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Share effective strategies for reducing production costs by polyurethane catalyst A-1

2月 15th, 2025 News

Introduction

Polyurethane (PU) is a polymer material produced by the reaction of isocyanate and polyols. It is widely used in coatings, foams, elastomers, adhesives and other fields. Its excellent mechanical properties, chemical resistance and processability make it one of the indispensable and important materials in modern industry. However, the production process of polyurethane is complex and costly, especially the choice of catalyst has a crucial impact on reaction efficiency and product quality. Therefore, how to reduce production costs and improve economic benefits by optimizing catalysts has become an urgent problem that needs to be solved in the polyurethane industry.

A-1 catalyst, as a highly efficient polyurethane catalyst, has been widely used at home and abroad in recent years. It can not only significantly increase the reaction rate and shorten the production cycle, but also effectively reduce the generation of by-products, thereby improving the purity and quality of the product. The main component of A-1 catalyst is organometallic compounds, which have good thermal stability and catalytic activity, and can promote the reaction between isocyanate and polyol at lower temperatures and reduce energy consumption. In addition, the A-1 catalyst also has the advantages of strong selectivity and low usage, which can further reduce production costs.

This article will discuss A-1 catalysts, analyze their product parameters, application fields, and mechanisms in detail, and combine domestic and foreign literature to explore how to reduce costs and increase efficiency of polyurethane production by optimizing the use of catalysts. The article will also provide specific experimental data and case analysis by comparing the performance of different catalysts, helping readers better understand the advantages of A-1 catalyst and its application value in actual production.

Product parameters of A-1 catalyst

A-1 catalyst is a high-performance polyurethane catalyst, and its product parameters directly affect its performance in polyurethane production. The following are the main physical and chemical properties of A-1 catalysts, as well as their recommended dosage in different application scenarios.

1. Physical Characteristics

parameter name Unit value
Appearance – Light yellow transparent liquid
Density g/cm³ 0.98 ± 0.02
Viscosity mPa·s 50 ± 5
Flashpoint °C >60
Moisture content % <0.1
pH value – 7.0 ± 0.5
Solution – Easy soluble in alcohols, ketones, and ester solvents

2. Chemical Characteristics

parameter name Unit value
Main ingredients – Organic Bismuth Compound
Molecular Weight g/mol 350 ± 10
Active ingredient content % 98 ± 1
Thermal Stability °C 200
Storage Stability month 12
Reactive activity – High
Selective – High

3. Recommended dosage

The amount of A-1 catalyst is used depends on the specific polyurethane production process and the required product performance. Generally speaking, the recommended amount of A-1 catalyst is 0.1% to 0.5% by weight of polyol. The specific amount can be adjusted according to the following factors:

  • Reaction type: For rigid foam, it is recommended to use a lower catalyst dosage (0.1%-0.3%) to avoid excessively fast foaming speed leading to uneven structure; for soft foaming, for soft foaming, Or elastomer, the catalyst dosage (0.3%-0.5%) can be appropriately increased to speed up the reaction rate.
  • Reaction temperature: At lower temperatures (such as 20°C-40°C), the amount of catalyst is needed to ensure smooth progress of the reaction; at higher temperatures (such as 60°C), the amount of catalyst is needed to be increased to ensure smooth progress of the reaction; -80°C) can reduce the amount of catalyst, becauseHigh temperatures themselves speed up the reaction.
  • Raw material ratio: When the ratio of isocyanate to polyol is high, the amount of catalyst can be appropriately reduced; conversely, when the ratio is low, the amount of catalyst needs to be increased to ensure complete reaction.
  • Product requirements: For polyurethane products that require high hardness and high strength, the catalyst usage should be controlled at a low level to avoid excessive crosslinking; for soft and elastic products, the catalyst usage can be Increase appropriately.

4. Safety and environmental protection

A-1 catalyst has good safety and environmental protection and complies with international standards. Its main component, organic bismuth compounds, have less harm to the human body and the environment and are low-toxic substances. According to EU REACH regulations and relevant regulations of the US EPA, A-1 catalysts are classified as non-hazardous goods and can be transported and stored under conventional conditions. In addition, no harmful gases or volatile organic compounds (VOCs) are produced during the production and use of A-1 catalyst, which meets the requirements of green chemical industry.

5. Comparison with other catalysts

To show the advantages of A-1 catalyst more intuitively, we compared it with other polyurethane catalysts commonly found on the market. Table 2 lists the key parameters and performance characteristics of several typical catalysts.

Catalytic Model Main Ingredients Activity Selective Domic Range Environmental Price (yuan/kg)
A-1 Organic Bismuth High High 0.1%-0.5% Excellent 120
T-12 Stanate in General 0.5%-1.0% Poor 80
DABCO Term amine Low Low 1.0%-2.0% Poor 60
BZ-2 Organic zinc in High 0.3%-0.8% Excellent 100

As can be seen from Table 2, the A-1 catalyst performs excellently in terms of activity, selectivity and environmental protection, especially in terms of usage, which not only helps to reduce production costs, but also reduces Impact on the environment. In addition, although the price of A-1 catalyst is slightly higher than that of some traditional catalysts, the overall cost advantage is still obvious considering its efficient catalytic performance and low dosage.

Mechanism of action of A-1 catalyst

The main component of A-1 catalyst is organic bismuth compounds, and its mechanism of action is closely related to its unique chemical structure. During the synthesis of polyurethane, the A-1 catalyst significantly improves the reaction rate and selectivity by promoting the reaction between isocyanate (NCO) and polyol (Polyol, OH). The following is an analysis of the specific mechanism of action of A-1 catalyst:

1. Promote the reaction between NCO and OH

The synthesis of polyurethane is caused by the addition reaction of isocyanate and polyol to form a urethane segment. The rate of this reaction depends on the type and amount of catalyst. Organic bismuth ions (Bi³?) in A-1 catalyst can form coordination bonds with isocyanate groups (-N=C=O), reducing their electron cloud density, thereby enhancing their nucleophilic attack on hydroxyl groups (-OH). ability. This coordination effect makes the reaction between NCO and OH more likely to occur, thereby increasing the reaction rate.

Study shows that the promotion effect of A-1 catalyst on the NCO and OH reaction is mainly reflected in the following aspects:

  • Reduce activation energy: The A-1 catalyst reduces the activation energy of the reaction through coordination with the NCO group, making the reaction easier to proceed. According to the Arrhenius equation, a decrease in activation energy results in a significant increase in the reaction rate constant.
  • Increase reaction sites: A-1 catalyst can adsorb around NCO groups, forming more reaction sites, increasing the collision frequency between NCO and OH, thereby improving the reaction rate.
  • Inhibit side reactions: A-1 catalyst has high selectivity and can preferentially promote the main reaction between NCO and OH and inhibit the occurrence of other side reactions, such as the self-polymerization of isocyanate Or side reaction with water. This not only improves the purity of the product, but also reduces unnecessary by-product generation.

2. Control the reaction rate

An important feature of A-1 catalyst is its ability to effectively control the reaction rate over a wide temperature range. At low temperatureUnder conditions, the A-1 catalyst can significantly accelerate the reaction between NCO and OH, so that the reaction can be carried out at lower temperatures, thereby reducing energy consumption. Under high temperature conditions, the activity of the A-1 catalyst is relatively low, avoiding the problem of structural unevenness or excessive by-products caused by excessive reaction.

Study shows that the relationship between the activity and temperature of A-1 catalyst can be expressed by the following formula:

[ k = A cdot e^{-frac{E_a}{RT}} ]

Where (k) is the reaction rate constant, (A) refers to the prefactor, (E_a) is the activation energy, (R) is the gas constant, and (T) is the absolute temperature. By adjusting the amount of A-1 catalyst and the reaction temperature, the synthesis rate of polyurethane can be accurately controlled to meet different process needs.

3. Improve product performance

A-1 catalyst can not only increase the reaction rate, but also significantly improve the performance of polyurethane products. Since the A-1 catalyst has high selectivity, it can preferentially promote the main reaction between NCO and OH and avoid the occurrence of side reactions. Therefore, the resulting polyurethane products have higher purity and better performance. Specifically, the application of A-1 catalyst can bring about the following performance improvements:

  • Mechanical Strength: A-1 catalyst can promote the orderly arrangement of polyurethane molecular chains and form a tighter network structure, thereby improving the mechanical strength and wear resistance of the product.
  • Heat resistance: The A-1 catalyst has good thermal stability and can maintain activity at higher temperatures, making polyurethane products have better heat resistance.
  • Flexibility: The A-1 catalyst can regulate the crosslinking density of the polyurethane molecular chain and generate an elastomer with moderate crosslinking, thereby improving the flexibility and resilience of the product.
  • Dimensional Stability: The A-1 catalyst can effectively control the size and distribution of bubbles during the foaming process, so that the polyurethane foam has better dimensional stability and uniformity.

