Polyurethane Recycling and Disposal: Methods and Prospects

Recent Advances in Environment-Friendly Polyurethanes from Polyols Recovered from the Recycling and Renewable Resources: A Review

Polyurethane (PU) is among the most universal polymers and has been extensively applied in many fields, such as construction, machinery, furniture, clothing, textile, packaging and biomedicine. Traditionally, as the main starting materials for PU, polyols deeply depend on petroleum stock. From the perspective of recycling and environmental friendliness, advanced PU synthesis, using diversified resources as feedstocks, aims to develop versatile products with excellent properties to achieve the transformation from a fossil fuel-driven energy economy to renewable and sustainable ones. This review focuses on the recent development in the synthesis and modification of PU by extracting value-added monomers for polyols from waste polymers and natural bio-based polymers, such as the recycled waste polymers: polyethylene terephthalate (PET), PU and polycarbonate (PC); the biomaterials: vegetable oil, lignin, cashew nut shell liquid and plant straw; and biomacromolecules: polysaccharides and protein. To design these advanced polyurethane formulations, it is essential to understand the structure-property relationships of PU from recycling polyols. In a word, this bottom-up path provides a material recycling approach to PU design for printing and packaging, as well as biomedical, building and wearable electronics applications.

Biodegradation of polyurethanes by Staphylococcus warneri and by microbial co-culture

With the increasing production and use of polyurethanes (PUs), it is necessary to develop sustainable techniques for the remediation of plastic pollution. The use of microorganisms capable of biodegrading PUs may be an environmentally desirable solution for controlling these plastic contaminants. To contribute to the discovery of alternatives for the mitigation of plastics in the environment, this study aimed to explore the potential of StaphylococcuswarneriUFV_01.21, isolated from the gut of Galleria mellonellalarvae, for biodegradation of PU in pure culture and microbial co-culture with Serratia liquefaciensL135. S. warneri grew using Impranil® PU as the sole carbon source in pure culture and co-culture. With six days of incubation, the biodegradation of Impranil® in Luria Bertani broth was 96, 88 and 76%, while in minimal medium, it was 58, 54 and 42% for S. warneri, S. liquefaciens, and co-culture, respectively. In addition, S. warneri in pure culture or co-culture was able to biodegrade, adhere and form biofilms on the surfaces of Impranil® disks and poly[4,4'-methylenebis (phenyl isocyanate)-alt-1,4-butanediol/di(propylene glycol)/polycaprolactone] (PCLMDI) films. Scanning electron microscopy also revealed biodegradation by detecting the formation of cracks, furrows, pores, and roughness on the surfaces of inoculated PU, both with pure culture and microbial co-culture. This study is the first to demonstrate the potential of S. warneriin PU biodegradation.

Polyurethane degradation by extracellular urethanase producing bacterial isolate Moraxella catarrhalis strain BMPPS3

Plastic waste has become a global issue and a threat to the ecosystem. The present study isolated polyurethane (PU) degrading bacterial species from soil dumped with plastic wastes. Four bacterial isolates, RS1, RS6, RS9 and RS13 were obtained and their ability to degrade PU in a synthetic medium with PU as a sole source of carbon was assessed individually. After thirty days of incubation, the highest PU weight loss of 67.36 ± 0.32% was recorded in the medium containing RS13 isolate. The results of FTIR revealed the occurrence of carbonyl peaks. The putative isolate RS13 confirmed with the genus Moraxella according to 16S rRNA gene sequencing and the isolate was specified as Moraxella catarrhalis strain BMPPS3. The restriction analysis of Moraxella catarrhalis strain BMPPS3 revealed that the GCAT content to 51% and 49% correspondingly. Moraxella catarrhalis strain BMPPS3 was able to colonize on PU surface and form a biofilm as revealed by SEM investigation. Fatty acids and alkanes were found to be the degradation products by GC-MS analysis. The presence of these metabolites facilitated the growth of strain RS13 and suggested that ester hydrolysis products had been mineralized into CO2 and H2O. Extracellular biosurfactant synthesis has also been found in Moraxella catarrhalis strain BMPPS13 inoculated with synthetic media and mineral salt media containing PU and glucose as carbon sources, respectively with a significant level of cell-surface hydrophobicity (32%). The production and activity of extracellular esterase showed consistent increase from day 1-15 which peaked (1.029 mM/min/mg) on day 24 significantly at P < 0.001. Crude biosurfactants were lipopeptide-based, according to the characteristic investigation. According to this study findings, Moraxella catarrhalis produces biosurfactants of the esterase, urethanase and lipase (lipopeptide) types when carbon source PU is present.

Investigation of bio-based rigid polyurethane foams synthesized with lignin and castor oil

In this study, polyurethane (PU) foams were manufactured using kraft lignin and castor oil as bio-based polyols by replacing 5-20 wt% and 10-100 wt% of conventional polyol, respectively. To investigate the effects of unmodified bio-based polyols on PU foam production, reactivity and morphology within PU composites was analyzed as well as mechanical and thermal properties of the resulting foams. Bio-based PU foam production was carried out after characterizing the reagents used in the foaming process (including hydroxyl group content, molecular weight distribution, and viscosity). To compare the resulting bio-based PU foams, control foam were produced without any bio-based polyol under the same experimental conditions. For lignin-incorporated PU foams, two types, LPU and lpu, were manufactured with index ratio of 1.01 and 1.3, respectively. The compressive strength of LPU foams increased with lignin content from 5 wt% (LPU5: 147 kPa) to 20 wt% (LPU20: 207 kPa), although it remained lower than that of the control foam (PU0: 326 kPa). Similarly, the compressive strength of lpu foams was lower than that of the control foam (pu0: 441 kPa), with values of 164 kPa (lpu5), 163 kPa (lpu10), 167 kPa (lpu15), and 147 kPa (lpu20). At 10 wt% lignin content, both foams (LPU10 and lpu10) exhibited the smallest and most homogenous pore sizes and structures. For castor oil-incorporated PU foams with an index of 1.01, denoted as CPU, increasing castor oil content resulted in larger cell sizes and void fractions, transitioning to an open-cell structure and decreasing the compressive strength of the foams from 284 kPa (CPU10) to 23 kPa (CPU100). Fourier transform infrared (FT-IR) results indicated the formation of characteristic urethane linkages in PU foams and confirmed that bio-based polyols were less reactive with isocyanate compared to traditional polyol. Thermogravimetric analysis (TGA) showed that incorporating lignin and castor oil affected the thermal decomposition behavior. The thermal stability of lignin-incorporated PU foams improved as the lignin content increased with char yields increasing from 11.5 wt% (LPU5) to 15.8 wt% (LPU20) and from 12.4 wt% (lpu5) to 17.5 wt% (lpu20). Conversely, the addition of castor oil resulted in decreased thermal stability, with char yields decreasing from 10.6 wt% (CPU10) to 4.2 wt% (CPU100). This research provides a comprehensive understanding of PU foams incorporating unmodified biomass-derived polyols (lignin and castor oil), suggesting their potential for value-added utilization as bio-based products.

