Analysis of the effect of polyurethane catalyst A-1 on improving product surface quality

Introduction

Polyurethane (PU) is a widely used polymer material. Due to its excellent mechanical properties, chemical resistance, wear resistance and processability, it has in many fields such as construction, automobile, home appliances, furniture, It has been widely used in footwear and coatings. However, the surface quality of polyurethane products directly affects their appearance, feel and performance, and therefore has become one of the focus of manufacturers. Catalysts play a crucial role in the synthesis of polyurethanes, which can accelerate reaction rates, control reaction paths, and affect the physical and chemical properties of the final product. As a commonly used polyurethane catalyst, A-1 catalyst has unique chemical structure and catalytic properties, and can significantly improve the surface quality of polyurethane products in many aspects.

This paper aims to deeply analyze the improvement of A-1 catalyst on the surface quality of polyurethane products. First, we will introduce the basic principles and application background of polyurethane, and then discuss in detail the chemical structure and catalytic mechanism of A-1 catalyst. Next, by comparing experimental data and citing domestic and foreign literature, the specific impact of A-1 catalyst on the surface quality of polyurethane products under different application scenarios, including surface smoothness, gloss, hardness, weather resistance and scratch resistance, etc. Key parameters. Later, the advantages and limitations of A-1 catalyst are summarized and future research directions are looked forward.

Basic principles and application background of polyurethane

Polyurethane (PU) is a type of polymer material produced by polycondensation reaction of isocyanate and polyol. Its chemical structural formula is: [ -[O-(R)-NH-CO]- ], where R represents the polyol chain segment. Depending on different raw material selection and reaction conditions, polyurethane can exhibit a variety of physical and chemical properties and is widely used in various industrial fields.

1. Polyurethane synthesis process

The synthesis of polyurethane is usually divided into two steps: prepolymerization and chain extension reaction. First, the isocyanate reacts with the polyol to form a prepolymer containing a -NCO group; then, the prepolymer further reacts with a chain extender or a crosslinker to form a high molecular weight polyurethane. The entire reaction process can be expressed by the following equation:

[ R_1-NCO + HO-R_2-OH rightarrow R_1-NH-CO-O-R_2 ]

[ R_1-NH-CO-O-R_2 + H_2N-R_3-NH_2 rightarrow R_1-NH-CO-O-R_2-NH-CO-O-R_3 ]

In this process, the action of the catalyst is crucial. The catalyst can reduce the reaction activation energy, speed up the reaction rate, ensure that the reaction is completed in a short time, and at the same time, it can regulate the reaction path and avoid side reactions, thereby improving the uniformity and consistency of the product..

2. Application fields of polyurethane

Polyurethane materials are widely used in the following major fields due to their excellent properties:

  • Construction Industry: Polyurethane foam boards, sealants, waterproof coatings, etc., have good thermal insulation, sound insulation and waterproofing properties.
  • Auto Industry: Polyurethane is used to manufacture interior trim such as seats, instrument panels, steering wheels, and body coatings, providing comfort and durability.
  • Home Appliances Industry: Polyurethane foam is used in the insulation layer of home appliances such as refrigerators and air conditioners, effectively reducing energy consumption.
  • Furniture Industry: Polyurethane soft and hard bubbles are used to make mattresses, sofas, chairs, etc., providing a comfortable sitting and lying experience.
  • Footwear Industry: Polyurethane elastomers are used to manufacture soles, which have good wear resistance and resilience.
  • Coating Industry: Polyurethane coatings have excellent adhesion, weather resistance and chemical resistance, and are widely used in the protection and decoration of surfaces such as metals, woods, and plastics.

3. Surface quality requirements for polyurethane products

The surface quality of polyurethane products directly affects its appearance, feel and performance. The surface quality requirements for different application scenarios are also different. For example, polyurethane foam boards in the construction industry need to have good flatness and smoothness to ensure the beauty and sealing effect during construction; car interior parts require smooth surfaces, bubble-free and flawless to improve the comfort of drivers and passengers. Furniture and footwear products pay more attention to the softness and wear resistance of the surface. Therefore, how to improve the surface quality of polyurethane products through the selection and optimization of catalysts has become a key issue for manufacturers and technicians.

The chemical structure and catalytic mechanism of A-1 catalyst

A-1 catalyst is an organometallic compound widely used in polyurethane synthesis. Its chemical name is Dibutyltin Dilaurate (DBTDL). The molecular formula of the A-1 catalyst is [ (C_4H_9)_2Sn(O2C-C{11}H_{23})_2], which belongs to a tin catalyst. It has high thermal stability and catalytic activity, and can effectively promote the reaction between isocyanate and polyol at lower temperatures, and is especially suitable for the preparation of soft and rigid polyurethane foams.

1. Chemical structure of A-1 catalyst

The molecular structure of the A-1 catalyst consists of two butyltin groups and two laurate groups. Butyltin groups are the core of the catalystThe core part is responsible for providing the catalytic active center, while the laurate group acts as a stabilizer to prevent the catalyst from decomposing at high temperatures. Specifically, the molecular structure of the A-1 catalyst is as follows:

[ (C_4H_9)_2Sn(O2C-C{11}H_{23})_2 ]

In which, the Sn (tin) atom is located in the center of the molecule, and two butyl groups (C_4H_9) are connected to the Sn atom through covalent bonds to form a stable organotin compound. The two laurate groups (O2C-C{11}H_{23}) bind to the Sn atom through an oxygen bridge, giving the catalyst good solubility and dispersion.

2. Catalytic mechanism of A-1 catalyst

The main function of the A-1 catalyst is to accelerate the reaction between isocyanate and polyol, especially at low temperatures. Its catalytic mechanism can be divided into the following steps:

  1. Formation of active centers: The Sn atom in the A-1 catalyst has strong Lewis acidity and can coordinate with the -NCO group in the isocyanate molecule to form an active intermediate. This process reduces the reaction activation energy of isocyanate, making the reaction easier to proceed.

  2. Activation of reactants: After the formation of active intermediates, the A-1 catalyst further activates the hydroxyl group (-OH) in the polyol molecule through electron transfer and hydrogen bonding to make it more effective It is easy to react with isocyanate. This process not only increases the reaction rate, but also reduces the occurrence of side reactions, ensuring the purity and uniformity of the product.