4. Inhibit side reactions

In the synthesis of polyurethane, in addition to the main reaction between NCO and OH, some side reactions may also occur, such as the self-polymerization of isocyanate and the side reaction with water. These side reactions will not only reduce the purity of the product, but also produce a large number of by-products and increase production costs. The A-1 catalyst has high selectivity, can preferentially promote the main reaction and inhibit the occurrence of side reactions, thereby improving the quality and yield of the product.

Study shows that the inhibitory effect of A-1 catalyst on side reactions is mainly reflected in the following aspects:

  • Inhibiting the autopolymerization of isocyanate: A-1 catalyst can form coordination bonds with NCO groups, preventing its autopolymerization, thereby reducing the isocyanate dimer or multimer generate.
  • Inhibit side reactions with water: A-1 catalyst can preferentially bind to NCO groups, reducing its chance of contact with water molecules, thereby inhibiting the reaction of isocyanate with water to form carbon dioxide and urea Possibility of byproducts.

Application of A-1 catalyst in polyurethane production

A-1 catalyst has been widely used in polyurethane production due to its high efficiency, environmental protection and strong selectivity. Depending on different types of polyurethane products, A-1 catalyst can flexibly adjust the dosage and usage conditions to meet various process needs. The following are specific application cases of A-1 catalysts in the production of different types of polyurethanes.

1. Polyurethane foam

Polyurethane foam is a common type of product among polyurethane materials and is widely used in building insulation, furniture manufacturing, automotive interiors and other fields. During the foam production process, the A-1 catalyst can significantly increase the foaming rate, shorten the curing time, and control the size and distribution of the bubbles, so that the foam has better uniformity and dimensional stability.

Rough Foam

Rough polyurethane foam is mainly used in thermal insulation layers for building insulation and refrigeration equipment. In the production of rigid foams, the amount of A-1 catalyst is usually 0.1% to 0.3% by weight of the polyol. Because the density of rigid foam is low and the reaction rate is faster, the amount of catalyst needs to be strictly controlled to avoid excessively fast foaming speed leading to uneven structure. The A-1 catalyst can effectively promote the reaction between NCO and OH, while inhibiting the occurrence of side reactions, so that the foam has better mechanical strength and heat resistance.

Soft foam

Soft polyurethane foam is mainly used in filling materials in furniture, mattresses, car seats and other fields. In the production of soft foams, the amount of A-1 catalyst is usually 0.3% to 0.5% by weight of the polyol. Because the soft foam has a high density and relatively slow reaction rate, it is necessary to increase the amount of catalyst to speed up the reaction rate. The A-1 catalyst can promote the reaction between NCO and OH, while controlling the size and distribution of bubbles, so that the foam has better flexibility and resilience.

2. Polyurethane elastomer

Polyurethane elastomers are a type of material with high elasticity and wear resistance, and are widely used in sports soles, conveyor belts, seals and other fields. In the production of elastomers, the A-1 catalyst can significantly increase the reaction rate, shorten the curing time, and regulate the crosslinking density, so that the elastomers have better mechanical properties and durability.

Casted elastomer

CastingType polyurethane elastomers are mainly used to make large parts, such as rollers, gears, etc. In the production of castable elastomers, the amount of A-1 catalyst is usually 0.2% to 0.4% by weight of the polyol. Since the reaction volume of the cast-type elastomer is large and the reaction rate is slow, it is necessary to increase the amount of catalyst to speed up the reaction rate. The A-1 catalyst can promote the reaction between NCO and OH, while regulating the crosslinking density, so that the elastomer has better mechanical strength and wear resistance.

Thermoplastic elastomer

Thermoplastic polyurethane elastomer (TPU) is a reproducible elastomer material, widely used in films, pipes, cables and other fields. In the production of TPU, the amount of A-1 catalyst is usually 0.1% to 0.3% by weight of the polyol. Because the TPU is high in processing temperature, the A-1 catalyst has good thermal stability and can maintain activity at higher temperatures, making the TPU have better heat resistance and processing performance.

3. Polyurethane coating

Polyurethane coatings have excellent adhesion, wear resistance and weather resistance, and are widely used in automobiles, ships, bridges and other fields. In the production of coatings, the A-1 catalyst can significantly increase the drying rate of the coating film, shorten the curing time, and increase the hardness and gloss of the coating film.

Solvent-based coatings

Solvent-based polyurethane coatings are mainly used for anticorrosion coatings on metal surfaces. In the production of solvent-based coatings, the amount of A-1 catalyst is usually 0.1% to 0.3% by weight of polyol. Because the drying rate of solvent-based coatings is fast, the A-1 catalyst can effectively promote the reaction between NCO and OH, making the coating film have better adhesion and corrosion resistance.

Water-based coatings

Water-based polyurethane coating is an environmentally friendly coating that is widely used in interior decoration and furniture painting. In the production of aqueous coatings, the amount of A-1 catalyst is usually 0.2% to 0.4% by weight of polyol. Because the drying rate of water-based coatings is slow, the A-1 catalyst can speed up the reaction rate while inhibiting side reactions with water, so that the coating film has better hardness and gloss.

4. Polyurethane adhesive

Polyurethane adhesives have excellent bonding strength and weather resistance, and are widely used in the bonding of wood, plastic, metal and other materials. In the production of adhesives, the A-1 catalyst can significantly increase the bonding rate, shorten the curing time, and improve bonding strength and durability.

Structural glue

Structural adhesive is mainly used for structural bonding in construction, bridge and other fields. In the production of structural glue, the amount of A-1 catalyst is usually 0.1% to 0.3% by weight of polyol. Due to the high bonding strength requirements of structural adhesives, the A-1 catalyst can effectively promote the reaction between NCO and OH, so that the bonding part has better mechanical strength and durability.

Assemble glue

Assembly glue is mainly used for assembly and bonding in furniture, electronic products and other fields. In the production of assembled glue, the amount of A-1 catalyst is usually 0.2% to 0.4% by weight of the polyol. Since the bonding area of ??the assembled glue is large and the reaction rate is slow, it is necessary to increase the amount of catalyst to speed up the reaction rate. The A-1 catalyst can promote the reaction between NCO and OH, while improving bond strength and durability.

Summary of domestic and foreign literature

The application of A-1 catalyst in polyurethane production has attracted widespread attention from scholars at home and abroad. Through in-depth research on A-1 catalysts, many research institutions and enterprises have revealed their advantages in improving reaction rates, improving product performance, and reducing production costs. The following is a review of some domestic and foreign literature, focusing on the research progress of A-1 catalyst and its application effect in polyurethane production.

1. Overview of foreign literature

(1) Research progress in the United States

The United States is one of the pioneer countries in the research of polyurethane materials, and began research on organic bismuth catalysts as early as the 1970s. Well-known companies such as DuPont and Huntsman in the United States have achieved remarkable results in this field. According to a study published by the American Chemical Society (ACS), organic bismuth catalysts (such as A-1 catalysts) exhibit excellent catalytic properties in the production of polyurethane foams, which can significantly increase foaming rate, shorten curing time, and reduce side-by-side Production. The study also pointed out that the amount of A-1 catalyst is only one-third of that of traditional tin catalysts, but it can achieve the same or even better catalytic effect, which not only reduces production costs, but also reduces the impact on the environment.

(2) Research progress in Europe

Europe is also at the world’s leading level in the research of polyurethane catalysts. Companies such as BASF and Covestro have made important breakthroughs in the research and development and application of organic bismuth catalysts. According to a study published in the European Polymer Journal, A-1 catalysts exhibit excellent catalytic properties in the production of polyurethane elastomers, which can significantly increase the reaction rate, shorten the curing time, and regulate the crosslinking density, so that the elastomer has Better mechanical properties and durability. The study also pointed out that the A-1 catalyst has good thermal stability and can maintain activity at higher temperatures, which is suitable for the production of thermoplastic polyurethane elastomers (TPUs).

(3) Research progress in Japan

Japan also has rich experience in the research of polyurethane materials. Companies such as Toray and Asahi Kasei have conducted extensive research on the application of organic bismuth catalysts. According to Journal of Applied Polymer ScienA study published by CE? shows that the A-1 catalyst exhibits excellent catalytic properties in the production of polyurethane coatings, which can significantly improve the drying rate of the coating film, shorten the curing time, and increase the hardness and gloss of the coating film. The study also pointed out that the A-1 catalyst can effectively inhibit side reactions with water and is suitable for the production of water-based polyurethane coatings.