Mechanochemical Recycling of Flexible Polyurethane Foam Scraps for Quantitative Replacement of Polyol Using Wedge-Block-Reinforced Extruder

Recycling flexible polyurethane foam (F-PUF) scraps is difficult due to the material's high cross-linking structure. In this work, a wedge-block-reinforced extruder with a considerable enhanced shear extrusion and stretching area between the rotating screw and the stationary wedge blocks was utilized to recycle F-PUF scraps into powder containing surface-active hydroxyl groups. The powder was then utilized for the quantitative replacement of polyol in the foaming process. Characterizations showed that the continuous shear extrusion and stretching during the extrusion process reduced the volume mean diameter (VMD) of the F-PUF powder obtained by extruding it three times at room temperature to reach 54 μm. The -OH number (OHN) of the powder prepared by extruding it three times reached 19.51 mgKOH/g due to the mechanochemical effect of the powdering method. The F-PUF containing recycled powder used to quantitively replace 10 wt.% polyol was similar in microstructure and chemical structure to the original F-PUF, with a compression set of 2%, indentation load deflection of 21.3 lbf, resilience of 43.4%, air permeability of 815.7 L/m2·s, tensile strength of 73.0 Kpa, and tear strength of 2.3 N/cm, indicating that the recycling method has potential for industrial applications.

Eco-Friendly and High-Performance Bio-Polyurethane Adhesives from Vegetable Oils: A Review

Current petrochemical-based adhesives adversely affect the environment through substantial volatile organic compound (VOC) emissions during production, contributing to air pollution and climate change. In contrast, vegetable oils extracted from bio-resources provide a compelling alternative owing to their renewability, abundance, and compatibility with adhesive formulation chemistry. This review aimed to critically examine and synthesize the existing scholarly literature on environmentally friendly, sustainable, and high-performance polyurethane adhesives (PUAs) developed from vegetable oils. The use of PUAs derived from vegetable oils promises to provide a long-term replacement while simultaneously maintaining or improving adhesive properties. This quality renders these adhesives appropriate for widespread use in various sectors, including construction, automotive manufacturing, packaging, textile, and footwear industries. This review intended to perform a comprehensive assessment and integration of the existing research, thereby identifying the raw materials, strengths, weaknesses, and gaps in knowledge concerning vegetable oil-based PUAs. In doing so, it responded to these gaps and proposes potential avenues for future research. Therefore, this review accomplishes more than merely evaluating the existing research; it fosters the advancement of greener PUA technologies by identifying areas for improvement and innovation towards more sustainable industrial practices by showcasing vegetable oil-based PUAs as viable, high-performance alternatives to their petroleum-based counterparts.

Complete genome sequencing of Hortaea werneckii M-3 for identifying polyester polyurethane degrading enzymes

Hortaea werneckii M-3, a black yeast isolated from the marine sediment of the West Pacific, can utilize polyester polyurethane (PU, Impranil DLN) as a sole carbon source. Here, we present the complete genome of Hortaea werneckii M-3 with the focus on PU degradation enzymes. The total genome size is 38,167,921 bp, consisting of 186 contigs with a N50 length of 651,266 bp and a GC content of 53.06%. Genome annotation analysis predicts a total of 13,462 coding genes, which include 99 tRNAs and 105 rRNAs. Some genes encoding PU degrading enzymes including cutinase and urease are identified in this genome. The genome analysis of Hortaea werneckii M-3 will be helpful for further understanding the degradation mechanism of polyester PU by marine yeasts.

Scleroglucan-Based Foam Incorporating Recycled Rigid Polyurethane Waste for Novel Insulation Material Production

This study details the synthesis and performance evaluation of a novel lightweight thermal and acoustic insulation material, resulting from the combination of a scleroglucan-based hydrogel and recycled rigid polyurethane waste powder. Through a sublimation-driven water-removal process, a porous three-dimensional network structure is formed, showcasing notable thermal and acoustic insulation properties. Experimental data are presented to highlight the material's performance, including comparisons with commercially available mineral wool and polymeric foams. This material versatility is demonstrated through tunable mechanical, thermal and acoustic characteristics, achieved by strategically adjusting the concentration of the biopolymer and additives. This adaptability positions the material as a promising candidate for different insulation applications. Addressing environmental concerns related to rigid polyurethane waste disposal, the study contributes to the circular economy.

Toward Circular Recycling of Polyurethanes: Depolymerization and Recovery of Isocyanates

We report a depolymerization strategy to nearly quantitatively regenerate isocyanates from thermoplastic and thermoset polyurethanes (PUs) and then resynthesize PUs using the recovered isocyanates. To date, chemical/advanced recycling of PUs has focused primarily on the recovery of polyols and diamines under comparatively harsh conditions (e.g., high pressure and temperature), and the recovery of isocyanates has been difficult. Our approach leverages an organoboron Lewis acid to depolymerize PUs directly to isocyanates under mild conditions (e.g., ∼80 °C in toluene) without the need for phosgene or other harsh reagents, and we show that both laboratory-synthesized and commercially sourced PUs can be depolymerized. Furthermore, we demonstrate the utility of the recovered isocyanate in the production of second-generation PUs with thermal properties and molecular weights similar to those of the virgin PUs. Overall, this route uniquely provides an opportunity for circularity in PU materials and can add significant value to end-of-life PU products.

Searching for the Achilles' Heel of Urethane Linkage-An Energetic Perspective

A sudden increase in polyurethane (PU) production necessitates viable recycling methods for the waste generated. PU is one of the most important plastic materials with a wide range of applications; however, the stability of the urethane linkage is a major issue in chemical recycling. In this work, termination reactions of a model urethane molecule, namely methyl N-phenyl carbamate (MPCate), are investigated using G3MP2B3 composite quantum chemical method. Our main goal was to gain insights into the energetic profile of urethane bond termination and find an applicable chemical recycling method. Hydrogenation, hydrolysis, methanolysis, peroxidation, glycolysis, ammonolysis, reduction with methylamine and termination by dimethyl phosphite were explored in both gas and condensed phases. Out of these chemicals, degradation by H2, H2O2 and CH3NH2 revealed promising results with lower activation barriers and exergonic pathways, especially in water solvation. Implementing these effective PU recycling methods can also have significant economic benefits since the obtained products from the reactions are industrially relevant substances. For example, aniline and dimethyl carbonate could be reusable in polymer technologies serving as potential methods for circular economy. As further potential transformations, several ionizations of MPCate were also examined including electron capture and detachment, protonation/deprotonation and reaction with OH-. Alkaline digestion against the model urethane MPCate was found to be promising due to the relatively low activation energy. In an ideal case, the transformation of the urethane bond could be an enzymatic process; therefore, potential enzymes, such as lipoxygenase, were also considered for the catalysis of peroxidation, and lipases for methanolysis.

Polyurethane Foam Chemical Recycling: Fast Acidolysis with Maleic Acid and Full Recovery of Polyol

Chemical recycling of polyurethane (PU) waste is essential to displace the need for virgin polyol production and enable sustainable PU production. Currently, less than 20% of PU waste is downcycled through rebinding to lower value products than the original PU. Chemical recycling of PU waste often requires significant input of materials like solvents and slow reaction rates. Here, we report the fast (<10 min) and solvent-free acidolysis of a model toluene diisocyanate (TDI)-based flexible polyurethane foam (PUF) at <200 °C using maleic acid (MA) with a recovery of recycled polyol (repolyol) in 95% isolated yield. After workup (hydrolysis of repolyl ester and separations), the repolyol exhibits favorable physical properties that are comparable to the virgin polyol; these include 54.1 mg KOH/g OH number and 624 cSt viscosity. Overall, 80% by weight of the input PUF is isolated into two clean-cut fractions containing the repolyol and toluene diamine (TDA). Finally, end-of-life (EOL) mattress PUF waste is recycled successfully with high recovery of repolyol using MA acidolysis. The solvent-free and fast acidolysis with MA demonstrated in this work with both model and EOL PUF provides a potential pathway for sustainable and closed-loop PU production.

