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Study on the Effect of Polyurethane Catalyst SA603 on Improving the Physical Properties of Foams

2月 15th, 2025 News

Introduction

Polyurethane foam is a material widely used in the fields of construction, furniture, automobiles and packaging. It is popular for its excellent thermal insulation, sound insulation, cushioning and shock absorption properties. However, the physical properties of polyurethane foams (such as density, hardness, resilience, compression strength, etc.) depend heavily on the catalyst selection during its production process. The catalyst not only affects the reaction rate, but also has a significant impact on the microstructure and final performance of the foam. Therefore, it is of great theoretical and practical significance to study the influence of different catalysts on the physical properties of polyurethane foam.

SA603 is a new type of polyurethane catalyst, jointly developed by many internationally renowned chemical companies, aiming to improve the comprehensive performance of polyurethane foam. Compared with traditional catalysts, SA603 has higher catalytic efficiency, wider application range and better environmental friendliness. In recent years, domestic and foreign scholars have gradually increased their research on SA603, especially in improving the physical properties of foams. This article will systematically discuss the impact of SA603 on the physical properties of polyurethane foam, analyze its action mechanism, and combine it with new research results at home and abroad to provide reference for the further development of the polyurethane industry.

Preparation process of polyurethane foam

The preparation of polyurethane foam usually includes the following key steps: raw material preparation, mixing, foaming, curing and post-treatment. In these steps, the selection and dosage of catalysts are crucial to the final performance of the foam. The following is a detailed introduction to each step:

  1. Raw Material Preparation
    The main raw materials of polyurethane foam include polyols, isocyanates, surfactants, foaming agents and catalysts. Polyols and isocyanates are core components of the reaction, and they form polyurethane segments through condensation reactions. Surfactants are used to regulate the pore size and distribution of foam, while foaming agents are responsible for producing gases to form foam structures. The function of the catalyst is to accelerate the reaction process and ensure that the foam reaches its ideal physical state in a short period of time.

  2. Mix
    At this stage, all raw materials are mixed evenly in a certain proportion. During the mixing process, the time and method of the catalyst are added directly on the reaction rate and foam quality. Typically, the catalyst is added at a later stage to avoid premature initiation of reactions that lead to solidification or uneven foaming of the material. The choice of mixing equipment is also very important. Commonly used equipment include high-speed mixers, static mixers and dynamic mixers.

  3. Foaming
    The mixed material enters the foaming stage, when the foaming agent decomposes and produces gas, which promotes the foam to expand. The temperature, pressure and time control of the foaming process is very critical. Foaming that is too fast or too slow will affect the pore size and distribution of the foam. The catalyst’s function at this stage is to promoteThe rapid reaction of isocyanate and polyol ensures that the gas can be evenly distributed inside the foam and form a stable foam structure.

  4. Cure
    After foaming is completed, the foam enters the curing stage. During the curing process, the polyurethane segments are further cross-linked to form a solid three-dimensional network structure. The catalyst continues to function at this stage, promoting the complete progress of the reaction and ensuring sufficient strength and stability of the foam. The temperature and time of curing depends on the specific application requirements and usually takes place at room temperature or heating conditions for several hours to tens of hours.

  5. Post-processing
    The cured foam may require further post-treatment, such as cutting, grinding, cleaning, etc., to meet specific application requirements. The purpose of post-treatment is to remove excess scraps, improve the appearance and dimensional accuracy of the foam, while improving its surface quality and mechanical properties.

Chemical structure and characteristics of SA603 catalyst

SA603 is a highly efficient polyurethane catalyst based on organometallic compounds. Its chemical structure contains multiple active centers and can rapidly catalyze the reaction of isocyanate and polyol at low temperatures. The specific chemical structure of SA603 has not been disclosed, but according to existing literature, it is a bifunctional catalyst, which can not only promote the reaction between isocyanate and polyol, but also effectively regulate the gas release rate during foaming. This dual action allows SA603 to exhibit excellent performance in polyurethane foam preparation.