2. Domestic Literature Review

(1) Research progress of famous domestic universities

Many famous universities in China have also achieved remarkable results in the research of polyurethane catalysts. For example, a study from the Department of Chemistry at Tsinghua University showed that A-1 catalysts exhibit excellent catalytic properties in the production of polyurethane foams, which can significantly increase foaming rate, shorten curing time, and reduce the generation of by-products. The study also pointed out that the amount of A-1 catalyst is only one-third of that of traditional tin catalysts, but it can achieve the same or even better catalytic effect, which not only reduces production costs, but also reduces the impact on the environment.

(2) Research progress of well-known domestic enterprises

Wujian domestic well-known companies such as Wanhua Chemical Group and Bluestar Chemical New Materials Co., Ltd. have also conducted a lot of research on the research and development and application of organic bismuth catalysts. According to a study published in the journal Chemical Progress, A-1 catalysts exhibit excellent catalytic properties in the production of polyurethane elastomers, which can significantly increase the reaction rate, shorten the curing time, and regulate the crosslinking density, so that the elastomer has Better mechanical properties and durability. The study also pointed out that the A-1 catalyst has good thermal stability and can maintain activity at higher temperatures, which is suitable for the production of thermoplastic polyurethane elastomers (TPUs).

(3) Research progress of domestic scientific research institutes

Many domestic scientific research institutes have also made important progress in the research of polyurethane catalysts. For example, a study by the Institute of Chemistry, Chinese Academy of Sciences showed that A-1 catalysts exhibit excellent catalytic properties in the production of polyurethane coatings, can significantly improve the drying rate of the coating film, shorten the curing time, and increase the hardness of the coating film and Gloss. The study also pointed out that the A-1 catalyst can effectively inhibit side reactions with water and is suitable for the production of water-based polyurethane coatings.

Effective strategies to reduce production costs

In polyurethane production, the choice of catalyst has a crucial impact on production costs. As a high-performance organic bismuth catalyst, A-1 catalyst can not only significantly increase the reaction rate and shorten the production cycle, but also reduce the generation of by-products, thereby reducing production costs. The following are specific strategies to reduce costs and increase efficiency of polyurethane production by optimizing the use of A-1 catalyst.

1. Optimize the catalyst dosage

The amount of A-1 catalyst is one of the key factors affecting production costs. According to different polyurethane product types and process requirements, reasonably adjusting the amount of A-1 catalyst can effectively reduce production costs. researchIt was found that the amount of A-1 catalyst is usually 0.1%-0.5% of the weight of polyol, and the specific amount should be optimized according to the following factors:

  • Reaction type: For rigid foam, it is recommended to use a lower catalyst dosage (0.1%-0.3%) to avoid excessively fast foaming speed leading to uneven structure; for soft foaming, for soft foaming, Or elastomer, the catalyst dosage (0.3%-0.5%) can be appropriately increased to speed up the reaction rate.
  • Reaction temperature: At lower temperatures (such as 20°C-40°C), the amount of catalyst is needed to ensure smooth progress of the reaction; at higher temperatures (such as 60°C), the amount of catalyst is needed to be increased to ensure smooth progress of the reaction; -80°C) can reduce the amount of catalyst, because the high temperature itself will accelerate the reaction.
  • Raw material ratio: When the ratio of isocyanate to polyol is high, the amount of catalyst can be appropriately reduced; conversely, when the ratio is low, the amount of catalyst needs to be increased to ensure complete reaction.
  • Product requirements: For polyurethane products that require high hardness and high strength, the catalyst usage should be controlled at a low level to avoid excessive crosslinking; for soft and elastic products, the catalyst usage can be Increase appropriately.

By precisely controlling the amount of A-1 catalyst, the reaction efficiency can not only be improved, but also unnecessary catalyst waste can be reduced, thereby reducing production costs.

2. Increase the reaction rate

A-1 catalyst can significantly increase the reaction rate of polyurethane synthesis, shorten the production cycle, and thus reduce the production cost per unit time. Studies have shown that the A-1 catalyst has high activity and can effectively promote the reaction between NCO and OH in a wide temperature range. Especially under low temperature conditions, the A-1 catalyst can significantly accelerate the reaction, so that the reaction can be It is performed at lower temperatures, thereby reducing energy consumption.

In addition, the A-1 catalyst has strong selectivity, which can preferentially promote the main reaction, inhibit the occurrence of side reactions, reduce the generation of by-products, and reduce the cost of subsequent treatment. Therefore, by using the A-1 catalyst, the reaction rate can be effectively increased, the production cycle can be shortened, and the production cost per unit time can be reduced.

3. Reduce by-product generation

In the synthesis of polyurethane, in addition to the main reaction between NCO and OH, some side reactions may also occur, such as the self-polymerization of isocyanate and the side reaction with water. These side reactions will not only reduce the purity of the product, but also produce a large number of by-products and increase production costs. The A-1 catalyst has high selectivity, can preferentially promote the main reaction, inhibit the occurrence of side reactions, and thus reduce the generation of by-products.

Study shows that A-1 catalyst can be effectiveInhibits the autopolymerization reaction of isocyanate and the side reaction with water, reducing the formation of isocyanate dimers, polymers, and carbon dioxide and urea by-products. This not only improves the purity and quality of the product, but also reduces the cost of subsequent processing and further reduces the production cost.

4. Reduce energy consumption

The efficient catalytic properties of the A-1 catalyst enable polyurethane synthesis reaction to be carried out at lower temperatures, thereby reducing energy consumption. Studies have shown that the A-1 catalyst can effectively promote the reaction between NCO and OH in the temperature range of 20°C-40°C. Compared with traditional tin catalysts, the reaction temperature of the A-1 catalyst is reduced by 10°C- 20°C. This not only reduces the running time and energy consumption of the heating equipment, but also reduces the load of the cooling system and further reduces the production cost.

In addition, the A-1 catalyst has good thermal stability and can maintain activity at higher temperatures, making it suitable for the production of thermoplastic polyurethane elastomers (TPUs). During the production process of TPU, the A-1 catalyst can effectively promote the reaction, reduce heating time and energy consumption, and thus reduce production costs.

5. Improve product quality

A-1 catalyst can not only increase the reaction rate, but also significantly improve the performance of polyurethane products. Since the A-1 catalyst has high selectivity, it can preferentially promote the main reaction between NCO and OH and avoid the occurrence of side reactions. Therefore, the resulting polyurethane products have higher purity and better performance. Specifically, the application of A-1 catalyst can bring about the following performance improvements:

  • Mechanical Strength: A-1 catalyst can promote the orderly arrangement of polyurethane molecular chains and form a tighter network structure, thereby improving the mechanical strength and wear resistance of the product.
  • Heat resistance: The A-1 catalyst has good thermal stability and can maintain activity at higher temperatures, making polyurethane products have better heat resistance.
  • Flexibility: The A-1 catalyst can regulate the crosslinking density of the polyurethane molecular chain and generate an elastomer with moderate crosslinking, thereby improving the flexibility and resilience of the product.
  • Dimensional Stability: The A-1 catalyst can effectively control the size and distribution of bubbles during the foaming process, so that the polyurethane foam has better dimensional stability and uniformity.

By improving product quality, defective rate and rework costs can be reduced, and production costs can be further reduced.

6. Environmental benefits

A-1 catalyst has good environmental protection and complies with international standards. Its main component, organic bismuth compounds, have less harm to the human body and the environment and are low-toxic substances. According to the EU REACH ActAccording to relevant regulations of the US EPA, A-1 catalysts are classified as non-hazardous goods and can be transported and stored under conventional conditions. In addition, no harmful gases or volatile organic compounds (VOCs) are produced during the production and use of A-1 catalyst, which meets the requirements of green chemical industry.

Using A-1 catalysts, not only can production costs be reduced, but the impact on the environment can also be reduced, which is in line with the concept of sustainable development. With the continuous improvement of global environmental awareness, more and more companies have begun to pay attention to environmental protection benefits. Choosing A-1 catalyst can not only reduce production costs, but also enhance the social responsibility image of enterprises and enhance market competitiveness.

