Patent for recycling waste PU foam into moldable polymer

The patent covers a thermochemical recycling process that uses vitrimerization technology to transform post-consumer and industrial polyurethane foam waste into reusable materials. EGI is commercializing the technology through its subsidiary, VitriCycle.

Polyurethane foam has long posed a recycling challenge because it is a thermoset material that cannot simply be melted and remolded like thermoplastics. As a result, much of the foam recovered from discarded mattresses and furniture has historically been landfilled or used in low-value applications such as carpet underlay (rebond). While most advanced recycling methods have concentrated on returning the foam into the precursor chemicals of polyols and isocyanates.

The newly patented process converts waste foam into dense vitrimerized sheets and pellets that can be processed using conventional manufacturing equipment. According to VitriCycle, the technology can reduce foam volume by more than 90%, creating materials suitable for injection molding, thermoforming and sheet-based applications.

Products developed from the technology include KindHide, a leather-like material produced primarily from recycled polyurethane content and targeted at wallets, bags and accessories, as well as KindPrint printable sheets and molding compounds for consumer and industrial products.

"The foam industry is the largest user of polyurethane in the United States," said Victor Young, founder and chief executive officer of EGI. "Our patented technology creates a practical path to recycle these materials into valuable new products rather than sending them to landfills."

The company says the process was developed specifically to address the growing volume of polyurethane foam waste generated by the mattress, furniture and automotive sectors.

An independent evaluation commissioned by the Mattress Recycling Council concluded that VitriCycle's process transforms thermoset polyurethane mattress foam into processable vitrimerized materials that can be converted into pellets and customized for a variety of end uses. The report noted that the technology could create higher-value outlets for recovered mattress foam than many existing recycling routes.

For the polyurethane industry, the patent represents another step toward commercial-scale circularity for foam products. While chemical recycling technologies for polyurethane have attracted significant attention in recent years, one of the key challenges has been developing processes that can economically handle the large volumes of flexible foam entering the waste stream.

By creating materials suitable for consumer goods such as wallets and phone cases, VitriCycle is attempting to establish a higher-value destination for post-consumer foam while reducing reliance on virgin polyurethane feedstocks.

Photo: VitriCycle's KindHide material is produced from recycled polyurethane foam using the company's patented vitrimerization process. Credit: Vitricycle

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