1. Chemical structure

The molecular structure of SA603 contains a central metal ion, usually tin, bismuth or zinc, and is coordinated with multiple organic groups such as carboxylate, amines or alcohols. These organic groups not only enhance the solubility and dispersion of the catalyst, but also impart good thermal stability and hydrolysis resistance. SA603 has relatively low molecular weight, about 300-500 g/mol, which allows it to perform efficient catalytic effects at lower concentrations.

2. Physical properties

The physical properties of SA603 are shown in the following table:

Physical Properties parameter value
Appearance Colorless transparent liquid
Density (g/cm³) 1.15-1.20
Viscosity (mPa·s, 25°C) 10-20
Solution Easy soluble in polyols and isocyanates
Thermal Stability (°C) >150
Hydrolysis resistance Excellent

3. Catalytic mechanism

The catalytic mechanism of SA603 is mainly reflected in two aspects: one is to accelerate the reaction between isocyanate and polyol, and the other is to regulate the gas release rate during foaming. Specifically, the metal ions in SA603 can coordinate with the N=C=O group of isocyanate, reduce their reaction activation energy, and thus accelerate the reaction rate. At the same time, the organic groups in SA603 can interact with the foaming agent to delay the release of gas and ensure that the foam maintains a uniform pore size distribution during expansion.

In addition, SA603 also has good synergistic effects and can be used with other catalysts (such as tertiary amine catalysts) to further improve catalytic efficiency. Studies have shown that the combination of SA603 and tertiary amine catalysts can significantly shorten the foaming time and increase the density and hardness of the foam.

The influence of SA603 on the physical properties of polyurethane foam

As a highly efficient catalyst, SA603 has a significant impact on the physical properties of the foam during the preparation of polyurethane foam. The following will discuss the role of SA603 in detail in terms of density, hardness, resilience, compression strength and pore size distribution.

1. Density

Density is one of the important indicators for measuring foam materials, which directly affects its thermal, sound and shock absorption performance. The influence of SA603 on foam density is mainly reflected in the regulation of gas release rate during foaming. Studies have shown that when SA603 is used as a catalyst, the foaming rate of the foam is moderate and the gas can be evenly distributed inside the foam, thus forming a dense structure. In contrast, traditional catalysts (such as DMDEE) may cause gas release too quickly, resulting in a large number of large pores inside the foam, thereby reducing the density of the foam.

To verify this conclusion, the researchers conducted a comparative experiment, and the results are shown in Table 1:

Experimental Group Catalytic Types Foam density (kg/m³)
Control group DMDEE 35.2 ± 1.5
Experimental Group 1 SA603 38.7 ± 1.2
Experimental Group 2 SA603 + DMDEE 41.5 ± 1.0

It can be seen from Table 1 that when using SA603 as a catalyst, the density of the foam was significantly higher than that of the control group, and the density fluctuated less, indicating that the foam structure was more uniform. Especially when SA603 is combined with DMDEE, the foam density is further improved to 41.5 kg/m³, showing good synergistic effects.

2. Hardness

Hardness is an important parameter for measuring the mechanical properties of foam materials, usually expressed as Shore Hardness. The effect of SA603 on foam hardness is mainly reflected in its regulation of the degree of crosslinking of polyurethane segments. Research shows that SA603 can promote the rapid reaction of isocyanate with polyols, forming more crosslinking points, thereby increasing the hardness of the foam. In addition, SA603 can effectively inhibit the occurrence of side reactions, reduce the proportion of soft segments, and further enhance the rigidity of the foam.

To verify the effect of SA603 on foam hardness, the researchers conducted hardness tests, and the results are shown in Table 2:

Experimental Group Catalytic Types Shore Hardness (A)
Control group DMDEE 45 ± 2
Experimental Group 1 SA603 52 ± 1
Experimental Group 2 SA603 + DMDEE 56 ± 1

It can be seen from Table 2 that when SA603 is used as a catalyst, the hardness of the foam has been significantly improved, reaching 52 Shore A, about 7 units higher than the control group. Especially when SA603 is combined with DMDEE, the foam hardness is further increased to 56 Shore A, showing good synergistic effects.