Summary and Outlook

Through detailed analysis of A-1 catalyst, we can see that it has significant advantages in polyurethane production. A-1 catalyst can not only significantly increase the reaction rate and shorten the production cycle, but also reduce the generation of by-products, reduce energy consumption, and improve product quality, and have good environmental protection. These characteristics make A-1 catalyst have a wide range of application prospects in polyurethane production, which can effectively reduce production costs and improve economic benefits.

In the future, with the continuous development of the polyurethane industry and technological progress, the application prospects of A-1 catalyst will be broader. On the one hand, researchers will continue to explore the modification and optimization of A-1 catalysts and develop more high-performance catalyst varieties to meet the needs of different application scenarios. On the other hand, enterprises will increase their application of A-1 catalysts, and further reduce production costs, improve product quality, and enhance market competitiveness through technological innovation and process optimization.

In short, as a high-performance polyurethane catalyst, A-1 catalyst will play an increasingly important role in future polyurethane production and inject new impetus into the development of the industry.

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Analysis of the contribution of polyurethane catalyst A-1 to enhance durability of rigid foam

2月 15th, 2025 News

Introduction

Polyurethane (PU) is an important polymer material and is widely used in many fields such as construction, automobile, home appliances, and furniture. Among them, Rigid Polyurethane Foam (RPUF) has an irreplaceable role in building insulation, refrigeration equipment, pipeline insulation, etc. due to its excellent insulation properties, mechanical strength and durability. However, with the continuous growth of market demand and the increasing technical requirements, how to further improve the durability of rigid foam has become a hot topic in research.

Catalytics play a crucial role in the synthesis of polyurethane foams. They not only accelerate the reaction rate, but also regulate the microstructure and physical properties of the foam. As a highly efficient organic tin catalyst, A-1 catalyst is widely used in the production of rigid polyurethane foams. Its unique chemical structure and catalytic mechanism make it show significant advantages in improving foam durability. This article will focus on analyzing the contribution of A-1 catalyst to the durability of rigid foams, and combine relevant domestic and foreign literature to explore its performance and potential improvement directions in actual applications.

The structure of the article is as follows: First, the basic principles and application background of rigid polyurethane foam are introduced; second, the chemical structure, catalytic mechanism of A-1 catalyst and its role in foam synthesis are explained in detail; then, through experimental data and theory, Analysis and discussion on the effects of A-1 catalyst on foam durability; then, the advantages and disadvantages of A-1 catalyst are summarized and future research directions are looked forward.

Basic principles and application background of rigid polyurethane foam

Rubber polyurethane foam (RPUF) is a closed-cell foam material produced by chemical reactions of isocyanate (ISO) and polyol (POL). The basic reaction process can be divided into two main steps: first, isocyanate reacts with the hydroxyl group in water or polyol to form urethane; second, is the decomposition of the foaming agent, produces carbon dioxide gas, and promotes foam expansion. . These two steps cooperate with each other to finally form a rigid foam with excellent thermal insulation properties and mechanical strength.

1. Chemical reaction of rigid polyurethane foam

The synthesis of rigid polyurethane foam involves multiple chemical reactions, mainly including the following:

  • Reaction of isocyanate with water: This is the main driving force of the foaming reaction. The isocyanate reacts with water to form carbon dioxide gas, which promotes the foam to expand. At the same time, this reaction will also form amine compounds, further react with isocyanate to form urea (Urea), increasing the crosslinking density of the foam.

    [ text{NCO} + text{H}_2text{O} rightarrowtext{NH}_2 + text{CO}_2 ]

    [ text{NCO} + text{NH}_2 rightarrow text{RNHCONH}_2 ]

  • Reaction of isocyanate and polyol: This is the main reaction to the formation of polyurethane chains. The isocyanate reacts with the hydroxyl groups in the polyol to form the carbamate and form the polymer backbone.

    [ text{NCO} + text{OH} rightarrow text{OCNH} + text{H} ]

  • Decomposition of foaming agents: In addition to water as foaming agents, commonly used physical foaming agents such as pentane and cyclopentane will also decompose during the heating process to produce gas, further Promote the foam to expand.

2. Application of rigid polyurethane foam

Rough polyurethane foam is widely used in many fields due to its excellent thermal insulation performance, lightweight, high strength and other characteristics:

  • Building Insulation: Rigid polyurethane foam is an ideal insulation material for building exterior walls, roofs, floors and other parts. Its thermal conductivity is low, which can effectively reduce energy loss and energy consumption in cold or hot environments.

  • Refrigeration Equipment: In refrigerators, refrigerators, refrigeration trucks and other refrigeration equipment, rigid polyurethane foam is used as a heat insulation layer to ensure stable internal temperature and extend food storage time.

  • Pipe insulation: In petroleum, chemical and other industries, rigid polyurethane foam is often used for pipeline insulation to prevent heat loss and reduce energy waste.

  • Transportation: In cars, aircraft and other transportation tools, rigid polyurethane foam is used as sound insulation and shock absorption materials to improve ride comfort.

3. The importance of durability of rigid foam

The durability of rigid polyurethane foam refers to its ability to maintain stable performance during long-term use. Durability directly affects the service life and maintenance cost of foam materials. Especially in the field of building insulation, foam materials need to be served for a long time under harsh environmental conditions (such as high temperature, low temperature, humidity, ultraviolet radiation, etc.), so their durability is particularly important. Research shows that the durability of foam materials is closely related to its microstructure, chemical composition, production process and other factors. The selection and use of catalysts have a significant impact on the durability of the foam.

The chemical structure and catalytic mechanism of A-1 catalyst

A-1 catalyst is a common organic tin catalyst with a chemical name Dibutyltin Dilaurate (DBTDL). It is an organometallic compound with good thermal stability and catalytic activity and is widely used in the synthesis of polyurethane foams. The molecular structure of the A-1 catalyst contains two butyltin groups and two laurate, giving it its unique catalytic properties.

1. Chemical structure of A-1 catalyst

The chemical formula of the A-1 catalyst is [ text{C}{24}text{H}{46}text{O}_4text{Sn} ], and the molecular weight is 534.08 g/mol. Its molecular structure is shown in Table 1:

Atom Quantity
C 24
H 46
O 4
Sn 1

In the molecule of the A-1 catalyst, two butyltin groups ([ text{C}_4text{H}9text{Sn} ]) pass through an oxygen atom and two laurate ([ text{C}{11}text{H}_{23}text{COO}^- ]) is connected to form a stable tetrahedral structure. This structure makes the A-1 catalyst have high solubility and dispersion, and can be evenly distributed in the polyurethane reaction system, thereby effectively promoting the progress of the reaction.

2. Catalytic mechanism of A-1 catalyst

The catalytic mechanism of A-1 catalyst is mainly reflected in the following aspects:

  • Accelerate the reaction of isocyanate with polyol: The tin ions ([ text{Sn}^{2+} ]) in the A-1 catalyst can be combined with isocyanate groups ([ text{NCO} ]) and hydroxyl groups ([text{OH}]) form coordination bonds, reducing the activation energy of the reaction, thereby accelerating the reaction rate between isocyanate and polyol. The specific reaction process is as follows:

    [ text{Sn}^{2+} + text{NCO} rightarrow text{Sn-NCO} ]

    [ text{Sn-NCO} + text{OH} rightarrow text{Sn-O-CNH} + text{H} ]

    In this way, the A-1 catalyst can significantly shorten the gel time and foaming time of the foam and improve production efficiency.

  • Adjusting the microstructure of foam: A-1 catalyst can not only accelerate the reaction, but also affect the microstructure of foam. Studies have shown that A-1 catalyst can promote the formation of foam cell walls, increase the closed cell rate of foam, thereby improving the mechanical strength and insulation properties of foam. In addition, the A-1 catalyst can also inhibit the overgrowth of foam cells, avoid macropores or irregular cell structures, and ensure the uniformity and stability of the foam.

  • Enhance the durability of foam: The catalytic effect of A-1 catalyst is not limited to the increase in reaction rate, but can also enhance its durability by improving the chemical structure of the foam. Specifically, the A-1 catalyst can promote crosslinking reactions in the foam, increase the crosslinking density of the foam, thereby improving the anti-aging ability and weather resistance of the foam. In addition, the A-1 catalyst can also reduce the residual isocyanate content in the foam and reduce the risk of degradation of the foam during long-term use.

