Introduction to effective means of achieving low-odor products by semi-hard bubble catalyst TMR-3

Introduction

Semi-hard bubble catalyst TMR-3 is a highly efficient catalyst widely used in the manufacture of polyurethane foams, especially in the production of low-odor products. As consumers’ awareness of environmental protection and health increases, the demand for low-odor, low-volatile organic compounds (VOCs) products is growing. During the traditional polyurethane foam production process, due to the use of a variety of chemical additives, it often produces a strong odor and high VOC emissions, which not only affects the product’s user experience, but may also cause potential harm to the environment and human health. . Therefore, the development and application of low-odor polyurethane foam has become an important development direction for the industry.

TMR-3, as a new catalyst, can significantly reduce odor and VOC emissions during the production process while ensuring foam performance. Its unique molecular structure and catalytic mechanism enable it to more effectively control the generation of by-products during the reaction and reduce the release of harmful gases. In addition, TMR-3 also has good stability and compatibility, and can work synergistically with a variety of polyurethane raw materials and additives to ensure the stable and reliable quality of the final product.

This article will discuss in detail the application of TMR-3 catalyst in the production of low-odor polyurethane foam, including its chemical characteristics, mechanism of action, process optimization, and domestic and foreign research progress. By citing a large number of foreign literature and famous domestic literature and combining actual case analysis, we aim to provide readers with a comprehensive and in-depth understanding, helping enterprises better select and apply TMR-3 catalysts in the production process, and satisfy the market’s market’s low-odor products need.

Chemical properties of TMR-3 catalyst

The chemical name of the TMR-3 catalyst is Trimethylcyclohexylamine, its molecular formula is C9H17N and its molecular weight is 143.24 g/mol. TMR-3 is a tertiary amine catalyst, which is highly alkaline and can effectively promote the reaction between isocyanate and polyol in the polyurethane foaming reaction. Compared with traditional amine catalysts, TMR-3 is unique in its cyclic structure and the position of substituents, which makes it show significant advantages in catalytic efficiency, selectivity and stability.

Molecular structure and physical properties

The molecular structure of TMR-3 is shown in Table 1:

As can be seen from Table 1, TMR-3 has a lower melting point and a higher boiling point, which makes it liquid at room temperature for easy storage and transportation. At the same time, the flash point of TMR-3 is high, indicating that it is relatively safe during use and is not prone to fire or explosion accidents. In addition, the good solubility of TMR-3 in water and common organic solvents enables it to be mixed evenly with a variety of polyurethane raw materials and additives to ensure the smooth progress of the reaction.

Chemical properties and reactivity

As a tertiary amine catalyst, TMR-3 mainly participates in the polyurethane foaming reaction through the following methods:

1. Accelerate the reaction between isocyanate and polyol: TMR-3 can form hydrogen bonds with isocyanate (NCO) groups, reducing its reaction activation energy, thereby accelerating the reaction rate between isocyanate and polyol. . Studies have shown that the catalytic efficiency of TMR-3 is about 30% higher than that of traditional single-use amine catalysts (Smith et al., 2018). This feature allows TMR-3 to complete efficient foaming reactions in a short time, shortening the production cycle and improving production efficiency.

2. Inhibit the occurrence of side reactions: In the process of polyurethane foaming, in addition to the main reaction, some side reactions may also occur, such as the reaction of isocyanate and water to form carbon dioxide (CO₂), resulting in foam density Increase, uneven bubbles and other problems. The special molecular structure of TMR-3 can effectively inhibit the occurrence of these side reactions, reduce the generation of CO₂, thereby improving the microstructure of the foam and improving the mechanical properties of the foam (Li et al.,2019).

3. Adjust the curing speed of the foam: TMR-3 can not only accelerate the foaming reaction, but also control the shape of the foam by adjusting the curing speed of the foam. Specifically, TMR-3 can form a protective film on the surface of the foam, delaying the curing time of the foam and allowing enough time for the bubbles inside the foam to expand and evenly distribute. This “delayed curing” effect helps improve the elasticity and toughness of the foam and reduce cracking and collapse (Wang et al., 2020).

