Polyurethane foaming catalyst LED-103: An economical catalyst that can effectively reduce production costs
Introduction
Polyurethane (PU) materials have become one of the indispensable materials in modern industry due to their excellent physical properties and wide application fields. Polyurethane foaming materials are widely used in construction, automobiles, furniture, home appliances and other fields. However, during the polyurethane foaming process, the selection and use of catalysts have a crucial impact on the performance and production cost of the product. This article will introduce a new polyurethane foaming catalyst, LED-103, in detail, and discuss how it can effectively reduce production costs and improve product quality.
1. Overview of polyurethane foaming catalyst
1.1 Basic principles of polyurethane foaming
Polyurethane foaming is a process in which isocyanate reacts with polyols to form polyurethane, and at the same time releases carbon dioxide gas to form a foam structure. In this process, the catalyst plays a key role in accelerating the reaction, regulating the foam structure, and controlling the foaming time.
1.2 Function of catalyst
Catalytics mainly play the following roles in the polyurethane foaming process:
- Accelerating reaction: The catalyst can significantly accelerate the reaction rate between isocyanate and polyol and shorten the foaming time.
- Adjust the foam structure: By controlling the type and amount of catalyst, the structural parameters such as the pore size and density of the foam can be adjusted.
- Control foaming time: The type and amount of catalyst can affect the start and end time of foaming, thereby controlling the entire foaming process.
1.3 Limitations of traditional catalysts
The traditional polyurethane foaming catalysts such as amine catalysts, organotin catalysts, etc., can meet the basic foaming needs, but there are some limitations in practical applications:
- Higher cost: The price of traditional catalysts is higher, increasing production costs.
- Environmental Protection Issues: Some traditional catalysts contain harmful substances, which cause pollution to the environment.
- Unstable performance: The performance fluctuates greatly under different temperature and humidity conditions, affecting product quality.
2. Introduction to LED-103 catalyst
2.1 Basic characteristics of LED-103
LED-103 is a new type of polyurethane foaming catalyst with the following basic characteristics:
- High-efficiency Catalysis: LED-103 can significantly accelerate the reaction between isocyanate and polyol and shorten the foaming time.
- Economic: The price of LED-103 is relatively low, which can effectively reduce production costs.
- Environmentality: LED-103 does not contain harmful substances and meets environmental protection requirements.
- Stability: LED-103 has stable performance under different temperature and humidity conditions and can ensure product quality.
2.2 Chemical structure of LED-103
The chemical structure of LED-103 has been carefully designed to show excellent catalytic properties during polyurethane foaming. Its molecular structure contains multiple active groups, which can react efficiently with isocyanate and polyol.
2.3 Physical properties of LED-103
| Project | parameter value |
|---|---|
| Appearance | Colorless transparent liquid |
| Density (g/cm³) | 1.05 |
| Viscosity (mPa·s) | 50 |
| Flash point (?) | 120 |
| Solution | Easy soluble in water and organic solvents |
III. Application of LED-103 in polyurethane foaming
3.1 Application Areas
LED-103 is widely used in the following fields:
- Building Insulation Materials: Used to produce polyurethane hard bubble insulation boards to improve the insulation performance of buildings.
- Auto interior: used to produce interior parts such as car seats, dashboards, etc. to improve comfort and safety.
- Furniture Manufacturing: Used to produce sofas, mattresses and other furniture to improve the comfort and durability of products.
- Home Appliance Manufacturing: Used to produce insulation layers for home appliances such as refrigerators and refrigerators to improve energy efficiency.
3.2 Application Effect
InIn practical applications, LED-103 shows the following advantages:
- Shorten foaming time: LED-103 can significantly shorten foaming time and improve production efficiency.
- Improve the foam structure: LED-103 can adjust the pore size and density of the foam and improve the physical properties of the foam.
- Reduce production costs: The price of LED-103 is low, which can effectively reduce production costs.
- Improving product quality: LED-103 has stable performance under different environmental conditions and can ensure product quality.
3.3 Application Cases
The following is an application case of LED-103 in building insulation materials:
| Project | Traditional catalyst | LED-103 Catalyst |
|---|---|---|
| Foaming time (s) | 120 | 90 |
| Foam density (kg/m³) | 40 | 38 |
| Heat insulation performance (W/m·K) | 0.022 | 0.020 |
| Production cost (yuan/ton) | 12000 | 10000 |
It can be seen from the table that after using LED-103 catalyst, the foaming time was shortened by 25%, the foam density was reduced by 5%, the insulation performance was improved by 9%, and the production cost was reduced by 16.7%.
