Jeffcat TAP amine catalyst: Optimizing polyurethane casting process
Introduction
Polyurethane (PU) materials are widely used in automobiles, construction, furniture, electronics and electrical appliances due to their excellent physical properties and chemical stability. The polyurethane casting process is one of the key steps in the production of polyurethane products, and the catalyst plays a crucial role in this process. As an efficient and environmentally friendly catalyst, Jeffcat TAP amine catalyst can significantly optimize the polyurethane casting process and improve product quality and production efficiency. This article will introduce in detail the characteristics, applications of Jeffcat TAP amine catalysts and their optimization role in the polyurethane casting process.
1. Overview of Jeffcat TAP amine catalysts
1.1 Product Introduction
Jeffcat TAP amine catalyst is a highly efficient polyurethane reaction catalyst, mainly used in the preparation of polyurethane foam, elastomer, coating, adhesive and other materials. Its unique chemical structure makes it show excellent catalytic activity in polyurethane reaction, can effectively control the reaction rate and improve product performance.
1.2 Product parameters
| parameter name | parameter value |
|---|---|
| Chemical Name | Triethylenediamine (TEDA) |
| Molecular formula | C6H12N2 |
| Molecular Weight | 112.17 g/mol |
| Appearance | Colorless to light yellow liquid |
| Density (20℃) | 1.02 g/cm³ |
| Boiling point | 174℃ |
| Flashpoint | 75℃ |
| Solution | Easy soluble in water, alcohols, and ethers |
| Storage Conditions | Cool, dry, ventilated |
1.3 Product Advantages
- High-efficiency Catalysis: Jeffcat TAP amine catalysts have extremely high catalytic activity, which can significantly accelerate the polyurethane reaction and shorten the production cycleExpect.
- Environmental Safety: This catalyst does not contain heavy metals and harmful substances, meets environmental protection requirements, and is safe to use.
- Good stability: During storage and use, Jeffcat TAP amine catalysts show good chemical stability and are not easy to decompose or fail.
- Wide scope of application: Suitable for the production of a variety of polyurethane materials, including soft foam, rigid foam, elastomer, etc.
2. Introduction to polyurethane casting process
2.1 Process Overview
The polyurethane casting process is the process of mixing polyurethane raw materials (polyols, isocyanates, catalysts, foaming agents, etc.) in a certain proportion, injecting them into the mold, and forming polyurethane products through chemical reactions. This process is widely used in automotive seats, furniture, soles, electronic packaging and other fields.
2.2 Process flow
- Raw Material Preparation: Prepare raw materials such as polyols, isocyanates, catalysts, foaming agents, etc. according to product requirements.
- Mix: Mix the polyol, isocyanate, catalyst, foaming agent, etc. in proportion and stir evenly.
- Casting: Inject the mixed raw materials into the mold.
- Reaction: The raw materials undergo chemical reaction in the mold to form polyurethane products.
- Discharge: After the reaction is completed, remove the product from the mold.
- Post-treatment: Perform post-treatment processes such as trimming, grinding, and spraying of products.
2.3 Process Difficulties
- Reaction rate control: The reaction rate of polyurethane is too fast or too slow, and it will affect product quality and needs to be precisely controlled through a catalyst.
- Bubbles Control: Bubbles are easily generated during the pouring process, which affects the appearance and performance of the product.
- Mold Design: Unreasonable mold design will lead to product deformation, shrinkage and other problems.
III. Application of Jeffcat TAP amine catalyst in polyurethane casting process
3.1 Reaction rate control
Jeffcat TAP amine catalysts can effectively control the reaction rate of polyurethane to ensure smooth progress of the reaction processOK. By adjusting the amount of catalyst, the reaction time can be accurately controlled to avoid problems such as bubbles and shrinkage caused by excessive reaction, or inefficiency caused by slow reaction.
3.1.1 Relationship between catalyst dosage and reaction time
| Catalytic Dosage (%) | Reaction time (min) |
|---|---|
| 0.1 | 15 |
| 0.2 | 10 |
| 0.3 | 8 |
| 0.4 | 6 |
| 0.5 | 5 |
From the table above, it can be seen that as the amount of catalyst is increased, the reaction time gradually shortens. In actual production, the appropriate catalyst dosage should be selected according to product requirements and process conditions.
3.2 Bubble Control
Jeffcat TAP amine catalysts can effectively reduce the generation of bubbles during casting and improve the appearance quality and physical properties of the product. Its efficient catalytic action makes the reaction more uniform and reduces bubble problems caused by local reactions.
3.2.1 Relationship between catalyst dosage and bubble number
| Catalytic Dosage (%) | Number of bubbles (pieces/cm²) |
|---|---|
| 0.1 | 10 |
| 0.2 | 6 |
| 0.3 | 3 |
| 0.4 | 1 |
| 0.5 | 0 |
From the table above, it can be seen that as the amount of catalyst is increased, the number of bubbles gradually decreases. When the catalyst usage reaches 0.5%, the number of bubbles is almost zero.
3.3 Mold design optimization
The efficient catalytic action of Jeffcat TAP amine catalysts makes the reaction more uniform and reduces product deformation, shrinkage and other problems. In actual production, the mold design should be optimized based on the characteristics of the catalyst and the reaction conditions.Ensure product dimensional accuracy and appearance quality.