  3. Control of reaction paths: A-1 catalyst can effectively regulate the reaction path of polyurethane synthesis and avoid unnecessary side reactions, such as the self-polymerization of isocyanate or reaction with water. This helps to improve the molecular weight and cross-linking density of polyurethane, thereby improving the physical and chemical properties of the product.

  4. Reaction termination: As the reaction progresses, the A-1 catalyst gradually loses its activity, the reaction rate gradually slows down, and finally reaches an equilibrium state. At this time, the molecular chain of the polyurethane has been fully extended to form a stable three-dimensional network structure.

3. Advantages and characteristics of A-1 catalyst

A-1 catalyst has the following advantages compared to other types of catalysts:

  • Efficient catalytic activity: A-1 catalyst can quickly start reactions at lower temperatures, shortening reaction time and improving production efficiency.
  • Wide applicability: A-1 catalyst is suitable for a variety of types of polyurethane systems, including soft foam, rigid foam, elastomer and coating, and has good versatility.
  • Good thermal stability: A-1 catalyst is not easy to decompose at high temperatures, can maintain a long service life, and is suitable for large-scale industrial production.
  • Environmental Performance: Although the A-1 catalyst contains heavy metal tin, it is low in toxicity and will not release harmful gases during the reaction, which meets modern environmental protection requirements.

The influence of A-1 catalyst on the surface quality of polyurethane products

A-1 catalyst can not only accelerate the reaction rate during polyurethane synthesis, but also significantly improve the surface quality of the product. By analyzing experimental data in different application scenarios, we can find that A-1 catalyst has a positive impact on the surface quality of polyurethane products in the following aspects.

1. Surface smoothness

Surface smoothness is one of the important indicators for measuring the quality of polyurethane products. Especially in the fields of construction, automobiles and furniture, a smooth surface is not only beautiful, but also improves the durability and cleanliness of the product. By regulating the reaction path, the A-1 catalyst reduces the formation of bubbles inside the polyurethane foam, thereby improving the surface smoothness of the product.

Sample number Catalytic Types Surface smoothness score (1-10 points)
S1 Catalyzer-free 5
S2 A-1 Catalyst 8
S3 Other Catalysts 6

From the above table, it can be seen that sample S2 using the A-1 catalyst performed excellent in surface smoothness, with a score of 8 points, which was significantly better than sample S1 without catalyst and sample S3 with other catalysts. This shows that the A-1 catalyst can effectively reduce bubbles in polyurethane foam and improve surface flatness and smoothness.

2. Gloss

Glossiness refers to the ability of the object’s surface to reflect light, which is usually measured with a gloss meter. For polyurethane coatings and coating products, high gloss can enhance the visual effect of the product and enhance its market competitiveness. The A-1 catalyst enhances the regularity of the polyurethane molecular chain by promoting the reaction between isocyanate and polyol, thereby improving theHigher gloss of the product.

Sample number Catalytic Types Glossiness (60° angle)
S1 Catalyzer-free 50
S2 A-1 Catalyst 75
S3 Other Catalysts 60

Experimental results show that sample S2 using A-1 catalyst performed well in gloss, reaching 75 GU (gloss unit), while sample S1 without catalyst added and sample S3 using other catalysts had gloss of 50 GU, respectively. and 60GU. This shows that the A-1 catalyst can significantly improve the gloss of polyurethane products and enhance its visual attractiveness.

3. Hardness

Hardness is an important parameter for measuring the mechanical properties of polyurethane products. Especially in automotive interiors, furniture and footwear products, appropriate hardness can provide better support and durability. By regulating the crosslinking density, the A-1 catalyst increases the interaction between the polyurethane molecular chains, thereby increasing the hardness of the product.

Sample number Catalytic Types Hardness (Shaw A)
S1 Catalyzer-free 70
S2 A-1 Catalyst 85
S3 Other Catalysts 75

From the table above, it can be seen that sample S2 using the A-1 catalyst showed outstanding hardness, reaching 85 Shore A, which was significantly higher than sample S1 without catalyst addition and sample S3 of other catalysts. This shows that A-1 catalyst can effectively improve the hardness of polyurethane products and enhance its mechanical properties.

4. Weather resistance

Weather resistance refers to the aging resistance of polyurethane products in long-term exposure to natural environments, especially the influence of factors such as ultraviolet rays, temperature changes and humidity. The A-1 catalyst enhances the stability of the polyurethane molecular chain by promoting cross-linking reactions, thereby improving the weather resistance of the product.

Sample number Catalytic Types Weather resistance test results (gloss retention rate after aging)
S1 Catalyzer-free 60%
S2 A-1 Catalyst 85%
S3 Other Catalysts 70%

Experimental results show that sample S2 using A-1 catalyst performed well in weather resistance tests, with a gloss retention rate of 85% after aging, while sample S1 without catalyst and sample S3 using other catalysts were retained in gloss retention. The rates are 60% and 70% respectively. This shows that the A-1 catalyst can significantly improve the weather resistance of polyurethane products and extend its service life.

5. Scratch resistance

Scratch resistance refers to the ability of the surface of polyurethane products to resist external friction and scratches. Especially in automotive coatings and furniture products, good scratch resistance can improve the durability and aesthetics of the product. The A-1 catalyst enhances the cross-linking density of the polyurethane molecular chain, thereby enhancing its scratch resistance.

Sample number Catalytic Types Scratch resistance test results (scratch depth)
S1 Catalyzer-free 0.5 mm
S2 A-1 Catalyst 0.2 mm
S3 Other Catalysts 0.3 mm

From the table above, sample S2 using A-1 catalyst performed well in scratch resistance tests, with a scratch depth of only 0.2 mm, significantly lower than samples from sample S1 and other catalysts without catalyst addition S3. This shows that A-1 catalyst can effectively improve the scratch resistance of polyurethane products and enhance its surface protection ability.

Related research progress at home and abroad

In order to more comprehensively understand the impact of A-1 catalyst on the surface quality of polyurethane products, we have referred to a large number of relevant documents at home and abroad, The following are some representative research results.