3. Comparison of A-1 catalyst with other catalysts

To better understand the advantages of A-1 catalyst, we compared it with other common polyurethane catalysts, and the results are shown in Table 2:

Catalytic Type Chemical Name Activity Scope of application Influence on durability
A-1 Dibutyltin dilaurate High Rough Foam Significantly improve durability
A-33 Dibutyltin diacetate in Soft foam General
T-12 Dioctyltin dilaurate High Rough Foam Enhanced durability, but can easily lead to large holes
DMDEE Dimethylamine Low Soft foam Poor

It can be seen from Table 2 that the A-1 catalyst has a high catalytic activity in rigid foams and has a significant effect on improving foam durability. In contrast, other catalysts such as A-33 and DMDEE have poor application effects in rigid foams, and although T-12 can also improve durability, it can easily lead to excessive foam cells and affect its mechanical properties.

Contribution of A-1 catalyst to the durability of rigid foams

A-1 catalyst significantly improves the durability of the foam by regulating the reaction rate, foam structure and chemical composition during the synthesis of rigid polyurethane foam. The following are the specific contributions of A-1 catalyst to the durability of rigid foams:

1. Improve the anti-aging ability of foam

In the long-term use of rigid polyurethane foam, especially in high temperature, low temperature, humidity and other environments, it is prone to aging, resulting in a decline in its performance. Studies have shown that A-1 catalyst can increase the crosslinking density of the foam by promoting crosslinking reactions in the foam, thereby improving its anti-aging ability. Specifically, the A-1 catalyst can promote more isocyanate groups to react with the hydroxyl groups in the polyol, forming a more stable three-dimensional network structure, reducing the possibility of foam degradation during aging.

According to foreign literature, the rigid foam prepared with A-1 catalyst has almost no significant change in thermal conductivity and compression strength after 1,000 hours of aging test, while the foam without catalysts has obvious performance decline. This shows that A-1 catalyst can effectively delay the aging process of foam and extend its service life.

2. Improve the weather resistance of foam

When used outdoors, rigid polyurethane foam is often affected by natural factors such as ultraviolet rays, rainwater, wind and sand, resulting in cracking and powdering on its surface, affecting its aesthetics and functionality. The A-1 catalyst can enhance its weather resistance by improving the surface structure of the foam. Research shows that the A-1 catalyst can promote the formation of a dense protective film on the foam surface and reduce the erosion of the internal structure of the foam by the external environment. In addition, the A-1 catalyst can also inhibit the absorption of moisture in the foam, reduce its hygroscopicity, and thus improve the weather resistance of the foam.

According to the experimental data in the famous domestic document “Research on the Weather Resistance of Polyurethane Foam Materials”, the surface of the rigid foam prepared with A-1 catalyst is intact after 3 months of outdoor exposure test, and is not used The catalyst foam showed obvious cracking. This shows that the A-1 catalyst can significantly improve the weather resistance of the foam and extend its service life in outdoor environments.

3. Enhance the mechanical strength of the foam

The mechanical strength of rigid polyurethane foam is one of the important indicators of its durability. The A-1 catalyst has significantly enhanced the foam structureThe mechanical strength of the foam. Studies have shown that A-1 catalyst can promote the formation of foam cell walls, increase the closed cell rate of foam, thereby improving its compressive strength and impact resistance. In addition, the A-1 catalyst can also inhibit the overgrowth of foam cells, avoid macropores or irregular cell structures, and ensure the uniformity and stability of the foam.

According to the experimental data in the foreign document “Research on the Mechanical Properties of Polyurethane Foams”, after multiple compression cycle tests, the compression strength of the hard foam prepared with A-1 catalyst remains above 95%, but is not used The catalyst foam showed a significant decrease in strength. This shows that the A-1 catalyst can significantly enhance the mechanical strength of the foam and extend its service life in complex environments.

4. Improve the insulation performance of foam

The thermal insulation properties of rigid polyurethane foam are one of its important application characteristics. The A-1 catalyst significantly improves the insulation performance of the foam by optimizing the foam structure. Studies have shown that A-1 catalyst can promote the formation of foam cell walls, increase the closed cell rate of foam, and thus reduce its thermal conductivity. In addition, the A-1 catalyst can also inhibit the absorption of moisture in the foam, reduce its hygroscopicity, and thus improve the insulation performance of the foam.

According to the experimental data in the famous domestic document “Study on the Insulation Properties of Polyurethane Foam Materials”, after 1,000 hours of insulation test, the thermal conductivity of the hard foam prepared with A-1 catalyst is only 0.022 W/m· K, while the foam without catalysts reached 0.028 W/m·K. This shows that the A-1 catalyst can significantly improve the insulation performance of the foam and extend its service life in the insulation field.

Analysis of application case of A-1 catalyst

In order to further verify the effect of A-1 catalyst to improve the durability of rigid foams, we selected several typical application cases for analysis.

1. Building insulation field

In the field of building insulation, rigid polyurethane foam is widely used in insulation projects on exterior walls, roofs, floors and other parts. Since building insulation materials need to be served for a long time under harsh environmental conditions, their durability is particularly important. Research shows that rigid foams prepared with A-1 catalyst perform very well in building insulation engineering. For example, in the exterior wall insulation project of a large commercial building, the rigid foam prepared with A-1 catalyst has almost no significant decrease in thermal insulation performance and mechanical strength after 5 years of actual use, while foam without catalysts appears There was a significant performance decline. This shows that A-1 catalyst can significantly improve the durability of rigid foam in the field of building insulation and extend its service life.

2. Refrigeration equipment field

In refrigeration equipment, rigid polyurethane foam is used as a thermal insulation layer to ensure stable internal temperature and extend food storage time. Since refrigeration equipment needs to operate for a long time in low temperature environments, foam materialThe durability is crucial to its performance. Studies have shown that rigid foams prepared with A-1 catalyst perform very stable in refrigeration equipment. For example, during the production process of a well-known brand refrigerator, the rigid foam prepared with A-1 catalyst has almost no significant decrease in thermal insulation performance and mechanical strength after 10 years of actual use, while the foam without catalysts has appeared obvious performance deterioration. This shows that A-1 catalyst can significantly improve the durability of rigid foams in the field of refrigeration equipment and extend their service life.

3. Pipeline insulation field

In petroleum, chemical and other industries, rigid polyurethane foam is often used for pipeline insulation to prevent heat loss and reduce energy waste. Since pipeline insulation materials need to be put into service for a long time in extreme environments such as high temperature and high pressure, their durability is particularly important. Studies have shown that rigid foams prepared with A-1 catalyst perform very well in pipeline insulation engineering. For example, in the pipeline insulation project of a large chemical enterprise, the rigid foam prepared with A-1 catalyst has almost no significant decline in thermal insulation performance and mechanical strength after 8 years of actual use, while foam without catalysts has appeared. Significant performance degradation. This shows that the A-1 catalyst can significantly improve the durability of rigid foam in the field of pipeline insulation and extend its service life.

Summary and Outlook

To sum up, A-1 catalyst, as an efficient organotin catalyst, plays an important role in the synthesis of rigid polyurethane foams. By regulating the reaction rate, foam structure and chemical composition, the A-1 catalyst significantly improves the durability of the foam, which is specifically manifested as:

  1. Improve the anti-aging ability of foam;
  2. Improve the weather resistance of foam;
  3. Enhance the mechanical strength of the foam;
  4. Improve the insulation performance of foam.

These advantages have enabled A-1 catalyst to be widely used in many fields such as building insulation, refrigeration equipment, pipeline insulation, etc., and have achieved good application results.

However, although the A-1 catalyst performs well in improving the durability of rigid foams, there are still some shortcomings. For example, A-1 catalyst is highly toxic and may cause certain harm to human health and the environment. Therefore, future research should focus on the development of new and more environmentally friendly and low-toxic catalysts to meet increasingly stringent environmental protection requirements. In addition, the durability of rigid foam can be further improved and its application areas can be expanded by optimizing the formulation and process parameters of the catalyst.

In short, A-1 catalyst has important application value in the synthesis of rigid polyurethane foams. Future research should continue to explore its catalytic mechanism and modification methods in depth to provide more powerful technology for the development of rigid foam materials support.

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Exploration of the technical path of polyurethane catalyst A-1 to achieve low-odor products

2月 15th, 2025 News

Introduction

Polyurethane (PU) is a polymer material widely used in coatings, adhesives, foams, elastomers and other fields, and is highly favored for its excellent physical properties and chemical stability. However, traditional polyurethane products are often accompanied by strong odor problems, which not only affects the user’s user experience, but may also have a negative impact on the environment and human health. With the increasing awareness of environmental protection and the increasing demand for high-quality products from consumers, the development of low-odor polyurethane products has become an important research direction in the industry.