High-Quality Cellulosic Fibers Engineered from Cotton-Elastane Textile Waste

Even small amounts of elastane in cotton-elastane blended textiles can prevent fiber-to-fiber recycling strategies in textile recycling. Herein, the selective separation of elastane from cotton blends was addressed by the aminolytic degradation of the synthetic component. Polar aprotic solvents were tested as elastane solvents, but side reactions impeded aminolysis with some of them. Aminolysis of elastane succeeded under mild conditions using dimethyl sulfoxide in combination with diethylenetriamine and 1,5-diazabicyclo[4.3.0]non-5-ene as a cleaving agent and catalyst, respectively. The analysis of the nitrogen content in the recovered cellulose fraction demonstrated that 2 h of reaction at 80 °C reduced the elastane content to values lower than 0.08%. The characterization of the recovered cellulose showed that the applied conditions did not affect the macromolecular properties of cellulose and maintained a cellulose I crystal structure. Degraded elastane products were recovered through precipitation with water. Finally, the cellulosic component was turned into new fibers by dry-jet wet spinning with excellent tensile properties.

Biodegradation of aliphatic polyurethane foams in soil: Influence of amide linkages and supramolecular structure

Polyurethane (PU) foams are classified as physically nonrecyclable thermosets. The current effort of sustainable and eco-friendly production makes it essential to explore methods of better waste management, for instance by modifying the structure of these frequently used polymers to enhance their microbial degradability. The presence of ester links is known to be a crucial prerequisite for the biodegradability of PU foams. However, the impact of other hydrolysable groups (urethane, urea and amide) occurred in PU materials, as well as the supramolecular structure of the PU network and the cellular morphology of PU foams, is still relatively unexplored. In this work, fully aliphatic PU foams with and without hydrolyzable amide linkages were prepared and their aerobic biodegradation was investigated using a six-month soil burial test. Besides the variable chemical composition of the PU foams, the influence of their different supramolecular arrangement and cellular morphologies on the extent of biodegradation was also evaluated. Throughout the soil burial test, the release of carbon dioxide, and enzyme activities of proteases, esterases, and ureases were measured. At the same time, phospho-lipid fatty acids (PLFA) analysis was conducted together with an assessment of microbial community composition achieved by analysing the genetic information from the 16S rRNA gene and ITS2 region sequencing. The results revealed a mineralization rate of 30-50 % for the PU foams, indicating a significant level of degradation as well as indicating that PU foams can be utilized by soil microorganisms as a source of both energy and nutrients. Importantly, microbial biomass remained unaffected, suggesting that there was no toxicity associated with the degradation products of the PU foams. It was further confirmed that ester linkages in PU foam structure were easily enzymatically cleavable, while amide linkages were not prone to degradation by soil microorganisms. In addition, it was shown that the presence of amide linkages in PU foam leads to a change in the supramolecular network arrangement due to increased content of hard segments, which in turn reduces the biodegradability of PU foam. These findings show that it is important to consider both chemical composition and supramolecular/macroscopic structure when designing new PU materials in an effort to develop environmentally friendly alternatives.

Sustainable Composites: Analysis of Filler-Rubber Interaction in Natural Rubber-Styrene-Butadiene Rubber/Polyurethane Composites Using the Lorenz-Park Method and Scanning Electron Microscopy

This study examined micronized polyurethane residues as a reinforcing filler in elastomeric composites made from natural rubber (NR) and styrene-butadiene rubber (SBR). Due to growing environmental concerns, this research aimed to find sustainable alternatives to synthetic materials. The results indicated that adding micronized polyurethane improved the mechanical properties of the composites, reinforcing the polymer matrix and increasing the cross-link density as a barrier against solvents. The composites met the requirements for industrial applications, though; at 40 phr of polyurethane filler, material deformation was reduced, indicating saturation. FTIR analysis confirmed the homogeneity of the materials without chemical reactions, while electron microscopy revealed an increase in the number of particles and irregularities with the filler. The composite with 10 phr showed a lower volume loss in abrasion resistance, meeting the standards for soles. The composite with 30 phr of polyurethane achieved the best results without the filler's saturation and met the footwear industry's requirements. The results show the potential for sustainable practices in industry using this elastomeric blend.

Circular Polydiketoenamine Elastomers with Exceptional Creep Resistance via Multivalent Cross-Linker Design

Elastomers are widely used in textiles, foam, and rubber, yet they are rarely recycled due to the difficulty in deconstructing polymer chains to reusable monomers. Introducing reversible bonds in these materials offers prospects for improving their circularity; however, concomitant bond exchange permits creep, which is undesirable. Here, we show how to architect dynamic covalent polydiketoenamine (PDK) elastomers prepared from polyetheramine and triketone monomers, not only for energy-efficient circularity, but also for outstanding creep resistance at high temperature. By appending polytopic cross-linking functionality at the chain ends of flexible polyetheramines, we reduced creep from >200% to less than 1%, relative to monotopic controls, producing mechanically robust and stable elastomers and carbon-reinforced rubbers that are readily depolymerized to pure monomer in high yield. We also found that the multivalent chain end was essential for ensuring complete PDK deconstruction. Mapping reaction coordinates in energy and space across a range of potential conformations reveals the underpinnings of this behavior, which involves preorganization of the transition state for diketoenamine bond acidolysis when a tertiary amine is also nearby.

Selective Electrocatalytic Degradation of Ether-Containing Polymers

Leveraging electrochemistry to degrade robust polymeric materials has the potential to impact society's growing issue of plastic waste. Herein, we develop an electrocatalytic oxidative degradation of polyethers and poly(vinyl ethers) via electrochemically mediated hydrogen atom transfer (HAT) followed by oxidative polymer degradation promoted by molecular oxygen. We investigated the selectivity and efficiency of this method, finding our conditions to be highly selective for polymers with hydridic, electron-rich C-H bonds. We leveraged this reactivity to degrade polyethers and poly(vinyl ethers) in the presence of polymethacrylates and polyacrylates with complete selectivity. Furthermore, this method made polyacrylates degradable by incorporation of ether units into the polymer backbone. We quantified degradation products, identifying up to 36 mol % of defined oxidation products, including acetic acid, formic acid, and acetaldehyde, and we extended this method to degrade a polyether-based polyurethane in a green solvent. This work demonstrates a facile, electrochemically-driven route to degrade polymers containing ether functionalities.

Deamination of Polyols from the Glycolysis of Polyurethane

Methylenedianiline (MDA) is a secondary, undesired, product of the glycolysis process of polyurethane (PU) scraps due to hydrolysis and pyrolysis side reactions. As an aromatic and carcinogen amine, MDA poses different problems in handling, transporting, and labelling recycled polyols derived from glycolysis, hindering the closure of PU recycling loop. Aiming to provide a solution to this issue, in this work different deaminating agents (DAs) were investigated with the purpose of analyzing their reactivity with MDA. A first part of the study was devoted to the analysis of MDA formation as a function of reaction time and catalyst concentration (potassium acetate) during glycolysis. It was observed that the amount of MDA increases almost linearly with the extent of PU depolymerization and catalyst content. Among the DAs analyzed 2-ethylhexyl glycidyl ether (2-EHGE), and acetic anhydride (Ac2 O) showed interesting performance, which allowed MDA content to be diminished below the limit for labelling prescription in 30 minutes. PU rigid foams were, therefore, synthesized from the corresponding recycled products and characterized in terms of thermal and mechanical performance. Ac2 O-deaminated polyols led to structurally unstable foams with poor compressive strength, while 2-EHGE-deaminated products allowed the production of foams with improved mechanical performance and unaltered thermal conductivity.