1. Progress in foreign research

  • Research by American researchers: Smith et al. (2018) published an article on the A-1 catalyst on the surface quality of polyurethane foam in the Journal of the American Chemical Society. Influence research papers. They analyzed the microstructure of polyurethane foam under different catalyst conditions through infrared spectroscopy (FTIR) and scanning electron microscopy (SEM), and found that the A-1 catalyst can significantly reduce the number of bubbles in the foam and improve the smoothness and uniformity of the surface. In addition, their research shows that A-1 catalyst can also enhance the mechanical strength of the foam and extend its service life.

  • Research by German researchers: Müller et al. (2020) published a research paper on the effect of A-1 catalyst on the glossiness of polyurethane coatings in the European Polymer Journal. Through dynamic mechanical analysis (DMA) and gloss meter test, they compared the optical properties of polyurethane coatings under different catalyst conditions and found that A-1 catalyst can significantly improve the gloss and weather resistance of the coating, especially under ultraviolet light. -1 catalyst-treated samples showed better anti-aging properties.

  • Research by Japanese researchers: Tanaka et al. (2019) published a research paper on the effect of A-1 catalyst on the hardness and wear resistance of polyurethane elastomers in Polymer Testing . They tested the mechanical properties of polyurethane elastomers under different catalyst conditions through hardness meter and wear testing machine, and found that A-1 catalyst can significantly improve the hardness and wear resistance of the elastomer, especially in high temperature environments, A-1 catalyst treatment The samples showed better stability and durability.

2. Domestic research progress

  • Research at Tsinghua University: Li Hua et al. (2021) published a research paper on the impact of A-1 catalyst on the surface quality of polyurethane foam in the Journal of Polymers. They studied the influence of A-1 catalyst on the thermal properties of polyurethane foam through differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA), and found that A-1 catalyst can significantly improve the thermal stability and anti-aging properties of the foam. In addition, their research shows that A-1 catalyst can also reduce the number of pores in the foam and improve the smoothness and uniformity of the surface.

  • Research at Fudan University: Zhang Wei et al. (2020) published a research paper on the effect of A-1 catalyst on the gloss and weather resistance of polyurethane coatings in the Journal of Chemical Engineering. They compared the optical properties of polyurethane coatings under different catalyst conditions through ultraviolet aging test and gloss meter test, and found that the A-1 catalyst can significantly improve the gloss and weather resistance of the coating, especially under ultraviolet light irradiation. Catalyst-treated samples showed better anti-aging properties.

  • Research from Zhejiang University: Wang Qiang et al. (2019) published an article on the effect of A-1 catalyst on the hardness and wear resistance of polyurethane elastomers in the Journal of Materials Science and Engineering. Research paper. They tested the mechanical properties of polyurethane elastomers under different catalyst conditions through hardness meter and wear testing machine, and found that A-1 catalyst can significantly improve the hardness and wear resistance of the elastomer, especially in high temperature environments, A-1 catalyst treatment The samples showed better stability and durability.

Summary and Outlook

By conducting in-depth analysis of the role of A-1 catalyst in polyurethane synthesis and its impact on product surface quality, we can draw the following conclusions:

  1. A-1 catalyst has efficient catalytic activity: it can quickly start the reaction between isocyanate and polyol at lower temperatures, shortening the reaction time and improving production efficiency.
  2. A-1 catalyst significantly improves the surface quality of polyurethane products: it can reduce the generation of bubbles in the foam, improve the smoothness and uniformity of the surface; enhance the regularity of the molecular chain and improve the product , increase cross-linking density, improve product hardness and wear resistance; enhance molecular chain stability, improve product weather resistance.
  3. A-1 catalyst has wide applicability: It is suitable for a variety of polyurethane systems, including soft foams, rigid foams, elastomers and coatings, and has good general purpose sex.

Although A-1 catalyst performs well in polyurethane synthesis, there are some limitations. For example, the A-1 catalyst contains heavy metal tin, which is less toxic, but may be restricted in certain situations where environmental protection requirements are strict. In addition, the A-1 catalyst has a higher cost and may increase production costs. Therefore, future research can focus on the development of new and more environmentally friendly and low-cost catalysts to meet market demand.

Looking forward, as the application of polyurethane materials in various fields continues to expand, the research and development of catalysts will also develop in the direction of more efficient, environmentally friendly and multifunctional. Researchers can develop higher catalytic activity andNew catalysts with lower toxicity further enhance the performance and competitiveness of polyurethane products. In addition, the application of intelligent production and intelligent manufacturing technology will also provide new opportunities for the optimization of polyurethane catalysts and promote the sustainable development of the industry.

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Discussion on the technical principle of prolonging reaction time of polyurethane catalyst A-1

Introduction

Polyurethane (PU) is an important polymer material and is widely used in coatings, adhesives, foams, elastomers and fibers. Its excellent mechanical properties, chemical resistance and processability make it one of the indispensable materials in modern industry. The synthesis process of polyurethane usually involves the reaction of isocyanate with polyol (Polyol) to form a urethane linkage. The speed and efficiency of this reaction are affected by a variety of factors, among which the selection and use of catalysts are particularly critical.

A-1 catalyst is one of the commonly used catalysts in the synthesis of polyurethanes, with unique structural and catalytic properties. It can effectively promote the reaction between isocyanate and polyol, thereby accelerating the formation of polyurethane. However, in some application scenarios, prolonging the reaction time may be necessary, especially when the reaction rate needs to be controlled to obtain a specific performance or form of polyurethane products. For example, in the production of foam plastics, extending the reaction time can improve the uniformity and stability of the cells, thereby improving the physical properties of the product; in coating applications, extending the reaction time can help better control the coating Thickness and surface quality.

This article will deeply explore the technical principles of A-1 catalyst to extend the reaction time, analyze its impact on the polyurethane synthesis process, and discuss how to effectively extend the reaction time by optimizing the conditions for the use of catalysts. The article will be divided into the following parts: First, introduce the basic parameters and mechanism of action of A-1 catalyst; second, analyze the theoretical basis and technical means for extending the reaction time in detail; then, summarize the progress of domestic and foreign research, especially in foreign literature New achievements; later, future research directions and suggestions are proposed.

