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

Introduction

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

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

The basic properties and mechanism of SA603 catalyst

1. Product parameters

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

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

2. Mechanism of action

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

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

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

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

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

3. Progress in domestic and foreign research

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

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

Example of application of SA603 in building thermal insulation materials

1. Polyurethane hard bubble exterior wall insulation system

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

Case Background

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

Process flow

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

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

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

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

Application Effect

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

References

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

2. Polyurethane spray foam roof insulation system

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

Case Background

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

Process flow

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

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

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

Application Effect

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

References

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

3. Polyurethane composite insulation board

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

Case Background

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

Process flow

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

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

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

Application Effect

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

References

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

Summary and Outlook

1. Application prospects of SA603

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

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

2. Future research direction

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

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

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

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

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

3. Conclusion

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

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