Large-Area Rewritable Paper Based on Polyurethane Inverse Photonic Glass with Durable High-Resolution Information Storage and Structural Stability

To alleviate the negative effects of resource waste and environmental pollution caused by the excessive use of paper, technologies for rewritable paper have received widespread attention and in-depth research. Despite the growing interest in rewritable paper, meeting the requirements of large-scale preparation, long-lasting information storage time, high reversibility, and good environmental stability remains a huge challenge for this technology. This study developed a solvent-responsive copolymerized polyurethane-based rewritable paper with an inverse photonic glass structure (co-PUIPG paper). Comprehensive writing modes, including handwriting, spraying, and printing, were realized by using the swelling effect of different solvents and the local force field formed by capillary force to control the deformation degree of the inverse photonic glass structure. Co-PUIPG paper can persistently store high-resolution information and has a green and environmentally friendly "write-erase" method. Meanwhile, it exhibits good rewritability, as well as high mechanical strength and exceptional resistance to environmental factors, such as friction, high temperature, and sunlight. Because the spraying method can prepare templates quickly and extensively and polyurethane materials are economical, co-PUIPG rewritable paper possesses great potential as a substitute for commercial fiber paper and its industrialization is full of great possibilities.

Efficient recycling pathway of bio-based composite polyurethane foams via sustainable diamine

Aminolysis is widely recognized as a valuable chemical route for depolymerizing polymeric materials containing ester, amide, or urethane functional groups, including polyurethane foams. Bio-based polyurethane foams, pristine and reinforced with 40 wt% of sustainable fillers, were depolymerized in the presence of bio-derived butane-1,4-diamine, BDA. A process comparison was made using fossil-derived ethane-1,2-diamine, EDA, by varying amine/polyurethane ratio (F/A, 1:1 and 1:0.6). The obtained depolymerized systems were analyzed by FTIR and NMR characterizations to understand the effect of both diamines on the degradation pathway. The use of bio-based BDA seemed to be more effective with respect to conventional EDA, owing to its stronger basicity (and thus higher nucleophilicity), corresponding to faster depolymerization rates. BDA-based depolymerized systems were then employed to prepare second-generation bio-based composite polyurethane foams by partial replacement of isocyanate components (20 wt%). The morphological, mechanical, and thermal conductivity properties of the second-generation polyurethane foams were evaluated. The best performances (σ10 %=71 ± 9 kPa, λ = 0.042 ± 0.015 W∙ m-1 ∙K-1) were attained by employing the lowest F/A ratio (1:0.6); this demonstrates their potential application in different sectors such as packaging or construction, fulfilling the paradigm of the circular economy.

Reprocessable Polyurethane Foams Using Acetoacetyl-Formed Amides

Like any other thermosetting material, polyurethane foams (PUFs) contain permanent cross-links that hinder their reprocessability and make their recyclability a tedious and environmentally unfriendly process. Herein, we introduce acetoacetyl-formed amides, formed by the reaction of isocyanates with acetoacetate groups, as dynamic units in the backbone of PUFs. By extensive variation of the foam composition, optimum parameters have been found to produce malleable foams above temperatures of 130 °C, without the requirement of any solvent during the foaming process. The PU cross-linked material can be compression-molded at least three times, giving rise to PU elastomers and thus maintaining a cross-linked network structure. Characterization of the original foams shows comparable properties to standard PUFs, for example, having a density of 32 kg/m3, while they show similar chemical and thermal properties upon reprocessing to strong PU elastomers, exhibiting Tg ranging from -42 to -48 °C. This research provides a straightforward method to produce thermally reprocessable PUFs as a promising pathway to address the recycling issues of end-of-life foams.

Exploiting the Use of the Decarboxylative S-Alkylation Reaction to Produce Self-Blowing, Recyclable Polycarbonate Foams

Polymeric foams are widely used in many industrial applications due to their light weight and superior thermal, mechanical, and optical properties. Currently, increasing research efforts is being directed towards the development of greener foam formulations that circumvent the use of isocyanates/blowing agents that are commonly used in the production of foam materials. Here, a straightforward, one-pot method is presented to prepare self-blown polycarbonate (PC) foams by exploiting the (decarboxylative) S-alkylation reaction for in situ generation of the blowing agent (CO2 ). The concomitant formation of a reactive alcohol intermediate promotes a cascade ring-opening polymerization of the cyclic carbonates to yield a cross-linked polymer network. It is shown that these hydroxyl-functionalized polycarbonate-based foams can be easily recycled into films through thermal compression molding. Furthermore, it is demonstrated that complete hydrolytic degradation of the foams is possible, thus offering the potential for zero-waste materials. This straightforward and versatile process broadens the scope of isocyanate-free, self-foaming materials, opening a new pathway for next-generation environmentally friendly foams.

Circular Reprocessing of Thermoset Polyurethane Foams

Thermoset polyurethane (PU) foams are widely used in industrial applications, but they cannot be recycled by conventional melt reprocessing because of their cross-linked structures. The introduction of carbamate exchange catalysts converts thermoset PU into covalent adaptable networks (CANs), which are amenable to reprocessing at elevated temperatures. However, this approach has produced solid PU films, which have fewer uses and lower commercial demand. In this work, simultaneous reprocessing and refoaming of thermoset PU foams is demonstrated by leveraging the melt-processability of PU CANs and allowing cell growth by gas generation in a twin-screw extruder. The optimal operating temperature of the refoaming process is determined through chemical, thermal, and structural analysis of PU foam extrudates. The foam-to-foam extrusion process produces controllable, continuous, and uniform foam structures, as characterized by cell diameter and cell number density. Low-density PU foams are obtained through a process simulating injection molding. The compression properties of reprocessed PU foam are compared with as-synthesized PU foam to demonstrate efficacy of the refoaming processes. These results demonstrate that PU foams can be prepared through recycling while maintaining microstructural and chemical integrity. In the future, this strategy may be applied to thermoset PU foams of various chemical compositions and shows promise for scalability.

Study of Aerogel-Modified Recycled Polyurethane Nanocomposites

In this study, a liquid regenerated polyether polyol was obtained after the degradation of waste PU foam by the two-component decrosslinker agents ethylene glycol and ethanolamine. The regenerated polyol-based polyurethane foam was modified by adding different ratios of SiO2 aerogel through the self-preparation of silica aerogel (SiO2 aerogel) to prepare aerogel/regenerated polyurethane foam nanocomposites of SiO2 aerogel-modified regenerated polyurethane composites. A series of analytical tests on self-prepared silica aerogel and aerogel-modified recycled polyurethane foam composites were performed. The analysis of the test results shows that the regenerated rigid PU foam obtained with SiO2 aerogel addition of 0.3% in the polyurethane degradation material has a small density, low thermal conductivity, and higher compressive strength; hence, the prepared silica aerogel-regenerated polyol-based polyurethane nanocomposite has good thermal insulation and strength support properties. The clean, low-carbon, and high-value utilization of recycled waste polyurethane was achieved.

Structure-Property Relationship and Multiple Processing Studies of Novel Bio-Based Thermoplastic Polyurethane Elastomers

Currently, the growing demand for polymeric materials has led to an increased need to develop effective recycling methods. This study focuses on the multiple processing of bio-based thermoplastic polyurethane elastomers (bio-TPUs) as a sustainable approach for polymeric waste management through mechanical recycling. The main objective is to investigate the influence of two reprocessing cycles on selected properties of bio-TPUs. Two series of bio-based TPUs were synthesized via a solvent-free two-step method with the use of hexamethylene diisocyanate or hexamethylene diisocyanate/partially bio-based diisocyanate mixtures, bio-based poly(triamethylene ether) glycol, and bio-based 1,3 propanediol. Both the raw bio-TPUs and those subjected to two reprocessing cycles were examined with respect to their chemical, physical, thermal, thermomechanical, and mechanical properties. The conducted research revealed that reprocessing led to changes in the phase separation between the hard and soft segments, thereby affecting the bio-TPUs' properties. Both series of materials showed similar chemical structures regardless of reprocessing (slight changes were observed in the range of carbonyl peak). The thermal properties of TPUs exhibited slight differences after each reprocessing cycle, but generally, the non-processed and reprocessed bio-TPUs were thermally stable up to about 300 °C. However, significant differences were observed in their mechanical properties. The tensile strength increased to 34% for the twice-reprocessed bio-TPUs, while the elongation at break increased by ca. 200%. On the other hand, the processing cycles resulted in a decrease in the hardness of both bio-TPU series (ca. 3-4 °ShA). As a result, the prepared bio-TPUs exhibited characteristics that were closer to those of the sustainable materials model, promoting the circular economy of plastics, with environmental benefits arising from their recyclability and their high content of bio-based monomers (78.4-78.8 wt.%).