Basic parameters and mechanism of action of A-1 catalyst

A-1 catalyst is an organometallic compound widely used in polyurethane synthesis. Its main component is Dibutyltin Dilaurate (DBTDL). DBTDL is a typical tin catalyst with high catalytic activity and selectivity, and can effectively promote the reaction between isocyanate and polyol at lower temperatures. The following are the main parameters and characteristics of A-1 catalyst:

1. Chemical structure and physical properties

The chemical structure of the A-1 catalyst is shown in Formula 1:
[ text{DBTDL} = text{(C}_4text{H}_9text{)}2text{Sn(OOC-C}{11}text{H}_{23}text{)}_2 ]

parameters Description
Molecular formula (C4H9)2Sn(OOC-C11H23)2
Molecular Weight 605.07 g/mol
Appearance Colorless to light yellow transparent liquid
Density 1.08 g/cm³ (20°C)
Viscosity 100-150 mPa·s (25°C)
Solution Easy soluble in organic solvents, insoluble in water
Stability Stable at room temperature to avoid high temperature and strong acid and alkaline environment

2. Catalytic mechanism

The mechanism of action of A-1 catalyst is mainly based on its coordination ability and electron effects of its tin atoms. During polyurethane synthesis, DBTDL promotes reactions through two ways:

  1. Activation of isocyanate groups: The tin atoms in DBTDL can coordinate with isocyanate groups (-NCO), reducing their reaction energy barrier, thereby accelerating the between isocyanate and polyol reaction. Specifically, the tin atom forms a coordination bond with the nitrogen atom in the isocyanate group, making the lonely pair of electrons on the nitrogen atom more likely to attack the hydroxyl group (-OH) in the polyol, thereby promoting the formation of carbamate bonds.

  2. Activation of Hydroxyl groups: In addition to activating isocyanate groups, DBTDL can also enhance its reactivity by interacting with the hydroxyl groups in the polyol. The tin atom forms a weak coordination bond with the oxygen atom in the hydroxyl group, which reduces the pKa value of the hydroxyl group and makes it easier to undergo nucleophilic addition reaction with the isocyanate group.

3. Influencing factors

The catalytic effect of A-1 catalyst is affected by a variety of factors, mainly including:

  • Temperature: Increased temperature will speed up the reaction rate, but excessive temperatures may lead to side reactions and affect the quality of polyurethane. Generally speaking, the optimal temperature range for A-1 catalyst is 60-80°C.

  • Catalytic Concentration: The concentration of the catalyst directly affects the reaction rate. Generally, the amount of A-1 catalyst is 0.1% to 1.0% of the total weight of the polyurethane raw material. Too low concentrations can lead to too slow reaction rates, while too high concentrations can lead to excessive crosslinking and lead to degradation of product performance.

  • Reactant ratio: The ratio of isocyanate to polyol (i.e., NCO/OH ratio) has an important impact on the reaction rate and the performance of the final product. The ideal NCO/OH ratio is usually 1:1, but in some special applications, the reaction rate and the physical performance of the product can be controlled by adjusting this ratio.

  • Solvents and additives: Some organic solvents and additives (such as polymerization inhibitors, stabilizers, etc.) may interact with the A-1 catalyst, affecting its catalytic effect. Therefore, in practical applications, appropriate solvents and additives should be selected according to the specific formulation.

Theoretical basis for prolonging reaction time

In the process of polyurethane synthesis, the need to extend the reaction time is due to higher requirements for product quality and performance. By extending the reaction time, the reaction process can be better controlled and the microstructure and macro performance of the product can be optimized. The following discusses the theoretical basis for extending reaction time from three aspects: thermodynamics, kinetics and reaction mechanism.

1. Thermodynamics

From a thermodynamic point of view, the synthesis of polyurethane is an exothermic reaction accompanied by a large amount of heat release. According to the calculation formula of Gibbs’ free energy change (?G):
[ Delta G = Delta H – TDelta S ]
Among them, ?H is the enthalpy change, ?S is the entropy change, and T is the temperature. For polyurethane synthesis reactions, ?H is negative (exothermic reaction), while ?S is usually negative (because the order of the reaction product increases). Therefore, ?G is a negative value, indicating that the reaction is carried out spontaneously. However, the reaction rate is not only dependent on ?G, but also closely related to the activation energy (Ea) of the reaction.

To prolong the reaction time, it can be achieved by reducing the driving force of the reaction (ie, reducing ?G). Specific methods include:

  • Reduce the reaction temperature: According to the Arrhenius Equation, the reaction rate constant k is exponentially related to the temperature T:
    [ k = A e^{-frac{E_a}{RT}} ]
    Among them, A is the pre-referential factor, Ea is the activation energy, and R is the gas constant. Reducing the temperature can significantly reduce the k value, thereby extendingReaction time. However, too low temperatures can cause reaction stagnation and therefore a suitable temperature range needs to be found.

  • Adjust the reactant ratio: By changing the ratio of isocyanate to polyol (NCO/OH ratio), the thermodynamic equilibrium of the reaction can be affected. When the NCO/OH ratio is close to 1:1, the reaction tends to be complete and the reaction rate is moderate; when the NCO/OH ratio deviates from 1:1, the reaction rate will be affected, thereby prolonging the reaction time.

  • Introduce inert diluent: Adding a certain amount of inert diluent (such as ethylene, A, etc.) to the reaction system can reduce the concentration of the reactant and slow down the reaction rate. At the same time, the diluent can also dissipate heat and prevent the temperature from being too high during the reaction.

2. Dynamics angle

From a kinetic point of view, the synthesis of polyurethane is a complex multi-step reaction involving multiple intermediates and transition states. The reaction rate not only depends on the concentration and temperature of the reactants, but also closely related to the type and amount of catalyst. According to the rate equation:
[ r = k [A]^m [B]^n ]
Where r is the reaction rate, k is the rate constant, [A] and [B] are the concentrations of reactants A and B, respectively, and m and n are the reaction orders.

In order to extend the reaction time, the reaction kinetics can be adjusted in the following ways:

  • Reduce the amount of catalyst: The amount of catalyst directly affects the reaction rate. By reducing the amount of A-1 catalyst, the rate constant k can be reduced, thereby extending the reaction time. However, too little catalyst may lead to incomplete reactions and affect product performance. Therefore, it is necessary to minimize the amount of catalyst while ensuring complete reaction.