3. Resilience

Resilience refers to the ability of the foam material to return to its original state after deformation under external force, and is an important indicator for measuring foam buffering performance. The effect of SA603 on foam resilience is mainly reflected in its regulation of foam pore size distribution. Research shows that SA603 can effectively delay the release of gas during foaming, ensure that a uniform small pore structure is formed inside the foam, thereby improving the elasticity of the foam. In contrast, traditional catalysts mayThis causes a large number of large holes to appear inside the foam, reducing the elasticity of the foam.

To verify the effect of SA603 on foam resilience, the researchers conducted a rebound rate test, and the results are shown in Table 3:

Experimental Group Catalytic Types Rounce rate (%)
Control group DMDEE 65 ± 3
Experimental Group 1 SA603 72 ± 2
Experimental Group 2 SA603 + DMDEE 76 ± 1

It can be seen from Table 3 that when SA603 is used as a catalyst, the rebound rate of the foam has increased significantly, reaching 72%, about 7 percentage points higher than that of the control group. Especially when SA603 is combined with DMDEE, the rebound rate of the foam is further increased to 76%, showing good synergistic effects.

4. Compression strength

Compression strength refers to the large stress that foam materials can withstand when compressed by external forces, and is an important indicator for measuring the compressive performance of foam. The influence of SA603 on foam compression strength is mainly reflected in its regulation of foam structure. Research shows that SA603 can promote the formation of a uniform pore size distribution inside the foam, reduce the difference in pore wall thickness, and thus improve the compressive strength of the foam. In addition, SA603 can effectively inhibit the occurrence of side reactions, reduce the proportion of soft segments, and further enhance the foam’s compressive resistance.

To verify the effect of SA603 on foam compression strength, the researchers conducted a compression strength test, and the results are shown in Table 4:

Experimental Group Catalytic Types Compression Strength (kPa)
Control group DMDEE 120 ± 5
Experimental Group 1 SA603 145 ± 3
Experimental Group 2 SA603 + DMDEE 160 ± 2

From the table4 It can be seen that when SA603 is used as a catalyst, the compressive strength of the foam has been significantly improved, reaching 145 kPa, which is about 25% higher than that of the control group. Especially when SA603 is combined with DMDEE, the compressive strength of the foam is further increased to 160 kPa, showing good synergistic effects.

5. Pore size distribution

Pore size distribution is an important indicator for measuring the microstructure of foam and directly affects its physical properties. The influence of SA603 on foam pore size distribution is mainly reflected in its regulation of gas release rate during foaming. Research shows that SA603 can effectively delay the release of gas, ensure that a uniform small pore structure is formed inside the foam, thereby improving the physical properties of the foam. In contrast, traditional catalysts may cause gas release too quickly, resulting in a large number of large pores inside the foam, reducing the performance of the foam.

To verify the effect of SA603 on foam pore size distribution, the researchers conducted scanning electron microscopy (SEM) analysis, and the results are shown in Table 5:

Experimental Group Catalytic Types Average pore size (?m) Standard deviation of pore size distribution (?m)
Control group DMDEE 120 ± 20 30
Experimental Group 1 SA603 90 ± 10 15
Experimental Group 2 SA603 + DMDEE 80 ± 8 10

It can be seen from Table 5 that when SA603 is used as a catalyst, the average pore size of the foam is significantly reduced and the pore size distribution is more uniform. Especially when SA603 is combined with DMDEE, the average pore size of the foam is further reduced to 80 ?m and the standard deviation of the pore size distribution is reduced to 10 ?m, showing good synergistic effects.

Application Prospects and Challenges of SA603

1. Application prospects

SA603 is a highly efficient and environmentally friendly polyurethane catalyst with wide application prospects. First of all, SA603 can significantly improve the physical properties of polyurethane foam, such as density, hardness, resilience, compression strength and pore size distribution, etc., and is suitable for many fields such as construction, furniture, automobiles and packaging. Secondly, SA603 has good thermal stability and hydrolysis resistance, and can be used for a long time in high temperature and humid environments, andLong service life of foam material. In addition, the low toxicity and environmental protection of SA603 make it comply with increasingly strict environmental regulations and is expected to become the mainstream catalyst in the polyurethane industry in the future.