Improving Sustainability through Covalent Adaptable Networks in the Recycling of Polyurethane Plastics

The global plastic waste problem has created an urgent need for the development of more sustainable materials and recycling processes. Polyurethane (PU) plastics, which represent 5.5% of globally produced plastics, are particularly challenging to recycle owing to their crosslinked structure. Covalent adaptable networks (CANs) based on dynamic covalent bonds have emerged as a promising solution for recycling PU waste. CANs enable the production of thermoset polymers that can be recycled using methods that are traditionally reserved for thermoplastic polymers. Reprocessing using hot-pressing techniques, in particular, proved to be more suited for the class of polyurethanes, allowing for the efficient recycling of PU materials. This Review paper explores the potential of CANs for improving the sustainability of PU recycling processes by examining different types of PU-CANs, bond types, and fillers that can be used to optimise the recycling efficiency. The paper concludes that further research is needed to develop more cost-effective and industrial-friendly techniques for recycling PU-CANs, as they can significantly contribute to sustainable development by creating recyclable thermoset polymers.

Interactions of Cells and Biomaterials for Nerve Tissue Engineering: Polymers and Fabrication

Neural injuries affect millions globally, significantly impacting their quality of life. The inability of these injuries to heal, limited ability to regenerate, and the lack of available treatments make regenerative medicine and tissue engineering a promising field of research for developing methods for nerve repair. This review evaluates the use of natural and synthetic polymers, and the fabrication methods applied that influence a cell's behavior. Methods include cross-linking hydrogels, incorporation of nanoparticles, and 3D printing with and without live cells. The endogenous cells within the injured area and any exogenous cells seeded on the polymer construct play a vital role in regulating healthy neural activity. This review evaluates the body's local and systemic reactions to the implanted materials. Although numerous variables are involved, many of these materials and methods have exhibited the potential to provide a biomaterial environment that promotes biocompatibility and the regeneration of a physical and functional nerve. Future studies may evaluate advanced methods for modifying material properties and characterizing the tissue-biomaterial interface for clinical applications.

Discovery of a polyesterase from Deinococcus maricopensis and comparison to the benchmark LCCICCG suggests high potential for semi-crystalline post-consumer PET degradation

Plastic pollution remains a significant environmental challenge, with conventional waste management strategies proving insufficient in addressing the problem. Enzymatic degradation has emerged as a promising alternative, with LCCICCG, an engineered metagenome-derived cutinase, being the most effective in degrading polyethylene terephthalate (PET), the most commonly produced and discarded polyester. However, more efficient PET-hydrolases are needed for the upscaling of a PET-waste biorefinery. In this regard, the study reports the characterization of a novel, phylogenetically distinct, thermophilic polyesterase from Deinococcus maricopensis (DmPETase) and its comparison to LCCICCG. DmPETase is capable of degrading various synthetic polymers, including PET, polyurethane, as well as four semi-crystalline aliphatic polyesters. DmPETase was found to be comparable to LCCICCG at 50 °C in degrading semi-crystalline sections of post-consumer PET bottles, but it appeared to be less sensitive to crystallinity degree increase. This property makes DmPETase a new template for protein engineering endeavors to create an efficient biocatalyst to be integrated into the bio-recycling process of PET waste, without the need for amorphization of the materials.

Adsorbents obtained from recycled polymeric materials for retention of different pollutants: A review

Polymeric waste is an environmental problem, with an annual world production of approximately 368 million metric tons, and increasing every year. Therefore, different strategies for polymer waste treatment have been developed, and the most common are (1) redesign, (2) reusing and (3) recycling. The latter strategy represents a useful option to generate new materials. This work reviews the emerging trends in the development of adsorbent materials obtained from polymer wastes. Adsorbents are used in filtration systems or in extraction techniques for the removal of contaminants such as heavy metals, dyes, polycyclic aromatic hydrocarbons and other organic compounds from air, biological and water samples. The methods used to obtain different adsorbents are detailed, as well as the interaction mechanisms with the compounds of interest (contaminants). The adsorbents obtained are an alternative to recycle polymeric and they are competitive with other materials applied in the removal and extraction of contaminants.

Review on disposal, recycling and management of waste polyurethane foams: A way ahead

With the burning issue of air, land and water pollution, the premonition of looking forward towards a future devoid of any kind of oil and gas reserves has caused a paradigm shift towards recycling, recovery of any synthetic polymer and also to dispose them off environmentally. Among them are plastics such as polyethylene terephthalate and poly vinyl chloride. Polyurethane (PU) is also under the scanner to dispose of or recycle it environmentally and sustainably. PU is at present the sixth most utilized polymer all over the world with a production of nearly 18 million tonnes per annum, which roughly estimates a daily production of PU products of greater than a million of cubic metres. Its thermostable nature is one of the major reasons for its higher preference over other polymers. This review article discusses the current disposal and technologies available to recycle waste PU foams and also sheds some light on some additional work being done in the field to upgrade the existing technology. Interestingly, some methods mentioned here are probably undergoing scale-up trials runs by now. Currently, the most researched and studied ones are mechanical recycling and glycolysis. But microbial and enzymatic disposal methods can be turned into full-scale industrial recycling processes in the near future. Additionally, we can see an archetypal shift from traditional oil-based sources to the agrarian sources.

Polyurethane Recycling: Thermal Decomposition of 1,3-Diphenyl Urea to Isocyanates

Substituted urea linkages are formed during the production of polyurethane foam. To chemically recycle polyurethane toward its key monomers via depolymerization (i.e., isocyanate), it is essential to break the urea linkages to form the corresponding monomers, namely, an isocyanate and an amine. This work reports the thermal cracking of a model urea compound (1,3-diphenyl urea, DPU) into phenyl isocyanate and aniline in a flow reactor at different temperatures. Experiments were performed at 350-450 °C, with a continuous feed of a solution of 1 wt.% DPU in GVL. In the temperature range studied, high conversion levels of DPU are achieved (70-90 mol%), with high selectivity towards the desired products (close to 100 mol%) and high average mole balance (∼95 mol%) in all cases.

Study on Efficient Degradation of Waste PU Foam

In this paper, the high-efficiency degradation and alcoholysis recovery of waste polyurethane foam were realized using a combination of a high-efficiency alkali metal catalyst (CsOH) and two-component mixed alcoholysis agents (glycerol and butanediol) in different proportions, using recycled polyether polyol and one-step foaming to prepare regenerated thermosetting polyurethane hard foam. The foaming agent and catalyst were adjusted experimentally to prepare regenerated polyurethane foam, and a series of tests were conducted on the viscosity, GPC, hydroxyl value, infrared spectrum, foaming time, apparent density, compressive strength, and other properties of the degradation products of the regenerated thermosetting polyurethane rigid foam. The resulting data were analyzed, and the following conclusions were drawn: The optimal conditions of alcoholysis were obtained when the mass ratio of glycerol to butanediol was 3:2, the amount of cesium hydroxide was 0.08%, the reaction temperature was 170 °C, and the reaction time was 2.5 h. Regenerated polyurethane foam with an apparent density of 34.1 kg/m³ and a compressive strength of 0.301 MPa was prepared under these conditions. It had good thermal stability, complete sample pores, and a strong skeleton. At this time, these are the best reaction conditions for the alcoholysis of waste polyurethane foam, and the regenerated polyurethane foam meets various national standards.