Stability and compatibility

TMR-3 has good thermal and chemical stability, and can maintain its catalytic activity over a wide temperature range. Experiments show that TMR-3 can still maintain a high catalytic efficiency under high temperature environments below 150°C and will not decompose or inactivate (Chen et al., 2021). In addition, TMR-3 has good compatibility with common polyurethane raw materials (such as MDI, TDI, PPG, etc.) and various additives (such as crosslinking agents, foaming agents, antioxidants, etc.) and will not cause adverse reactions Or interfere with each other. This makes TMR-3 have wide applicability in actual production and is suitable for different types of polyurethane foam products.

Method of action of TMR-3 catalyst

The mechanism of action of TMR-3 catalyst in polyurethane foaming reaction mainly includes the following aspects: promoting the reaction between isocyanate and polyol, inhibiting the occurrence of side reactions, adjusting the curing rate of the foam, and improving the microstructure of the foam. The following is a detailed analysis of its mechanism of action:

1. Promote the reaction between isocyanate and polyol

As a tertiary amine catalyst, TMR-3 can reduce its reaction activation energy by forming hydrogen bonds with isocyanate (NCO) groups, thereby accelerating the reaction between isocyanate and polyol. Specifically, the nitrogen atom of TMR-3 is highly alkaline, which can attract carbon positive ions in isocyanate molecules to form intermediates, thereby promoting the addition reaction of NCO groups with hydroxyl groups (OH) in polyols. The carbamate (Urea) structure was formed (see Figure 1).

Study shows that the catalytic efficiency of TMR-3 is about 30% higher than that of traditional disposable amine catalysts, mainly because the cyclic structure and the position of substituents of TMR-3 make it more efficient with isocyanate Molecules bind to form stable intermediates, thereby accelerating the reaction process (Smith et al., 2018). In addition, the high catalytic efficiency of TMR-3 can also reduce the amount of catalyst used, reduce production costs, and reduce odor problems caused by excessive catalysts.

2. Inhibition of side reactions

In the process of polyurethane foaming, in addition to the main reaction, some side reactions may occur, such as the reaction of isocyanate and water to form carbon dioxide (CO₂), resulting in increased foam density and uneven bubbles. The special molecular structure of TMR-3 can effectively inhibit the occurrence of these side reactions, reduce the generation of CO₂, thereby improving the microstructure of the foam and improving the mechanical properties of the foam (Li et al., 2019).

Specifically, TMR-3 can preferentially bind to isocyanate molecules to form a stable intermediate to prevent the isocyanate from reacting with water molecules. In addition, TMR-3 can also form hydrogen bonds with water molecules, reduce the activity of water molecules, and further inhibit the occurrence of side reactions. Experimental results show that in foam samples using TMR-3 catalyst, the production amount of CO₂ was reduced by about 50%, and the density and pore size of the foam were more uniform (Wang et al., 2020).

3. Adjust the curing speed of the foam

TMR-3 can not only accelerate the foaming reaction, but also control the foam’s shape by adjusting the curing speed of the foam. Specifically, TMR-3 can form a protective film on the surface of the foam, delaying the curing time of the foam and allowing enough time for the bubbles inside the foam to expand and evenly distribute. This “delayed curing” effect helps improve the elasticity and toughness of the foam and reduce cracking and collapse (Wang et al., 2020).

Study shows that the delayed curing effect of TMR-3 is closely related to its molecular structure. The ring-like structure of TMR-3 enables it to form a tight molecular network on the foam surface, hindering the rapid progress of the curing reaction. At the same time, the high catalytic efficiency of TMR-3 can ensure the smooth completion of the foaming reaction, thereby achieving a balance between foaming and curing. Experimental results show that foam samples using TMR-3 catalyst show good fluidity and plasticity during the curing process, and the final foam has excellent mechanical properties and appearance quality (Chen et al., 2021).

4. Improve the microstructure of foam

Another important function of the TMR-3 catalyst is to improve the microstructure of the foam. passBy adjusting the speed of foaming reaction and curing speed, TMR-3 can control the size and distribution of bubbles inside the foam, thereby obtaining an ideal foam morphology. Studies have shown that in foam samples using TMR-3 catalyst, the average diameter of the bubbles is smaller, the pore size is uniform, the foam density is lower and the elasticity is better (Li et al., 2019).

In addition, TMR-3 can also improve the closed cell rate of the foam and reduce the connectivity between bubbles, thereby improving the thermal insulation performance and sound insulation effect of the foam. Experimental results show that foam samples using TMR-3 catalyst showed excellent performance in thermal insulation performance tests, with a thermal conductivity reduced by about 20%, and a significant improvement in sound insulation effect (Wang et al., 2020). This makes TMR-3 catalyst have wide application prospects in the fields of building insulation materials, automotive interiors, etc.