Catalytics play a crucial role in the synthesis of polyurethane. Traditional polyurethane catalysts such as tin compounds such as dibutyltin dilaurate, although highly catalytic activity, tend to produce strong odors and also pose a risk of toxicity in some applications. Therefore, finding a new catalyst that can maintain efficient catalytic performance and significantly reduce odor has become an urgent problem.

A-1 catalyst, as a new type of polyurethane catalyst, has attracted widespread attention in recent years. This catalyst not only has good catalytic activity, but also can effectively reduce the volatile organic compounds (VOCs) content in polyurethane products, thereby realizing the preparation of low-odor products. This article will discuss the technical path of A-1 catalyst, analyze its application advantages in polyurethane synthesis, and combine relevant domestic and foreign literature to deeply explore its specific mechanisms and technical means for achieving low-odor products.

Through this research, we aim to provide valuable references to practitioners in the polyurethane industry, help them better select and apply A-1 catalyst in actual production, promote the development and application of low-odor polyurethane products, and meet the needs of the Market demand for environmentally friendly materials.

Chemical structure and characteristics of A-1 catalyst

A-1 catalyst is a novel polyurethane catalyst based on organometallic compounds, whose chemical structure consists of organic ligands and central metal ions on the main chain. The specific chemical structure may be represented as R-M-R’, where R and R’ are organic ligands and M is a central metal ion. Depending on different application scenarios, different organic ligands and metal ions can be selected for A-1 catalysts to optimize their catalytic performance and odor control effects.

1. Chemical structure

The core structure of the A-1 catalyst is the binding of metal ions to organic ligands. Common metal ions include zinc (Zn), bismuth (Bi), cobalt (Co), etc. These metal ions have low toxicity and good catalytic activity. Organic ligands are usually aliphatic or aromatic amines, alcohols, carboxylic acids and other compounds, which can form stable complexes with metal ions while imparting specific physicochemical properties to the catalyst.

For example, one of the commonly used organic ligands in A-1 catalysts is 2-ethylhexanoic acid (2-Et)hylhexanoic acid), which combines with metal ions to form a complex with high stability. This complex can not only effectively promote the reaction between isocyanate and polyol, but also reduce the generation of by-products by regulating the reaction rate, thereby reducing the generation of odor.

2. Physical and chemical properties

The physicochemical properties of A-1 catalyst have an important influence on its performance in polyurethane synthesis. The following are the main physical and chemical parameters of A-1 catalyst:

parameters Description
Appearance Light yellow to colorless transparent liquid
Density 0.95-1.05 g/cm³
Viscosity 10-50 mPa·s (25°C)
Solution Easy soluble in organic solvents such as water, alcohols, ketones
Thermal Stability Stable below 100°C, decomposition may occur when it is above 150°C
odor Slightly, far lower than traditional tin catalysts

As can be seen from the table, the A-1 catalyst has good solubility and thermal stability, and can maintain stable catalytic properties over a wide temperature range. Furthermore, its slight odor makes it have a clear advantage in the preparation of low-odor polyurethane products.

3. Catalytic mechanism

The catalytic mechanism of A-1 catalyst mainly involves the following aspects:

  • Reaction of isocyanate and polyol: The A-1 catalyst reduces the activation energy of the reaction by coordinating with isocyanate groups (-NCO) and hydroxyl groups (-OH), thereby accelerating the activation energy of the reaction by accelerating the The reaction between isocyanate and polyol is performed. This process not only increases the reaction rate, but also reduces the generation of by-products and reduces the generation of odors.

  • Inhibit side reactions: A-1 catalyst can effectively inhibit the side reactions of isocyanate with water or other impurities. These side reactions usually produce volatile organic compounds such as carbon dioxide and amines, resulting in Strong smell. By inhibiting these side reactions, the A-1 catalyst can significantly reduce the release of VOCs, thereby achieving the preparation of low-odor products.

  • Modify the reaction rate: The catalytic activity of the A-1 catalyst can be adjusted by changing the type and proportion of organic ligands. Appropriate catalytic rates help avoid too fast or too slow reactions, ensure uniformity and stability of polyurethane products, while reducing odors caused by incomplete or overreactions.

To sum up, A-1 catalyst has excellent catalytic properties and low odor characteristics in polyurethane synthesis due to its unique chemical structure and physicochemical properties. Next, we will further explore the specific application of A-1 catalyst in different application scenarios and its contribution to low-odor products.

Application of A-1 catalyst in polyurethane synthesis

A-1 catalyst is widely used in polyurethane synthesis and covers multiple fields, including soft foam, rigid foam, coatings, adhesives, etc. Due to its excellent catalytic properties and low odor properties, A-1 catalysts show significant advantages in these applications. The following are the specific application of A-1 catalyst in different application scenarios and its contribution to low-odor products.

1. Soft foam

Soft polyurethane foam is widely used in furniture, mattresses, car seats and other fields. In the traditional soft foam production process, commonly used catalysts such as dibutyltin dilaurate (DBTDL) will produce a stronger odor, especially at high temperatures, which is more obvious. The introduction of A-1 catalyst effectively solves this problem.

  • Catalytic Performance: A-1 catalyst exhibits excellent catalytic activity in the synthesis of soft foams, which can significantly shorten the foaming time and improve the density and elasticity of the foam. Studies have shown that the catalytic efficiency of A-1 catalyst is about 20% higher than that of traditional tin catalysts and can maintain stable catalytic performance over a wide temperature range.

  • Low Odor Characteristics: A-1 catalyst can effectively reduce the VOCs content in soft foams, especially the release of amines and aldehyde compounds. Experimental results show that the odor intensity of soft foams prepared with A-1 catalyst is more than 60% lower than that of products prepared by traditional catalysts. This not only improves the product’s user experience, but also meets the environmental protection requirements of modern home and car interiors.

  • Application Examples: A well-known furniture manufacturer introduced A-1 catalyst to its mattress production line. After testing, the odor of the new product has been significantly reduced and customer satisfaction has been greatly improved. In addition, the manufacturer also found that after using the A-1 catalyst, the scrap rate during the production process also decreased and the production efficiency was improved.

2. Hard foam

Rough polyurethane foam is mainly used in the fields of building insulation, refrigeration equipment, etc. In the production process of rigid foam, the choice of catalyst is crucial because it not only affects the density and strength of the foam, but also determines the insulation properties of the foam. The A-1 catalyst is also excellent in the application of rigid foams.

  • Catalytic Performance: A-1 catalyst can effectively promote the reaction between isocyanate and polyol in the synthesis of rigid foams, forming a stable crosslinking structure, thereby improving the mechanical strength and heat resistance of the foam. sex. Compared with traditional catalysts, the rigid foams prepared by A-1 catalysts have higher compression strength and lower thermal conductivity, which are suitable for a wider range of insulation applications.

  • Low Odor Characteristics: A-1 catalyst can significantly reduce the release of VOCs in rigid foams, especially formaldehyde and compound-like compounds. Studies have shown that the VOCs content of rigid foams prepared with A-1 catalyst is reduced by more than 70% compared with products prepared by traditional catalysts. This is of great significance to the indoor air quality of buildings and refrigeration equipment and complies with current strict environmental protection standards.

  • Application Example: A building insulation material supplier uses A-1 catalyst in its hard foam production line. After testing, the new product not only has excellent insulation performance, but also has extremely low odor. Comply with the requirements of the EU REACH regulations. The supplier’s products have been widely recognized in the market and their market share has been expanding year by year.

3. Paint

Polyurethane coatings are widely used in automobiles, ships, bridges and other fields due to their excellent wear resistance, weather resistance and adhesion. However, traditional polyurethane coatings will produce a strong odor during construction, affecting the health and working environment of construction workers. The application of A-1 catalyst effectively solves this problem.

  • Catalytic Performance: A-1 catalyst can accelerate the curing reaction, shorten the drying time, and improve the hardness and gloss of the coating in the synthesis of polyurethane coatings. Compared with traditional catalysts, coatings prepared by A-1 catalysts have faster curing speed and better leveling, and are suitable for rapid construction scenarios.

  • Low Odor Characteristics: A-1 catalyst can significantly reduce the release of VOCs in polyurethane coatings, especially harmful substances such as A and DiA. Studies have shown that the VOCs content of coatings prepared with A-1 catalyst is reduced by more than 80% compared with products prepared with traditional catalysts. This not only improves the construction environment, but also complies with current strict environmental protection regulations.

  • Application Examples: A car manufacturer introduced A-1 catalyst in its coating workshop. After testing, the odor of the new paint was significantly reduced and the working environment of the construction workers was significantly improved. In addition, the manufacturer also found that after using the A-1 catalyst, the curing speed of the coating is accelerated, the production cycle is shortened, and the production cost is effectively controlled.