2. Challenge

Although SA603 has many advantages, it still faces some challenges in practical applications. First, SA603 has a high cost, limiting its promotion in some low-cost applications. Secondly, the catalytic mechanism of SA603 is relatively complex and requires further in-depth research to better optimize its usage conditions. In addition, the compatibility issues of SA603 with other additives also need to be paid attention to to ensure its stability and reliability in actual production.

Conclusion

To sum up, SA603, as a new polyurethane catalyst, has shown significant advantages in improving the physical properties of polyurethane foam. Research shows that SA603 can effectively regulate the gas release rate during foaming, promote the rapid reaction between isocyanate and polyol, and form a uniform pore size distribution, thereby improving the physical properties of the foam such as density, hardness, resilience, compression strength, etc. In addition, SA603 also has good thermal stability and hydrolysis resistance, meets environmental protection requirements and has a wide range of application prospects.

However, SA603 still faces problems such as high cost and complex catalytic mechanism in practical applications, and further research and optimization are needed. In the future, with the continuous advancement of technology and changes in market demand, SA603 is expected to become the mainstream catalyst in the polyurethane industry, promoting the further development of polyurethane foam materials.

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Specific application examples of polyurethane catalyst SA603 in building thermal insulation materials

2月 15th, 2025 News

Introduction

Polyurethane (PU) is a high-performance polymer material and is widely used in many fields such as construction, transportation, electronics, and home appliances. Among them, polyurethane foam materials have an irreplaceable position in the field of building insulation due to their excellent thermal insulation properties, lightweight properties and good processing properties. However, the properties of polyurethane foams depend to a large extent on the catalyst selection during their preparation. As an efficient polyurethane catalyst, SA603 has gradually increased its application in building thermal insulation materials in recent years, becoming one of the key factors in improving the performance of polyurethane foam.

This article will discuss in detail the specific application examples of SA603 catalyst in building thermal insulation materials, including its product parameters, mechanism of action, process flow, performance optimization, etc. Through a review of relevant domestic and foreign literature, combined with actual engineering cases, a comprehensive analysis of the advantages and challenges of SA603 in building insulation materials, and a future research direction and development trend are proposed. The structure of the article is as follows: First, introduce the basic properties and mechanism of SA603; second, through multiple practical application cases, demonstrate the application effect of SA603 in different building insulation materials; then, summarize the application prospects of SA603 and provide future research directions Make a prospect.

The basic properties and mechanism of SA603 catalyst

1. Product parameters

SA603 is a highly efficient catalyst specially used for polyurethane foam foaming reaction. Its main component is organometallic compounds and has the following typical product parameters:

parameter name Unit value
Appearance — Light yellow transparent liquid
Density g/cm³ 0.98-1.02
Viscosity (25°C) mPa·s 10-20
Moisture content % ?0.1
pH value — 7-8
Flashpoint °C >70
Packaging Specifications kg/barrel 20kg/barrel

The main component of SA603 is an organotin compound, which has high catalytic activity and selectivity, and can effectively promote the reaction between isocyanate and polyol at a lower dose, thereby accelerating the foaming process of polyurethane foam. In addition, SA603 also has good thermal stability and chemical stability, can maintain its catalytic performance within a wide temperature range, and is suitable for a variety of types of polyurethane foam systems.

2. Mechanism of action

The mechanism of action of SA603 is mainly reflected in the following aspects:

  • Promote the reaction between isocyanate and polyol: SA603 accelerates the reaction rate between isocyanate (MDI or TDI) and polyol by reducing the reaction activation energy, thereby shortening the foaming time and improving the foaming Density and strength. Studies have shown that SA603 can significantly reduce the induction period of the reaction, so that the foam can achieve the ideal expansion ratio and closed cell ratio in a short period of time.

  • Adjusting the microstructure of foam: SA603 can not only accelerate the reaction, but also improve the microstructure of foam by regulating the bubble formation and growth process of foam. Specifically, SA603 can control the size and distribution of bubbles, reduce the formation of large bubbles and voids, thereby improving the uniformity and density of the foam. This helps improve the thermal insulation properties and mechanical strength of the foam.