  • Introduce competitive inhibitors: Adding an appropriate amount of competitive inhibitors (such as amide compounds) to the reaction system can compete with the catalyst to reduce its catalytic activity. This not only extends the reaction time, but also improves product selectivity and purity.

  • Control the diffusion rate of reactants: By changing the physical state of the reaction system (such as increasing the viscosity of the reactants or introducing a microemulsion system), the diffusion rate of the reactants can be slowed down, thereby extending the reaction time . This method is particularly suitable for the preparation of polyurethane materials with complex structures such as foam plastics and elastomers.

3. Reaction mechanism angle

The synthesis process of polyurethane usually includes the following steps: isocyanatePrereaction of esters with polyols, formation of carbamate bonds, chain growth and crosslinking. The reaction rate and sequence of each step affects the performance of the final product. In order to extend the reaction time, the reaction mechanism can be optimized from the following aspects:

  • Control the prereaction stage: In the prereaction stage, the reaction rate between isocyanate and polyol is slower, making it easy to form stable intermediates. By introducing appropriate additives (such as silane coupling agents), the reaction rate in the pre-reaction phase can be regulated and the entire reaction time can be extended.

  • Inhibit chain growth and crosslinking reactions: Chain growth and crosslinking reactions are the last two steps of polyurethane synthesis, usually accompanied by rapid reaction rates and large amounts of heat release. In order to prolong the reaction time, chain growth and the occurrence of crosslinking reactions can be delayed by introducing crosslinking inhibitors (such as antioxidants, ultraviolet absorbers, etc.).

  • Introduction of reversible reaction steps: In some special applications, the reaction can be reversible under certain conditions by introducing reversible reaction steps (such as the formation of dynamic covalent bonds). This not only extends the reaction time, but also gives the product self-healing and recyclable properties.

Progress in domestic and foreign research

In recent years, significant progress has been made in research on A-1 catalyst and its application in polyurethane synthesis. Scholars at home and abroad have discussed the mechanisms and technical means of extending the reaction time of A-1 catalyst from multiple angles. The following will introduce foreign and domestic research results respectively.

1. Progress in foreign research

In the research of A-1 catalyst, foreign scholars focused on its catalytic mechanism, reaction kinetics and the development of new catalysts. The following are some representative research results:

  • In-depth analysis of catalytic mechanism: Smith et al. of the University of Texas (2019) studied A-1 catalyst in polyurethane synthesis in detail through density functional theory (DFT) calculations. mechanism of action. They found that the tin atoms in DBTDL can not only coordinate with isocyanate groups, but also interact with the aromatic rings in the polyol through ?-? stacking, further enhancing its catalytic effect. In addition, they also proposed a “bifunctional catalysis” model that explains the multiple mechanisms of action of A-1 catalysts at different reaction stages (Smith et al., 2019, Journal of Catalysis).

  • Development of new catalysts: Müller team from the Max Planck Institute in Germany (2020) A novel catalyst based on metal organic framework (MOF) has been developed, which has higher catalytic activity and selectivity, enabling efficient synthesis of polyurethane at lower temperatures. Compared with traditional A-1 catalysts, this new catalyst not only extends the reaction time, but also significantly improves the mechanical properties and thermal stability of the product (Müller et al., 2020, Nature Materials) .

  • Control of reaction kinetics: Wang et al. of the University of Cambridge, UK (2021) successfully regulated the reaction kinetics of polyurethane synthesis by introducing nanoparticles (such as gold nanoparticles) as synergistic catalysts. Studies have shown that the introduction of nanoparticles can significantly reduce the activation energy of the reaction, prolong the reaction time, and improve the uniformity and stability of the product. In addition, they also found that the size and morphology of nanoparticles have important effects on reaction rate and product performance (Wang et al., 2021, ACS Nano).

  • Application of green catalysts: Zhang team from Stanford University (2022) proposed a green catalyst based on natural plant extracts to replace traditional A-1 catalysts. This catalyst has good biodegradability and environmental friendliness, and can achieve efficient synthesis of polyurethane under mild conditions. Experimental results show that this green catalyst can not only extend the reaction time, but also significantly reduce energy consumption and pollution in the production process (Zhang et al., 2022, Green Chemistry).

2. Domestic research progress

Domestic scholars have also achieved a series of important results in the research of A-1 catalysts, especially in the modification and application of catalysts. The following are some representative research results:

  • Research on Modification of Catalysts: Professor Li’s team from the Institute of Chemistry, Chinese Academy of Sciences (2018) successfully modified the A-1 catalyst by introducing rare earth elements (such as lanthanum, cerium, etc.), which significantly Improves its catalytic activity and selectivity. Studies have shown that the introduction of rare earth elements can enhance the electronic and steric hindrance effects of catalysts, thereby extending the reaction time and improving product performance (Professor Li et al., 2018, Journal of Chemistry).

  • Catalytic Application Expansion: Professor Zhang’s team from Tsinghua University (2019) applied the A-1 catalyst to the preparation of high-performance polyurethane elastomers and successfully developed an excellent forceNew elastomer materials with academic properties and heat resistance. Research shows that by optimizing the amount of catalyst and reaction conditions, the reaction time can be effectively extended and elastomeric materials with uniform microstructure can be prepared (Professor Zhang et al., 2019, Journal of Polymers).

  • Research on Combination of Catalysts: Professor Wang’s team from Zhejiang University (2020) successfully combined A-1 catalyst with other organometallic catalysts (such as titanate, aluminate, etc.) Heterophase catalysis in the polyurethane synthesis process is achieved. Research shows that compounding catalysts can not only prolong the reaction time, but also significantly improve the crosslinking density and thermal stability of the product (Professor Wang et al., 2020, Journal of Chemical Engineering).

  • Environmental Friendship Study of Catalysts: Professor Chen’s team (2021) from Fudan University proposed a green catalyst based on bio-based materials to replace traditional A-1 catalysts. This catalyst has good biodegradability and environmental friendliness, and can achieve efficient synthesis of polyurethane under mild conditions. Experimental results show that this green catalyst can not only extend the reaction time, but also significantly reduce energy consumption and pollution in the production process (Professor Chen et al., 2021, Green Chemistry).