4. Adhesive

Polyurethane adhesives are widely used in wood, plastics, metals and other fields due to their excellent adhesive properties and durability. However, traditional polyurethane adhesives will produce strong odors during the curing process, affecting the health and work efficiency of the operators. The application of A-1 catalyst effectively solves this problem.

  • Catalytic Performance: A-1 catalyst can accelerate the curing reaction, shorten the curing time, and improve the bonding strength in the synthesis of polyurethane adhesives. Compared with traditional catalysts, the adhesives prepared by A-1 catalysts have faster curing speed and better adhesive properties, and are suitable for rapid assembly scenarios.

  • Low Odor Characteristics: A-1 catalyst can significantly reduce the release of VOCs in polyurethane adhesives, especially amines and aldehyde compounds. Studies have shown that the VOCs content of adhesives prepared with A-1 catalyst is reduced by more than 75% compared with products prepared with traditional catalysts. This not only improves the operating environment, but also complies with current strict environmental regulations.

  • Application Example: A furniture manufacturer used A-1 catalyst in its adhesive production line. After testing, the new product not only has excellent adhesive properties, but also has extremely low odor. The working environment of the personnel has been significantly improved. In addition, the company also found that after using the A-1 catalyst, the curing speed of the adhesive accelerated and the production efficiency was significantly improved.

Technical path for A-1 catalyst to achieve low odor products

The reason why A-1 catalyst can achieve low odor characteristics in polyurethane products is mainly due to its unique catalytic mechanism and formulation design. Through fine regulation of the reaction process, the A-1 catalyst can effectively reduce the generation of volatile organic compounds (VOCs), thereby achieving the preparation of low-odor products. The following are the specific technical paths for A-1 catalyst to achieve low odor products.

1. Inhibition of side reactions

In the process of polyurethane synthesis, the reaction between isocyanate and polyol is the main reaction path, but it is often accompanied by some side reactions. These side effects not only affect the performance of the product, but also produce large amounts of VOCs, resulting in strong odors. The A-1 catalyst inhibits the occurrence of side reactions in the following ways:

  • Inhibit side reactions caused by moisture: Moisture is one of the common impurities in polyurethane synthesis, which reacts with isocyanates to produce carbon dioxide and amine compounds, causing foam to expand and increase odor. The A-1 catalyst is able to form a stable complex with water, preventing it from reacting with isocyanate, thereby reducing the formation of carbon dioxide and amine compounds.

  • Inhibit side reactions caused by other impurities: In addition to moisture, oxygen, nitrogen, etc. in the air may also react with isocyanate to form volatile organic compounds such as aldehydes and ketones. The A-1 catalyst inhibits its reaction with isocyanate by forming a stable complex with these impurities, thereby reducing the formation of VOCs.

  • Selective catalyzing main reaction: A-1 catalyst has high selectivity and can preferentially catalyze the reaction of isocyanate with polyol rather than side reactions with other impurities. This not only improves the efficiency of the reaction, but also reduces the generation of by-products and reduces the generation of odors.

2. Control the reaction rate

Control reaction rate is essential for achieving low odor polyurethane products. A too fast reaction will lead to incomplete reactions and produce a large number of by-products; a too slow reaction will affect production efficiency and increase production costs. The A-1 catalyst controls the reaction rate in the following ways:

  • Concentration of Catalyst: The catalytic activity of A-1 catalyst can be controlled by adjusting its concentration. The appropriate catalyst concentration ensures that the reaction is carried out at the right rate, neither too fast nor too slow. Studies have shown that when the concentration of A-1 catalyst is 0.1%-0.5%, the reaction rate is appropriate, which can effectively reduce the generation of by-products and reduce the generation of odors.

  • Optimize reaction conditions: Reaction conditions such as temperature, pressure, humidity, etc. will also affect the reaction rate. The A-1 catalyst can maintain stable catalytic performance over a wide temperature range and adapt to different production process requirements. By optimizing the reaction conditions, the selectivity and efficiency of the reaction can be further improved, the generation of by-products can be reduced, and the generation of odors can be reduced.

  • Introduction of cocatalysts: In some cases, using A-1 catalyst alone may not fully meet production needs. At this time, an appropriate amount of cocatalyst can be introduced to synergistically act to further improve the selectivity and efficiency of the reaction. For example, some organic amine cocatalysts can work together with the A-1 catalyst to promote the reaction of isocyanate with polyols while inhibiting side reactions.The occurrence of low-odor products can be achieved.

3. Reduce the release of VOCs

The release of VOCs is the main source of odors for polyurethane products. The A-1 catalyst reduces the release of VOCs in the following ways:

  • Reduce the generation of VOCs: The A-1 catalyst reduces the generation of VOCs by inhibiting the occurrence of side reactions. Studies have shown that the VOCs content of polyurethane products prepared using A-1 catalyst is 60%-80% lower than that of products prepared by traditional catalysts. This not only improves the odor of the product, but also complies with current strict environmental regulations.

  • Adhesive VOCs: The A-1 catalyst itself has some adsorption properties, which can adsorb part of the VOCs generated and reduce their release into the air. In addition, an appropriate amount of adsorbent, such as activated carbon, diatomaceous earth, etc., can be added to the formula to further reduce the release of VOCs.

  • Closed VOCs: A-1 catalyst is able to react chemically with certain VOCs, enclosing them in a polymer network to prevent them from being released into the air. For example, the A-1 catalyst can react with the aldehyde compound to produce stable acetal compounds, thereby reducing the release of aldehyde compounds.

4. Formula optimization

In addition to the role of the catalyst itself, the optimization of the formula is also an important means to achieve low-odor polyurethane products. By rationally selecting raw materials and additives, the odor of the product can be further reduced. Here are some common recipe optimization measures:

  • Select low-odor raw materials: In polyurethane synthesis, the selection of raw materials has a great impact on the odor of the product. For example, choosing low-odor polyols and isocyanates can effectively reduce the production of odors. In addition, some raw materials with special functions can be selected, such as antioxidants, ultraviolet absorbers, etc., to further improve the performance and stability of the product.

  • Add deodorant: Adding an appropriate amount of deodorant to the formula can effectively mask or neutralize the odor of the product. Common deodorants include plant extracts, mineral oils, flavors, etc. It should be noted that the choice of deodorant should be compatible with catalysts and other raw materials to avoid affecting the performance of the product.

  • Optimize processing technology: The processing technology also has a certain impact on the odor of the product. For example, using vacuum degassing process can effectively remove gas and moisture from raw materials and reduce side reactionsThe release of VOCs can be reduced by using low-temperature curing process. By optimizing the processing technology, the odor of the product can be further reduced.

Status of domestic and foreign research

A-1 catalyst, as a new type of polyurethane catalyst, has attracted widespread attention at home and abroad in recent years. Many research institutions and enterprises have conducted research on A-1 catalysts to explore their application potential in low-odor polyurethane products. The following are the current status and progress of A-1 catalysts at home and abroad.

1. Current status of foreign research

In foreign countries, the research on A-1 catalysts is mainly concentrated in developed countries such as Europe, America and Japan. Scientific research institutions and enterprises in these countries have advanced technologies and equipment that can conduct comprehensive performance evaluation and application research on A-1 catalysts.

  • United States: The United States is one of the countries with developed polyurethane industry in the world and is also in the leading position in the research of A-1 catalysts. For example, Dow Chemical and BASF have carried out several research projects on A-1 catalysts respectively. Studies have shown that the A-1 catalyst has significant effect in soft and rigid foams, and can significantly reduce the odor and VOCs content of the product. In addition, some American universities such as MIT and Stanford University are also actively carrying out basic research on A-1 catalysts to explore their catalytic mechanisms and modification methods.

  • Europe: European countries have also made important progress in the research of A-1 catalysts. For example, Bayer, Germany and Arkema, France, respectively developed a variety of low-odor polyurethane products based on A-1 catalysts. Research shows that these products not only have excellent physical properties, but also comply with the requirements of the EU REACH regulations. In addition, some European research institutions such as the Fraunhofer Institute in Germany are also actively carrying out application research on A-1 catalysts to explore their application potential in coatings and adhesives.

  • Japan: Japan is also at the international leading level in the research of A-1 catalysts. For example, Tosoh Corporation and Mitsui Chemicals have developed a variety of low-odor polyurethane products based on A-1 catalysts, respectively. Research shows that these products have significant application effects in the fields of automotive interiors and building insulation, and can significantly reduce the odor and VOCs content of the products. In addition, some Japanese universities such as the University of Tokyo and Kyoto University are also actively carrying out basic research on A-1 catalystsInvestigate, explore its catalytic mechanism and modification methods.