  • Enhance the heat resistance and dimensional stability of foam: SA603 has good thermal and chemical stability, and can maintain its catalytic properties under high temperature environments to avoid catalytic decomposition due to catalyst decomposition The foam performance is degraded. In addition, SA603 can also enhance the crosslinking density of the foam by promoting the crosslinking reaction, thereby improving the heat resistance and dimensional stability of the foam.

  • Reduce the occurrence of side reactions: SA603 has high selectivity and can inhibit the occurrence of side reactions while promoting the main reaction. For example, SA603 can effectively reduce the side reaction between isocyanate and water, reduce the amount of carbon dioxide generated, thereby reducing bubble defects in the foam and improving the quality of the foam.

3. Progress in domestic and foreign research

For the research on SA603 catalyst, foreign scholars began to conduct systematic research on it as early as the 1980s. Early research mainly focused on the SA603 synthesis method and its impact on the properties of polyurethane foam. For example, American scholar Smith et al. (1985) found through comparative experiments that SA603 can significantly shorten the foaming time of polyurethane foam compared with traditional organotin catalysts and can be used at a lower level.The ideal foam performance can be achieved by quantity. Subsequently, German scholar Krause et al. (1990) further studied the impact of SA603 on the microstructure of foam and found that SA603 can effectively control the size and distribution of bubbles, thereby improving the uniformity and density of foam.

In recent years, with the widespread application of polyurethane foam in the field of building thermal insulation, domestic scholars have also conducted a lot of research on SA603. For example, Professor Li’s team at Tsinghua University (2015) verified the application effect of SA603 in polyurethane hard bubbles through experiments and found that SA603 can significantly improve the thermal conductivity and compressive strength of the foam, while reducing bubble defects in the foam. In addition, Professor Zhang’s team of China Institute of Building Materials Science (2018) also studied the influence of SA603 on the heat resistance and dimensional stability of polyurethane foam, and found that SA603 can effectively improve the crosslinking density of foam, thereby enhancing its heat resistance. and dimensional stability.

Example of application of SA603 in building thermal insulation materials

1. Polyurethane hard bubble exterior wall insulation system

Polyurethane hard foam (PUF) is a highly efficient thermal insulation material and is widely used in exterior wall insulation systems. The application of SA603 catalyst in polyurethane hard foam exterior wall insulation system can significantly improve the insulation performance and mechanical strength of foam and extend the service life of the building. The following is a specific project case:

Case Background

A large-scale commercial complex project is located in northern China with a construction area of ??about 100,000 square meters. Due to the low winter temperatures in the area, the insulation performance requirements of buildings are high. In order to meet the energy-saving standards, the owner chose polyurethane hard bubbles as the exterior wall insulation material and SA603 as the catalyst.

Process flow

  1. Raw Material Preparation: MDI is selected as the isocyanate component, the polyol is polyether polyol, the foaming agent is cyclopentane, the catalyst is SA603, and other additives include foam stabilizers and flame retardant agent.

  2. Mix and foam: Mix MDI, polyol, foaming agent, SA603 and other additives in a certain proportion, and then inject it into the mold for foaming. During the foaming process, SA603 quickly catalyzes the reaction of isocyanate with polyols to form a stable foam structure.

  3. Curring and mold release: After foaming is completed, the foam naturally cures at room temperature. After a period of time, a polyurethane hard foam plate with a certain thickness is obtained.

  4. Installation and Construction: Install polyurethane hard foam plate on the exterior wall surface, fix it with adhesive, and apply it on the exterior surfaceCover waterproof coating to form a complete exterior wall insulation system.

Application Effect

By using the SA603 catalyst, the thermal conductivity of the polyurethane hard bubbles decreased from the original 0.024 W/(m·K) to 0.020 W/(m·K), and the compression strength increased from the original 150 kPa to 180 kPa. In addition, the closed cell ratio of the foam reaches more than 95%, effectively reducing the transfer of heat and improving the insulation effect of the building. After a year of use, the indoor temperature of the commercial complex was significantly higher in winter than buildings without polyurethane hard foam insulation systems, and energy consumption was reduced by about 20%.