IV. Economic analysis of LED-103
4.1 Cost comparison
Compared with traditional catalysts, LED-103 is cheaper and can effectively reduce production costs. The following is a cost comparison table:
| Catalytic Type | Price (yuan/ton) | Doing (kg/ton) | Total cost (yuan/ton) |
|---|---|---|---|
| Traditional catalyst | 15000 | 10 | 15000 |
| LED-103 Catalyst | 10000 | 8 | 8000 |
It can be seen from the table that after using LED-103 catalyst, the catalyst cost per ton of product was reduced by 7,000 yuan, a decrease of 46.7%.
4.2 Improvement of production efficiency
LED-103 can significantly shorten foaming time and improve production efficiency. The following is a production efficiency comparison table:
| Catalytic Type | Foaming time (s) | Production efficiency (ton/hour) |
|---|---|---|
| Traditional catalyst | 120 | 5 |
| LED-103 Catalyst | 90 | 6.67 |
It can be seen from the table that after using LED-103 catalyst, the production efficiency has increased by 33.3%.
4.3 Product quality improvement
LED-103 has stable performance under different environmental conditions and can ensure product quality. The following is a product quality comparison table:
| Catalytic Type | Foam density (kg/m³) | Heat insulation performance (W/m·K) | Product Pass Rate (%) |
|---|---|---|---|
| Traditional catalyst | 40 | 0.022 | 95 |
| LED-103 Catalyst | 38 | 0.020 | 98 |
It can be seen from the table that after using LED-103 catalyst, the foam density was reduced by 5%, the insulation performance was improved by 9%, and the product pass rate was improved by 3%.
V. Environmental protection analysis of LED-103
5.1 Environmental performance
LED-103 does not contain harmful substances and meets environmental protection requirements. The following is a comparison table of environmental performance:
| Catalytic Type | Hazardous substance content (ppm) | Environmental Certification |
|---|---|---|
| Traditional catalyst | 500 | None |
| LED-103 Catalyst | 0 | Passed ISO14001 certification |
It can be seen from the table that LED-103 does not contain harmful substances and has passed ISO14001 environmental certification.
5.2 Environmental benefits
After using LED-103 catalyst, the emission of harmful substances can be reduced and the pollution to the environment can be reduced. The following is a comparison table of environmental benefits:
| Catalytic Type | Hazardous substance emissions (kg/ton) | Environmental benefits (yuan/ton) |
|---|---|---|
| Traditional catalyst | 5 | 0 |
| LED-103 Catalyst | 0 | 500 |
It can be seen from the table that after using LED-103 catalyst, the environmental benefit per ton of product is 500 yuan.
VI. Future development of LED-103
6.1 Technology improvement
In the future, LED-103 catalyst will continue to undergo technological improvements to further improve its catalytic and environmentally friendly properties. Possible improvement directions include:
- Improve catalytic efficiency: By optimizing the molecular structure, further improve catalytic efficiency and shorten foaming time.
- Reduce the dosage: By improving the production process, reduce the dosage of catalysts and further reduce production costs.
- Enhanced environmental performance: By introducing more environmentally friendly materials, the environmental performance of the catalyst can be further enhanced.
6.2 Market prospects
With the continuous improvement of environmental protection requirements and the intensification of market competition, the market prospects of LED-103 catalysts are broad. It is expected that LED-103 catalysts will be widely used in the following fields in the next few years:
- Building insulation materials: With the increase in building energy conservation requirements, LED-103 catalysts will be more widely used in building insulation materials.
- Auto Interior: With the advancement of the trend of lightweighting in automobiles, LED-103 catalysts will be more widely used in automotive interiors.
- Furniture Manufacturing: As consumers increase their requirements for furniture comfort and environmental protection, LED-103 catalysts will be more widely used in furniture manufacturing.
- Home Appliance Manufacturing: With the improvement of the energy efficiency requirements of home appliances, LED-103 catalysts will be more widely used in home appliance manufacturing.
Conclusion
LED-103, as a new type of polyurethane foaming catalyst, has the advantages of efficient catalysis, economy, environmental protection and stability, and can effectively reduce production costs and improve product quality. In the future, with the continuous improvement of technology and the increasing market demand, LED-103 catalysts will be widely used in more fields, making greater contributions to the development of the polyurethane industry.
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