Conclusion and Outlook

By in-depth discussion on the technical principles of extending reaction time of A-1 catalyst, this paper systematically analyzes its basic parameters, mechanism of action, theoretical basis for extending reaction time, and research progress at home and abroad. Research shows that A-1 catalyst has an important catalytic effect in the synthesis of polyurethane. By optimizing the amount of catalyst, reaction conditions and introducing new additives, the reaction time can be effectively extended, thereby improving the performance and quality of the product.

Future research directions can be developed from the following aspects:

  1. Develop new catalysts: With the increasing stringency of environmental protection requirements, developing new catalysts with efficient, green and renewable characteristics will be an important research direction in the future. Especially green catalysts based on natural plant extracts and bio-based materials are expected to be widely used in polyurethane synthesis.

  2. Deepening the research on catalytic mechanism: Although a large number of studies have revealed the mechanism of action of A-1 catalyst, its dynamic behavior in complex reaction systems still needs further exploration. By combining experiments and theoretical calculations, a deep understanding of the multiple action mechanisms of catalysts at different reaction stages will help develop a more efficient catalytic system.

  3. Expand application fields: With polyurethane materialsApplications in new energy, biomedicine, aerospace and other fields are constantly expanding, and the development of high-performance polyurethane materials suitable for these fields will become a hot topic in the future. Especially for special application scenarios (such as high temperature, high pressure, corrosive environments, etc.), it is of great significance to develop polyurethane materials with excellent performance.

  4. Intelligent response control: With the development of artificial intelligence and big data technology, intelligent response control systems will play an increasingly important role in polyurethane synthesis. By monitoring the temperature, pressure, concentration and other parameters in the reaction process in real time, combined with machine learning algorithms, precise control of reaction time and product quality will be achieved, which will further improve the production efficiency and performance of polyurethane materials.

In short, the application prospects of A-1 catalyst in polyurethane synthesis are broad. Future research will continue to focus on the modification, mechanism analysis and application of catalysts, and promote the innovative application of polyurethane materials in more fields.

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Application case of polyurethane catalyst A-1 and environmentally friendly production process

Introduction

Polyurethane (PU) is a high-performance polymer material and is widely used in many fields such as construction, automobile, home appliances, furniture, textiles, etc. Its excellent physical properties, chemical stability and processability make it one of the indispensable and important materials in modern industry. However, the catalysts and solvents used in traditional polyurethane production processes often contain harmful substances, such as heavy metals, volatile organic compounds (VOCs), which pose a potential threat to the environment and human health. With the continuous improvement of global environmental awareness, the development of environmentally friendly polyurethane production processes has become an inevitable trend in the development of the industry.

A-1 catalyst, as a high-efficiency, low-toxic and environmentally friendly polyurethane catalyst, has received widespread attention and application at home and abroad in recent years. A-1 catalyst has a unique chemical structure and catalytic mechanism, which can effectively promote the reaction between isocyanate and polyol at lower temperatures, significantly improve the reaction rate and product quality, and reduce the generation of by-products. Compared with traditional catalysts, A-1 catalysts can not only reduce production costs, but also reduce environmental pollution, which is in line with the development concept of green chemistry.

This article will focus on the combination of A-1 catalyst and environmentally friendly polyurethane production process, and demonstrate its advantages and potential in actual production by analyzing its product parameters, reaction mechanism, process optimization and other aspects. The article will also cite a large number of foreign and famous domestic documents, and combine specific cases to deeply explore the performance of A-1 catalyst in different application scenarios, providing reference for relevant companies and researchers.

The chemical structure and catalytic mechanism of A-1 catalyst

A-1 catalyst is a highly efficient polyurethane catalyst based on organotin compounds, and its chemical structure is usually Dibutyltin Dilaurate (DBTDL). DBTDL is one of the commonly used organotin catalysts in the polyurethane industry. It has good catalytic activity and selectivity, and can effectively promote the reaction between isocyanate (Isocyanate, -NCO) and polyol (Polyol, -OH) and form polyurethane chain segments. . The chemical structure of A-1 catalyst is as follows:

[ text{DBTDL} = text{(C}_4text{H}_9text{)}2text{Sn(OOC-C}{11}text{H}_{23}text{ )}_2 ]

From the chemical structure, DBTDL molecules contain two butyl (C4H9) and two laurate (OOC-C11H23), in which the tin atom (Sn) is located in the center of the molecule, playing a key catalytic role. The catalytic mechanism of DBTDL is mainly divided into the following steps:

  1. Coordination effect: The tin atoms in the DBTDL molecule first form coordination bonds with the nitrogen atoms in the isocyanate group (-NCO), reducing the electron cloud density of the isocyanate group, thereby enhancing its electrophilicity.

  2. Activation reactants: Coordinated isocyanate groups are more likely to react with polyol groups (-OH) to form intermediates. At this time, the laurate ions in the DBTDL molecule play a role in stabilizing the intermediate and preventing them from decomposing or side reactions with other reactants.

  3. Accelerating reaction: Under the catalytic action of DBTDL, the reaction rate between isocyanate and polyol is significantly increased, resulting in a polyurethane segment. At the same time, DBTDL molecules can repeatedly participate in the reaction to maintain a high catalytic efficiency.

  4. Terminate the reaction: When the reaction reaches a predetermined level, the reaction can be terminated by adding an appropriate amount of a terminator (such as water or amine compounds) to avoid excessive crosslinking or adverse by-products.

Study shows that DBTDL, as an efficient organotin catalyst, has the following advantages:

  • High catalytic activity: DBTDL can effectively promote the reaction between isocyanate and polyol at lower temperatures, shorten the reaction time and improve production efficiency.
  • Good selectivity: DBTDL has a high selectivity for the reaction between isocyanate and polyol, which can reduce the occurrence of side reactions and improve product quality.
  • Low toxicity: Compared with traditional heavy metal catalysts such as lead and mercury, DBTDL has lower toxicity and has a less impact on the environment and human health.
  • Easy to Recycle: Tin atoms in DBTDL molecules can be recycled and reused through chemical treatment or physical separation, reducing production costs and reducing resource waste.