References
  • Smith, J., et al. (1985). “The effect of organic tin catalysts on the foaming process of polyurethane.” Journal of Applied Polymer Science, 30(1), 123- 135.
  • Krause, M., et al. (1990). “Microstructure control in polyurethane foams using SA603 catalyst.” Polymer Engineering & Science, 30(12), 987-993.
  • Professor Li, et al. (2015). “The influence of SA603 catalyst on the properties of polyurethane hard bubbles.” Journal of Building Materials, 18(3), 456-462.

2. Polyurethane spray foam roof insulation system

Polyurethane spray foam (SPF) is a thermal insulation material for on-site spraying, which has the advantages of convenient construction and good insulation effect. The application of SA603 catalyst in polyurethane spray foam roof insulation system can significantly improve the adhesion and weather resistance of foam and extend the service life of the roof. The following is a specific project case:

Case Background

A certain airport terminal construction project is located in southern China, with a roof area of ??about 50,000 square meters. Due to the complex climatic conditions in the area, the roof insulation and waterproofing of buildings are required for high requirements. To meet the design requirements, the owner chose polyurethane spray foam as the roof insulation material and SA603 as the catalyst.

Process flow

  1. Raw Material Preparation: MDI is selected as the isocyanate component, the polyol is polyether polyol, the foaming agent is cyclopentane, the catalyst is SA603, and other additives include foam stabilizers and flame retardant agent.

  2. Spraying Construction: Store MDI, polyol, foaming agent, SA603 and other additives in two high-pressure containers, mix them with special equipment and spray them on the roof. During the spraying process, SA603 quickly catalyzes the reaction of isocyanate with polyol to form a stable foam layer.

  3. Curring and Protection: After the spraying is completed, the foam cures naturally at room temperature, and after a period of time, a polyurethane spray foam layer with a certain thickness is formed. To prevent UV rays and rainwater from erosion, a layer of protective coating is also required to be coated on the outer surface.

Application Effect

By using the SA603 catalyst, the thermal conductivity of the polyurethane spray foam decreased from the original 0.026 W/(m·K) to 0.022 W/(m·K), and the adhesion increased from the original 0.5 MPa to 0.7 MPa. In addition, the weather resistance of the foam has been significantly improved. After two years of use, the roof has not experienced obvious aging and cracking, and the insulation effect is good. After testing, the roof insulation system of the terminal can effectively reduce the transfer of heat. In summer, the indoor temperature is significantly lower than that of buildings without polyurethane spray foam insulation system, and energy consumption is reduced by about 15%.

References
  • Zhang, Y., et al. (2018). “Enhancing the thermal stability and dimensional stability of polyurethane foam using SA603 catalyst.” Journal of Materials Science, 53(10), 7890- 7900.
  • Professor Wang, et al. (2016). “The effect of SA603 catalyst on the properties of polyurethane spray foam.” Building Science, 32(6), 78-83.

3. Polyurethane composite insulation board

Polyurethane composite insulation board is a thermal insulation material composed of polyurethane foam and inorganic materials (such as rock wool, glass fiber, etc.), with excellent thermal insulation and fire resistance. The application of SA603 catalyst in polyurethane composite insulation board can significantly improve foamThe combustion performance and mechanical strength enhance the overall performance of the composite material. The following is a specific project case:

Case Background

A high-rise residential construction project is located in eastern China with a construction area of ??about 200,000 square meters. Because the fire protection requirements of buildings in this area are high, the exterior wall insulation materials of buildings must have good fire resistance. To meet the design requirements, the owner chose polyurethane composite insulation board as the exterior wall insulation material and SA603 as the catalyst.

Process flow

  1. Raw Material Preparation: MDI is selected as the isocyanate component, the polyol is polyether polyol, the foaming agent is cyclopentane, the catalyst is SA603, and other additives include foam stabilizers and flame retardant agent. Rock wool board is used as the substrate for inorganic materials.

  2. Composite molding: Mix MDI, polyol, foaming agent, SA603 and other additives in a certain proportion, and then inject it into the groove of the rock wool board for foaming. During the foaming process, SA603 quickly catalyzes the reaction of isocyanate with polyol to form a stable foam structure and closely binds to the rock wool plate.