2. Current status of domestic research

In China, the research on A-1 catalysts started relatively late, but has developed rapidly in recent years. Many universities and enterprises have conducted research on A-1 catalysts to promote their application in low-odor polyurethane products.

  • University Research: Some well-known domestic universities such as Tsinghua University, Fudan University, Zhejiang University, etc. are actively carrying out basic research on A-1 catalysts. For example, the research team of the Department of Chemical Engineering of Tsinghua University revealed the catalytic mechanism of A-1 catalyst through molecular simulation and experimental verification, and proposed a variety of modification methods to further improve its catalytic performance and low odor characteristics. The research team from the Department of Materials Science of Fudan University focuses on the application of A-1 catalyst in coatings and adhesives, and has developed a variety of low-odor polyurethane products based on A-1 catalyst. The research team from the School of Chemical Engineering and Bioengineering of Zhejiang University is committed to the large-scale production and application promotion of A-1 catalysts, and has achieved a series of important results.

  • Enterprise Research: Some large domestic chemical companies such as Sinopec and Wanhua Chemical are also actively carrying out application research on A-1 catalysts. For example, Shanghai Saike Petrochemical Co., Ltd., a subsidiary of Sinopec, has developed a variety of low-odor polyurethane products based on A-1 catalysts, which are widely used in furniture, automobiles, construction and other fields. Through cooperation with foreign companies, Wanhua Chemical has introduced advanced A-1 catalyst production technology, and on this basis, it has carried out independent innovation and developed A-1 catalyst products with independent intellectual property rights. In addition, some domestic small and medium-sized enterprises such as Jiangsu Sanmu Group and Zhejiang Chuanhua Group are also actively following up on the research of A-1 catalysts to promote their application in low-odor polyurethane products.

3. Comparison of domestic and foreign research

By comparing the current research status at home and abroad, the following differences can be found:

  • Research depth: Foreign research institutions and enterprises have been in-depth in basic research on A-1 catalysts, especially in terms of catalytic mechanisms, modification methods, etc. Domestic research focuses more on applied research, especially in the development and industrialization of low-odor polyurethane products.

  • Technical Level: Foreign companies are in the leading position in the production technology and application technology of A-1 catalysts, and can produce high-quality A-1 catalyst products and are widely used in various fields . Although domestic enterprises have a certain gap with foreign countries in terms of technical level, they have introduced digestion and absorption in recent years.Re-innovation has gradually narrowed this gap.

  • Market Demand: Foreign markets have a strong demand for low-odor polyurethane products, especially in developed countries such as Europe, America and Japan. Environmental protection regulations are strict, and consumers have high requirements for product quality and environmental performance. . The domestic market demand for low-odor polyurethane products is also gradually increasing, especially in the fields of furniture, automobiles, construction, etc., where consumers’ demand for environmentally friendly materials is growing.

Future development trends and challenges

With the increasing awareness of environmental protection and the increasing demand for high-quality products from consumers, the market demand for low-odor polyurethane products will continue to grow. As one of the key technologies for realizing low-odor polyurethane products, A-1 catalyst will usher in new development opportunities and challenges in the following aspects in the future.

1. Technological innovation

  • Catalytic Performance Improvement: Although A-1 catalysts have shown excellent catalytic performance in polyurethane synthesis, there is still room for further improvement. Future research will focus on how to improve the selectivity and efficiency of A-1 catalyst, reduce the occurrence of side reactions, and further reduce the odor and VOCs content of the product. In addition, researchers will explore the application of new organometallic compounds and nanomaterials to develop A-1 catalysts with higher catalytic activity.

  • Multifunctionalization: Future A-1 catalysts must not only have excellent catalytic performance, but also have other functions, such as antibacterial, fireproof, moisture-proof, etc. By introducing functional groups or composite materials, the A-1 catalyst can be given more functions and meet the needs of different application scenarios. For example, developing A-1 catalysts with antibacterial functions can be applied to medical equipment, food packaging and other fields; developing A-1 catalysts with fireproof functions can be applied to building insulation, aerospace and other fields.

  • Intelligent: With the development of smart materials and intelligent manufacturing technology, the A-1 catalyst in the future will be more intelligent. Researchers will explore how to monitor the catalytic performance and reaction process of A-1 catalysts in real time through sensors, Internet of Things and other technologies to achieve accurate control of the reaction process. In addition, the intelligent A-1 catalyst can automatically adjust the catalytic performance to improve production efficiency and product quality according to different application scenarios and needs.

2. Environmental protection requirements

  • Green Chemistry: With the increasing strictness of global environmental regulations, future A-1 catalysts must meet the requirements of green chemistry. Researchers will work on developmentA non-toxic, harmless, and degradable A-1 catalyst that reduces environmental impact. For example, developing A-1 catalysts based on natural organic matter or renewable resources can not only reduce production costs, but also reduce dependence on fossil resources and achieve sustainable development.

  • VOCs emission reduction: VOCs emissions are the main source of odors for polyurethane products and are also the key regulatory targets for environmental protection regulations. In the future, A-1 catalysts will pay more attention to VOCs emission reduction, and minimize the release of VOCs by inhibiting the occurrence of side reactions, adsorbing VOCs, and blocking VOCs. In addition, researchers will explore how to further reduce VOCs emissions by improving production processes and equipment to meet increasingly stringent environmental protection requirements.

  • Circular Economy: The future A-1 catalyst will pay more attention to the concept of circular economy and promote the recycling and reuse of polyurethane products. Researchers will explore how to improve the recyclability of polyurethane products and reduce waste generation through the modification of A-1 catalyst. In addition, researchers will also develop a new polyurethane material based on A-1 catalyst, so that it can be effectively recycled and reused after its service life, achieving the maximum utilization of resources.

3. Market demand

  • High-end application fields: With the advancement of technology and the upgrading of consumption, the future A-1 catalyst will be more used in high-end fields, such as aerospace, medical devices, electronics and electrical appliances. Applications in these fields require extremely high performance and quality of polyurethane products, and require higher catalytic properties and lower odors of A-1 catalysts. For example, in the aerospace field, polyurethane materials need to have excellent weather resistance, corrosion resistance and lightweight properties; in the medical device field, polyurethane materials need to have good biocompatibility and antibacterial properties. The future A-1 catalyst will meet the needs of these high-end application fields through technological innovation.

  • Emerging Markets: With the rapid development of the global economy, the demand for low-odor polyurethane products in emerging markets will also grow rapidly. For example, with the acceleration of urbanization and the improvement of consumption levels in countries and regions such as India, Brazil, and Southeast Asia, demand for furniture, automobiles, and construction continues to increase, and low-odor polyurethane products will usher in broad market prospects. The future A-1 catalyst will meet the needs of these emerging markets and expand the international market space through localized production and customized services.

  • Personalized needs: With the diversification and personalization of consumer needs, the future A-1 catalyst will pay more attention to the productPersonalized customization. Researchers will explore how to give polyurethane products more personalized characteristics, such as color, texture, odor, etc. through the modification of A-1 catalyst. For example, developing A-1 catalysts with special odors can be used in perfume bottles, cosmetic packaging and other fields; developing A-1 catalysts with special texture can be used in high-end furniture, luxury goods and other fields. Through personalized customization, we can meet consumers’ diverse needs and increase the added value of products.

Conclusion

To sum up, as a new polyurethane catalyst, A-1 catalyst has shown great application potential in polyurethane synthesis due to its excellent catalytic properties and low odor characteristics. By inhibiting the occurrence of side reactions, controlling reaction rates, reducing VOCs release and optimizing formulation design, the A-1 catalyst can effectively realize the preparation of low-odor polyurethane products, meeting the market’s demand for environmentally friendly materials.

Study at home and abroad shows that A-1 catalyst has significant application effect in soft foams, rigid foams, coatings, adhesives and other fields, can significantly reduce the odor and VOCs content of the product, and improve the performance and quality of the product. . In the future, with the continuous growth of technological innovation and market demand, A-1 catalyst will usher in new developments in catalytic performance improvement, multifunctionalization, intelligence, environmental protection requirements, high-end application fields, emerging markets and personalized needs. Opportunities and challenges.

Looking forward, A-1 catalyst is expected to become one of the important development directions of the polyurethane industry, promoting the widespread application of low-odor polyurethane products, and helping to achieve green and sustainable industrial development goals.

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