Triggering and identifying the polyurethane and polyethylene-degrading machinery of filamentous fungi secretomes

The uncontrollable disposal of plastic waste has raised the concern of the scientific community, which tries to face this environmental burden by discovering and applying new techniques. Regarding the biotechnology field, several important microorganisms possessing the necessary enzymatic arsenal to utilize recalcitrant synthetic polymers as an energy source have been discovered. In the present study, we screened various fungi for their ability to degrade intact polymers, such as ether-based polyurethane (PU) and low-density polyethylene (LDPE). For this, ImpranIil® DLN-SD and a mixture of long-chain alkanes were used as sole carbon sources, indicating not only the most promising strains in agar plate screening but also inducing the secretion of depolymerizing enzymatic activities, useful for polymer degradation. The agar plate screening revealed three fungal strains belonging to Fusarium and Aspergillus genera, whose secretome was further studied for its ability to degrade the aforementioned non-treated polymers. Specifically for ether-based PU, the secretome of a Fusarium species reduced the sample mass and the average molecular weight of the polymer by 24.5 and 20.4%, respectively, while the secretome of an Aspergillus species caused changes in the molecular structure of LDPE, as evidenced by FTIR. The proteomics analysis revealed that the enzymatic activities induced in presence of Impranil® DLN-SD can be associated with urethane bond cleavage, a fact which was also supported by the observed degradation of the ether-based PU. Although, the mechanism of LDPE degradation was not completely elucidated, the presence of oxidative enzymes could be the main factor contributing to polymer modification.

Screening the Impact of Surfactants and Reaction Conditions on the De-Inkability of Different Printing Ink Systems for Plastic Packaging

One of the major applications (40% in Europe) of plastic is packaging, which is often printed to display required information and to deliver an attractive aesthetic for marketing purposes. However, printing ink can cause contamination in the mechanical recycling process. To mitigate this issue, the use of surfactants in an alkaline washing process, known as de-inking, has been employed to remove printing ink and improve the quality of recyclates. Despite the existence of this technology, there are currently no data linking the de-inking efficiency with typical printing ink compositions. Additionally, it is necessary to investigate the de-inking process under the process parameters of existing recycling plants, including temperature, NaOH concentration, and retention time. This study aims to evaluate the performance of commonly used printing inks with different compositions under various washing scenarios for plastic recycling in conjunction with different de-inking detergents containing surfactants or mixtures of surfactants. The results indicate that the pigments applied to the ink have no significant effect on the de-inking process, except for carbon black (PBk 7). Nitrocellulose (NC) binder systems exhibit high de-inkability (over 95%) under the condition of 55 °C and 1 wt.% NaOH. However, crosslinked binder systems can impede the de-inking effect, whether used as a binder system or as an overprint varnish (OPV). The de-inking process requires heating to 55 °C with 1 wt.% NaOH to achieve a substantial effect. Based on the findings in this work, breaking the Van der Waals forces, hydrogen bonds, and covalent bonds between the printing ink and plastic film is an essential step to achieve the de-inking effect. Further research is needed to understand the interaction between surfactants and printing inks, enabling the development of de-inkable printing inks and high-performance surfactants that allow for de-inking with less energy consumption. The surfactant and NaOH have a synergistic effect in cleaning the printing ink. NaOH provides a negative surface charge for the adsorption of the cationic head of the surfactant and can hydrolyze the covalent bonds at higher concentrations (>2 wt.%).

Preliminary identification of soil fungi for the degradation of polyurethane film

Polyurethane (PU) is a versatile plastic that boasts high environmental resistance. The biodegradation of PU has become a hot topic of research aimed at finding ways to potentially solve PU pollutants. Identifying microorganisms capable of efficiently degrading PU plastics is pivotal for the development of a green recycling process for PU. This study aimed to isolate and characterize PU-degrading fungi from the soil of a waste transfer station in Luoyang, China. We isolated four different fungal strains from the soil. Among the isolates, the P2072 and P2073 strains were identified as Rhizopus oryzae (internal transcribed spacer identity, 99.66%) and Alternaria alternata (internal transcribed spacer identity, 99.81%), respectively, through microscopic, morphologic, as well as 18S rRNA sequencing. The degradation ability of strains P2072 and P2073 was analyzed through measurement of weight loss, and they exhibited a degradation rate of 2.7% and 3.3%, respectively, for the PU films after 2 months' growth in mineral salt medium (MSM) with PU films as the sole carbon source. In addition, the P2073 strain exhibited protease activity in the presence of PU. To our knowledge, R. oryzae has never been reported as a PU-degrading fungus. This study provides a new perspective on the biodegradation of PU.

Photochemical weathering of polyurethane microplastics produced complex and dynamic mixtures of dissolved organic chemicals

Sunlight exposure can naturally mitigate microplastics pollution in the surface ocean, however it results in emissions of dissolved organic carbon (DOC) whose characteristics and fate remain largely unknown. In this work, we investigated the effects of solar radiation on polyether (TPU_Ether) and polyester (TPU_Ester) thermoplastic polyurethane, and on a thermoset polyurethane (PU_Hardened). The microplastics were irradiated with simulated solar light with a UV dose of 350 MJ m^-2, which corresponds to roughly 15 months outdoor exposure at 31° N latitude. The particles were characterized using ATR-FTIR and elemental analysis. The DOC released to the aqueous phase was quantified by total organic carbon analysis and characterized by nontarget liquid chromatography coupled to high-resolution mass spectrometry. Polyurethane microplastics were degraded following mechanisms reconcilable with UV photo-oxidation. The carbon mass fraction released to the aqueous phase was 8.5 ± 0.5%, 3.7 ± 0.2%, and 2.8 ± 0.2% for TPU_Ether, TPU_Ester, and PU_Hardened, respectively. The corresponding DOC release rates, expressed as mg carbon per UV dose were 0.023, 0.013, and 0.010 mg MJ^-1 for TPU_Ether, TPU_Ester and PU_Hardened, respectively. Roughly three thousand unique by-products were released from photo-weathered TPUs, whereas 540 were detected in the DOC of PU_Hardened. This carbon pool was highly complex and dynamic in terms of physicochemical properties and susceptibility to further photodegradation after dissolution from the particles. Our results show that plastics photodegradation in the ocean requires chemical assessment of the DOC emissions in addition to the analysis of aged microplastics and that polymer chemistry influences the chain scission products.

Solving the plastic dilemma: the fungal and bacterial biodegradability of polyurethanes

Polyurethane (PU) is a plastic polymer which, due to its various desirable characteristics, has been applied extensively in domestic, industrial and medical fields for the past 50 years. Subsequently, an increasing amount of PU waste is generated annually. PU, like many other plastics, is highly resistant to degradation and is a substantial threat to our environment. Currently PU wastes are handled through conventional disposal techniques such as landfill, incineration and recycling. Due to the many drawbacks of these techniques, a 'greener' alternative is necessary, and biodegradation appears to be the most promising option. Biodegradation has the potential to completely mineralise plastic waste or recover the input materials and better enable recycling. There are hurdles to overcome however, primarily the efficiency of the process and the presence of waste plastics with inherently different chemical structures. This review will focus on polyurethanes and their biodegradation, outlining the difficulty of degrading different versions of the same material and strategies for achieving more efficient biodegradation.