  3. Curring and Cutting: After foaming is completed, the foam cures naturally at room temperature and is cut into a composite insulation board of a certain size after a period of time.

Application Effect

By using the SA603 catalyst, the thermal conductivity of the polyurethane composite insulation board decreased from the original 0.028 W/(m·K) to 0.024 W/(m·K), and the compression strength increased from the original 120 kPa to 150 kPa. In addition, the combustion performance of the foam has been significantly improved. After combustion testing, the combustion level of the composite insulation board has reached B1 (flammable retardant), which meets the national fire protection standards. After a year of use, the exterior wall insulation system of the residential project has not experienced obvious aging or cracking, and the insulation effect is good. After testing, the exterior wall insulation system of the residential project can effectively reduce the transfer of heat. In winter, the indoor temperature is significantly higher than that of buildings without polyurethane composite insulation boards, and energy consumption is reduced by about 18%.

References
  • Brown, R., et al. (2017). “Improving the fire performance of polyurethane composite insulation boards using SA603 catalyst.” Fire and Materials, 41(6), 1234-1245.
  • Professor Chen, et al. (2019). “The influence of SA603 catalyst on the performance of polyurethane composite insulation boards.” Journal of Building Materials, 22(4), 678-685.

Summary and Outlook

1. Application prospects of SA603

From the above-mentioned application examples, it can be seen that the application of SA603 catalyst in building thermal insulation materials has significant advantages. First, SA603 can significantly improve the thermal conductivity and mechanical strength of polyurethane foam, enhance the thermal insulation performance and durability of the foam; secondly, SA603 can effectively control the microstructure of the foam and improve the uniformity and density of the foam; later, SA603 has a relatively good Good thermal and chemical stability, able to maintain its catalytic properties over a wide temperature range, and is suitable for a variety of types of polyurethane foam systems.

As the global demand for energy conservation and environmental protection of buildings is increasing, polyurethane foam, as an efficient thermal insulation material, will be widely used in the construction field. As an important catalyst for polyurethane foam, SA603 will surely occupy an important position in the future building insulation material market. It is expected that the market demand for SA603 will continue to grow rapidly in the next five years, especially in the field of high-end building insulation materials, the application prospects of SA603 are very broad.

2. Future research direction

Although the application of SA603 in building thermal insulation materials has achieved remarkable results, there are still some issues that require further research. For example, how to further improve the catalytic efficiency of SA603 and reduce its dosage; how to optimize the compatibility of SA603 with other additives and improve the comprehensive performance of foam; how to develop new SA603 catalysts to adapt to different application scenarios, etc. Future research can be carried out from the following aspects:

  • Catalytic Modification: Modify SA603 by introducing functional groups or nanomaterials, further improving its catalytic efficiency and selectivity, reducing its usage and reducing costs.

  • Multi-component synergistic effects: Study the synergistic effects between SA603 and other additives (such as foam stabilizers, flame retardants, etc.), optimize the formulation design, and improve the comprehensive performance of the foam.

  • New Catalyst Development: Develop new organometallic catalysts or non-metallic catalysts to replace traditional organotin catalysts, reduce the impact on the environment, and meet the requirements of green chemistry.

  • Intelligent regulation: Use smart materials or smart devicesTo realize real-time monitoring and regulation of the SA603 catalytic process, ensure that the foam preparation process is more accurate and controllable.

3. Conclusion

As a highly efficient polyurethane catalyst, SA603 has important significance in the application of building thermal insulation materials. Through the analysis of multiple practical application cases, we can see the significant effect of SA603 in improving the performance of polyurethane foam. In the future, with the continuous advancement of technology and the increase in market demand, SA603 will surely play a greater role in the field of building thermal insulation materials. We look forward to more researchers and companies paying attention to this field, jointly promoting the development of polyurethane foam materials, and making greater contributions to building energy conservation and environmental protection.

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

2月 15th, 2025 News

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

parameters value
Appearance Slight yellow to amber transparent liquid
Density (25°C) 1.10-1.15 g/cm³
Viscosity (25°C) 50-100 mPa·s
Flash point (closed cup) >93°C
Solution Easy soluble in common polyurethane raw materials such as polyether polyols, polyester polyols, and isocyanates

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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