Optimization of low-odor foaming gel balance catalyst in soft foam production process
Introduction
Soft foam materials are widely used in furniture, car seats, mattresses and other fields. The choice of catalysts in their production processes has an important impact on the performance, odor and environmental protection of the product. In recent years, low-odor foam gel balance catalysts have gradually become the focus of industry attention due to their environmental protection and high efficiency. This article will discuss in detail how to improve the production process of soft foam by optimizing low-odor foam gel balance catalyst, covering product parameters, process optimization, performance improvement and other aspects.
1. Overview of low-odor foam gel balance catalyst
1.1 The role of catalyst
In the production process of soft foam, catalysts are mainly used to adjust the equilibrium of foaming reaction and gel reaction. The foaming reaction produces gas, which causes the material to expand; the gel reaction cures the material to form a stable foam structure. The type and amount of catalyst directly affect the density, hardness, elasticity and other properties of the foam.
1.2 Characteristics of low-odor catalysts
Low odor foam gel balance catalyst reduces the release of volatile organic compounds (VOCs) by optimizing the formulation, thereby reducing the odor of foam. Such catalysts usually have the following characteristics:
- Low Volatility: Reduce odor during production and use.
- Efficiency: Improve reaction rate and shorten production cycle.
- Environmental protection: Comply with environmental protection regulations and reduce harm to the environment and the human body.
2. Product parameters of low-odor foam gel balance catalyst
2.1 Main components of catalyst
Low odor foam gel equilibrium catalyst is usually composed of the following components:
| Ingredients | Function | Typical content (%) |
|---|---|---|
| Organic amine | Promote foaming reaction | 30-50 |
| Metal Catalyst | Promote gel reaction | 10-20 |
| Stabilizer | Improve the stability of the catalyst | 5-10 |
| Solvent | Adjust the viscosity of the catalyst | 20-40 |
2.2 Physical and chemical properties of catalyst
| parameters | Typical |
|---|---|
| Appearance | Colorless to light yellow liquid |
| Density (g/cm³) | 0.9-1.1 |
| Viscosity (cP) | 50-200 |
| pH value | 8-10 |
| Flash point (℃) | >100 |
2.3 Performance indicators of catalysts
| Indicators | Typical |
|---|---|
| Foaming rate | 10-30 seconds |
| Gel Time | 30-60 seconds |
| Odor level | Low (compliant with ISO 16000-28 standards) |
| Environmental | Compare with REACH and RoHS standards |
3. Optimization of soft foam production process
3.1 Raw material selection and ratio
The raw materials for soft foam production mainly include polyols, isocyanates, catalysts, foaming agents and stabilizers. By optimizing the ratio of raw materials, the performance of the foam can be significantly improved.
| Raw Materials | Typical ratio (%) | Optimization Suggestions |
|---|---|---|
| Polyol | 60-70 | Select low viscosity and high reactive polyols |
| Isocyanate | 30-40 | Select low volatile isocyanate |
| Catalyzer | 1-2 | Use low-odor foam gel balance catalyst |
| Frothing agent | 1-3 | Select environmentally friendly foaming agent |
| Stabilizer | 0.5-1 | Increase the amount of stabilizer to improve foam stability |
3.2 Production process flow optimization
The production process of soft foam mainly includes steps such as raw material mixing, foaming, maturation and post-treatment. By optimizing each step, production efficiency and product quality can be improved.
3.2.1 Raw material mixing
- Mixing temperature: Control at 20-30℃ to avoid excessive temperatures leading to excessive reaction.
- Mixing Time: Ensure that the components are well mixed, usually 30-60 seconds.
3.2.2 Foaming
- Foaming temperature: Control at 30-40℃ to ensure uniform foaming reaction.
- Foaming time: Adjusted according to the type and amount of catalyst, usually 10-30 seconds.
3.2.3 Cultivation
- Mature temperature: Control at 50-60℃ to promote gel reaction.
- Mature Time: Usually 1-2 hours to ensure that the foam is completely cured.
3.2.4 Post-processing
- Cutting: Cut according to product requirements to ensure dimensional accuracy.
- Surface treatment: Perform surface coating or embossing treatment to improve product appearance and performance.
3.3 Optimization of catalyst dosage
The amount of catalyst is used directly affects the equilibrium of foaming and gel reaction. By optimizing the amount of catalyst, the performance of the foam can be improved.
| Catalytic Dosage (%) | Foaming rate (seconds) | Gel time (seconds) | Foam density (kg/m³) | Foam hardness (N) |
|---|---|---|---|---|
| 1.0 | 15 | 40 | 25 | 120 |
| 1.5 | 12 | 35 | 23 | 110 |
| 2.0 | 10 | 30 | 20 | 100 |
It can be seen from the above table that as the amount of catalyst is increased, the foaming rate and gel time are shortened, and the foam density and hardness are reduced. Therefore, in actual production, the appropriate amount of catalyst should be selected according to product needs.
IV. Application cases of low-odor foaming gel balance catalyst
4.1 Soft foam for furniture
In the production of soft foam for furniture, the application of low-odor foam gel balance catalysts has significantly improved the environmental protection and comfort of the product.
| parameters | Traditional catalyst | Low Odor Catalyst | Optimization effect |
|---|---|---|---|
| Odor level | in | Low | Reduce odor significantly |
| Foam density | 25 kg/m³ | 23 kg/m³ | Reduce density and improve comfort |
| Foam hardness | 120 N | 110 N | Reduce hardness and improve elasticity |
| Production cycle | 2 hours | 1.5 hours | Short production cycle |
4.2 Soft foam for car seats
In the production of soft foam for car seats, the application of low-odor foam gel balance catalysts improves the environmental protection and durability of the product.
| parameters | Traditional catalyst | Low Odor Catalyst | Optimization effect |
|---|---|---|---|
| Odor level | in | Low | Reduce odor significantly |
| Foam density | 30 kg/m³ | 28 kg/m³ | Reduce density and improve comfort |
| Foam hardness | 150 N | 140 N | Reduce hardness and improve elasticity |
| Durability | General | Excellent | Improving durability |
5. Future development trends of low-odor foam gel balance catalysts
5.1 Promotion of environmental protection regulations
As environmental regulations become increasingly strict, the market demand for low-odor foam gel balance catalysts will continue to grow. In the future, the production of catalysts will pay more attention to environmental protection and sustainability.
5.2 Technological Innovation
Developing higher efficiency and lower odor catalysts through technological innovation will be the main direction of future development. For example, the research and development of nanocatalysts is expected to further improve catalytic efficiency.
5.3 Expansion of application areas
Low odor foam gel balance catalyst is not only suitable for soft foams, but also for hard foams, elastomers and other fields. Its application scope will be further expanded in the future.
Conclusion
The application of low-odor foaming gel balance catalyst in soft foam production processes has significantly improved the environmental protection, comfort and production efficiency of the product. By optimizing the selection, dosage and production process of catalysts, we can further
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