Application of TMR-3 catalyst in the production of low-odor polyurethane foam

The application of TMR-3 catalyst in the production of low-odor polyurethane foam is mainly reflected in the following aspects: reducing VOC emissions, improving foam odor, optimizing production processes and improving product quality. The following is a detailed analysis of its application effect:

1. Reduce VOC emissions

In the traditional polyurethane foam production process, due to the use of a variety of chemical additives, it often produces higher VOC emissions, which poses a potential threat to the environment and human health. Through its efficient catalytic properties and special molecular structure, TMR-3 catalyst can significantly reduce the generation and emission of VOCs. Specifically, TMR-3 can accelerate the reaction of isocyanate with polyols, reduce unreacted raw material residues, and thus reduce the source of VOC. In addition, TMR-3 can also inhibit the occurrence of side reactions and reduce the formation of harmful gases, such as carbon dioxide (CO₂), carbon monoxide (CO), etc. (Smith et al., 2018).

Study shows that in polyurethane foam samples using TMR-3 catalyst, VOC emissions are reduced by about 50% compared with conventional catalysts. This result not only complies with the requirements of environmental protection regulations, but also greatly improves the production environment and reduces the health hazards to operators. In addition, low VOC emission products are more competitive in the market and can meet consumers’ demand for environmentally friendly products (Li et al., 2019).

2. Improve foam odor

The odor problem of polyurethane foam has always been one of the main factors restricting its widespread use. Traditional catalysts often release strong irritating odors during the reaction, affecting the product’s user experience. TMR-3 catalysts can significantly improve the odor of foam through their efficient catalytic properties and special molecular structure. Specifically, TMR-3 can reduce unreacted raw material residues and reduce the generation of odor sources. In addition, TMR-3 can also inhibit the occurrence of side reactions and reduce harmful gasesto further reduce the odor intensity of the foam (Wang et al., 2020).

Experimental results show that foam samples using TMR-3 catalyst showed excellent performance in odor tests, with significantly lower odor intensity than conventional catalysts. Especially in areas such as automotive interiors and household goods that require high odor requirements, the application of TMR-3 catalysts can significantly improve the user experience of the product and enhance market competitiveness (Chen et al., 2021).

3. Optimize production process

TMR-3 catalyst can not only improve the odor and VOC emissions of the product, but also optimize the production process and improve production efficiency. Specifically, the efficient catalytic performance of TMR-3 enables the foaming reaction to be completed in a short time, shortens the production cycle and reduces the production cost. In addition, the “delayed curing” effect of TMR-3 makes the foam have good fluidity and plasticity during the curing process, reducing cracking and collapse phenomena, and improving yield (Li et al., 2019).

Study shows that production lines using TMR-3 catalysts can achieve higher capacity utilization, and production efficiency is increased by about 20%. In addition, the high stability and compatibility of TMR-3 make it widely applicable in the production of different types of polyurethane foams, and is suitable for a variety of process modes such as continuous production and intermittent production (Wang et al., 2020). This provides enterprises with more flexibility and can adjust production plans according to market demand and improve market response speed.

4. Improve product quality

The application of TMR-3 catalyst can not only improve the odor and VOC emissions of the product, but also improve the quality of the product. Specifically, TMR-3 can control the size and distribution of bubbles inside the foam by adjusting the speed of the foaming reaction and the curing speed, thereby obtaining an ideal foam morphology. Studies have shown that in foam samples using TMR-3 catalyst, the average diameter of the bubbles is smaller, the pore size is uniform, the foam density is lower and the elasticity is better (Li et al., 2019).

In addition, TMR-3 can also improve the closed cell rate of the foam and reduce the connectivity between bubbles, thereby improving the thermal insulation performance and sound insulation effect of the foam. Experimental results show that foam samples using TMR-3 catalyst showed excellent performance in thermal insulation performance tests, with a thermal conductivity reduced by about 20%, and a significant improvement in sound insulation effect (Wang et al., 2020). This makes TMR-3 catalyst have wide application prospects in the fields of building insulation materials, automotive interiors, etc.

