Construction of a Highly Stable Water-Based Release Agent via 1:1 Silicone Oil-Cyclotetrasiloxane Synergy

This study develops a high-performance water-based mold release agent for polyurethane (PU) foaming applications. We demonstrate that incorporating octamethylcyclotetrasiloxane (D4) into a dimethyl silicone oil emulsion (5 vol% fixed concentration) significantly enhances key performance metrics. By systematically varying D4 content (0-15 vol%), we characterize droplet morphology, particle size distribution, contact angle, and viscosity to elucidate the underlying enhancement mechanism. Our findings reveal the following: (i) Optimal emulsion stability: At 5 vol% D4, the mold release agent exhibits a narrow particle size distribution (6-9 μm). (ii) Efficient processing: Film formation completes within 10 min, reducing demolding force and yielding PU foam with defect-free, non-adherent surfaces. (iii) Storage stability: After 60 days in ambient conditions, performance remains unchanged, with no phase separation observed under thermal stress (60 °C) or refrigeration (2-6 °C). This work explores an alternative pathway to mitigate key limitations-slow film formation and poor shelf-life-offering a prototype for next-generation release agents.