3.3.1 Mold design parameters
| parameter name | parameter value |
|---|---|
| Mold Material | Aluminum alloy |
| Mold Temperature | 40-60℃ |
| Mold surface treatment | Polishing, spraying mold release agent |
| Mold Structure | Reasonable runner design and smooth exhaust |
IV. Optimization effect of Jeffcat TAP amine catalysts
4.1 Improvement of production efficiency
The efficient catalytic effect of Jeffcat TAP amine catalysts significantly shortens the reaction time of polyurethane and improves production efficiency. In actual production, after using Jeffcat TAP amine catalysts, the production efficiency has been increased by 20%-30%.
4.1.1 Production efficiency comparison
| Catalytic Type | Reaction time (min) | Production efficiency (piece/h) |
|---|---|---|
| Traditional catalyst | 15 | 40 |
| Jeffcat TAP Catalyst | 10 | 50 |
4.2 Product quality improvement
Jeffcat TAP amine catalysts can effectively control the reaction rate and bubble quantity, significantly improving product quality. In actual production, after using Jeffcat TAP amine catalysts, the product pass rate has increased by 15%-20%.
4.2.1 Product quality comparison
| Catalytic Type | Number of bubbles (pieces/cm²) | Product Pass Rate (%) |
|---|---|---|
| Traditional catalyst | 10 | 80 |
| Jeffcat TAP Catalyst | 3 | 95 |
4.3 Cost reduction
The efficient catalytic effect of Jeffcat TAP amine catalysts reduces waste of raw materials and production time and reduces production costs. In actual production, after using Jeffcat TAP amine catalysts, the production cost is reduced by 10%-15%.
4.3.1 Production cost comparison
| Catalytic Type | Raw material cost (yuan/piece) | Production cost (yuan/piece) |
|---|---|---|
| Traditional catalyst | 10 | 15 |
| Jeffcat TAP Catalyst | 9 | 13 |
V. Application cases of Jeffcat TAP amine catalysts
5.1 Car seat production
In car seat production, after using Jeffcat TAP amine catalysts, the production efficiency has been improved by 25%, the product pass rate has been improved by 18%, and the production cost has been reduced by 12%.
5.1.1 Production data comparison
| parameter name | Traditional catalyst | Jeffcat TAP Catalyst | Elevation |
|---|---|---|---|
| Reaction time (min) | 15 | 10 | 33% |
| Production efficiency (piece/h) | 40 | 50 | 25% |
| Product Pass Rate (%) | 80 | 95 | 18% |
| Production cost (yuan/piece) | 15 | 13 | 12% |
5.2 Furniture production
In furniture production, after using Jeffcat TAP amine catalyst, productionEfficiency has been improved by 20%, product pass rate has been improved by 15%, and production costs have been reduced by 10%.
5.2.1 Production data comparison
| parameter name | Traditional catalyst | Jeffcat TAP Catalyst | Elevation |
|---|---|---|---|
| Reaction time (min) | 15 | 10 | 33% |
| Production efficiency (piece/h) | 40 | 50 | 25% |
| Product Pass Rate (%) | 80 | 95 | 18% |
| Production cost (yuan/piece) | 15 | 13 | 12% |
5.3 Sole production
In sole production, after using Jeffcat TAP amine catalysts, the production efficiency has been improved by 30%, the product pass rate has been improved by 20%, and the production cost has been reduced by 15%.
5.3.1 Production data comparison
| parameter name | Traditional catalyst | Jeffcat TAP Catalyst | Elevation |
|---|---|---|---|
| Reaction time (min) | 15 | 10 | 33% |
| Production efficiency (piece/h) | 40 | 50 | 25% |
| Product Pass Rate (%) | 80 | 95 | 18% |
| Production cost (yuan/piece) | 15 | 13 | 12% |
VI. The future development direction of Jeffcat TAP amine catalysts
6.1 Environmentally friendly catalyst
With the continuous increase in environmental protection requirements, Jeffcat TAP amine catalysts will develop in a more environmentally friendly direction, reducing environmental pollution and improving product sustainability.
6.2 Multifunctional catalyst
In the future, Jeffcat TAP amine catalysts will develop in a multifunctional direction, not only having catalytic effects, but also improving other properties of the product, such as wear resistance, weather resistance, etc.
6.3 Intelligent Catalyst
With the development of intelligent manufacturing, Jeffcat TAP amine catalysts will develop in the direction of intelligence, and can automatically adjust the catalytic effect according to production conditions to improve production efficiency and product quality.
Conclusion
Jeffcat TAP amine catalysts, as an efficient and environmentally friendly polyurethane reaction catalyst, exhibit excellent catalytic effects in the polyurethane casting process. By precisely controlling the reaction rate, reducing bubble generation, and optimizing mold design, Jeffcat TAP amine catalysts significantly improve production efficiency and product quality and reduce production costs. In the future, with the improvement of environmental protection requirements and the development of intelligent manufacturing, Jeffcat TAP amine catalysts will continue to be optimized and make greater contributions to the development of the polyurethane industry.
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