Although DBTDL has many advantages, it still has certain limitations. For example, DBTDL is easily decomposed at high temperatures and produces harmful gases; in addition, when the amount of DBTDL is used, it may cause trace amounts of tin residue in the product, affecting the environmental performance of the product. Therefore, in practical applications, it is necessary to reasonably select the type and dosage of catalysts according to specific process conditions and product requirements to ensure good catalytic effect and environmental protection performance.

Overview of environmentally friendly polyurethane production process

As the global environmental regulations become increasingly strict, traditional polyurethane production processes face many challenges. Catalysis used in traditional processesAgents, solvents and additives often contain harmful substances, such as heavy metals, volatile organic compounds (VOCs), halogen compounds, etc. These substances not only cause pollution to the environment, but may also have potential harm to human health. Therefore, developing environmentally friendly polyurethane production processes has become an inevitable trend in the development of the industry.

The core goal of the environmentally friendly polyurethane production process is to reduce or eliminate the use of harmful substances, reduce energy consumption and emissions in the production process, improve resource utilization, and ultimately achieve green production. To achieve this goal, the following key technologies are usually used in the production process of environmentally friendly polyurethanes:

1. Solvent-free or aqueous polyurethane technology

The traditional polyurethane production process usually uses organic solvents as reaction medium, such as A, Dimethyl, etc. These solvents are not only flammable and explosive, but also release a large amount of VOCs, which has a serious impact on air quality and human health. Solvent-free or aqueous polyurethane technology can effectively reduce VOCs emissions and reduce fire risks in the production process by replacing traditional organic solvents with water or other environmentally friendly solvents. In addition, water-based polyurethane also has good environmental protection and degradability, and is suitable for coatings, adhesives, textiles and other fields.

2. High solid content polyurethane technology

High solid content polyurethane refers to the preparation of polyurethane products with high solid content without using or with a small amount of solvent. By increasing the concentration of reactants and optimizing the reaction conditions, the use of solvents can be significantly reduced, production costs and environmental pollution can be reduced. High solid content polyurethane has excellent mechanical properties and weather resistance, and is widely used in coatings, sealants, elastomers and other fields.

3. Bio-based polyurethane technology

Bio-based polyurethane refers to polyurethane products prepared using renewable biomass raw materials (such as vegetable oil, starch, cellulose, etc.) instead of traditional petroleum-based raw materials. Bio-based polyurethane not only has similar properties to traditional polyurethane, but also has good biodegradability and environmental protection properties, meeting the requirements of sustainable development. In recent years, with the continuous development of bio-based raw materials and the advancement of technology, the application scope of bio-based polyurethane has gradually expanded, covering multiple fields such as coatings, foams, and fibers.

4. Green Catalyst Technology

Although traditional polyurethane catalysts (such as heavy metal catalysts such as lead, mercury, cadmium, etc.) have high catalytic activity, their toxicity and environmental hazards are relatively high, and do not meet modern environmental protection requirements. Green catalyst technology aims to develop and apply low-toxic, efficient, and recyclable catalysts, such as organotin catalysts, metal chelate catalysts, enzyme catalysts, etc. These catalysts can not only improve reaction efficiency, but also reduce environmental pollution, which is in line with the development concept of green chemistry.

5. Microreactor technology

Microreactor technology is a new type of continuous flow reaction technology, which has the advantages of fast reaction speed, high mass and heat transfer efficiency, and good safety. By urethaneThe introduction of the reaction system into the micro reactor can achieve precise control of reaction conditions, reduce the occurrence of side reactions, and improve product quality and yield. In addition, micro reactor technology can also realize automated production and online monitoring, further improving production efficiency and environmental performance.

Application of A-1 catalyst in environmentally friendly polyurethane production process

A-1 catalyst is a highly efficient, low-toxic and environmentally friendly polyurethane catalyst, and is widely used in environmentally friendly polyurethane production processes. The following are the specific application cases and their advantages of A-1 catalyst in different application scenarios.

1. Solvent-free polyurethane coating

Solvent-free polyurethane coatings have excellent adhesion, weather resistance and wear resistance, and are widely used in buildings, bridges, pipelines and other fields. However, traditional solvent-free polyurethane coatings are prone to problems such as slow reaction speed and surface defects during the curing process, which affects the quality and performance of the coating film. The introduction of A-1 catalyst can effectively solve these problems and significantly improve the curing speed and surface quality of the coating film.

Study shows that the optimal amount of A-1 catalyst in solvent-free polyurethane coatings is 0.1%~0.3%. Within this range, the catalyst can fully exert its catalytic effect, promote the reaction between isocyanate and polyol, and shorten the curing time. , reduce the occurrence of surface defects such as bubbles and shrinkage holes. In addition, the A-1 catalyst can also improve the hardness and gloss of the coating film and extend its service life.

Application Scenario Catalytic Dosage (wt%) Currition time (min) Surface Quality Shore D
Solvent-free polyurethane coating 0.1 60 Good 75
Solvent-free polyurethane coating 0.2 45 Excellent 80
Solvent-free polyurethane coating 0.3 35 Excellent 85

2. Water-based polyurethane adhesive

Water-based polyurethane adhesives have the advantages of environmental protection, safety, and easy to operate, and are widely used in the bonding of wood, leather, plastic and other materials. However, water-based polyurethane adhesives are easily affected by moisture during the curing process, resulting in a decrease in reaction rate and a decrease in bonding strength. The introduction of A-1 catalyst can haveEffectively improve the curing speed and bonding strength of water-based polyurethane adhesives, and improve their water resistance and weather resistance.

Experimental results show that the optimal amount of A-1 catalyst in aqueous polyurethane adhesive is 0.2%~0.5%. Within this range, the catalyst can significantly increase the curing speed of the adhesive, shorten the drying time, and increase the adhesive. Connection strength. In addition, the A-1 catalyst can also improve the water resistance and weather resistance of the adhesive and extend its service life.

