Amine-based Delayed-Action Catalysts (DACs) play a crucial role in the production of polyurethane foam. These catalysts can significantly improve the performance of foam products by controlling the reaction rate and foam formation process. In recent years, with the continuous increase in consumers’ requirements for furniture comfort, the application of amine foam delay catalysts has gradually expanded from the traditional industrial field to high-end furniture manufacturing. This article will discuss in detail the innovative applications of amine foam delay catalysts in improving furniture comfort, including their working principles, product parameters, application cases and future development trends. <\/p>\n
Worldwide, the furniture industry is undergoing unprecedented changes. Consumers no longer focus only on the appearance and function of furniture, but more on their comfort and health. According to the Global Furniture Market Report (2022), it is estimated that the global furniture market size will reach US$650 billion by 2027, of which the high-end furniture market is growing particularly rapidly. Consumer demand for furniture comfort has driven advances in materials science, especially the application of polyurethane foam. Polyurethane foam has become one of the first choice materials in modern furniture manufacturing due to its excellent resilience, breathability and durability. <\/p>\n
However, traditional polyurethane foam plastics have some problems in the production process, such as difficulty in precise control of reaction rates, uneven foam density, inconsistent surface hardness, etc. These problems not only affect the comfort of the furniture, but may also lead to unstable product quality. To solve these problems, amine foam delay catalysts emerged. Such catalysts provide finer control during foam foaming, thereby improving the quality and performance of the foam. <\/p>\n
The research on amine foam delay catalysts began in the 1980s and was mainly used in the production of foam plastics in the fields of car seats, mattresses, etc. With the continuous advancement of technology, the application scope of amine catalysts has gradually expanded, especially in furniture manufacturing, and significant progress has been made. Foreign scholars such as Bayer MaterialScience (now Covestro), BASF and other companies have conducted a lot of research in this field and developed a variety of highly efficient amine delay catalysts. Domestic, universities such as Tsinghua University and Beijing University of Chemical Technology have also conducted in-depth research in this field and achieved a series of important results. <\/p>\n
For example, Bayer MaterialScience proposes a tertiary amine-based delay catalyst in its patent document (US Patent 4,937,267,1990) that can effectively delay the reaction rate during foam foaming, thereby achieving a more uniform foam structure. Domestic scholars Zhang Wei and others (2019) successfully developed a delay catalyst suitable for soft polyurethane foam by introducing new amine compounds, which significantly improved the elasticity and comfort of the foam. <\/p>\n
To sum up, the application of amine foam delay catalysts in improving furniture comfort has broad prospects. This article will explore the application of this innovative technology from multiple perspectives, aiming to provide valuable reference for furniture manufacturers and researchers. <\/p>\n
The working principle of Amine-based Delayed-Action Catalysts (DACs) is to achieve precise control of foam structure and performance by adjusting the foaming reaction rate of polyurethane foam. Specifically, amine catalysts affect the foam formation process through chemical reactions with isocyanate and polyols. The following are the main mechanisms of action of amine foam delay catalysts:<\/p>\n
The core function of the amine foam delay catalyst is to inhibit the occurrence of the reaction in the early stage of foam foaming and start the reaction at a predetermined time point. This delay effect can be achieved by selecting different types of amine compounds. For example, tertiary amine catalysts can maintain a relatively stable chemical environment in the early stage of foaming due to their low reactivity, thereby delaying the start-up time of the reaction. Studies have shown that the delay effect of tertiary amine catalysts is closely related to their molecular structure, especially the number and position of amine groups have a significant impact on their reactivity. <\/p>\n
According to the study of Kolb et al. (2005), tertiary amine catalysts such as dimethylcyclohexylamine (DMCHA) and N,N-dimethylamine (DMAE) exhibit lower catalysis in the early stages of foam foaming active, but can quickly accelerate the reaction process in the later stage of the reaction. This “slow start, fast end” characteristic allows the foam to achieve ideal density and structure in a short time, thereby improving product uniformity and consistency. <\/p>\n
Amine foam delay catalysts can not only delay the start of the reaction, but also accurately control the reaction rate throughout the foaming process. By adjusting the type and dosage of the catalyst, fine control of the foam expansion speed and curing time can be achieved. This is especially important for the production of high-quality polyurethane foams, because too fast or too slow reactions will lead to uneven foam structure, which will affect the performance of the product. <\/p>\n
Tego AM Plus developed by BASF as an example, this amine-based delay catalyst can provide continuous catalytic action during foam foaming, ensuring stable and controllable reaction rate. Experimental results show that foam produced using Tego AM Plus has better pore distribution\ufffdHigher resilience can significantly improve the comfort of furniture. In addition, the catalyst can maintain good catalytic performance under low temperature environments and is suitable for various complex production processes. <\/p>\n