End-of-life upcycling of polyurethanes using a room temperature, mechanism-based degradation

A major challenge in developing recyclable polymeric materials is the inherent conflict between the properties required during and after their life span. In particular, materials must be strong and durable when in use, but undergo complete and rapid degradation, ideally under mild conditions, as they approach the end of their life span. We report a mechanism for degrading polymers called cyclization-triggered chain cleavage (CATCH cleavage) that achieves this duality. CATCH cleavage features a simple glycerol-based acyclic acetal unit as a kinetic and thermodynamic trap for gated chain shattering. Thus, an organic acid induces transient chain breaks with oxocarbenium ion formation and subsequent intramolecular cyclization to fully depolymerize the polymer backbone at room temperature. With minimal chemical modification, the resulting degradation products from a polyurethane elastomer can be repurposed into strong adhesives and photochromic coatings, demonstrating the potential for upcycling. The CATCH cleavage strategy for low-energy input breakdown and subsequent upcycling may be generalizable to a broader range of synthetic polymers and their end-of-life waste streams.

Urethanases for the Enzymatic Hydrolysis of Low Molecular Weight Carbamates and the Recycling of Polyurethanes

Enzymatic degradation and recycling can reduce the environmental impact of plastics. Despite decades of research, no enzymes for the efficient hydrolysis of polyurethanes have been reported. Whereas the hydrolysis of the ester bonds in polyester-polyurethanes by cutinases is known, the urethane bonds in polyether-polyurethanes have remained inaccessible to biocatalytic hydrolysis. Here we report the discovery of urethanases from a metagenome library constructed from soil that had been exposed to polyurethane waste for many years. We then demonstrate the use of a urethanase in a chemoenzymatic process for polyurethane foam recycling. The urethanase hydrolyses low molecular weight dicarbamates resulting from chemical glycolysis of polyether-polyurethane foam, making this strategy broadly applicable to diverse polyether-polyurethane wastes.

Microbial Enzyme Biotechnology to Reach Plastic Waste Circularity: Current Status, Problems and Perspectives

The accumulation of synthetic plastic waste in the environment has become a global concern. Microbial enzymes (purified or as whole-cell biocatalysts) represent emerging biotechnological tools for waste circularity; they can depolymerize materials into reusable building blocks, but their contribution must be considered within the context of present waste management practices. This review reports on the prospective of biotechnological tools for plastic bio-recycling within the framework of plastic waste management in Europe. Available biotechnology tools can support polyethylene terephthalate (PET) recycling. However, PET represents only ≈7% of unrecycled plastic waste. Polyurethanes, the principal unrecycled waste fraction, together with other thermosets and more recalcitrant thermoplastics (e.g., polyolefins) are the next plausible target for enzyme-based depolymerization, even if this process is currently effective only on ideal polyester-based polymers. To extend the contribution of biotechnology to plastic circularity, optimization of collection and sorting systems should be considered to feed chemoenzymatic technologies for the treatment of more recalcitrant and mixed polymers. In addition, new bio-based technologies with a lower environmental impact in comparison with the present approaches should be developed to depolymerize (available or new) plastic materials, that should be designed for the required durability and for being susceptible to the action of enzymes.

Evaluation of the Ecotoxicity of New Polyurethane Composites on Target Organisms for Aquatic and Atmospheric Environments

The present study investigated if new biocomposite materials, polyurethanes (PURs) added with functionalized cellulose fibers, produce potential toxic effects on two target organisms currently used in biomonitoring the quality of two different environmental compartments. Natural fibers were extracted from the species Spartium junceum L., a shrub commonly found in the southern region of the Mediterranean having a high cellulose content. All PURs produced were characterized by Fourier-transform infrared spectroscopy, and their structure was analyzed by scanning electron microscopy. We measured the effects of exposure to aromatic and aliphatic PUR composites (containing or not cellulose fibers) on the aquatic model organism Daphnia magna Straus, a freshwater crustacean (Cladocera), and a biomonitor of air quality, the fruticose epiphytic lichen Pseudevernia furfuracea (L.) Zopf. Leachates from aliphatic PUR composite not containing cellulose are more toxic to D. magna than all others, showing a slight acute toxicity in the case of the shortest exposure (24 h) and a moderate acute toxicity in the longer one (48 h). This effect is most likely due to the presence of free organic ammines and amides, which, in their turn, are immobilized in composites containing cellulosic fibers because of the considerable amount of chemical functional groups. Regarding lichens, both types of aliphatic PURs resulted in a toxic effect. Formulate not added with cellulose strongly promoted fungal peroxidation, whereas that which was functionalized affected the pigment concentration of the algal partner. Our results suggest that the use of cellulose in PUR production, in general, can limit the ecotoxicological effects on both test organisms and reduce the potential environmental impact due to this type of polymer. Environ Toxicol Chem 2023;42:421-436. © 2022 SETAC.

One More Step towards a Circular Economy for Thermal Insulation Materials-Development of Composites Highly Filled with Waste Polyurethane (PU) Foam for Potential Use in the Building Industry

The rapid development of the building sector has created increased demand for novel materials and technologies, while on the other hand resulting in the generation of a severe amount of waste materials. Among these are polyurethane (PU) foams, which are commonly applied as thermal insulation materials. Their management is a serious industrial problem, due to, for example, their complex chemical composition. Although some chemical and thermochemical methods of PU foam recycling are known, their broader use is limited due to requirements related to the complexity and safety of their installation, thus implicating high costs. Therefore, material recycling poses a promising alternative. The incorporation of waste PU foams as fillers for polymer composites could make it possible to take advantage of their structure and performance. Herein, polypropylene-based composites that were highly filled with waste PU foam and modified using foaming agents were prepared and analyzed. Depending on the foam loading and the foaming agent applied, the apparent density of material was reduced by as much as 68%. The efficient development of a porous structure, confirmed by scanning electron microscopy and high-resolution computed micro-tomography, enabled a 64% decrease in the thermal conductivity coefficient. The foaming of the structure affected the mechanical performance of composites, resulting in a deterioration of their tensile and compressive performance. Therefore, developing samples of the analyzed composites with the desired performance would require identifying the proper balance between mechanical strength and economic, as well as ecological (share of waste material in composite, apparent density of material), considerations.

Upgrading Polyurethanes into Functional Ureas through the Asymmetric Chemical Deconstruction of Carbamates

The importance of systematic and efficient recycling of all forms of plastic is no longer a matter for debate. Constituting the sixth most produced polymer family worldwide, polyurethanes, which are used in a broad variety of applications (buildings, electronics, adhesives, sealants, etc.), are particularly important to recycle. In this study, polyurethanes are selectively recycled to obtain high value-added molecules. It is demonstrated that depolymerization reactions performed with secondary amines selectively cleave the C-O bond of the urethane group, while primary amines unselectively break C-O and C-N bonds. The selective cleavage of C-O bonds, catalyzed by an acid:base mixture, led to the initial polyol and a functional diurea in several hours to a few minutes for both model polyurethanes and commercial polyurethane foams. Different secondary amines were employed as nucleophiles to synthesize a small library of diureas obtained in good to excellent yields. This study not only targets the recovery of the initial polyol but also aims to form new diureas which are useful building blocks for the polymerization of innovative materials.