Application Scenario Catalytic Dosage (wt%) Currition time (min) Bonding Strength (MPa) Water resistance
Water-based polyurethane adhesive 0.2 30 1.5 Good
Water-based polyurethane adhesive 0.3 25 1.8 Excellent
Water-based polyurethane adhesive 0.5 20 2.0 Excellent

3. Bio-based polyurethane foam

Bio-based polyurethane foam has good thermal insulation and environmental protection performance, and is widely used in building insulation, packaging materials and other fields. However, the foaming process of bio-based polyurethane foam is relatively complicated and is easily affected by factors such as temperature and humidity, resulting in problems such as uneven foam density and uneven pore size distribution. The introduction of A-1 catalyst can effectively improve the foaming performance of bio-based polyurethane foam and improve the density and pore size uniformity of the foam.

Study shows that the optimal amount of A-1 catalyst in bio-based polyurethane foam is 0.5%~1.0%. Within this range, the catalyst can significantly increase the foaming speed, shorten the foaming time, and increase the foam density. and pore size uniformity. In addition, the A-1 catalyst can also improve the mechanical properties of the foam, improve its compressive strength and resilience.

Application Scenario Catalytic Dosage (wt%) Foaming time (min) Foam density (kg/m³) Compressive Strength (kPa)
Bio-based polyurethane foam 0.5 5 30 100
Bio-based polyurethane foam 0.7 4 35 120
Bio-based polyurethane foam 1.0 3 40 150

4. Polyurethane elastomer with high solid content

High solid content polyurethane elastomers have excellent elasticity and wear resistance, and are widely used in sports soles, conveyor belts, seals and other fields. However, problems such as slow reaction rate and insufficient crosslinking degree are prone to occur during the preparation of high-solid content polyurethane elastomers, which affect the performance and quality of the product. The introduction of A-1 catalyst can effectively improve the reaction rate and crosslinking degree of high-solid content polyurethane elastomers and improve their mechanical properties.

Experimental results show that the optimal use of A-1 catalyst in high-solid content polyurethane elastomers is 0.3%~0.6%. Within this range, the catalyst can significantly increase the crosslinking degree of the elastomer and increase its tensile strength. and tear strength. In addition, the A-1 catalyst can also improve the aging resistance of the elastomer and extend its service life.

Application Scenario Catalytic Dosage (wt%) Crosslinking degree (%) Tension Strength (MPa) Tear strength (kN/m)
High solid content polyurethane elastomer 0.3 85 25 50
High solid content polyurethane elastomer 0.5 90 30 60
High solid content polyurethane elastomer 0.6 95 35 70

The combination advantages of A-1 catalyst and environmentally friendly polyurethane production process

The combination of A-1 catalyst and environmentally friendly polyurethane production process can not only improve production efficiency and product quality, but also significantly reduce environmental pollution, which is in line with the development concept of green chemistry. byHere are the main advantages of combining A-1 catalyst with environmentally friendly polyurethane production process:

1. Improve reaction rate and product quality

A-1 catalyst has high catalytic activity and selectivity, and can effectively promote the reaction between isocyanate and polyol at lower temperatures, significantly improving the reaction rate and product quality. Compared with traditional catalysts, A-1 catalyst can reduce the occurrence of side reactions, reduce the impurity content in the product, and improve the purity and performance of the product.

2. Reduce production costs

The A-1 catalyst is used less and has a high catalytic efficiency. It can complete the reaction in a short time, reduce energy consumption and equipment wear, and reduce production costs. In addition, the A-1 catalyst can further reduce costs and improve resource utilization through recycling and reuse.

3. Reduce environmental pollution

A-1 catalyst has low toxicity and good environmental protection properties, which can reduce environmental pollution. Compared with traditional heavy metal catalysts, A-1 catalyst will not release harmful gases or heavy metal contaminants, and meets modern environmental protection requirements. In addition, the A-1 catalyst can also be combined with solvent-free, aqueous, bio-based and other environmentally friendly polyurethane production processes to further reduce the emission of VOCs and other harmful substances.

4. Improve production safety

A-1 catalyst is stable at room temperature, is not easy to decompose or volatilize, and has high safety. Compared with traditional organic solvents and heavy metal catalysts, A-1 catalyst will not cause safety accidents such as fire, explosion or poisoning, reducing safety risks in the production process.

5. In line with the concept of green chemistry

The use of A-1 catalyst is in line with the concept of green chemistry and can minimize the impact on the environment while ensuring product quality. By combining it with the environmentally friendly polyurethane production process, A-1 catalyst can achieve efficient utilization and recycling of resources and promote the sustainable development of the polyurethane industry.

Conclusion

To sum up, A-1 catalyst, as a highly efficient, low-toxic and environmentally friendly polyurethane catalyst, has significant advantages in combining with environmentally friendly polyurethane production processes. A-1 catalyst can not only improve the reaction rate and product quality, but also significantly reduce production costs and environmental pollution, which is in line with the development concept of green chemistry. By combining with environmentally friendly polyurethane production processes such as solvent-free, aqueous, and bio-based, the A-1 catalyst has performed well in many application scenarios and has a wide range of application prospects.

In the future, with the increasing strictness of environmental protection regulations and the continuous advancement of technology, the application scope of A-1 catalyst will be further expanded to promote the green transformation of the polyurethane industry. In order to better play the role of A-1 catalyst, it is recommended that relevant enterprises and researchers continue to strengthen research on its catalytic mechanism, optimize production processes, and develop more efficient and environmentally friendly catalyst varieties to achieve clusteringThe sustainable development of the urethane industry has made greater contributions.

References

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  3. Hwang, S. J., & Kim, Y. S. (2009). “Environmental-friendly polyurethane synthesis using water as a solve.” Journal of Applied Polymer Science, 112(6), 3455-3462.
  4. Zhang, L., & Wang, X. (2015). “Development of green catalysts for polyurethane synthesis.” Green Chemistry, 17(10), 4567-4575.
  5. Li, Z., & Chen, J. (2018). “Biobased polyurethanes: Recent progress and future prospects.” Progress in Polymer Science, 80, 1-32.
  6. Smith, R. L., & Jones, M. (2012). “Microreactor technology for polyurethane synthesis.” Chemical Engineering Journal, 181-183, 104-111.
  7. Yang, F., & Liu, H. (2016). “High-solid-content polyurethane coatings: Challenges andopportunities.” Progress in Organic Coatings, 94, 1-12.
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