Another important role of amine foam retardation catalysts is to improve the microstructure of the foam. By delaying the reaction start-up and controlling the reaction rate, the catalyst can promote the uniform distribution of foam bubbles and reduce the phenomenon of bubble bursting and merging. This not only helps to increase the density and strength of the foam, but also enhances its breathability and softness, thereby enhancing the furniture experience. <\/p>\n
According to research by Beijing University of Chemical Technology (2018), foams produced using amine-based delay catalysts have a finer pore structure and a more uniform pore size distribution. Experimental results show that this optimized foam structure can effectively absorb impact forces, provide better support effects, and maintain good breathability, avoiding the feeling of stuffiness after long-term use. This is particularly important for furniture such as mattresses and sofas that require long-term load-bearing. <\/p>\n
Amine foam retardation catalysts can also improve the thermal and dimensional stability of the foam. During the foam foaming process, the catalyst reduces the occurrence of side reactions by adjusting the reaction rate and avoids the decomposition and shrinkage of the foam at high temperature. This is especially important for the production of furniture parts of large sizes or complex shapes, as these parts usually require processing and forming at higher temperatures. <\/p>\n
For example, the Baycat series catalysts developed by Covestro can maintain stable catalytic properties under high temperature conditions, ensuring that the foam does not deform or crack during processing. Experimental data show that foam produced using Baycat catalyst can still maintain good physical properties in high temperature environments above 100\u00b0C and is suitable for manufacturing high-end furniture. <\/p>\n
In addition to improving the quality and performance of the foam, amine foam delay catalysts also have good environmental protection and safety. Many new amine catalysts use low-volatile organic compounds (VOC) formulations to reduce the emission of harmful gases during production. In addition, some catalysts are biodegradable and meet the requirements of modern society for green materials. <\/p>\n
According to the EU REACH regulations (Registration, Evaluation, Authorization and Restriction of Chemicals), amine foam delay catalysts must meet strict environmental standards. In order to meet this challenge, domestic and foreign companies have launched new catalyst products that meet REACH requirements. For example, the Jeffcat series catalysts launched by Huntsman not only have excellent catalytic performance, but also comply with the requirements of REACH regulations and are widely used in high-end furniture manufacturing. <\/p>\n
Amine foam delay catalysts significantly improve the performance of polyurethane foam plastics through various mechanisms such as delaying reaction start-up, controlling reaction rate, improving foam structure, improving foam stability and environmental protection. These characteristics have made amine catalysts widely used in furniture manufacturing, especially in improving furniture comfort. Next, we will introduce in detail the product parameters of amine foam delay catalysts and their specific applications in furniture manufacturing. <\/p>\n
The performance and application effect of Amine-based Delayed-Action Catalysts (DACs) are closely related to their chemical composition, physical properties and process parameters. To better understand the characteristics of these catalysts, this section will introduce their main product parameters in detail and perform a comparison and analysis in a tabular form. The following are some common amine foam delay catalysts and their key parameters:<\/p>\n
The chemical composition of amine foam retardation catalysts determines its catalytic activity, reaction rate and retardation effect. According to the different amine groups, amine catalysts can be divided into tertiary amines, secondary amines and primary amines. Among them, tertiary amine catalysts are often used to delay reaction start due to their low reaction activity; secondary amine and primary amine catalysts have high catalytic activity and are suitable for rapid reaction and curing stages. <\/p>\n
Catalytic Type<\/strong><\/th>\n| Chemical Name<\/strong><\/th>\n | CAS number<\/strong><\/th>\n | Main Features<\/strong><\/th>\n<\/tr>\n\n | Term amines<\/td>\n | Dimethylcyclohexylamine (DMCHA)<\/td>\n | 101-85-6<\/td>\n | Low reactivity, good delay effect, suitable for soft foam<\/td>\n<\/tr>\n | Term amines<\/td>\n | N,N-dimethylamine (DMAE)<\/td>\n | 109-89-7<\/td>\n | Medium reactive activity, suitable for medium-density foam<\/td>\n<\/tr>\n | Second amines<\/td>\n | Dimethylamino (DMAEOL)<\/td>\n | 109-88-6<\/td>\n | High reactive activity, suitable for rapid curing<\/td>\n<\/tr>\n | Primary amines<\/td>\n | Triamine (TEOA)<\/td>\n | 102-71-6<\/td>\n | Extremely high reactivity, suitable for rigid foam<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n | 2. Physical properties<\/h4>\nThe physical properties of amine foam retardation catalysts, such as melting point, boiling point, density and solubility, directly affect their application effect in the production process. The following are the physical parameters of several common amine catalysts:<\/p>\n
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