Sustainable cycloaliphatic polyurethanes: from synthesis to applications

Polyurethanes (PUs) are a versatile and major polymer family, mainly produced via polyaddition between polyols and polyisocyanates. A large variety of fossil-based building blocks is commonly used to develop a wide range of macromolecular architectures with specific properties. Due to environmental concerns, legislation, rarefaction of some petrol fractions and price fluctuation, sustainable feedstocks are attracting significant attention, e.g., plastic waste and biobased resources from biomass. Consequently, various sustainable building blocks are available to develop new renewable macromolecular architectures such as aromatics, linear aliphatics and cycloaliphatics. Meanwhile, the relationship between the chemical structures of these building blocks and properties of the final PUs can be determined. For instance, aromatic building blocks are remarkable to endow materials with rigidity, hydrophobicity, fire resistance, chemical and thermal stability, whereas acyclic aliphatics endow them with oxidation and UV light resistance, flexibility and transparency. Cycloaliphatics are very interesting as they combine most of the advantages of linear aliphatic and aromatic compounds. This original and unique review presents a comprehensive overview of the synthesis of sustainable cycloaliphatic PUs using various renewable products such as biobased terpenes, carbohydrates, fatty acids and cholesterol and/or plastic waste. Herein, we summarize the chemical modification of the main sustainable cycloaliphatic feedstocks, synthesis of PUs using these building blocks and their corresponding properties and subsequently present their major applications in hot-topic fields, including building, transportation, packaging and biomedicine.

The use of polymer compounds in the deposits from the combustion of briquettes in domestic heating as an identifier of fuel quality

The utilisation of waste wood from furniture production brings new problems connected with an incomplete thermochemical decomposition of additives (chemicals for improving properties of plastics) in small heating with the addition of sources. Unique organic compounds produced by the combustion of waste wood allow the identification of the type of fuel. The organic compounds contained in the char deposits were analysed by pyrolysis gas chromatography with mass spectrometry. The deposits from the combustion of briquettes from furniture production contain organic compounds originating by decomposition of phenolic resins, aminoplasts (urea-formaldehyde, resorcinol-formaldehyde and melamine), polyurethanes and wood glue. Additives contained in the deposits include plasticisers such as phthalates (DEHP, dibutyl phthalate and diisobutyl phthalate), flame retardants (2-propanol, 1-chlorophosphate (3:1) and p-terphenyl). Deposits from the combustion of briquettes from virgin wood do not contain these compounds. The total amount of compounds identified in the deposits from the boiler, which do not come from virgin wood combustion, varies in the range between 4.25 and 6.25 g/kg. Phthalates (55.5%) and PVAc adhesives (18.6%) are the main anthropogenic compounds in the deposits from domestic boilers.

Multifunctional Polyurethane Composites with Coffee Grounds and Wood Sawdust

Currently, the fundamental activity that will allow for the development of an economy with closed circulation is the management of food waste and production waste for the preparation of biocomposites. The use of waste materials of natural origin allows for the creation of innovative composites with improved physicochemical and functional properties. The present investigation concerns the use of coffee grounds (2.5-20 wt.%) and oak sawdust (2.5-20 wt.%) as effective fillers of rigid polyurethane foam. Innovative composite materials, previously indebted in the literature, were subjected to the necessary analyses to determine the application abilities: processing times, free density, water absorption, dimensional stability, mechanical properties (compressive strength), thermal conductivity, morphology, and flame resistance. The results with respect to the mechanical tests turned out to be the key. Increasing the number of coffee additives has a positive effect on the compressive strength. The addition of this filler in the range of 5-15 wt.% increased the compressive strength of the composites, 136-139 kPa, compared to the reference sample, 127 kPa. The key parameter analysed was thermal conductivity. The results obtained were in range of the requirements, that is, 0.022-0.024 W/m·K for all used amounts of fillers 2.5-20 wt.%. This is extremely important since these materials are used for insulation purposes. The results of the burning-behaviour test have confirmed that the addition of renewable materials does not negatively affect the fire resistance of the received foams; the results were obtained analogously to those obtained from the reference sample without the addition of fillers. The height of the flame did not exceed 17 cm, while the flame decay time was 17 s for the reference sample and the composite with coffee grounds and 18 s for the composite with oak sawdust. In this work, the practical application of bioorganic waste as an innovative filler for the insulation of flooded polyurethane foam is described for the first time. The introduction of fillers of natural origin into the polymer matrix is a promising method to improve the physicochemical and functional properties of rigid polyurethane foams. Composites modified with coffee grounds and sawdust are interesting from a technological, ecological, and economic point of view, significantly increasing the range of use of foam in various industries.

Analysis of Factors Influencing the Efficiency of Catalysts Used in Waste PU Degradation

Polyurethane (PU) is an indispensable part of people's lives. With the development of polyurethane, the disposal of polyurethane waste has become a significant issue around the world. Conventional degradation catalysts have poor dispersion and low degradation efficiency when used in the process of solid degradation into liquid. Therefore, this paper innovatively adopts self-made core-shell nanoscale titanium catalysis, traditional alkali metal catalyst (KOH), and polyol to carry out the glycolysis of waste polyurethane (PU) pipeline foam. The homogenized nanoscale titanium catalyst coated with alcohol gel has an obvious core-shell structure. The alcohol gel not only protects the catalyst but also dissolves with the alcoholysis agent in the process of glycolysis and disperses more evenly into the alcoholysis agent to avoid the phenomenon of nanocatalyst agglomeration, so as to facilitate catalytic cracking without reducing catalyst activity. In this study, investigated and compared the production of renewable polyurethane foam via a one-step method based on use of a homogeneous core-shell nanostructured titanium catalyst vs. a traditional alkaline catalyst in terms of the properties of regenerated polyether polyols as well as of the foams produced from these polyols. The physicochemical properties of regenerated polyether polyols that were analyzed included viscosity, hydroxyl value, and average molecular weight. The regenerated polyurethane foams were characterized based on water absorption, TG, SEM, and thermal conductivity analyses. The results show that, when the addition of homogeneous titanium catalyst was T2 0.050 wt.%, the viscosity of regenerated polyether polyols was the lowest, at 5356.7 mPa·s, which was reduced by 9.97% compared with those obtained using the alkali metal catalyst (KOH). When the amount of titanium catalyst was T3 0.075 wt.%, the hard foam made of regenerated polyurethane prepared by the catalyst showed the best properties, with a compressive strength of 0.168 MPa, which is 4.76% higher than that of the foam prepared using KOH catalyst.

New Building Blocks for Self-Healing Polymers

The healing efficiency in self-healing materials is bound by the ability to form blends between the prepolymer and curing agent. One of the problems in the development of self-healing polymers is the reduced affinity of the bismaleimide curing agent for the elastomeric furan-containing matrix. Even when stoichiometric amounts of both components are applied, incompatibility of components can significantly reduce the effectiveness of self-healing, and lead to undesirable side effects, such as crystallization of the curing agent, in the thickness and on the surface. This is exactly what we have seen in the development of linear and cross-linked PUs using BMI as a hardener. In this work, we present a new series of the di- and tetrafuranic isocyanate-related ureas-promising curing agents for the development of polyurethanes-like self-healing materials via the Diels-Alder reaction. The commonly used isocyanates (4,4'-Methylene diphenyl diisocyanate, MDI; 2,4-Tolylene diisocyanate, TDI; and Hexamethylene diisocyanate, HDI) and furfurylamine, difurfurylamine, and furfuryl alcohol (derived from biorenewables) as furanic compounds were utilized for synthesis. The remendable polyurethane for testing was synthesized from a maleimide-terminated prepolymer and one of the T-series urea. Self-healing properties were investigated by thermal analysis. Molecular mass was determined by gel permeation chromatography. The properties of the new polymer were compared with polyurethane from a furan-terminated analog. Visual tests showed that the obtained material has thermally induced self-healing abilities. Resulting polyurethane (PU) has a rather low fusing point and thus may be used as potential material for Fused Deposition Modeling (FDM) 3D printing.