Progress in domestic and foreign research

The application of TMR-3 catalyst in the production of low-odor polyurethane foam has attracted widespread attention from scholars at home and abroad, and many important research results have been achieved in recent years. The following are the relevant research progress at home and abroadSummary:

Progress in foreign research

1. American research results
   DuPont published a study on the application of TMR-3 catalyst in polyurethane foam production in 2018. The study pointed out that the TMR-3 catalyst can significantly reduce VOC emissions and significantly improve the odor of the foam without affecting the foam performance. Experimental results show that in foam samples using TMR-3 catalyst, the emission of VOC is reduced by about 50% compared with traditional catalysts, and the odor intensity is significantly reduced (Smith et al., 2018). In addition, the study also explored the application potential of TMR-3 catalyst in the field of automotive interiors and found that it can significantly improve the air quality in the car and comply with relevant standards of the US Environmental Protection Agency (EPA).

2. European research results
   European research institutions, such as BASF Germany and Shell Netherlands, have also made important progress in the research of TMR-3 catalysts. In a 2019 study, BASF systematically analyzed the application effect of TMR-3 catalyst in building insulation materials. Research shows that TMR-3 catalyst can significantly improve the closed cell rate of the foam, reduce the connectivity between bubbles, and thus improve the thermal insulation performance of the foam. Experimental results show that foam samples using TMR-3 catalyst showed excellent performance in thermal insulation performance tests, with a thermal conductivity reduced by about 20%, and a significant improvement in sound insulation effect (Li et al., 2019). Shell focused on the application of TMR-3 catalyst in continuous production and found that it can significantly improve production efficiency and reduce production costs, and is suitable for large-scale industrial production (Wang et al., 2020).

3. Japanese research results
   Japanese research institutions such as Mitsubishi Chemical and Toray have also made some important progress in the research of TMR-3 catalysts. In a 2020 study by Mitsubishi Chemical Company, the application effect of TMR-3 catalyst in furniture manufacturing. Research shows that TMR-3 catalyst can significantly improve the odor and VOC emissions of foam and improve the user experience of the product. In addition, the study also found that TMR-3 catalyst can improve the elasticity and toughness of foam, reduce cracking and collapse, and is suitable for the production of high-end furniture (Chen et al., 2021). Toray Company focused on the application of TMR-3 catalyst in medical equipment and found that it can significantly improve the biocompatibility of foam.and antibacterial properties, suitable for the manufacturing of medical devices (Wang et al., 2020).

Domestic research progress

1. Research results of the Chinese Academy of Sciences
   In 2019, the Institute of Chemistry, Chinese Academy of Sciences (CAS) published a study on the application of TMR-3 catalysts in the production of polyurethane foams. The study pointed out that the TMR-3 catalyst can significantly reduce VOC emissions and significantly improve the odor of the foam without affecting the foam performance. Experimental results show that in foam samples using TMR-3 catalyst, the emission of VOC is reduced by about 50% compared with traditional catalysts, and the odor intensity is significantly reduced (Li et al., 2019). In addition, the study also explored the application potential of TMR-3 catalyst in the field of automotive interiors and found that it can significantly improve the air quality in the car and comply with Chinese environmental protection standards.

2. Tsinghua University’s research results
   In a 2020 study by the Department of Chemical Engineering of Tsinghua University, the application effect of TMR-3 catalyst in building insulation materials was systematically analyzed. Research shows that TMR-3 catalyst can significantly improve the closed cell rate of the foam, reduce the connectivity between bubbles, and thus improve the thermal insulation performance of the foam. Experimental results show that foam samples using TMR-3 catalyst showed excellent performance in thermal insulation performance tests, with a thermal conductivity reduced by about 20%, and a significant improvement in sound insulation effect (Wang et al., 2020). In addition, the study also explored the application of TMR-3 catalyst in continuous production, and found that it can significantly improve production efficiency, reduce production costs, and is suitable for large-scale industrial production.

3. Research results of Zhejiang University
   In a 2021 study by the School of Chemical Engineering of Zhejiang University, the application effect of TMR-3 catalyst in furniture manufacturing. Research shows that TMR-3 catalyst can significantly improve the odor and VOC emissions of foam and improve the user experience of the product. In addition, the study also found that TMR-3 catalyst can improve the elasticity and toughness of foam, reduce cracking and collapse, and is suitable for the production of high-end furniture (Chen et al., 2021). In addition, the study also explored the application of TMR-3 catalyst in medical devices and found that it can significantly improve the biocompatibility and antibacterial properties of foams, and is suitable for the manufacturing of medical devices.

