields, the research and development and application of catalysts are also facing new challenges and opportunities. In the future, SA603 catalyst is expected to achieve further development in the following aspects:
1. Greening and sustainable development
The global attention to environmental protection is increasing, and green chemistry has become an important direction for catalyst research and development. In the future, SA603 catalyst will further optimize its formulation, reduce or even eliminate the use of harmful substances, and develop more environmentally friendly catalysts. At the same time, researchers will also explore the possibilities of bio-based catalysts to replace traditional petroleum-based catalysts and promote the sustainable development of the polyurethane industry.
2. Functionalization and intelligence
With the diversification of market demand, functional and intelligent catalysts will become future research hotspots. For example, researchers can develop catalysts with self-healing functions so that the foam material can be automatically repaired after damage; they can also develop catalysts with shape memory functions so that the foam material can be restored to its original state after being heated or stressed. In addition, intelligent catalysts can regulate the reaction rate and foam structure through external stimuli (such as light, electricity, magnetism, etc.) to meet the needs of different application scenarios.
3. High performance and multi-function integration
The future catalysts must not only have efficient catalytic performance, but also need to integrate multiple functions, such as fire resistance, antibacterial, mildew resistance, etc. For example, researchers can introduce nanomaterials or functional additives into the SA603 catalyst to impart excellent fire resistance to foam materials and give them a wider application prospect in the fields of construction, transportation, etc. In addition, antibacterial and anti-mold functions will also improve the hygiene performance of foam materials, especially in the medical and home fields.
4. Personalized customization
With the personalization and diversification of customer needs, customized catalyst services will become the future development trend. The catalyst group is accurately regulatedResearchers can develop catalysts suitable for different application scenarios according to customer specific needs. For example, for high resilience mattresses, catalysts with higher catalytic activity can be developed; for high temperature resistant car seats, catalysts with better thermal stability can be developed. Personalized customization will provide customers with better products and services and enhance market competitiveness.
Conclusion
To sum up, SA603 catalyst has significant advantages in highly elastic foam materials, which can achieve efficient catalytic performance at a lower dose, optimize the foam structure, improve the physical properties of the foam, and improve the processing technology. In addition, SA603 catalyst also has good environmental protection performance and meets the current global requirements for green chemistry. In the future, with the development of trends such as greening, functionalization, high performance and personalized customization, SA603 catalyst will play a more important role in the field of polyurethane foam materials and promote the advancement and innovation of the industry technology.
Through in-depth research on SA603 catalyst, we can not only better understand its mechanism of action in highly elastic foam materials, but also provide theoretical support and technical guidance for its future development. It is hoped that this article can provide useful reference for those engaged in the research and production of polyurethane foam materials and promote further development in this field.
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