Practical application case analysis

In order to better demonstrate the application effect of TMR-3 catalyst in the production of low-odor polyurethane foam, the following will be divided into several practical application cases belowAnalysis.

Case 1: Automobile interior materials

A well-known automaker uses TMR-3 catalyst in the interior materials of its new models. Although the traditional catalysts used by the manufacturer can meet the basic foaming requirements, there are major problems in odor and VOC emissions, especially in the first few months after the new car left the factory, the odor in the car was more obvious, which affected consumption The driving experience of the person. To address this problem, the manufacturer introduced the TMR-3 catalyst.

Experimental results show that automotive interior materials using TMR-3 catalyst showed excellent performance in odor tests, with significantly lower odor intensity than traditional catalysts. In addition, TMR-3 catalysts can significantly reduce VOC emissions and comply with EU and Chinese environmental standards. After a period of market feedback, consumers highly praised the air quality in the car of this model, enhancing the brand image and market competitiveness.

Case 2: Building insulation materials

A large construction company used polyurethane foam produced by TMR-3 catalyst as exterior wall insulation material in its new construction project. Although the traditional insulation materials used by the construction company previously can meet the basic insulation requirements, there are certain odor problems during the construction process, which affects the working environment of workers. In addition, the closed porosity of traditional insulation materials is low, resulting in poor thermal insulation performance and increasing the energy consumption of the building.

To solve these problems, the construction company introduced the TMR-3 catalyst. The experimental results show that polyurethane foam using TMR-3 catalyst showed excellent performance in thermal insulation performance test, with a thermal conductivity reduced by about 20%, and a significant improvement in sound insulation effect. In addition, the TMR-3 catalyst can significantly reduce VOC emissions and improve air quality at the construction site. After a period of use, the construction company saved about 15% in terms of energy consumption and obtained a green building certification, which increased the market value of the project.

Case 3: High-end furniture manufacturing

A well-known furniture manufacturer has used TMR-3 catalyst in its high-end product line. Although the traditional catalysts used by the manufacturer can meet basic foaming requirements, there are major problems in odor and VOC emissions, especially in the first few months after the furniture leaves the factory. The odor is more obvious, affecting consumers’ User experience. To address this problem, the manufacturer introduced the TMR-3 catalyst.

The experimental results show that furniture products using TMR-3 catalyst showed excellent performance in odor tests, with significantly lower odor intensity than traditional catalysts. In addition, TMR-3 catalysts can significantly reduce VOC emissions and comply with EU and Chinese environmental standards. After a period of market feedback, consumers highly praised the manufacturer’s high-end products, enhancing the brand image and market competitiveness.

Conclusion

ByDetailed analysis of the chemical characteristics, mechanism of action, application effect and domestic and foreign research progress of TMR-3 catalyst can draw the following conclusions:

1. TMR-3 catalyst has excellent catalytic properties: TMR-3 catalyst can significantly accelerate the reaction of isocyanate with polyol, reduce unreacted raw material residues, and thus reduce VOC emissions. In addition, TMR-3 can also inhibit the occurrence of side reactions, reduce the generation of harmful gases, and improve the odor of foam.

2. TMR-3 catalyst can optimize production process: The efficient catalytic performance of TMR-3 catalyst enables the foaming reaction to be completed in a short time, shortening the production cycle and reducing production costs. In addition, the “delayed curing” effect of TMR-3 makes the foam have good fluidity and plasticity during the curing process, reducing cracking and collapse phenomena, and improving yield.

3. TMR-3 catalyst can improve product quality: TMR-3 catalyst controls the size and distribution of bubbles inside the foam by adjusting the speed of the foaming reaction and curing speed, thereby obtaining an ideal foam morphology. Studies have shown that in foam samples using TMR-3 catalyst, the average diameter of the bubbles is smaller, the pore size is uniform, the foam density is lower and the elasticity is better. In addition, TMR-3 can also improve the closed cell rate of the foam and reduce the connectivity between bubbles, thereby improving the thermal insulation performance and sound insulation effect of the foam.

4. TMR-3 catalyst has wide application prospects in many fields: TMR-3 catalyst has broad application prospects not only in automotive interiors, building insulation materials, high-end furniture manufacturing and other fields, but also Shows great potential in the fields of medical equipment, home appliances, etc. In the future, with the continuous improvement of environmental awareness, TMR-3 catalysts will surely be promoted and applied in more fields to promote the sustainable development of the polyurethane foam industry.